TA400 Tier2

Gen 10
ARTICULATED
TRUCKS

TRUCKS

Issue Date: 15-Sep-2017

Maintenance Manual Language: English (en)
Revision No: 1.0
Reference No: 15505674
Serial Number: TELA1218 Original Instructions

© TEREX TRUCKS 2017

Record of Revisions

Record of Revisions
Revision No. Reason for Change Date
1.0 Issue 1.0 of Terex Trucks Maintenance Manual 15-Sep-2017

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 Table of Content

Table of Content
Table of Content...................................................................................................... 1
1 Introduction.................................................................................................1-1
1.1 Maintenance Manual Information................................................................... 1-2
1.2 Safety Information .......................................................................................... 1-2
(1) Proposition 65 Warnings............................................................................ 1-3
1.3 Identification Plate.......................................................................................... 1-3
1.4 Intended Use.................................................................................................. 1-4
(1) Basic Operation ......................................................................................... 1-4
(2) Operating Underground............................................................................. 1-4
(3) Environmental Requirements .................................................................... 1-4
1.5 Prohibited Use................................................................................................ 1-4
1.6 Warranty......................................................................................................... 1-5
1.7 Copyright........................................................................................................ 1-5
1.8 Theft Deterrent Practices ............................................................................... 1-6
2 Safety ...........................................................................................................2-1
2.1 Safety Alert Symbol........................................................................................ 2-2
2.2 General Safety ............................................................................................... 2-2
(1) Important Safety Notice ............................................................................. 2-3
(2) Safety Hazard Classifications.................................................................... 2-4
(3) Description of Safety Symbols................................................................... 2-5
2.3 Position of Safety Decals on the Machine...................................................... 2-6
2.4 Personal Safety............................................................................................ 2-13
(1) Read and Understand this Maintenance Manual and All Safety
Signs........................................................................................................ 2-13
(2) Personal Protective Equipment ............................................................... 2-14
2.5 Work Area Safety ......................................................................................... 2-15
(1) General Work Area Guidelines ................................................................ 2-15
(a) General Fire Precautions .................................................................... 2-15
(b) Flammable Fluid Precautions ............................................................. 2-15
(c) Mounting and Dismounting ................................................................. 2-16
(2) Measures for Protection Against Lightning.............................................. 2-16
(3) Transportation Safety .............................................................................. 2-17
(a) Roading............................................................................................... 2-17
(b) Articulation and Oscillation Lock ......................................................... 2-17
(c) Machine Lifting Precautions................................................................ 2-17
(d) Machine Tie Down Precautions .......................................................... 2-18
(4) Operation Safety...................................................................................... 2-19
(a) Pre-Starting and Starting .................................................................... 2-19
(b) Operating ............................................................................................ 2-20
(5) Accumulator Safety ................................................................................. 2-22
(6) Electrical Safety....................................................................................... 2-23
(7) Refrigerant............................................................................................... 2-24
(8) Maintenance Safety................................................................................. 2-25
(a) Body Prop ........................................................................................... 2-26
2.6 Mirrors and CCTV ........................................................................................ 2-28
2.7 Wheels and Tires ......................................................................................... 2-29
2.8 Lubrication and Servicing............................................................................. 2-31
3 Technical Data.............................................................................................3-1

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3.1 Dimensions .................................................................................................... 3-2

3.2 Carrying Capacity........................................................................................... 3-3
3.3 Operating Temperature .................................................................................. 3-3
3.4 Mechanical System ........................................................................................ 3-4
(1) Engine ....................................................................................................... 3-4
(2) Hydraulic System....................................................................................... 3-5
3.5 Electrical System............................................................................................ 3-5
(1) Electrical System ....................................................................................... 3-5
(2) Light Bulbs................................................................................................. 3-5
3.6 Standards....................................................................................................... 3-6
3.7 Vibration Data for Off Highway Articulated Dump Trucks............................... 3-7
(1) Guidelines for Use and Working Conditions of Earth-Moving Machinery to
Reduce Vibration Levels............................................................................ 3-8
3.8 Service Capacities ......................................................................................... 3-9
3.9 Vehicle Weights............................................................................................ 3-10
3.10 Towing .......................................................................................................... 3-11
3.11 Machine Components Specifications ........................................................... 3-11
(1) Wheels and Tires..................................................................................... 3-11
(a) Description .......................................................................................... 3-11
(b) Avoid Tire Explosion Hazard............................................................... 3-12
(2) Transmission ........................................................................................... 3-13
(3) Dropbox ................................................................................................... 3-14
(4) Axles........................................................................................................ 3-14
(5) Suspension.............................................................................................. 3-14
(6) Body ........................................................................................................ 3-15
(7) Brakes ..................................................................................................... 3-15
(8) Steering ................................................................................................... 3-16
(9) Body Hoist ............................................................................................... 3-16
4 Maintenance ................................................................................................4-1
4.1 Maintenance and Inspection Plan .................................................................. 4-2
(1) Maintenance Safety................................................................................... 4-2
(2) Maintenance Schedules ............................................................................ 4-3
(a) Every 10 Hours of Operation ................................................................ 4-3
(b) After First 10 Hours of Operation or Rebuilt Components .................... 4-4
(c) Every 50 Hours of Operation ................................................................ 4-5
(d) After First 100 Hours of Operation or Rebuilt Components .................. 4-5
(e) Every 250 Hours of Operation .............................................................. 4-6
(f) After First 250 Hours of Operation or Rebuilt Components .................. 4-7
(g) Every 500 Hours of Operation .............................................................. 4-8
(h) After First 500 Hours of Operation or Rebuilt Components .................. 4-9
(i) Every 1000 Hours of Operation ............................................................ 4-9
(j) Every 2000 Hours of Operation .......................................................... 4-11
(k) Every 3000 Hours of Operation .......................................................... 4-13
(l) Every 4000 Hours of Operation .......................................................... 4-13
(m) Every 6000 Hours of Operation .......................................................... 4-13
4.2 Non-scheduled Maintenance ....................................................................... 4-14
4.3 Air Condition Commissioning Procedure ..................................................... 4-15
4.4 Lubrication System....................................................................................... 4-16
(1) Recommended Lubricants....................................................................... 4-16
(a) Specific Information on Lubrication..................................................... 4-17

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(2) Lubrication Points .................................................................................... 4-18

5 Engine..........................................................................................................5-1
5.1 Description ..................................................................................................... 5-3
5.2 Operation ....................................................................................................... 5-5
5.3 Removal ......................................................................................................... 5-5
5.4 Installation ...................................................................................................... 5-9
5.5 S6 Engine Management System (EMS) ...................................................... 5-11
5.6 ECU/TCU Diagnostic Screen ....................................................................... 5-12
5.7 Failure Mode Identifiers................................................................................ 5-13
5.8 List of Fault Codes ....................................................................................... 5-14
5.9 Cleaning ....................................................................................................... 5-23
5.10 Drive Belts.................................................................................................... 5-24
(1) Description............................................................................................... 5-24
(2) Maintenance ............................................................................................ 5-24
(3) Removal .................................................................................................. 5-26
(4) Installation ............................................................................................... 5-26
5.11 Starting......................................................................................................... 5-27
5.12 Stopping ....................................................................................................... 5-28
5.13 Oil – Drain/Replenish ................................................................................... 5-29
(1) Maintenance ............................................................................................ 5-29
(2) Drain ........................................................................................................ 5-29
(3) Replenish/Check ..................................................................................... 5-29
5.14 Oil Filter – Replacement............................................................................... 5-30
5.15 Centrifugal Oil Filter ..................................................................................... 5-31
(1) Maintenance ............................................................................................ 5-31
(2) Cleaning .................................................................................................. 5-31
(3) Operational Testing................................................................................. 5-34
5.16 Air Cleaner ................................................................................................... 5-35
(1) Description............................................................................................... 5-36
(2) Removal .................................................................................................. 5-37
(3) Installation ............................................................................................... 5-37
(4) Filter Removal ......................................................................................... 5-38
(5) Filter Installation ...................................................................................... 5-38
5.17 Exhaust System ........................................................................................... 5-39
(1) Exhaust and Mounting............................................................................. 5-39
(2) Description............................................................................................... 5-40
(3) Removal .................................................................................................. 5-40
(a) Exhaust Front Section Pipe ................................................................ 5-40
(b) Exhaust Rear Section Pipe ................................................................. 5-41
(c) Exhaust Middle Section Pipe .............................................................. 5-41
(d) Silencer to Diverter Box Exhaust Pipe ................................................ 5-42
(e) Stack Pipe........................................................................................... 5-42
(f) Silencer ............................................................................................... 5-43
(4) Installation ............................................................................................... 5-44
(a) Exhaust Middle Section Pipe .............................................................. 5-44
(b) Exhaust Rear Section Pipe ................................................................. 5-45
(c) Exhaust Front Section Pipe ................................................................ 5-45
(d) Stack Pipe........................................................................................... 5-46
(e) Silencer to Diverter Box Exhaust Pipe ................................................ 5-46

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(f) Silencer ............................................................................................... 5-47

6 Transmission...............................................................................................6-1
6.1 Transmission and Mounting ........................................................................... 6-2
6.2 Description ..................................................................................................... 6-3
6.3 Transmission Modules ................................................................................... 6-4
6.4 Transmission Temperatures, Pressures and Ratios....................................... 6-6
6.5 Switches, Sensors & Solenoids ..................................................................... 6-7
6.6 Operation ..................................................................................................... 6-10
(1) Allison Series 4500 Automatic Shift Transmission .................................. 6-10
(2) 5th GEN Shift Controller ........................................................................... 6-11
(3) Displaying Diagnostic Data...................................................................... 6-12
(4) Displaying Prognostic Data ..................................................................... 6-13
(5) Allison 5th Gen Diagnostic Codes ........................................................... 6-14
(6) Transmission Retarder ............................................................................ 6-18
(7) Gear Activation ........................................................................................ 6-19
6.7 Pressure Checks.......................................................................................... 6-19
6.8 Transmission TCU Connections................................................................... 6-21
6.9 General Troubleshooting.............................................................................. 6-22
6.10 Removal ....................................................................................................... 6-23
6.11 Disassembly................................................................................................. 6-24
6.12 Removal of the Control Valve Module .......................................................... 6-26
6.13 Inspection..................................................................................................... 6-27
6.14 Installation of the Control Valve Module ....................................................... 6-28
6.15 Assembly...................................................................................................... 6-29
6.16 Installation .................................................................................................... 6-29
6.17 Service Tools................................................................................................ 6-29
6.18 Special Torque Specifications ...................................................................... 6-29
6.19 Maintenance................................................................................................. 6-30
(1) Periodic Inspections ................................................................................ 6-30
(2) Oil Level Check ....................................................................................... 6-30
(3) Manual Oil Level Check........................................................................... 6-31
(4) Cold Level Check .................................................................................... 6-31
(5) Hot Level Check ...................................................................................... 6-32
(6) Oil and Filter Change............................................................................... 6-32
6.20 Transmission - Power Take Off .................................................................... 6-34
(1) Description............................................................................................... 6-35
(2) Operation................................................................................................. 6-35
(3) Removal .................................................................................................. 6-35
(4) Disassembly ............................................................................................ 6-36
(5) Inspection ................................................................................................ 6-37
(6) Assembly ................................................................................................. 6-37
(7) Installation ............................................................................................... 6-38
(8) Service Tools ........................................................................................... 6-39
7 Dropbox .......................................................................................................7-1
7.1 Dropbox and Mounting................................................................................... 7-3
(1) Description................................................................................................. 7-4
(2) Operation................................................................................................... 7-4
(3) Switches and Pressure Points................................................................... 7-5
(a) Gear Selection ...................................................................................... 7-6

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(b)Diagnostic Points .................................................................................. 7-7

(4) Removal .................................................................................................... 7-9
(5) Disassembly ............................................................................................ 7-13
(a) Speed Selection Cylinder.................................................................... 7-18
(b) Yokes .................................................................................................. 7-18
(c) Casings ............................................................................................... 7-19
(d) Differential Shaft Assembly................................................................. 7-21
(e) Input Shaft and Counter Shaft Assemblies ......................................... 7-23
(f) Front Drive Gear ................................................................................. 7-25
(6) Inspection ................................................................................................ 7-26
(7) Assembly ................................................................................................. 7-27
(a) Front Drive Gear ................................................................................. 7-27
(b) Input Shaft Assembly .......................................................................... 7-28
(c) Differential Unit ................................................................................... 7-29
(d) Counter Shaft...................................................................................... 7-31
(e) Casings ............................................................................................... 7-32
(f) Final Assembly.................................................................................... 7-35
(8) Installation ............................................................................................... 7-38
(9) Maintenance ............................................................................................ 7-40
(a) Periodic Inspections............................................................................ 7-40
(b) Topping Up Oil .................................................................................... 7-40
(c) Bleeding the System ........................................................................... 7-41
(10) Service Tools ........................................................................................... 7-41
(11) Trouble Shooting ..................................................................................... 7-42
(12) Special Torque Specifications.................................................................. 7-43
(13) Dropbox Assembly Torque Specifications ............................................... 7-44
(14) Valve Block Torque Specifications ........................................................... 7-44
7.2 Dropbox Pump ............................................................................................. 7-45
(1) Description............................................................................................... 7-45
(2) Operation................................................................................................. 7-46
(3) Diagnostic Points..................................................................................... 7-46
(a) Dropbox Lubrication - Temperature/Pressure Table ........................... 7-46
(4) Removal .................................................................................................. 7-47
(5) Disassembly ............................................................................................ 7-48
(6) Inspection ................................................................................................ 7-49
(7) Assembly ................................................................................................. 7-49
(8) Installation ............................................................................................... 7-50
(9) Fault Diagnosis........................................................................................ 7-51
(10) Special Tools ........................................................................................... 7-51
7.3 Dropbox Oil Pressure Filter .......................................................................... 7-52
(1) Description............................................................................................... 7-52
(2) Removal .................................................................................................. 7-53
(3) Installation ............................................................................................... 7-54
(4) Changing Filter Element .......................................................................... 7-54
(5) Special Tools ........................................................................................... 7-55
7.4 Dropbox Suction Filter.................................................................................. 7-56
(1) Description............................................................................................... 7-56
(2) Operation................................................................................................. 7-57
(3) Changing Filter Element .......................................................................... 7-57

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8 Drivelines.....................................................................................................8-1
8.1 Front Drivelines .............................................................................................. 8-2
(1) Description................................................................................................. 8-3
(2) Removal .................................................................................................... 8-3
(3) Universal Joint Disassembly...................................................................... 8-5
(4) Inspection .................................................................................................. 8-6
(5) Universal Joint Assembly .......................................................................... 8-7
(6) Installation ................................................................................................. 8-8
(7) Special Tools ............................................................................................. 8-9
(8) Driveline Diagnosis Chart .......................................................................... 8-9
(9) Special Torque Specifications.................................................................... 8-9
8.2 Rear Drivelines............................................................................................. 8-10
(1) Description............................................................................................... 8-10
(2) Removal .................................................................................................. 8-11
(3) Universal Joint Disassembly.................................................................... 8-12
(4) Inspection ................................................................................................ 8-13
(5) Universal Joint Assembly ........................................................................ 8-13
(6) Installation ............................................................................................... 8-14
(7) Special Tools ........................................................................................... 8-15
(8) Driveline Diagnosis Chart ........................................................................ 8-15
9 Axle Group ..................................................................................................9-1
9.1 Differential Lock Controls ............................................................................... 9-3
(1) Description and Operation......................................................................... 9-3
(2) Removal and Disassembly ........................................................................ 9-5
(3) Assembly and Installation.......................................................................... 9-7
(4) Pressure Checks ....................................................................................... 9-8
(5) Maintenance .............................................................................................. 9-9
(6) Special Tools ............................................................................................. 9-9
9.2 Front Axle Group.......................................................................................... 9-10
(1) Front Axle ................................................................................................ 9-10
(a) Description .......................................................................................... 9-11
(b) Removal.............................................................................................. 9-12
(c) Installation........................................................................................... 9-13
(2) Differential Drive Head ............................................................................ 9-14
(a) Description .......................................................................................... 9-14
(b) Operation ............................................................................................ 9-15
(c) Removal.............................................................................................. 9-16
(d) Disassembly........................................................................................ 9-17
(e) Inspection............................................................................................ 9-19
(f) Assembly ............................................................................................ 9-19
(g) Installation........................................................................................... 9-29
(h) Gleason Gear Tooth System............................................................... 9-29
(i) Maintenance ....................................................................................... 9-31
(j) Special Tools....................................................................................... 9-31
(k) Diagnosis ............................................................................................ 9-31
(l) Diagnosis Chart .................................................................................. 9-32
(m) Special Torque Specifications ............................................................. 9-32
9.3 Centre Axle Group ....................................................................................... 9-33
(1) Centre Axle.............................................................................................. 9-33

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(2) Removal .................................................................................................. 9-35

(3) Installation ............................................................................................... 9-37
(4) Differential Drive Head ............................................................................ 9-38
(a) Description .......................................................................................... 9-38
(b) Removal.............................................................................................. 9-41
(c) Disassembly........................................................................................ 9-42
(d) Inspection............................................................................................ 9-49
(e) Assembly ............................................................................................ 9-50
(f) Installation........................................................................................... 9-69
(g) Gleason Gear Tooth System............................................................... 9-70
(h) Maintenance ....................................................................................... 9-71
(i) Special Tools....................................................................................... 9-71
(j) Diagnosis ............................................................................................ 9-71
(k) Diagnosis Chart .................................................................................. 9-72
(l) Special Torque Specifications ............................................................. 9-73
9.4 Rear Axle Group .......................................................................................... 9-74
(1) Rear Axle................................................................................................. 9-74
(2) Removal .................................................................................................. 9-76
(3) Installation ............................................................................................... 9-77
(4) Differential Drive Head ............................................................................ 9-78
(a) Description .......................................................................................... 9-78
(b) Operation ............................................................................................ 9-80
(c) Removal.............................................................................................. 9-80
(d) Disassembly........................................................................................ 9-82
(e) Inspection............................................................................................ 9-88
(f) Assembly ............................................................................................ 9-89
(g) Installation......................................................................................... 9-104
(h) Gleason Gear Tooth System............................................................. 9-105
(i) Maintenance ..................................................................................... 9-106
(j) Special Tools..................................................................................... 9-106
(k) Diagnosis .......................................................................................... 9-107
(l) Diagnosis Chart ................................................................................ 9-107
(m) Special Torque Specifications ........................................................... 9-108
9.5 Axle Group/Hub.......................................................................................... 9-109
(1) Operation............................................................................................... 9-109
(2) Removal and Disassembly .................................................................... 9-110
(3) Inspection .............................................................................................. 9-114
(4) Assembly and Installation...................................................................... 9-114
(5) Maintenance .......................................................................................... 9-121
(6) Special Tools ......................................................................................... 9-121
(7) Axle Diagnosis....................................................................................... 9-122
(8) Diagnosis Chart ..................................................................................... 9-122
(9) Special Torque Specifications................................................................ 9-122
9.6 Wheel Rim and Tire.................................................................................... 9-123
(1) Description and Operation..................................................................... 9-123
(2) Preparation for Servicing ....................................................................... 9-124
(3) Removing Tire and Rim Assembly from Machine.................................. 9-125
(4) Dismounting Tire from Rim .................................................................... 9-126
(5) Inspection .............................................................................................. 9-128
(6) Mounting Tire on Rim ............................................................................ 9-128

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(7) Mounting Tire and Rim Assembly on Machine ...................................... 9-129

(8) Air Tire Inflation...................................................................................... 9-130
(9) Nitrogen Tire Inflation ............................................................................ 9-131
(10) Tire Explosion Hazard ........................................................................... 9-133
(11) Maintenance .......................................................................................... 9-134
(12) Tire Care................................................................................................ 9-135
(13) Service Tools ......................................................................................... 9-136
(14) Tire Pressures ....................................................................................... 9-136
(15) Tubeless Tire Leak Diagnosis ............................................................... 9-137
(16) Special Torque Specification ................................................................. 9-137
10 Fuel System...............................................................................................10-1
10.1 Description ................................................................................................... 10-2
10.2 Operation ..................................................................................................... 10-4
10.3 Cleanliness Requirement ............................................................................. 10-5
10.4 Fuel Tank...................................................................................................... 10-6
(1) Removal .................................................................................................. 10-6
(2) Disassembly ............................................................................................ 10-8
(3) Assembly ................................................................................................. 10-8
(4) Installation ............................................................................................... 10-9
10.5 Maintenance............................................................................................... 10-10
(1) Fuel Filter............................................................................................... 10-10
(a) Removal............................................................................................ 10-10
(b) Installation......................................................................................... 10-10
(2) Fuel Filter - Water Separator ................................................................. 10-11
(3) Fuel Filler Cap ....................................................................................... 10-12
(a) Removal............................................................................................ 10-12
(b) Installation......................................................................................... 10-12
(4) Bleeding the Fuel System...................................................................... 10-13
(5) Special Tools ......................................................................................... 10-14
10.6 Troubleshooting.......................................................................................... 10-15
(1) SDP3 Fuel System Tests....................................................................... 10-19
10.7 Electronic Foot Pedal ................................................................................. 10-20
(1) Description............................................................................................. 10-20
(2) Removal ................................................................................................ 10-21
(3) Installation ............................................................................................. 10-22
(4) Maintenance .......................................................................................... 10-22
11 Hydraulic System...................................................................................... 11-1
11.1 Description ................................................................................................... 11-3
11.2 Main Hydraulic Valve.................................................................................... 11-3
(1) Description............................................................................................... 11-3
(a) System Relief...................................................................................... 11-7
(b) System Priority.................................................................................... 11-7
(c) Steering............................................................................................... 11-8
(d) Emergency Steering ........................................................................... 11-8
(e) Brake Charging ................................................................................... 11-8
(f) Service Brake...................................................................................... 11-8
(g) Park/Emergency Brake ....................................................................... 11-9
(h) Body Control ....................................................................................... 11-9
(i) Cooling Fan Drive System .................................................................. 11-9

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(j) Cold Start .......................................................................................... 11-10

(2) Removal ................................................................................................ 11-12
(3) Disassembly .......................................................................................... 11-15
(4) Assembly ............................................................................................... 11-17
(5) Installation ............................................................................................. 11-19
(6) Integral Valve Torque Values ................................................................. 11-22
(7) O-Ring Face Seals (ORFS)................................................................... 11-24
11.3 Hydraulic Tank............................................................................................ 11-25
(1) Description............................................................................................. 11-25
(2) Operation............................................................................................... 11-27
(3) Removal ................................................................................................ 11-29
(4) Disassembly and Inspection.................................................................. 11-32
(5) Assembly ............................................................................................... 11-34
(6) Installation ............................................................................................. 11-36
11.4 Main Hydraulic Pump ................................................................................. 11-37
(1) Description............................................................................................. 11-37
(2) Operation............................................................................................... 11-42
(3) Removal ................................................................................................ 11-45
(4) Disassembly .......................................................................................... 11-46
(a) Rear Pump........................................................................................ 11-46
(b) Front Pump ....................................................................................... 11-49
(c) Control Valve..................................................................................... 11-52
(5) Inspection .............................................................................................. 11-52
(a) Rotating Group.................................................................................. 11-52
(b) Pump Housing and Associated Parts ............................................... 11-53
(c) Driveshaft and Associated Parts....................................................... 11-53
(6) Assembly ............................................................................................... 11-54
(a) Front and Rear Pumps...................................................................... 11-54
(b) Control Valve..................................................................................... 11-59
(7) Installation ............................................................................................. 11-59
(8) Filling and Bleeding ............................................................................... 11-60
(9) Starting .................................................................................................. 11-62
(10) Pressure Checks ................................................................................... 11-62
(11) Troubleshooting ..................................................................................... 11-64
(12) Pump Settings ....................................................................................... 11-65
(a) Differential Pressure Setting ............................................................. 11-65
(b) Delivery Pressure Setting ................................................................. 11-66
(13) Adjustable O-Ring Seal Hydraulic Pipe Fittings .................................... 11-68
(14) Recommended Periodic Oil Change Periods and Oil Specifications ...... 11-70
(15) Wear Limits............................................................................................ 11-70
11.5 Maintenance............................................................................................... 11-70
(1) Checking Oil Level................................................................................. 11-70
(2) Replacing Filter Element ....................................................................... 11-71
(3) Transmission Cooler Fan Drive Troubleshooting .................................. 11-72
12 Steering System........................................................................................12-1
12.1 Description ................................................................................................... 12-3
12.2 Steering Column .......................................................................................... 12-6
(1) Description............................................................................................... 12-6
(2) Removal .................................................................................................. 12-7

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(3) Installation ............................................................................................... 12-8

12.3 Steering Control Valve................................................................................ 12-10
(1) Description............................................................................................. 12-10
(2) Operation............................................................................................... 12-12
(3) Removal ................................................................................................ 12-13
(4) Disassembly .......................................................................................... 12-14
(5) Inspection .............................................................................................. 12-15
(6) Assembly ............................................................................................... 12-15
(7) Installation ............................................................................................. 12-17
(8) Troubleshooting ..................................................................................... 12-19
12.4 Steering Cylinders...................................................................................... 12-20
(1) Description............................................................................................. 12-20
(2) Removal ................................................................................................ 12-22
(3) Disassembly .......................................................................................... 12-23
(4) Inspection .............................................................................................. 12-24
(5) Assembly ............................................................................................... 12-24
(6) Installation ............................................................................................. 12-25
(7) Maintenance .......................................................................................... 12-27
(8) Special Tools ......................................................................................... 12-27
12.5 Steering Lock ............................................................................................. 12-29
(1) Fit the Steering Lock.............................................................................. 12-29
(2) Stow the Steering Lock.......................................................................... 12-29
12.6 Emergency Steering Pump ........................................................................ 12-31
(1) Description............................................................................................. 12-31
(2) Operation............................................................................................... 12-32
(3) Removal ................................................................................................ 12-34
(4) Overhaul ................................................................................................ 12-35
(5) Disassembly .......................................................................................... 12-35
(a) Rotating Group.................................................................................. 12-37
(6) Inspection .............................................................................................. 12-38
(a) Rotating Group.................................................................................. 12-38
(b) Pump Housing and Associated Parts ............................................... 12-38
(c) Bearing Shells................................................................................... 12-38
(d) Driveshaft and Associated Parts....................................................... 12-39
(7) Assembly ............................................................................................... 12-39
(a) Rotating Group.................................................................................. 12-41
(8) Installation ............................................................................................. 12-42
12.7 Emergency Steering Valve Block ............................................................... 12-44
(1) Description............................................................................................. 12-44
(2) Removal ................................................................................................ 12-46
(3) Installation ............................................................................................. 12-47
12.8 System Hoses ............................................................................................ 12-49
(1) Removal ................................................................................................ 12-49
(a) LH Turn Supply Hose........................................................................ 12-49
(b) LH Turn LH Cylinder Supply Hose .................................................... 12-50
(c) LH Turn RH Cylinder Supply Hose ................................................... 12-51
(d) RH Turn Supply Hose ....................................................................... 12-51
(e) RH Turn LH Cylinder Supply Hose ................................................... 12-52
(f) RH Turn RH Cylinder Supply Hose................................................... 12-53
(g) Hydraulic Control Valve Load Sensing Hose .................................... 12-54

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(h) Steering Control Valve Supply Hose (1) ........................................... 12-55

(i) Steering Control Valve Supply Hose (2) ........................................... 12-55
(j) Steering Control Valve Return Hose (1)............................................ 12-56
(k) Steering Control Valve Return Hose (2)............................................ 12-57
(l) Emergency Steering Valve Supply Hose .......................................... 12-58
(m) Emergency Steering Pump Case Drain Hose................................... 12-58
(n) Emergency Steering Pump Load Sensing Hose............................... 12-59
(o) Emergency Steering Valve Pressure Hose....................................... 12-60
(p) Emergency Steering Valve Return Hose .......................................... 12-60
(2) Installation ............................................................................................. 12-62
(a) LH Turn Supply Hose........................................................................ 12-62
(b) LH Turn LH Cylinder Supply Hose .................................................... 12-63
(c) LH Turn RH Cylinder Supply Hose ................................................... 12-64
(d) RH Turn Supply Hose ....................................................................... 12-64
(e) RH Turn LH Cylinder Supply Hose ................................................... 12-65
(f) RH Turn RH Cylinder Supply Hose................................................... 12-66
(g) Hydraulic Control Valve Load Sensing Hose .................................... 12-67
(h) Steering Control Valve Supply Hose (1) ........................................... 12-68
(i) Steering Control Valve Supply Hose (2) ........................................... 12-68
(j) Steering Control Valve Return Hose (1)............................................ 12-69
(k) Steering Control Valve Return Hose (2)............................................ 12-70
(l) Emergency Steering Valve Supply Hose .......................................... 12-71
(m) Emergency Steering Pump Case Drain Hose................................... 12-71
(n) Emergency Steering Pump Load Sensing Hose............................... 12-72
(o) Emergency Steering Valve Pressure Hose....................................... 12-73
(p) Emergency Steering Valve Return Hose .......................................... 12-73
13 Body System .............................................................................................13-1
13.1 Description ................................................................................................... 13-2
13.2 Hydraulic Hoses and Tubes ......................................................................... 13-5
(1) Removal .................................................................................................. 13-5
(a) Main Hydraulic Valve Body Raise Hose.............................................. 13-5
(b) Main Hydraulic Valve Body Lower Hose ............................................. 13-6
(c) Main Hydraulic Valve Body Return Hose ............................................ 13-6
(d) Body Raise Tube ................................................................................ 13-7
(e) Body Lower Tube ................................................................................ 13-7
(f) Body Raise Hose ................................................................................ 13-8
(g) Body Lower Hose................................................................................ 13-8
(h) Cylinder Lower Tube ........................................................................... 13-9
(2) Installation ............................................................................................... 13-9
(a) Main Hydraulic Valve Body Raise Hose............................................ 13-10
(b) Main Hydraulic Valve Body Lower Hose ........................................... 13-11
(c) Main Hydraulic Valve Body Return Hose .......................................... 13-11
(d) Body Raise Tube .............................................................................. 13-12
(e) Body Lower Tube .............................................................................. 13-12
(f) Body Raise Hose .............................................................................. 13-13
(g) Body Lower Hose.............................................................................. 13-14
(h) Cylinder Lower Tube ......................................................................... 13-14
13.3 Body Control Lever .................................................................................... 13-15
(1) Description............................................................................................. 13-15

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(2) Removal ................................................................................................ 13-17

(3) Installation ............................................................................................. 13-18
13.4 Hoist Cylinders ........................................................................................... 13-19
(1) Description............................................................................................. 13-19
(2) Removal ................................................................................................ 13-21
(3) Disassembly .......................................................................................... 13-22
(4) Inspection .............................................................................................. 13-23
(5) Assembly ............................................................................................... 13-23
(6) Installation ............................................................................................. 13-24
(7) Maintenance .......................................................................................... 13-25
(8) Special Tools ......................................................................................... 13-25
14 Braking System.........................................................................................14-1
14.1 Description ................................................................................................... 14-4
14.2 Treadle Valve Pedal Assembly..................................................................... 14-8
(1) Description............................................................................................... 14-8
(a) Treadle Valve ...................................................................................... 14-9
(b) Service Brake Pedal Assembly......................................................... 14-11
(2) Operation............................................................................................... 14-12
(a) Normal Service Brake Application .................................................... 14-12
(b) Normal Service Brake Release......................................................... 14-12
(c) Emergency Stop Brake Application .................................................. 14-12
(d) Emergency Stop Brake Release....................................................... 14-13
(e) Advanced Engine Braking................................................................. 14-13
(3) Removal ................................................................................................ 14-14
(a) Treadle Valve .................................................................................... 14-14
(b) Service Brake Pedal Assembly......................................................... 14-15
(4) Disassembly .......................................................................................... 14-16
(a) Treadle Valve .................................................................................... 14-16
(b) Pedal Assembly ................................................................................ 14-17
(5) Assembly ............................................................................................... 14-18
(a) Pedal Assembly ................................................................................ 14-18
(b) Treadle Valve .................................................................................... 14-19
(6) Installation ............................................................................................. 14-20
(a) Pedal Assembly ................................................................................ 14-20
(b) Treadle Valve .................................................................................... 14-21
(7) Hose Removal ....................................................................................... 14-22
(a) Treadle Valve Pedal Assembly to Hydraulic Tank Hoses.................. 14-22
(b) Main Hydraulic Valve to Treadle Valve Pedal Assembly Hoses........ 14-23
(8) Hose Installation .................................................................................... 14-24
(a) Treadle Valve Pedal Assembly to Hydraulic Tank Hoses.................. 14-24
(b) Main Hydraulic Valve to Treadle Valve Pedal Assembly Hoses........ 14-25
14.3 Service Brakes ........................................................................................... 14-27
(1) Description and Operation..................................................................... 14-27
(2) Removal and Disassembly .................................................................... 14-29
(3) Assembly and Installation...................................................................... 14-34
(4) Special Tools ......................................................................................... 14-41
(5) Hose Removal ....................................................................................... 14-42
(a) Service Brakes Tractor Supply Hose ................................................ 14-42
(b) Service Brakes Front Axle Hoses ..................................................... 14-43

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(c) Remote Bleed Hoses ........................................................................ 14-44

(d) Service Brakes Tractor Supply Hose ................................................ 14-44
(e) Service Brakes Tractor Interface Hose ............................................. 14-45
(f) Service Brakes Trailer Supply Tube.................................................. 14-46
(g) Service Brakes Centre Axle Hoses................................................... 14-47
(h) Centre Axle Manifold Block to Centre Axle Service Brake
Hoses................................................................................................ 14-47
(i) Service Brakes Trailer Supply Hose to Rear Axle Manifold
Block ................................................................................................. 14-48
(j) Service Brakes Rear Axle Hoses...................................................... 14-49
(6) Hose Installation .................................................................................... 14-51
(a) Service Brakes Tractor Supply Hose ................................................ 14-51
(b) Service Brakes Front Axle Hoses ..................................................... 14-52
(c) Remote Bleed Hoses ........................................................................ 14-53
(d) Service Brakes Tractor Supply Hose ................................................ 14-54
(e) Service Brakes Tractor Interface Hose ............................................. 14-55
(f) Service Brakes Trailer Supply Tube.................................................. 14-56
(g) Service Brakes Centre Axle Hoses................................................... 14-57
(h) Centre Axle Manifold Block to Centre Axle Service Brake
Hoses................................................................................................ 14-58
(i) Service Brakes Trailer Supply Hose to Rear Axle Manifold
Block ................................................................................................. 14-59
(j) Service Brakes Rear Axle Hoses...................................................... 14-60
(7) Bleeding the Service Brakes ................................................................. 14-61
14.4 Accumulators ............................................................................................. 14-62
(1) Description............................................................................................. 14-62
(2) Removal ................................................................................................ 14-65
(3) Disassembly .......................................................................................... 14-67
(4) Inspection .............................................................................................. 14-68
(5) Assembly ............................................................................................... 14-69
(6) Installation ............................................................................................. 14-70
(7) Discharging............................................................................................ 14-72
(8) Charging ................................................................................................ 14-73
(9) Maintenance .......................................................................................... 14-76
(a) Testing Nitrogen Pressure................................................................. 14-76
(b) Testing Charge Valve for Leakage .................................................... 14-77
(10) Special Tools ......................................................................................... 14-79
(11) Hose Removal ....................................................................................... 14-80
(a) Accumulator to Main Hydraulic Valve Hoses .................................... 14-80
(12) Hose Installation .................................................................................... 14-82
(a) Accumulator to Main Hydraulic Valve Hoses .................................... 14-82
14.5 Interlock Solenoid Valve ............................................................................. 14-84
(1) Removal ................................................................................................ 14-84
(2) Installation ............................................................................................. 14-85
(3) Hose Removal ....................................................................................... 14-87
(a) Main Hydraulic Valve to Interlock Solenoid Valve Hose.................... 14-87
(b) Interlock Solenoid Valve to Treadle Valve Pedal Assembly
Hose.................................................................................................. 14-88
(c) Interlock Solenoid Valve to Hydraulic Tank Hose.............................. 14-89
(4) Hose Installation .................................................................................... 14-90

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(a)Main Hydraulic Valve to Interlock Solenoid Valve Hose.................... 14-90

(b)Interlock Solenoid Valve to Treadle Valve Pedal Assembly
Hose.................................................................................................. 14-91
(c) Interlock Solenoid Valve to Hydraulic Tank Hose.............................. 14-92
14.6 Parking Brake............................................................................................. 14-93
(1) Description............................................................................................. 14-93
(2) Removal ................................................................................................ 14-95
(3) Disassembly .......................................................................................... 14-96
(4) Inspection .............................................................................................. 14-97
(5) Assembly ............................................................................................... 14-98
(6) Installation ........................................................................................... 14-100
(7) Hose Removal ..................................................................................... 14-102
(a) Parking Brake Tractor Supply Hose................................................ 14-102
(b) Parking Brake Tractor Interface Hose............................................. 14-103
(c) Parking Brake Trailer Supply Tube ................................................. 14-103
(d) Parking Brake Trailer Supply Hose ................................................. 14-104
(8) Hose Installation .................................................................................. 14-106
(a) Parking Brake Tractor Supply Hose................................................ 14-106
(b) Parking Brake Tractor Interface Hose............................................. 14-107
(c) Parking Brake Trailer Supply Tube ................................................. 14-108
(d) Parking Brake Trailer Supply Hose ................................................. 14-108
(9) Bleeding the Parking Brake ................................................................. 14-110
15 Electrical System ......................................................................................15-1
15.1 Circuit Diagrams and Component Designations .......................................... 15-3
15.2 Main Controller Unit (MCU) .......................................................................... 15-9
(1) Description............................................................................................... 15-9
(2) Operating States.................................................................................... 15-10
(3) Error Codes ........................................................................................... 15-11
(4) Removal ................................................................................................ 15-15
(5) Installation ............................................................................................. 15-16
(6) Programming ......................................................................................... 15-17
(7) Diagnostics ............................................................................................ 15-20
(8) Special Tools ......................................................................................... 15-35
15.3 Transmission Controller Unit (TCU) ........................................................... 15-36
(1) Description............................................................................................. 15-37
(2) Removal ................................................................................................ 15-37
(3) Installation ............................................................................................. 15-38
(4) Diagnostics ............................................................................................ 15-38
15.4 Dashboard Display..................................................................................... 15-39
(1) Removal ................................................................................................ 15-39
(2) Installation ............................................................................................. 15-40
(3) Programming ......................................................................................... 15-41
(4) Diagnostics ............................................................................................ 15-43
15.5 S6 Engine Management System................................................................ 15-44
(1) Diagnostics ............................................................................................ 15-44
(2) Scania Diagnos & Programmer SDP 3.................................................. 15-44
15.6 Printed Circuit Board (PCB) ....................................................................... 15-48
(1) Removal ................................................................................................ 15-49
(a) Disassembly...................................................................................... 15-50
(b) Assembly .......................................................................................... 15-50

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(2) Installation ............................................................................................. 15-51

15.7 DC/DC Convertor ....................................................................................... 15-52
(1) Description............................................................................................. 15-52
(2) Removal ................................................................................................ 15-53
(3) Installation ............................................................................................. 15-54
15.8 Battery Box Assembly ................................................................................ 15-55
(1) Description............................................................................................. 15-56
(2) Removal ................................................................................................ 15-57
(3) Disassembly .......................................................................................... 15-58
(4) Assembly ............................................................................................... 15-58
(5) Installation ............................................................................................. 15-58
(6) Battery ................................................................................................... 15-59
(a) Removal............................................................................................ 15-59
(b) Installation......................................................................................... 15-60
(c) Maintenance ..................................................................................... 15-61
(7) Fuse Box ............................................................................................... 15-62
(a) Description ........................................................................................ 15-62
(b) Removal............................................................................................ 15-62
(c) Installation......................................................................................... 15-64
15.9 Control and Display Elements .................................................................... 15-65
(1) Controls and Instruments ...................................................................... 15-65
(2) Displays ................................................................................................. 15-66
(a) Functional Description ...................................................................... 15-66
(b) Menus ............................................................................................... 15-70
(3) Switches ................................................................................................ 15-75
(4) Controls ................................................................................................. 15-79
15.10Switches and Sensors................................................................................ 15-81
(1) Description............................................................................................. 15-82
16 Chassis ......................................................................................................16-1
16.1 Frames ......................................................................................................... 16-3
(1) Description............................................................................................... 16-4
(2) Inspection and Maintenance.................................................................... 16-5
16.2 Articulation and Oscillation Pivot .................................................................. 16-7
(1) Description and Operation....................................................................... 16-9
(2) Thru-Drive Driveshaft .............................................................................. 16-9
(a) Removal and Disassembly ................................................................. 16-9
(b) Inspection.......................................................................................... 16-10
(c) Assembly and Installation ................................................................. 16-11
(3) Articulation Components ....................................................................... 16-15
(a) Disconnecting Front and Rear Frames ............................................. 16-15
(b) Disassembly...................................................................................... 16-16
(c) Inspection.......................................................................................... 16-17
(d) Assembly .......................................................................................... 16-17
(e) Connecting Front and Rear Frames ................................................. 16-19
(4) Oscillation Components......................................................................... 16-21
(a) Disconnecting Front and Rear Frames ............................................. 16-21
(b) Disassembly...................................................................................... 16-23
(c) Inspection.......................................................................................... 16-24
(d) Assembly .......................................................................................... 16-24

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(e)
Connecting Front and Rear Frames ................................................. 16-27
(5) Maintenance .......................................................................................... 16-28
(a) Every 50 Hours ................................................................................. 16-29
(b) Every 250 Hours ............................................................................... 16-29
(c) Drain Gear Oil from the Pivot Assembly ........................................... 16-30
(d) Fill the Pivot Assembly with Gear Oil ................................................ 16-30
(e) Grease the Taper Roller Bearings..................................................... 16-30
(f) Grease the Pivot Assembly Bushes.................................................. 16-30
(6) Special Tools ......................................................................................... 16-31
(7) Special Torque Specifications................................................................ 16-31
16.3 Hood........................................................................................................... 16-32
(1) Removal ................................................................................................ 16-34
(2) Installation ............................................................................................. 16-36
(3) Maintenance .......................................................................................... 16-37
(4) Special Tools ......................................................................................... 16-37
(5) Raising the Hood ................................................................................... 16-38
(6) Lowering the Hood ................................................................................ 16-39
16.4 Mudflaps..................................................................................................... 16-40
(1) Removal ................................................................................................ 16-43
(a) LH Bottom Rear Mudflap .................................................................. 16-43
(b) LH Top Rear Mudflap ........................................................................ 16-44
(c) LH Top Front Mudflap ....................................................................... 16-44
(d) LH Wheel Arch Mudflap .................................................................... 16-44
(e) RH Bottom Rear Mudflap.................................................................. 16-45
(f) RH Top Rear Mudflap ....................................................................... 16-45
(g) RH Top Front Mudflap....................................................................... 16-46
(h) RH Wheel Arch Mudflap ................................................................... 16-46
(2) Installation ............................................................................................. 16-47
(a) LH Top Rear Mudflap ........................................................................ 16-47
(b) LH Bottom Rear Mudflap .................................................................. 16-47
(c) LH Top Front Mudflap ....................................................................... 16-48
(d) LH Wheel Arch Mudflap .................................................................... 16-48
(e) RH Top Rear Mudflap ....................................................................... 16-49
(f) RH Bottom Rear Mudflap.................................................................. 16-49
(g) RH Top Front Mudflap....................................................................... 16-50
(h) RH Wheel Arch Mudflap ................................................................... 16-50
16.5 Handrails and Fenders............................................................................... 16-51
(1) Removal ................................................................................................ 16-51
(a) LH Kick Plate .................................................................................... 16-51
(b) LH Handrail Filler Tube ..................................................................... 16-51
(c) LH Forward Outer Handrail............................................................... 16-51
(d) LH Rear Outer Handrail .................................................................... 16-52
(e) LH Rear Inner Handrail ..................................................................... 16-52
(f) LH Lower Step Assembly.................................................................. 16-52
(g) LH Fender Assembly ........................................................................ 16-53
(h) LH Step Support Arm Assembly ....................................................... 16-53
(i) RH Kick Plate.................................................................................... 16-54
(j) RH Forward Outer Handrail .............................................................. 16-54
(k) RH Rear Outer Handrail.................................................................... 16-54
(l) RH Rear Inner Handrail .................................................................... 16-55

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(m) RH Lower Step Assembly ................................................................. 16-55

(n) Adblue Cover Assembly.................................................................... 16-55
(o) RH Fender Assembly........................................................................ 16-56
(p) RH Step Support Arm Assembly....................................................... 16-56
(2) Installation ............................................................................................. 16-57
(a) LH Step Support Arm Assembly ....................................................... 16-57
(b) LH Fender Assembly ........................................................................ 16-57
(c) LH Lower Step Assembly.................................................................. 16-58
(d) LH Forward Outer Handrail............................................................... 16-58
(e) LH Rear Outer Handrail .................................................................... 16-58
(f) LH Rear Inner Handrail ..................................................................... 16-59
(g) LH Handrail Filler Tube ..................................................................... 16-59
(h) LH Kick Plate .................................................................................... 16-59
(i) RH Step Support Arm Assembly....................................................... 16-60
(j) RH Fender Assembly........................................................................ 16-60
(k) Adblue Cover Assembly ................................................................... 16-61
(l) RH Lower Step Assembly ................................................................. 16-61
(m) RH Forward Outer Handrail .............................................................. 16-61
(n) RH Rear Outer Handrail.................................................................... 16-62
(o) RH Rear Inner Handrail .................................................................... 16-62
(p) RH Kick Plate.................................................................................... 16-62
17 Suspension System..................................................................................17-1
17.1 Front Suspension ......................................................................................... 17-2
(1) Description............................................................................................... 17-3
(2) Removal .................................................................................................. 17-3
(a) Linkage ............................................................................................... 17-4
(b) Shock Absorber and Mount ................................................................ 17-4
(c) Bracket Assembly ............................................................................... 17-5
(3) Installation ............................................................................................... 17-6
(a) Bracket Assembly ............................................................................... 17-6
(b) Linkage ............................................................................................... 17-7
(c) Shock Absorber and Mount ................................................................ 17-8
(4) Adjustments........................................................................................... 17-10
(5) Special Torque Specifications................................................................ 17-11
17.2 Rear Suspension........................................................................................ 17-12
(1) Description............................................................................................. 17-15
(2) Removal ................................................................................................ 17-15
(a) Linkage ............................................................................................. 17-15
(b) Mount ................................................................................................ 17-16
(c) Equalizer Beam................................................................................. 17-17
(d) Bracket Assembly ............................................................................. 17-17
(3) Installation ............................................................................................. 17-18
(a) Equalizer Beam................................................................................. 17-18
(b) Bracket Assembly ............................................................................. 17-19
(c) Mount ................................................................................................ 17-20
(d) Linkage ............................................................................................. 17-21
(4) Maintenance .......................................................................................... 17-23
(5) Special Torque Specifications................................................................ 17-23
18 Cooling System.........................................................................................18-1

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18.1 Description ................................................................................................... 18-2

18.2 Brake Cooling............................................................................................... 18-4
(1) Description............................................................................................. 18-10
(2) Operation............................................................................................... 18-10
(3) Drain the System ................................................................................... 18-12
(a) Oil Cooled Disc Brakes ..................................................................... 18-13
(b) Cooler ............................................................................................... 18-13
(c) Cooling Lines .................................................................................... 18-14
(d) Cooling Oil Tank................................................................................ 18-15
(4) Removal ................................................................................................ 18-15
(a) Oil Cooled Disc Brakes ..................................................................... 18-16
(b) Cooler ............................................................................................... 18-16
(c) Brake Cooling Lines.......................................................................... 18-16
(d) Triple Pump....................................................................................... 18-17
(e) Ancillaries.......................................................................................... 18-18
(5) Disassembly .......................................................................................... 18-21
(a) Triple Pump....................................................................................... 18-21
(b) Relief Valve ....................................................................................... 18-24
(6) Inspection .............................................................................................. 18-25
(7) Assembly ............................................................................................... 18-26
(a) Triple Pump....................................................................................... 18-26
(b) Relief Valve ....................................................................................... 18-27
(8) Installation ............................................................................................. 18-28
(a) Oil Cooled Disc Brakes ..................................................................... 18-28
(b) Cooler ............................................................................................... 18-28
(c) Brake Cooling Lines.......................................................................... 18-29
(d) Triple Pump....................................................................................... 18-30
(e) Ancillaries.......................................................................................... 18-30
(f) Priming.............................................................................................. 18-31
(9) Fault Diagnosis...................................................................................... 18-33
(10) Special Tools ......................................................................................... 18-33
(11) Special Torque Specifications................................................................ 18-34
19 Operator's Compartment .........................................................................19-1
19.1 Cab............................................................................................................... 19-2
(1) Description............................................................................................... 19-7
(2) Removal .................................................................................................. 19-8
(3) Installation ............................................................................................. 19-10
(4) Tilting the Cab........................................................................................ 19-12
(5) Lowering the Cab .................................................................................. 19-14
(6) Mirror Arms............................................................................................ 19-15
(a) Removal............................................................................................ 19-15
(b) Installation......................................................................................... 19-15
(7) Replacing Glass .................................................................................... 19-16
(a) Water Leaks ...................................................................................... 19-17
(8) Maintenance .......................................................................................... 19-17
(9) Service Tools ......................................................................................... 19-17
19.2 Operator's Seat .......................................................................................... 19-18
(1) Description............................................................................................. 19-18
(2) Adjustment............................................................................................. 19-20

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(3) Operation............................................................................................... 19-21

(4) Removal ................................................................................................ 19-22
(5) Disassembly .......................................................................................... 19-22
(a) Horizontal Shock Absorber ............................................................... 19-23
(b) Vertical Shock Absorber.................................................................... 19-24
(c) Compressor ...................................................................................... 19-25
(d) Level Controller................................................................................. 19-26
(6) Inspection .............................................................................................. 19-27
(7) Assembly ............................................................................................... 19-27
(8) Installation ............................................................................................. 19-28
(9) Maintenance .......................................................................................... 19-28
(10) Special Torque Specifications................................................................ 19-28
19.3 Instructor's Seat ......................................................................................... 19-29
(1) Description............................................................................................. 19-29
(2) Removal ................................................................................................ 19-31
(3) Installation ............................................................................................. 19-32
(4) Maintenance .......................................................................................... 19-32
20 Heating, Ventilation and Air Conditioning..............................................20-1
20.1 HVAC Cab Distribution ................................................................................. 20-2
(1) Description............................................................................................... 20-2
20.2 HVAC Combi-unit ......................................................................................... 20-4
(1) Description............................................................................................... 20-4
20.3 Heating......................................................................................................... 20-5
(1) Description............................................................................................... 20-5
20.4 Air Conditioning............................................................................................ 20-6
(1) Description............................................................................................... 20-6
(2) Maintenance .......................................................................................... 20-10
(a) Discharging the System .................................................................... 20-12
(b) Charging New or Completely Empty Systems .................................. 20-14
(c) Final Charging of the System............................................................ 20-15
(3) Re-Start Procedure................................................................................ 20-15
(4) Troubleshooting ..................................................................................... 20-16
21 Body...........................................................................................................21-1
21.1 Body and Mounting ...................................................................................... 21-2
(1) Description............................................................................................... 21-3
(2) Operation................................................................................................. 21-4
(3) Removal .................................................................................................. 21-5
(4) Installation ............................................................................................... 21-6
(5) Body Shimming ....................................................................................... 21-7
(6) Raise the Body ........................................................................................ 21-8
(7) Lower the Body........................................................................................ 21-9
21.2 Body Prop .................................................................................................. 21-10
(1) Removal ................................................................................................ 21-10
(2) Installation ............................................................................................. 21-11
(3) Deploy the Body Prop............................................................................ 21-12
(4) Lower the Body Prop ............................................................................. 21-13
21.3 Proximity Switch......................................................................................... 21-15
(1) Description............................................................................................. 21-15
(2) Removal ................................................................................................ 21-15

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(3) Installation ............................................................................................. 21-16

21.4 Mudflaps..................................................................................................... 21-18
(1) Description............................................................................................. 21-18
(2) Removal ................................................................................................ 21-18
(3) Installation ............................................................................................. 21-19
21.5 Chain Operated Tailgate Option................................................................. 21-20
(1) Description............................................................................................. 21-20
(2) Removal ................................................................................................ 21-22
(3) Installation ............................................................................................. 21-23
(4) Maintenance .......................................................................................... 21-25
22 Miscellaneous ...........................................................................................22-1
22.1 Welding ........................................................................................................ 22-2
(1) General Welding Procedure .................................................................... 22-3
(a) Repair of Defects Out With the Vicinity of Alloy Steel Castings.......... 22-3
(b) Repair of Defects in Alloy Steel Castings and in the Welds Joining
Steel Castings..................................................................................... 22-3
22.2 Service Tools................................................................................................ 22-4
22.3 Standard Bolt and Nut Torque Specifications............................................... 22-5
(1) Self-Locking Fasteners............................................................................ 22-8
(2) Minimum Prevailing Torque - Removal.................................................... 22-9
22.4 Storage....................................................................................................... 22-10
(1) Temporary Storage ................................................................................ 22-10
(2) Under Six Months Extended Storage ................................................... 22-11
(3) Over Six Months Extended Storage ...................................................... 22-12
(4) Removal from Extended Storage .......................................................... 22-12
22.5 Disposal ..................................................................................................... 22-14
Appendix A Electrical Schematic Diagrams .................................................... A-1
Appendix B Hydraulic System Schematic Diagram ........................................ B-1
Brake Pedal - Detailed View...........................................................................B-3
Glossary of Terms
Index

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 Introduction 1

Table of Content
1 Introduction.................................................................................................1-1
1.1 Maintenance Manual Information................................................................... 1-2
1.2 Safety Information .......................................................................................... 1-2
(1) Proposition 65 Warnings............................................................................ 1-3
1.3 Identification Plate.......................................................................................... 1-3
1.4 Intended Use.................................................................................................. 1-4
(1) Basic Operation ......................................................................................... 1-4
(2) Operating Underground............................................................................. 1-4
(3) Environmental Requirements .................................................................... 1-4
1.5 Prohibited Use................................................................................................ 1-4
1.6 Warranty......................................................................................................... 1-5
1.7 Copyright........................................................................................................ 1-5
1.8 Theft Deterrent Practices ............................................................................... 1-6

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1 Introduction

1 Introduction
1.1 Maintenance Manual Information
NOTICE
• Only trained competent personnel must be allowed to operate this vehicle.
• The service engineer is responsible for adherence to and familiarization of the contents of
the Maintenance Manual and any Local / National regulations before servicing or operating
this vehicle.

This manual helps and guides service personnel to familiarize themselves with the safety,
technical data, maintenance schedules, recommended inspections and lubricants and all major
systems for Terex articulated trucks. Service personnel must read and understand this manual
before servicing or maintaining the machine.
All information, illustrations, and specifications contained in this publication are based on the
latest product information available at the time of publication. The right is reserved to do
changes at any time without notice.
Continuing improvement and advancement of the design may cause changes to your machine
which are not included in this publication. Each publication is reviewed and revised, as required,
to update and include these changes in later editions.
While reading this manual, you will notice references to controls and equipment which are not
found on all machines. It is important that you know your machine and its equipment and
how to operate it properly.
There is a dealer serving every part of the world where these products are sold. Your dealer
is ready to provide you with any additional information needed and must be consulted for
additional publications for this machine.
1.2 Safety Information
This manual describes general inspections, servicing, and operation with the normal safety
precautions required for normal servicing and operating conditions. It is not a guide however,
for other than normal conditions or situations, and therefore, servicemen and operators must be
safety conscious and alert to recognize potential servicing or operating safety hazards. Take
necessary precaution which assures safe servicing and operation of the machine.

� CAUTION
• These machines are equipped with cylinders containing compressed nitrogen gas.
Transportation of these machines by any method can require a special permit from the
appropriate authority of the country involved. Consult your dealer for details.

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 Introduction 1

(1) Proposition 65 Warnings

� WARNING
• Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
• Battery posts, terminals, and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm. Wash
hands after handling.

1.3 Identification Plate

Information regarding the machine model, code, and chassis serial number is found on the unit
serial number plate on the rear right of the front frame. The machine model and serial number
must always be referenced in any correspondence with your dealer or factory. For the machine
and major components serial plates information and location, refer to Figure 1.1.
1 3 4

TRUCKS

2 7 6 5 8 9
MOT05071

Figure 1.1 - Machine and Major Component Identification Plate Location

1. Engine 4. Seat 7. Front Axle
2. Transmission 5. Product Identification 8. Centre Axle
Plate
3. ROPS/FOPS 6. Dropbox 9. Rear Axle

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1 Introduction

1.4 Intended Use

� WARNING
• Unauthorized presence of persons in the danger zones, outside the operator's field of vision
is not permissible. Refer to 2.6 Mirrors and CCTV on page 2-28.

(1) Basic Operation

The basic machine is intended to be used under normal conditions, that is, outdoors, above
ground, off-road, for earthmoving, and in an ambient temperature between -18 °C (-0.4 °F) and
45 °C (113 °F) with maintained performance.
For use on public roads the machine must be adapted according to governing national
legislation.
If it is used for other purposes or in potentially dangerous conditions, e.g., explosive and/or
flammable environments or areas with asbestos dust, special safety regulations must
be followed and the machine must be equipped for such use and handling. Contact the
manufacturer/dealer for more information.
(2) Operating Underground
The need for ventilation of the exhausts must be checked before the machine is used in tunnels
or other underground operations. Other legislation and rules may be applicable, such as
national and labour laws.
(3) Environmental Requirements
Be aware of the environment when operating and during service and maintenance of the
machine. Always follow local and national environmental legislation applicable to all handling
of the machine.
1.5 Prohibited Use
� CAUTION
• Any use other than stated in 1.4 Intended Use on page 1-4 can be considered impermissible.
• The manufacturer cannot be held liable for any resulting damage. The risk is borne by
the user alone.

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 Introduction 1

1.6 Warranty
Your dealer registers you as the owner with Terex Trucks at the time of sale. If you have any
queries, consult your dealer in the first instance.
The warranty period for the machine’s replacement parts, under normal circumstances, covers
the first 24 months or 6000 hours of use. This period begins the day the machine is handed
over or put into operation.
The machine must be used correctly and serviced to the manufacturers recommendations as
authorised by Terex Trucks.
The correct grades of fuels, lubricants, and coolants must be used always and must be new
and clean when added to the machine. Failure to follow these rules can lead to failure of the
machine.
Servicing and repairs must only be carried out by trained and experienced dealer personnel.
This will ensure successful maintenance of the machine.
Only genuine approved spare parts must be used when the machine is serviced or repaired.
All claims during the warranty period are accepted only if the recommended maintenance and
service work has been carried out at the specified intervals.
It is important regular maintenance and service work is carried out after the warranty period
has expired. Regular maintenance is done to make sure that the machine is in good working
condition and does not cause unnecessary downtime and expense.
Modifications to this machine and/or changes to the specification which is not factory approved,
invalidates the machines warranty and possibly your own insurance cover.
1.7 Copyright
For further information on the subject matter detailed within this Maintenance Manual, please
refer to Terex Trucks Operations Manuals and Illustrated Parts Catalogue.
Alternatively, please contact;
Technology Department
Terex Trucks
Newhouse Industrial Estate
Motherwell, ML1 5RY
Tel; +44 (0) 1698 503117
email: stephen.charlesworth@terextrucks.com
www.terextrucks.com
The illustrations, technical information, data, and descriptive text in this manual, to the best of
our knowledge, were correct at the time of print. The right to change specifications, equipment,
and maintenance instructions at any time without notice, is reserved as part of the Terex Trucks
policy of continuous development and improvement of the product.
No part of this publication may be reproduced, transmitted in any form - electronic, mechanical,
photocopying, recording, translating or by any other means without prior permission of the
Technology Department - Terex Trucks.
Please refer to TEREX Specification Sheets or consult Factory Representatives to ensure
that information is current.

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1 Introduction

1.8 Theft Deterrent Practices

The owner/operator must take the following precautions to discourage theft, to aid in the
recovery of stolen machine, or to reduce vandalism.
(1) Actions to Discourage Theft and Vandalism
• Ensure that the battery master switch is in the OFF position.
• At night lock all doors and attach, secure or lock all anti-vandalism and anti-theft devices
on the machine.
• Immobilize the machine by removing a critical electrical or starting system device.
• Upon receipt of a machine, record the machine serial number and the serial numbers
of all major components and attachments. Keep this list up to date and filed in a safe
location for fast retrieval.
• Place a decal or notice on the machine that all serial numbers are recorded.
• Discourage the thief! Inspect the gates and fences of the machinery storage yard or
construction site. Keep machines in well-lit areas and ask the local law enforcement
authorities for make frequent checks around the storage yard or work site.
• Establish liaison with neighbors and ask them to watch equipment left at job sites and to
report any suspicious activities to the local law enforcement authorities.
• To detect losses or vandalism, make frequent inventories of machines.
(2) Actions to Aid in Recovery of Stolen Machines
• If there is a theft, immediately notify the law enforcement authorities having jurisdiction.
Provide the investigating officer with name, type of equipment, chassis, and serial numbers
of major attachments and components. It is helpful to show the investigating officer,
an Operations Manual, photographs, and advertising, to familiarize the officer with the
appearance of the machine.
• Report the theft to the insurance company. Provide the model and all serial numbers.
• Report the model and serial numbers of the stolen machine to a dealer handling the
respective line of equipment. Request that the dealer forward this same information to the
equipment manufacturer.

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 Safety 2

Table of Content
2 Safety ...........................................................................................................2-1
2.1 Safety Alert Symbol........................................................................................ 2-2
2.2 General Safety ............................................................................................... 2-2
(1) Important Safety Notice ............................................................................. 2-3
(2) Safety Hazard Classifications.................................................................... 2-4
(3) Description of Safety Symbols................................................................... 2-5
2.3 Position of Safety Decals on the Machine...................................................... 2-6
2.4 Personal Safety............................................................................................ 2-13
(1) Read and Understand this Maintenance Manual and All Safety
Signs........................................................................................................ 2-13
(2) Personal Protective Equipment ............................................................... 2-14
2.5 Work Area Safety ......................................................................................... 2-15
(1) General Work Area Guidelines ................................................................ 2-15
(a) General Fire Precautions .................................................................... 2-15
(b) Flammable Fluid Precautions ............................................................. 2-15
(c) Mounting and Dismounting ................................................................. 2-16
(2) Measures for Protection Against Lightning.............................................. 2-16
(3) Transportation Safety .............................................................................. 2-17
(a) Roading............................................................................................... 2-17
(b) Articulation and Oscillation Lock ......................................................... 2-17
(c) Machine Lifting Precautions................................................................ 2-17
(d) Machine Tie Down Precautions .......................................................... 2-18
(4) Operation Safety...................................................................................... 2-19
(a) Pre-Starting and Starting .................................................................... 2-19
(b) Operating ............................................................................................ 2-20
(5) Accumulator Safety ................................................................................. 2-22
(6) Electrical Safety....................................................................................... 2-23
(7) Refrigerant............................................................................................... 2-24
(8) Maintenance Safety................................................................................. 2-25
(a) Body Prop ........................................................................................... 2-26
2.6 Mirrors and CCTV ........................................................................................ 2-28
2.7 Wheels and Tires ......................................................................................... 2-29
2.8 Lubrication and Servicing............................................................................. 2-31

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2 Safety

2 Safety
2.1 Safety Alert Symbol
The Safety Alert System identifies important safety messages in this manual. When you see
this symbol, BE ALERT! Your safety is involved. Carefully read the message that follows and
inform other operators. Refer to Figure 2.1.

Figure 2.1 - Safety Alert Symbol

2.2 General Safety
� CAUTION
• These machines are equipped with cylinders containing compressed nitrogen gas.
Transportation of these machines by any method requires a special permit from the
appropriate authority of the country involved. Consult your dealer for details.

The machine must be properly operated and maintained to keep it in a safe, efficient operating
condition. Be sure that all controls are free of mud, grease, or other matter that causes
slips hazardous to the operator, serviceman, or other personnel or equipment. Report all
malfunctions to those personnel who are responsible for maintenance, and, do not operate the
equipment until corrected. Normal service or maintenance performed as required can prevent
unexpected and unnecessary downtime.

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 Safety 2

(1) Important Safety Notice

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

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, CAUTIONS and
NOTICES 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,
CAUTIONS and NOTICES 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.

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2 Safety

(2) Safety Hazard Classifications

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

� DANGER
DANGER indicates an imminently hazardous situation. If this situation is not avoided, it will
result in death or serious injury.

� WARNING
WARNING indicates a potentially hazardous situation. If this situation is not avoided, it could
result in death or serious injury.

� CAUTION
CAUTION indicates a potentially hazardous situation. If this situation is not avoided, it may
result in minor or moderate injury.

NOTICE
NOTICE indicates a potentially hazardous situation. If this situation is not avoided, it can result
in property damage.

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 Safety 2

(3) Description of Safety Symbols

Table 2.1 - Description of Safety Symbols
Symbol Description
Entanglement Hazard
Entanglement in drive shaft.

Crush Hazard
Crush from wheel machine run over.

Fall Hazard
Falling from a height.

Hearing Hazard
Loss or degradation of hearing.

Electrocution Hazard
Electric shock/ electrocution.

Explosion Hazard
Explosion during an operation or service procedure.

Flying Material Hazard

Struck by falling or flying material.

Injection Hazard
Skin injection from high pressure fluid.

Burn Hazard
Burns from corrosive material.

Burn Hazard
Burns from hot surface or liquid.

Inhalation Hazard
Inhalation of poisonous/ toxic fumes or dust.

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2 Safety

2.3 Position of Safety Decals on the Machine

There are a number of safety decals located on the machine, Refer to Table 2.2. Both ISO and
ANSI safety signs are shown. It is important that the warnings on these signs are carefully
noted before carrying out any work with or on the machine. If any decals are illegible or
damaged, they must be replaced immediately.
These safety decals are placed at various locations on the machine, Refer to Figure 2.2 and
Figure 2.3. The numbers in the figures refer to the item number in Table 2.2.

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 Safety 2

STOP 15
10 20
5 25 RE

AR

0 30
rpm 1
P 2

TA300-A11 GIGA V01.04.01

MCU HV008 SV08.08.08

40
30 km/h 50

88.88.2011 88.88.88
20

10

0
10

0
20
mph
30
40

50
60

70

80
ON
WINDOW

17

3
2

1
9
7
10 5

13

MOT05072

Figure 2.2 - Safety Decal Locations

TRUCKS

14 5 6 12

15 5

11

16

OIL FILTER
8
INSIDE BATTERY BOX HEADER TANK
MOT05073

Figure 2.3 - Safety Decal Locations

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2 Safety

Table 2.2 - Safety Decals

Decal
Item
ISO ANSI

Crush Hazard Warning - Seat Belt Crush Hazard Warning - Seat Belt
2172

Power Lines Warning Danger Power Lines

1817

Park Brake Warning Park Brake Warning

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 Safety 2

Decal
Item
ISO ANSI

Fall Hazard Warning Fall Hazard Warning

Warning Hot Warning Hot

Crush From Articulation Warning Crush From Articulation Warning

1818

Skin Injection Warning Skin Injection Warning

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2 Safety

Decal
Item
ISO ANSI
1835

Reverse Warning Reverse Warning

1815

Accumulator Warning Accumulator Warning

10

Pressurised Accumulator Warning Pressurised Accumulator Warning

11

Burn Hazard, Radiator Caution Burn Hazard, Radiator Caution

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 Safety 2

Decal
Item
ISO ANSI
1812

12

Crush Hazard Warning Crush Hazard Warning

13

Fall Hazard Warning Fall Hazard Warning

14

Batteries Warning Batteries Warning

15

Battery Isolation Battery Isolation

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2 Safety

Decal
Item
ISO ANSI

16

Warning Hot Warning Hot

MOT04580

<10 KPH

17

Speed Restriction Speed Restriction

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 Safety 2

2.4 Personal Safety

(1) Read and Understand this Maintenance Manual and All Safety Signs
Read this Maintenance Manual and learn the operating characteristics and limitations of the
machine. Know what operating clearances the machine requires.
• Read and understand all the safety signs before operation.
• If the safety signs obstructed by dirt or debris, clean them using mild soap and water before
operation.
• If the safety signs are damaged or illegible, replace them immediately, before operation.
Read the AEM Safety Manual and follow the recommended safety precautions.
Be aware of operating hazards that weather changes can create on the job. When a severe rain
or electrical storm strikes know proper procedures to follow.
Be aware of work-site conditions. Road haul, grade, turning circles and loading areas must
all be understood. Also be aware of all other construction equipment being used in the same
locality on the work-site.
Protective clothing must be worn, when appropriate.
Knowledge of specific risks to the jobsite not covered in this Maintenance Manual should be
taken into consideration.

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2 Safety

(2) Personal Protective Equipment

� CAUTION
• The protection offered by the roll over and falling object protective structure may be
impaired if it has been subjected to any modification or damage. Unauthorized modification
will void certification.

Never attempt to operate or work on a machine when not feeling physically fit.
Know what safety equipment are required and use it. Such equipment are: Hard hat, safety
glasses, reflector type vests, respirators, and ear plugs. Refer to Figure 2.4.
Never wear loose clothing, rings, watches, heavy gloves, that can catch levers and controls and
cause loss of control. Refer to Figure 2.5.
To assure nonslip control, keep hands and controls free from water, grease, and mud.
Handle fuels and lubricants carefully and clean up spills to avoid fire and slipping hazards.
Clean any mud, grease or oil from controls, handrails, ladders, and decks. Lash necessary
tools securely and remove all loose items before operating the machine. Never rush. Walk,
do not run.
Never carry more than one passenger and only in the passenger seat.

Figure 2.4 - Safety Equipment Figure 2.5 - Loose Clothing

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 Safety 2

2.5 Work Area Safety

(1) General Work Area Guidelines
(a) General Fire Precautions
Make sure that the machine has a fire extinguisher and that it is accessible and fully charged.
(Not furnished with the machine).
Never use an open flame as a light anywhere on, or around, the machine.
Clean all dirt, oil, grease, and other fluids from systems and components. Cleaning minimizes
fire hazards and aid in spotting loose or leaking lines, fittings, and so on.
Check the engine compartment for rubbish, oily rags, or other debris that could cause fires
before starting the engine.
Do not let greasy, oily rags, or similar hazards accumulate in the cab.
If the machine has been operated with an under-inflated tire, make sure that the tire has cooled
sufficiently before parking and leaving the machine unattended.
(b) Flammable Fluid Precautions

� CAUTION
• All relevant safety precautions must be taken to minimize chemical hazards during
operation, maintenance and dismantling the truck.
• Follow recommendations of manufacturer when handling and using engine-starting fluids
and disposing of spent containers. Do not puncture or burn empty containers. These
fluids are explosive and highly flammable.
• Never use an open flame match, lighter or other ignition source when checking fuel,
lubricant, coolant, and battery fluid levels, or when checking for fluid leaks. Use a flashlight
or other safe lighting only.

Do not use diesel fuel or other flammable fluids for cleaning purposes. Use approved,
nonflammable solvents.
Make sure all fluid system caps, drain cocks, valves, fittings, lines, and so on, are secure
and leak free.
Shut off the engine, use extra caution if the engine is hot when refueling. Ground the hose
spout to prevent sparks when the spout touches the fuel tank filler tube.
Never smoke while checking or adding fuel or other fluids or handling fluid containers and
lines. Refer to Figure 2.6.
Use care and do not stand downwind when adding fuel or other flammable fluids to tanks and
reservoirs. It avoids fluids being blown or splashed onto clothing.
Close fuel tank shut-off valves, if used, before servicing the fuel system.
When preparing machines or components for storage, seal and tape all openings and close
containers tightly to seal in all volatile inhibitor fluids and compounds used.

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2 Safety

Figure 2.6 - No Smoking Figure 2.7 - Mounting and Dismounting

(c) Mounting and Dismounting

� CAUTION
• Always face the access system and maintain at least three points of support for mounting
or dismounting the machine. Support with two hands and one foot, or two feet and one
hand. Refer to Figure 2.7.
• Always face the access system and maintain at least three points of support for mounting or
dismounting the machine.
• Ensure walkways, stairways, platforms, handrails, and hand holds are free of frost, ice, oil,
water, or anything else that could cause slip, trip, or falls.
• Inspect all ladders, handrails, decks and anti-slip surfaces for wear and damage.
• Never mount or dismount a moving machine. Never jump off the machine.

(2) Measures for Protection Against Lightning

If there is an electrical/lightening storm, park the machine in a safe place, dismount, and seek
shelter.

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 Safety 2

(3) Transportation Safety

(a) Roading
Match speed to road conditions.
Yield the right of way when required. Obey the rules of the road.
Stay as close to the side of the road as possible. Pass other equipment only when the road is
clear, there is sufficient space for pass, and reserve power available.
To inspect the machine and allow the tires to cool, stop at appropriate intervals. Tire air
pressure rises during operation. Do not reduce tire pressure. Excess speed causes tires to
heat up. Reduce your travel speed, not tire pressure.
Use accessory lights and devices at night or in poor visibility. Carry a flare kit. Do not overdrive
your headlights.
(b) Articulation and Oscillation Lock
Always connect the steering and oscillation lock bar before working in the articulation area,
before lifting the machine and during transportation of this machine by trailer/vessel. Refer to
Figure 2.8.
Always disconnect the steering and oscillation lock bar and secure in the 'Stowed' position
before operating the machine. The machine would not be free to steer otherwise. Refer to
Figure 2.9.

Figure 2.8 - Articulation and Oscillation Lock - Figure 2.9 - Articulation and Oscillation Lock -
‘Locked Position’ ‘Stowed Position’

(c) Machine Lifting Precautions

� CAUTION
• Be aware that this machine is free to oscillate if not lifted correctly. If in any doubt contact
your dealer for further information.

Before lifting, the machine must be parked on a level surface, wheels blocked, steering, and
oscillation lock bars connected.
The machine must be lifted using a spreader bar if possible. Lift using FOUR slings from
the lifting points provided at the bumper end of the front chassis and at the rear of the body.
Refer to Figure 2.10.

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2 Safety

TRUCKS CENTRE

FRONT

REAR
2 MOT05074 MOT05075

Figure 2.10 - Machine Lifting Instructions Figure 2.11 - Machine Tie Down Instructions
1. Lifting Points 2. Tie Down Points

(d) Machine Tie Down Precautions

The machine must be secured at the tie down points. Secure it at the bumper end of the
front chassis, front face of the trailer chassis and tow pin at the rear of the trailer chassis.
Refer to Figure 2.11.
Maximum tie down angle must be 60 °.
Use all suitable precautions to avoid damage to the machine when lifting.
Ensure that the loading area and shipping platforms are clean and free of ice, snow and any
other slippery materials.

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 Safety 2

(4) Operation Safety

� CAUTION
• Avoid operating with the load body raised on ground where there is a risk of overturning, for
example on steep inclines or soft ground. This may cause serious injury or death.
• Know clearances of all side and overhead obstructions such as wires and bridges, for
operating safely. Refer to Figure 2.16.
• Be especially aware of overhead power lines.
• Always know all traffic rules, signs, flags, and hand signals used on the job and know who
has the responsibility for signaling.
• Be aware of operating hazards that weather changes can create on the job. Make yourself
aware of procedures that must be followed when a severe rain or electrical storm strikes.
• Be aware of work-site conditions. Road haul, grade, turning circles and loading areas
must all be understood. Also be aware of all other construction equipment being used in
the same locality on the work-site.
• Be aware of ground conditions when approaching the dumping area. Braking requirements
will differ and will require specific attention.
• When operating in soft ground conditions observe the all safety recommendations. Refer to
the items that follow.
• Be aware of the different handling and braking characteristics.
• Understand the difference in performance when loaded and unloaded.
• Keep to designated vehicle routes.
• Load only on level ground with the parking brake applied.
• Check loads are evenly distributed.
• Adhere to site speed limits.
• Ensure that all frozen material or sticky material that has remained in the body after
dumping has been removed before the next run.

(a) Pre-Starting and Starting

Pre-Starting
If the engine has to be started and run indoors, ensure proper ventilation to remove deadly
exhaust gases. Refer to Figure 2.12.
To ensure that the machine is ready for operation, always perform Pre-Operating Checks.
Walk around the machine and ensure that no-one is working on, underneath or close to the
machine before starting the engine or operating the machine.
Adjust, secure, and latch the seat and fasten the seat belt before starting the machine.
Sound the horn before starting the engine or beginning to move the machine; two blasts for
forward and three blasts for reverse.

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2 Safety

Figure 2.12 - Warning - When Operating Figure 2.13 - Warning Sign

Indoors

Starting
Do not start the engine or operate any control if there is a 'DO NOT OPERATE' or similar
warning sign attached to any control. Refer to Figure 2.13.
Use jumper cables only as recommended. Improper use can result in battery explosion or
unexpected machine motion.
Always obey 5.11 Starting on page 5-27 instructions.
Do not bypass the neutral-start system of machine. The neutral start system must be repaired if
it malfunctions.
Start and operate the machine only from the operator's seat.
(b) Operating
Ensure all cab glass, mirrors and light lenses are clean during the machine operation for
maximum visibility. Ensure mirrors are properly set / positioned. Refer to Figure 2.14.
Always keep the cab floor clear of anything that could restrict full operation of the pedals.
Always make sure all gauges, warning/indicator lights and controls are working properly before
operating the machine. Refer to Figure 2.15.
Always perform Pre-Operating Checks to ensure the machine is ready for operation.
Always wear seat belts when operating the machine.
Do not operate if any personnel enter the immediate work area.
Sound the horn before starting the engine or beginning to move the machine; two blasts for
forward and three blasts for reverse.
Watch for ground crew and other personnel on foot. Sound the horn as a warning before setting
the machine in motion and when approaching ground crew.
Be sure the body is fully down before moving the machine.
Always try to face or look in the direction the machine is traveling.
Use extreme caution and turn on lights at night or when fog, dust, rain, or similar hazards limit
visibility. Do not overdrive your headlights.
Observe instruments frequently. Report any defects or unusual noises in the machine during
operation.
Stay in gear when driving downhill. Do not coast with transmission in neutral. Select the proper
gear and maintain safe speed with the service brakes or/and retarder. Always maintain safe
speeds for haul road operating conditions for maximum control. Reduce speed before turning.

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 Safety 2

In the event of a loss of electric power to the gear shift control, the transmission will
automatically lock in Neutral. If this occurs, stop the machine using the service brakes, apply
the Parking / Emergency brake. Do not operate the machine until the fault is corrected.
Always operate straight up or down slopes whenever possible, side-hill operation can cause
sideslip and possible roll-over.
Slow down when moving in congested areas. Do not race with other machines. Stop in
authorized areas only, except in emergency. Refer to Figure 2.18.
Brake firmly in one application. Never operate the machine if a warning light or park brake
service alarm is on. It indicates a fault in the braking system.
Always give loaded machines the right-of-way when your machine is empty.
Always watch for holes, soft edges or other hazards when backing to dump over a spoil bank.
Always apply the brakes with the Parking-Emergency brake control when the machine is being
loaded or when dumping a load.
Always stay in the cab when the machine is being loaded. Refer to Figure 2.17.
Always lower the body and shut down the machine according to the procedure under 5.12
Stopping on page 5-28 before leaving the machine unattended. If on a grade wheels must
be blocked.
Know clearances of all side and overhead obstructions such as wires, bridges, etc., for
operating safely. Refer to Figure 2.16.
Be especially aware of overhead power lines.
Always know all traffic rules, signs, flags and hand signals used on the job and know who
has the responsibility for signaling.

MOT05093 MOT05076

Figure 2.14 - Mirror Positioning and Figure 2.15 - Dashboard

Cleanliness

Figure 2.16 - Warning - Figure 2.17 - Warning - Stay Figure 2.18 - Warning - Truck
Heights In Cab Operation

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2 Safety

(5) Accumulator Safety

� CAUTION
• This machine is equipped with pre-charged nitrogen gas cylinders of more than 2.8 bar (40
psi). Special permits may be required when transporting the machine 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.

NOTICE
• The nitrogen pressure in an accumulator is directly influenced by changes in nitrogen
temperature.

Refer to safety decals 9 and 10, 2.3 Position of Safety Decals on the Machine on page 2-6.
There are three accumulators mounted on the exhaust cradle assembly on the rear left hand
side of the tractor; one for the front brake system and one for the rear. The front and rear brake
accumulators are supplemented by a third (primary) accumulator. The primary accumulator
supports the service brake system and the body pilot pressure system. All three accumulators
are of the piston type and are pre-charged with nitrogen to 103 bar (1 494 psi), at 20 °C (68 °F).
The cylinder pressure will increase or decrease proportionally with temperature changes. An
accumulator pressure reading can vary about 4.3 bar (62 psi) with 22 °C (72 °F) temperature
change. Such temperature changes could easily occur between noon and midnight of the
same day. Refer to Table 2.3 for nitrogen pressures at ambient temperatures of other than
20 °C (68 °F).
A diagnostic pressure point is provided, local to each brake accumulator, to facilitate the fitting
of pressure test apparatus.
Table 2.3 - Ambient Temperature - Nitrogen Pre-Charge Pressure
Ambient Temperature Nitrogen Pre-Charge Pressure
°C °F Bar psi
-20 -4 88.94 1 290
-10 14 92.45 1 341
0 32 95.97 1 391
10 50 99.48 1 443
20 68 103 1 494
30 86 106.52 1 545
40 104 110.03 1 596
50 122 113.55 1 647
60 140 117.06 1 698
70 158 120.58 1 749
80 176 124.09 1 800
90 194 127.61 1 851
100 212 131.12 1 902
110 230 134.64 1 953
120 248 138.15 2 004

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 Safety 2

(6) Electrical Safety

� CAUTION
• Never smoke cigarettes, allow open flames or sparks near batteries.
• Leave the battery box open when charging batteries in the machine for adequate ventilation.
Explosive gas (hydrogen) is produced.
• To avoid danger of fire-causing sparks, always disconnect batteries before repairing the
electrical system. Disconnect the battery ground cable first and reconnect last.
• Always disconnect batteries & alternator leads before carrying out any welding on the
machine.
• Never check the battery charge by placing metal objects across the battery posts; for the
avoidance of sparks at the battery posts. Refer to Figure 2.19.
• Use jumper cables only as recommended. Improper use can result in battery explosion
or unexpected machine motion.
• Never operate the engine starter for more than 30 seconds and allow two minutes between
long cranking periods for cooling. An overheated starter could cause a fire.
• If electric coolant or lubricant heaters are used, be sure to follow the heater manufacturers
recommendations for use to avoid electrical and/or fire hazards.

Figure 2.19 - Battery Maintenance

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2 Safety

(7) Refrigerant

� WARNING
• The refrigerant media is moderately hazardous to the health. In liquid form the refrigerant
could cause frostbite. When in the form of a gas at high concentration it has an anaesthetic
effect and at lower concentration it primarily affects the nervous system. Use personal
protective equipment.

� CAUTION
• The machine's air conditioning system is filled with refrigerant R134a at the factory. R134a
has no damaging effect on the atmosphere's ozone layer, however, it does contribute to the
greenhouse effect and must never be purposely released into the open air.

NOTICE
• R134a must never be mixed with another kind of refrigerant, e.g. R12, as this leads to
a breakdown of the unit.

In case of contact with escaping refrigerant, the following actions must be taken:
1 The gases formed by heated refrigerant, may be harmful to lungs and nervous system even
at low concentrations when no smell is apparent. High concentrations have an anaesthetic
effect. Exposed persons should be moved from the risk area and out into the fresh air.
Seek medical attention if there are remaining symptoms.
2 In liquid form, the refrigerant may cause frostbite. Warm the injured area carefully with
lukewarm water or warm clothing. Get medical attention, if there are remaining symptoms.
3 Contact a doctor if liquid refrigerant has come into contact with someone's eyes.
4 If a leak is suspected, leave the risk area and contact an accredited workshop to get
information about appropriate actions
Work on the air conditioning system must be performed by a qualified service technician. Do
not attempt to perform work on the air conditioning system.
Wear safety goggles, chemical resistant gloves (e.g. neoprene or butyl rubber) and appropriate
personal protective equipment to protect bare skin when there is a risk of contact with refrigerant.
Global Warming Potential (GWP) is a measure of how much heat a gas traps in the atmosphere
relative to that of carbon dioxide (CO2). GWP is calculated in terms of the 100 - year warming
potential of 1 kg of a greenhouse gas relative to 1 kg of CO2. Refer to Table 2.4.
Table 2.4 - Global Warming Potential (GWP)
Refrigerant
Type Quantity GWP
R-134a 1.4 kg 2002 tonne CO2 - eq

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 Safety 2

(8) Maintenance Safety

� WARNING
Escaping fluids under pressure can penetrate the skin.

Do not allow unauthorized personnel to service or maintain this machine. Study the Operations
Manual and Maintenance Manual before starting, operating, or servicing this machine. Always
follow procedures and safety precautions detailed throughout the Maintenance Manual.
The machine must be placed on a level ground surface and in the servicing position. Study
the Operations Manual and Maintenance Manual before starting, operating, or servicing this
machine.
Do not work under or near an unblocked or unsupported body. Always use the body safety
prop. The body safety prop must only be used when the body is empty. Refer to (a) Body
Prop on page 2-26.
Always attach a 'DO NOT OPERATE' or similar warning sign to the ignition switch or a
prominent control before cleaning, lubricating or servicing the machine.
Never allow anyone to work on the machine while it is moving. Make sure that there is no one
on the machine before working on it.
Do not work under or near any unblocked or unsupported linkage, part, or machine.
Always install the steering lock bar before adjustments or servicing the machine with the
engine running.
Always shut down the machine according to the procedure under '5.12 Stopping on page 5-28'.
Turn off the master switch before cleaning, lubricating or servicing the machine except as called
for in the Operations Manual or the Maintenance Manual.
Always relieve pressure before servicing any pressurized system. Follow the procedures and
safety precautions detailed in the relevant Maintenance Manual section. Refer to Figure 2.20.

Figure 2.20 - Warning – Pressurized Systems Figure 2.21 - Warning – Escaping Fluids

When changing oil in engine, transmission and hydraulic systems, or removing hydraulic lines,
remember that oil can be hot and can cause burns to unprotected skin. Refer to Figure 2.21.
When working on or around exhaust components, remember that the components can be
hot and can cause burns to unprotected skin.
Always deflate the tire before attempting to remove any embedded objects or removing the tire
and rim assembly from the machine.
Always use a self-attaching chuck with a long airline, and, stand to one side while the tire is
inflating. Refer to the Wheel Rim and Tire section in the Maintenance Manual.

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2 Safety

Do not work under or near an unblocked or unsupported raised cab. Always use the cab safety
prop with the locking pin. Refer to Figure 2.22 and Figure 2.23.

Figure 2.22 - Operators Cab Safety Prop Figure 2.23 - Operators Cab Safety Prop &
Locking Pin With Cab Raised

(a) Body Prop

� WARNING
• Never place yourself under an unsupported body due to the potential for crush.
• Do not start the engine when the battery master switch is in the OFF position and the light
adjacent to the battery master switch is ON.

(i) Deploy the Body Prop

PROCEDURE
1. Position vehicle in a level work area, ensure transmission is in neutral.
2. Apply the parking brake.
3. Raise the body.
4. Switch off the engine.
5. Remove the ignition key.
6. Attach ‘Do Not Operate’ or similar sign to the ignition switch.
7. Put the battery master switch to the OFF position.
8. Deploy the body prop from beneath the chassis. Refer to Figure 2.24
9. Exit from beneath the chassis.
10. Start the engine.
11. Lower the body onto the deployed body prop.

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 Safety 2

Figure 2.24 - Body Safety Prop

(ii) Lower the Body Prop

PROCEDURE
1. Ensure transmission is in neutral and parking brake is applied.
2. Raise the body.
3. Switch off the engine.
4. Remove the ignition key.
5. Attach ‘Do Not Operate’ or similar sign to the ignition switch.
6. Put the battery master switch to the OFF position.
7. Lower the body prop to beneath the chassis and secure in stowed position. Refer to Figure
2.24
8. Exit from beneath the chassis.
9. Start the engine.
10. Lower the body onto the frame.

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2 Safety

2.6 Mirrors and CCTV

� CAUTION
• The operator must survey their surroundings before entering the machine, and check their
field of vision before and during operation of the machine. All mirrors must be adjusted
when installed, and before operating the machine, to achieve optimum visibility. Correct
mirror adjustment minimizes the risk of injury to themselves and others. Site management
must utilize appropriate job-site organization to minimize hazards due to restricted visibility.
Modifications made to the machine can restrict the visibility and compromise compliance
with safety standards (ISO 5006:2006).

Make sure that all mirrors are installed and adjusted to optimize operator visibility. The mirrors,
illustrated in Figure 2.25, are all capable of adjustment. Make sure that the brackets which
support these mirrors are folded out from the cab for forming an angle of 90 degrees. These
brackets can be folded parallel to the cab for transportation of the machine. Set the mirrors in
the defined position shown in the illustration. Refer to Figure 2.26.
When all the mirrors have been fitted, the machine has a total of four mirrors, designated A to D
respectively, and positioned as illustrated. The area surrounding the machine is considered as
two distinct fields of view. It is illustrated in Figure 2.27 as: areas 1 to 9 in the immediate vicinity,
and areas 10 to 15 at a radius of 12 m from the operator when seated. Refer to Figure 2.28.
The operator MUST adjust the mirrors, and set the CCTV camera, to achieve visibility as
identified below:
• Areas 2, 8 and 10 can be directly viewed from the seating position of operator without
the need for mirrors.
• Adjust mirror A to facilitate the view of Areas 1, 2, 3, 14 and 15.
• Adjust mirror B such that Areas 4 and 14 are fully visible.
• Adjust mirror C such that Areas 6 and 12 are fully visible.
• Adjust mirror D to facilitate the view of Areas 7, 8, 9, 11 and 12.
• Set CCTV to facilitate vision of Areas 5 and 13.

A B C D
0
14

12
0
15
5

0
19

TRUCKS

MOT05077 MOT05078

Figure 2.25 - Mirrors Figure 2.26 - Mirror Alignment

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 Safety 2

2 3 4
15

1000
mm
1 14
5
2500 mm
9 1000 13
mm

1000
mm
12

8 7 6

2m
10 11

R1
MOT05079 MOT05080

Figure 2.27 - Field of Vision Figure 2.28 - Field of Vision

2.7 Wheels and Tires

(1) Description

� DANGER
• Never mix components of one manufacturer’s rims with those of another. Using the rim
base of one manufacturer with the lock ring of another or vice versa is dangerous. The
lock ring of one may not fully engage with the lock ring groove of the other. Always consult
the rim manufacturers for proper matching, assembly and safety instructions. The use of
and servicing of damaged, worn out or improperly assembled rim assemblies is a very
dangerous practice. Failure to comply with the above warnings could result in an explosion
from tire pressure causing serious property damage and serious personnel injury or death.

NOTICE
• Tires on this machine are factory inflated with dry nitrogen. It is recommended that
dry nitrogen be used exclusively for all tire pressure adjustments as well as inflation of
replacement tires.
• Nitrogen gas improves tire pressure retention, increases tire life by reducing carcass
oxidation from within, minimizes rim rust, and has no known detrimental effect on the
tire. It also reduces the potential of a tire explosion because it is an inert gas and will not
support combustion inside the tire. The same tire inflation pressure used for air inflation
must be used for nitrogen inflation. Only proper nitrogen charging equipment operated by
personnel trained in its use must be used.
• The tire inflation pressures listed are manufacturers’ recommendations for G.V.W. travelling
at maximum speed. TEREX Trucks advise that operators check tire inflation pressures with
tire manufacturers to ensure the correct setting for each particular application.
• The wheels have 3-piece earthmover rims with 19 stud fixing.

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2 Safety

Table 2.5 - Tire Specifications

TIRE INFLATION PRESSURE
Truck Brand Size Pattern Front Centre Rear
bar psi bar psi bar psi
Bridgestone 29.5 R25 VLT 4.0 58 5.0 73 5.0 73
Bridgestone 29.5 R25 VMT 4.0 58 5.0 73 5.0 73
Michelin 29.5 R25 XADN 2.8 40 3.8 55 3.8 55
Triangle 29.5 R25 TB516 4.0 58 4.9 71 4.9 71
TA400 Magna 29.5 R25 MA04 5.2 75 5.2 75 5.2 75
Techking 29.5 R25 ET6A 2.8 41 4.5 65 4.5 65
Maxam 29.5 R25 MS302 3.2 46 3.2 46 3.2 46
BKT 29.5 R25 SR40 4.5 65 4.5 65 4.5 65
Michelin 29.5 R25 XADN + 3.25 47 4.5 65 4.5 65

(2) Avoid Tire Explosion Hazard

� CAUTION
Whenever a machine’s tire(s) is (are) exposed to excessive heat such as a machine fire or
extremely hot brakes, the hazard of a subsequent violent tire explosion must be recognized. All
nearby persons must avoid approaching the machine so as not to be physically endangered in
the event of an explosion of the tire and rim parts. The machine must be moved to a remote
area, but only when this can be done with complete safety of the operator operating or towing
the machine. All other persons must stay clear of the machine. The fire or overheated brakes,
wheel etc., must be extinguished or cooled from a safe distance. Do not attempt to extinguish
the fire or cool the machine by use of hand-held fire extinguishers. If it is absolutely necessary to
approach a machine with a suspect tire, approach only from the front or the back. Stay at least
15 m (50 ft) from the tread area. Keep observers out of the area and at least 460 m (1500 ft)
from the tire sidewall. Refer to Figure 2.29. The tire(s) must be allowed at least eight (8) hours
cooling time after the machine is shut down or the fire extinguished before approaching closer.

Figure 2.29 - Warning – Tire Explosion

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 Safety 2

2.8 Lubrication and Servicing

� CAUTION
• Reusable fittings must not be used to install hoses intended to withstand a pressure
of more than 15 MPa (150 bar).
• Replacement hose assemblies must be constructed from hoses that have not been
previously used in operation as part of another hose assembly. The hose assembly must
fulfil all performance and marking requirements given in appropriate standards.

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2 Safety

Intentionally Left Blank

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 Technical Data 3

Table of Content
3 Technical Data.............................................................................................3-1
3.1 Dimensions .................................................................................................... 3-2
3.2 Carrying Capacity........................................................................................... 3-3
3.3 Operating Temperature .................................................................................. 3-3
3.4 Mechanical System ........................................................................................ 3-4
(1) Engine ....................................................................................................... 3-4
(2) Hydraulic System....................................................................................... 3-5
3.5 Electrical System............................................................................................ 3-5
(1) Electrical System ....................................................................................... 3-5
(2) Light Bulbs................................................................................................. 3-5
3.6 Standards....................................................................................................... 3-6
3.7 Vibration Data for Off Highway Articulated Dump Trucks............................... 3-7
(1) Guidelines for Use and Working Conditions of Earth-Moving Machinery
to Reduce Vibration Levels........................................................................ 3-8
3.8 Service Capacities ......................................................................................... 3-9
3.9 Vehicle Weights............................................................................................ 3-10
3.10 Towing .......................................................................................................... 3-11
3.11 Machine Components Specifications ........................................................... 3-11
(1) Wheels and Tires..................................................................................... 3-11
(a) Description .......................................................................................... 3-11
(b) Avoid Tire Explosion Hazard............................................................... 3-12
(2) Transmission ........................................................................................... 3-13
(3) Dropbox ................................................................................................... 3-14
(4) Axles........................................................................................................ 3-14
(5) Suspension.............................................................................................. 3-14
(6) Body ........................................................................................................ 3-15
(7) Brakes ..................................................................................................... 3-15
(8) Steering ................................................................................................... 3-16
(9) Body Hoist ............................................................................................... 3-16

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 3
3.1

Page 3-2
15-Sep-2017
3 Technical Data

3 318
(10-11)
Dimensions

Max
1 495 3 364
Body (4-11) 45° 3 129
Depth (11-0)
(10-3)
Technical Data

6 933
(22-9)
66°

3 633 5 658
(11-11)

Revision 1.0
(18-6)
5 575
(18-3)
TRUCKS
3 954
(13-0)

Figure 3.1 - Dimensions

TRUCKS 25° 3 152
3 752
(12-4) (10-4)
3 561 2 479
(11-8) (8-2)

916
539 540 (3-0)
(1-9) (1-9)
1 834 3 087 1 310 2 987 1 950 1 779
(6-0) (10-01) (4-4) (9-10) (6-5) (5-10)
2 596
(8-6) 11 115
3 358 (36-5)
Dimensions in mm (ft-in)
(11-0)

MOT05081

TA400 Tier2
Maintenance Manual
 Technical Data 3

Turning Dimensions

G
B A

F
E

MOT04994

Figure 3.2 - Turning Dimensions

A. Outer Tyre Clearance D. Inner Tyre Clearance G. Outermost Point
Diameter Diameter
B. Turning Radius = 1/2 E Machine Clearance
Turning Diameter Diameter
C. Turning Diameter F. Turning Centre

Table 3.1 - Dimensions

Dimensions - m (ft-in)
A. 19.37 (63-5) D. 10.35 (33-9)
C. 18.61 (61-1) E. 19.61 (64-3)

3.2 Carrying Capacity

The machine range has the capability to carry a maximum payload of 41.9 US ton (38 tonnes)
or a heaped capacity of 30.3 yd.3 (23.3 m3).
TA400 ADT has a maximum body depth of 1495 mm (4 ft 11 in).
3.3 Operating Temperature
The operating temperature of the machine is: -18 °C to +45 °C.

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3 Technical Data

3.4 Mechanical System

(1) Engine
Table 3.2 - Engine Specifications
ENGINE
Make / Model Scania DC13 074A
Fuel injection Scania PDE
Number of cylinders and configuration 6, straight
Working principle 4 stroke engine
Cylinder diameter (mm/in) 130/5.12
Piston Stroke (mm/in) 160/6.30
Displacement (dm³/in³) 12.7/775.0
Firing sequence 1-5-3-6-2-4
Power Range 331kW/444HP
Compression ratio 17.3:1
Engine direction of rotation, viewed from rear Anticlockwise
Fan direction of rotation, viewed from front Clockwise
Cooling Coolant (50% Water and 50% Glycol -
antifreeze)
Valve clearances, cold engine
intake valve (mm/in) 0.45/0.018
outlet valve (mm/in) 0.70/0.028
Number of teeth on the flywheel 158
Low idle speed (rpm) 500 –1,050
Maximum full-load speed (rpm) 2100
Maximum torque at speed (Nm/rpm) 2100/1350
Fuel Diesel (10 PPM)
Oil pan capacity 39 - 45 Litres
Weight, without coolant and oil (kg/lb) 1075/2370
Fuel Heater 24V, 250W

NOTICE
The Tier 2 Engines meet ACEA E7 specifications.

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 Technical Data 3

(2) Hydraulic System

The Hydraulic system conforms to ISO 4406. The cleanliness level of the hydraulic fluid
maintained within the hydraulic system is suitable for the most contaminant-sensitive
components.
Braking, steering and body hoist systems are controlled by a main hydraulic valve mounted
on frame. Systems are supplied with oil from a common tank by the main hydraulic pump,
driven from power takeoff on transmission. System components are protected by full flow
filtration on the return line.
Maximum hydraulic oil temperature : 90 °C
Table 3.3 - Hydraulic System
Pump:
Type Piston
Capacity at 2700 rev/min 5.4 litre/sec (85.6 US gal/min.)

3.5 Electrical System

(1) Electrical System
Table 3.4 - Electrical System
Electrical System
Type 24 Volt, Negative Ground
Battery Two, 12 Volt, 180 Ah each
Accessories 12/24 Volt
Alternator 1 Pole, 28V, 100A (EMS Controlled)
Starter Motor 1 Pole, 24V, 505 kW (EMS Controlled)

(2) Light Bulbs

� CAUTION
• Light bulbs could contain hazardous chemicals and cause an environmental hazard.
Always wear personal protective equipment when handling light bulbs.
• Follow local environmental guidelines when disposing light bulbs. Do not put lights bulbs in
general trash.
• Contact with chemicals contained in light bulbs could cause exposure to hazardous
chemicals.

It is recommended that light bulbs are of the highest quality, shake proof and with a long life.
Table 3.5 - Light Bulbs
Description Specification Remarks
Cabin Lighting 10W 24V Included in Light Unit
Headlights-Beam 35W 24V Included in Light Unit (H3
Halogen)
Headlights-Dipped 35W 24V Included in Light Unit (H3
Halogen)
Direction Indicators- 35W 24V Included in Light Unit (H3
Front Halogen)

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3 Technical Data

Description Specification Remarks

Work Lights-Front 35W 24V Included in Light Unit (H3
Halogen)
Reverse Light 70W 24V Included in Light Unit
Direction Indicators- LED - Included in Light Unit
Rear
Brake Lights-Rear LED - Included in Light Unit

3.6 Standards
NOTICE
• The result below is for the mode giving the highest exterior sound level when measured
and operated as per the prescribed procedures of the standard. Results shown are for
the machine in base configuration.
• Noise exposure level to the operator and bystander personnel may be higher depending
upon proximity to buildings, rock piles, machinery, etc. The actual job site noise exposure
level must be measured and applicable regulations complied with respect to employee
hearing protection.

Table 3.6 - Noise Levels

Noise Levels
REQUIREMENT REMARKS
NOISE STANDARD BUILD OPERATORS EAR (ISO6396) : 2008
≤ 80dB QUALIFIED

Table 3.7 - Visibility

Visibility
VISIBILITY STANDARD
OPERATORS FIELD OF VIEW ISO 5006 : 2017

Table 3.8 - EMC

EMC
STANDARD
ELECTRO MAGNETIC COMPATIBILITY
ISO 13766:2006

Table 3.9 - Vibration

Vibration
STANDARD
VIBRATION 2002/44/EC
ISO/TR 25398:2006

Table 3.10 - Cabin

Cabin
CAB ROPS ISO 3471 – 2008 QUALIFIED
CAB FOPS EN ISO 3449 – 2008 QUALIFIED

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 Technical Data 3

3.7 Vibration Data for Off Highway Articulated Dump Trucks

Hands and Arm Vibration
The weighted root mean square acceleration to which hand and arms of the operator are
exposed is less than 2.5 m/s² under normal operating conditions.
Whole Body Vibration (WBV)
This section provides data on WBV under real working conditions and provides a method for
estimating the WBV level for Off Highway Articulated Dump Trucks.
It must be noted that vibration levels are influenced by many different factors including :-
• Operator(training, behaviour, mode, stress)
• Jobsite (organization, preparation, environment, weather, material)
• Machine(type, quality of seat and suspension system, attachment, equipment, condition).
It is therefore not possible to get precise vibration levels for this machine. Using data extracted
from ISO/TR 25398:2006 vibration levels can be estimated, enabling the daily exposure to
vibration to be calculated.
Table 3.11 - From (ISO/TR 25398:2006 Annex B)
Average Vibration
Machine Operating Std Deviation m/s²
Levels m/s²
Type Condition
X axis Y axis Z axis X axis Y axis Z axis
Loading process 0.29 0.41 0.24 0.17 0.23 0.16
Travel with load 0.64 0.89 0.67 0.21 0.29 0.21
Articulated
Dump Truck Travel without 0.82 1.02 0.81 0.26 0.26 0.28
load
Unloading 0.49 0.42 0.30 0.25 0.33 0.18

To estimate vibration levels for this machine under typical conditions use the Average Vibration
Levels. With an experienced operator and good terrain conditions subtract the Std. Deviation
values from the Average Vibration Levels to get the estimated level. In severe applications
with poor terrain add the Std. Deviation to the Average Vibration Levels to get the estimated
vibration level.
ISO/TR 25398:2006 – “Earth-moving machinery - Guidelines for assessment of exposure to
whole-body vibration of ride-on machines - Use of harmonized data measured by international
institutes, organizations and manufacturers” provides a method for calculating operator
exposure to vibration using the vibration levels quoted above. These values are valid for
machines fitted with an operator seat in accordance to ISO7096:2008.

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3 Technical Data

(1) Guidelines for Use and Working Conditions of Earth-Moving Machinery

to Reduce Vibration Levels
Properly adjust and maintain machines, operate machines smoothly and maintaining the terrain
conditions can reduce whole-body vibrations. The following can help the users of earth-moving
machinery reduce whole-body vibration levels.
1 Use the right type and size of machine, equipment, and attachments.
2 Maintain machines according to the manufacturer’s recommendations:
• tire pressures
• brake and steering systems
• controls, hydraulic system and linkages
3 Maintain the terrain where the machine is working and travelling in good condition:
• remove any large rocks or obstacles
• fill any ditches and holes
• provide machines and schedule time to maintain terrain conditions.
4 Use a seat in conformance with ISO 7096:2008. Keep the seat maintained and adjusted:
• adjust the seat and suspension for the weight and size of the operator
• inspect and maintain the seat suspension and adjustment mechanisms.
5 Steer, brake, accelerate, shift gears, and move the attachments smoothly.
6 Adjust machine speed and travel path to minimize the vibration level:
• drive around obstacles and rough terrain conditions
• slow down when it is necessary to go over rough terrain
7 Minimize vibrations for long work cycle or long distance travelling:
• use machines equipped with suspension systems
• use lift arm suspensions on wheel loaders
• if no suspension system is available, reduce speed to prevent bouncing
• haul machines long distances between worksites

8 Back pain associated with whole-body vibrations can be caused by other risk factors.
To minimize the risk of back pain:
• adjust the seat and controls to achieve good posture
• adjust the mirrors to minimize twisted posture
• provide breaks to reduce long periods of sitting
• avoid jumping down from the cab or access system
• minimize repeated handling and lifting of loads
• minimize any shocks and jolts during sports and leisure activities.

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 Technical Data 3

3.8 Service Capacities

Table 3.12 - Service Capacities
COMPONENT *CAPACITY
Engine (Including Filters) 45 Litres (11.8 US gal)
Transmission (Including Filters) (dry fill) 48 Litres (12.6 US gal)
Hydraulic System (Including Lines) 341 Litres (90 US gal)
Cooling System 67 Litres (18 US gal)
Differential (Front) 33 Litres each (8.7 US gal)
Differential (Centre) 34 Litres (9 US gal)
Differential (Rear) 33 Litres each (8.7 US gal)
Planetaries 9 Litres each (2.4 US gal)
Dropbox 17 Litres (4.4 US gal)
Fuel Tank 350 Litres (130.5 US gal)
Drive shaft through Bearings 1.5 Litres (0.40 US gal)
Brake Cooling System 188 Litres (49.6 US gal)
* - Capacities given are approximate, work to dipstick, sight gauges or level plugs.

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3 Technical Data

3.9 Vehicle Weights

� WARNING
Maximum permissible gross vehicle weight including options, attachments, full fuel tank and
payload must not be exceeded.

Table 3.13 - Vehicle Weights

Vehicle Weights 29.5 R25 Tires
Standard Vehicle kg lb
Net Distribution
Front Axle 16743 36912
Centre Axle 7445 16534
Rear Axle 7393 19299
Vehicle, Net 31581 69624
Payload 38000 83775
Vehicle, Gross 69581 153399
Gross Distribution
Front Axle 18820 41491
Centre Axle 25000 55115
Rear Axle 25000 55115
Bare Chassis 24760 54586
Body 5400 11904
Body Hoists (Pair) 660 1455

Table 3.14 - Ground Pressures

Ground Pressures
At 15% sinkage of unloaded radius and specified weights
29.5 R25 Net Loaded
Front 112 kPa (16.2) psi) 121 kPa (17.5 psi)
Rear 53 kPa (7.7 psi) 180 kPa (26.1 psi)

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 Technical Data 3

3.10 Towing
� WARNING
Maximum permissible forces on tow points:
Front frame tow points 500 kN each
Rear tow pin 680 kN

3.11 Machine Components Specifications

(1) Wheels and Tires
(a) Description

� DANGER
• Never mix components of one manufacturer’s rims with those of another. Using the rim
base of one manufacturer with the lock ring of another or vice versa is dangerous. The
lock ring of one may not fully engage with the lock ring groove of the other. Always consult
the rim manufacturers for proper matching, assembly and safety instructions. The use of
and servicing of damaged, worn out or improperly assembled rim assemblies is a very
dangerous practice. Failure to comply with the above warnings could result in an explosion
from tire pressure causing serious property damage and serious personnel injury or death.

NOTICE
• Tires on this machine are factory inflated with dry nitrogen. It is recommended that
dry nitrogen be used exclusively for all tire pressure adjustments as well as inflation of
replacement tires.
• Nitrogen gas improves tire pressure retention, increases tire life by reducing carcass
oxidation from within, minimizes rim rust, and has no known detrimental effect on the
tire. It also reduces the potential of a tire explosion because it is an inert gas and will not
support combustion inside the tire. The same tire inflation pressure used for air inflation
must be used for nitrogen inflation. Only proper nitrogen charging equipment operated by
personnel trained in its use must be used.
• The tire inflation pressures listed are manufacturers’ recommendations for G.V.W. travelling
at maximum speed. Terex Trucks advise that operators check tire inflation pressures with
tire manufacturers to ensure the correct setting for each particular application.
• The wheels have 3-piece earthmover rims with 19 stud fixing.

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3 Technical Data

Table 3.15 - Tire Specifications

TIRE INFLATION PRESSURE
Truck Brand Size Pattern Front Centre Rear
bar psi bar psi bar psi
Bridgestone 29.5 R25 VLT 4.0 58 5.0 73 5.0 73
Bridgestone 29.5 R25 VMT 4.0 58 5.0 73 5.0 73
Michelin 29.5 R25 XADN 2.8 40 3.8 55 3.8 55
Triangle 29.5 R25 TB516 4.0 58 4.9 71 4.9 71
TA400 Magna 29.5 R25 MA04 5.2 75 5.2 75 5.2 75
Techking 29.5 R25 ET6A 2.8 41 4.5 65 4.5 65
Maxam 29.5 R25 MS302 3.2 46 3.2 46 3.2 46
BKT 29.5 R25 SR40 4.5 65 4.5 65 4.5 65
Michelin 29.5 R25 XADN + 3.25 47 4.5 65 4.5 65

(b) Avoid Tire Explosion Hazard

� CAUTION
• Whenever a machine’s tire(s) is (are) exposed to excessive heat such as a machine
fire or extremely hot brakes, the hazard of a subsequent violent tire explosion must be
recognized. All nearby persons must avoid approaching the machine so as not to be
physically endangered in the event of an explosion of the tire and rim parts. The machine
must be moved to a remote area, but only when this can be done with complete safety of
the operator operating or towing the machine. All other persons must stay clear of the
machine. The fire or overheated brakes, wheel etc., must be extinguished or cooled from a
safe distance. Do not attempt to extinguish the fire or cool the machine by use of hand-held
fire extinguishers. If it is absolutely necessary to approach a machine with a suspect tire,
approach only from the front or the back. Stay at least 15 m (50 ft) from the tread area.
Keep observers out of the area and at least 460 m (1500 ft) from the tire sidewall. Refer
to Figure 3.3. The tire(s) must be allowed at least eight (8) hours cooling time after the
machine is shut down or the fire extinguished before approaching closer.

Figure 3.3 - Warning – Tire Explosion

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 Technical Data 3

(2) Transmission
Make/Model
Allison 4500 Series with integral retarder mounted directly to the engine, fully automatic
transmission with planetary gearing, lock-up in all gear ranges. Electronic control with six
forward and one reverse gear.
Table 3.16 - Transmission
Transmission
Main 18.5 + 3.4 bar (269 + 50 lbf/in2)
Temperatures:
Normal 60 °C - 135° C (140 ° F- 275 °F)
Maximum 165 ° C (329 ° F)
Stall Speed 1600 – 1950 rev/min
Ratios:
Transmission Refer to Table 3.17

Table 3.17 - Transmission Data

Low Box (1.129) High Box (0.738)
Speed Time Speed Time
Gear Gear Ratio
(km/h) (s) (km/h) (s)
1C 4.2 0.6 6.5 1.1
4.7
1L 6 0.9 9.5 1.6
2C 8 1.5 12.3 3.1
2.21
2L 11.3 2.7 16 5.7
3L 16.5 5.3 25.3 12.4 1.53
4L 25.6 12.8 39.2 35.9 1
5L 33.9 25.6 51.9 129.2 0.76
6L 41.7 46.3 63.8 231.9 0.67
Reverse 5.0 7.8
Hot Engine Stall 1750 rpm
Speed (actual)
Cold Engine 1675 rpm
Stall Speed
(actual)

Transmission Oil
Only TES-295 Specification oil must be used in the Terex TA400 Allison transmission. Use of
any other oil will invalidate all warranty claims relating to the transmission and greatly reduce
the life and the performance of the transmission.
If ambient temperatures drop below -35 °C the transmission fluid must be pre-heated before
starting transmission operation. The fluid in the transmission sump may be pre-heated using
one of the following methods:
• Use an auxiliary heat source e.g: sump heater.
• Operate the transmission in Neutral with the engine running at idle for a minimum of 20
minutes, before shifting the transmission into range.

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3 Technical Data

(3) Dropbox
Remote mounted transfer gearbox taking drive from the transmission and feeding it via a
lockable differential to the front and rear wheels.
Table 3.18 - Dropbox
Dropbox
Ratios:
Low 1.129:1
High 0.738:1
Pressure:
High/Low actuation 15 ± 0.2 bar
Differential lock actuation 34-50 bar
Lubrication 2 ± 1 bar
Temperature:
Maximum 100 °C (212 °F)

(4) Axles
Three axles in permanent all-wheel drive (6 X 6) with differential coupling between each axle
to prevent driveline wind-up. Heavy-duty axles with fully floating axle shafts and outboard
planetary reduction gearing.
Automatic limited slip differentials in each axle. Center axle incorporates a through-drive
differential to transmit drive to the rear axle. This differential and the dropbox output differential
are locked simultaneously using one switch selected by the operator.
Table 3.19 - Ratios
Axle Ratios
Differential 3.70:1
Planetary 6.35:1
Total Reduction 23.50:1

(5) Suspension
Front
Four trailing links and a panhard rod locate the front axle giving a high roll centre. The optimized
front axle position along with the wide spaced main and rebound mounts, mounted directly
above the axle and long suspension travel, combine with two heavy duty dampers each side to
give excellent handling and ride.
Rear
Each axle is coupled to the frame by three rubber- bushed links with lateral restraint by a
transverse link. Pivoting inter-axle balance beams equalize load on each axle. Suspension
movement is cushioned by rubber/ metal laminated compression units between each axle and
underside of balance beam ends. Pivot points on rear suspension linkages are rubber-bushed
and maintenance-free.

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 Technical Data 3

(6) Body
The body is an all welded construction, fabricated from high hardness (min. 360 BHN)
1000 MPa (145,000 lbf/in2) yield strength steel. A 25° tail chute angle provides good load
retention without the tailgate.
Table 3.20 - Plate Thicknesses
Thickness
Floor and Tailchute 15 mm (0.59 in)
Sides 12 mm (0.47 in)
Front 8 mm (0.31 in)

Table 3.21 - Volume

Volume
Struck (SAE) 17.4 m3 (22.8 yd.3)
Heaped 2:1 (SAE) 23.3 m3 (30.3 yd.3)

(7) Brakes
Full hydraulic braking system with enclosed, forced oil- cooled multiple discs on each wheel.
Independent circuits for front and rear brake systems. Warning lights and audible alarm indicate
low brake system pressure. Brake system conforms to ISO 3450, SAE J1473.
Table 3.22 - Brakes
Brakes
Actuating Pressure 58 ± 2.4 bar (841 ± 35 lbf/in2)
Pump Type Triple stage gear
Capacity at 1 685 rev/min 8.9 l/s (2.35 US gal/min)
Braking surface (tractor) 590,240 mm2 (914.9 in2)/brake
Braking surface (trailer) 590,240 mm2 (914.9 in2)/brake

Parking
Spring-applied, hydraulic-released disc on the rear driveline.
Emergency
There is automatic application of the driveline brake if there is a pressure fall in the main
brake hydraulic system. Service brakes can also be applied using the parking-emergency
brake control.
Retardation
Standard exhaust brake and standard hydraulic retarder integral with transmission.

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3 Technical Data

(8) Steering
Hydrostatic power steering by two single-stage, double-acting, cushioned steering cylinders. A
ground driven pump mounted on the dropbox provides the emergency steering pressure. If
the emergency system activates, an audible alarm and warning light comes on. Conforms to
ISO 5010, SAE J53.
Table 3.23 - Steering
Steering
System Pressure 240 bar (3500 lbf/in²)
Steering Angle to either side 45°
Lock to Lock Turns, steering wheel 4

(9) Body Hoist

Two single-stage, double-acting hoist rams, cushioned at both ends of the stroke. Electro
servo assisted hoist control.
Table 3.24 - Body Hoist
Body Hoist
System Pressure 240 bar (3500 lbf/in²)
Control Valve Pilot Operated, Closed Centre
Body Raise Time (loaded) 14 sec
Body Lower Time (power down) 9 sec

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 Maintenance 4

Table of Content
4 Maintenance ................................................................................................4-1
4.1 Maintenance and Inspection Plan .................................................................. 4-2
(1) Maintenance Safety................................................................................... 4-2
(2) Maintenance Schedules ............................................................................ 4-3
(a) Every 10 Hours of Operation ................................................................ 4-3
(b) After First 10 Hours of Operation or Rebuilt Components .................... 4-4
(c) Every 50 Hours of Operation ................................................................ 4-5
(d) After First 100 Hours of Operation or Rebuilt Components .................. 4-5
(e) Every 250 Hours of Operation .............................................................. 4-6
(f) After First 250 Hours of Operation or Rebuilt Components .................. 4-7
(g) Every 500 Hours of Operation .............................................................. 4-8
(h) After First 500 Hours of Operation or Rebuilt Components .................. 4-9
(i) Every 1000 Hours of Operation ............................................................ 4-9
(j) Every 2000 Hours of Operation .......................................................... 4-11
(k) Every 3000 Hours of Operation .......................................................... 4-13
(l) Every 4000 Hours of Operation .......................................................... 4-13
(m) Every 6000 Hours of Operation .......................................................... 4-13
4.2 Non-scheduled Maintenance ....................................................................... 4-14
4.3 Air Condition Commissioning Procedure ..................................................... 4-15
4.4 Lubrication System....................................................................................... 4-16
(1) Recommended Lubricants....................................................................... 4-16
(a) Specific Information on Lubrication..................................................... 4-17
(2) Lubrication Points .................................................................................... 4-18

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4 Maintenance

4 Maintenance
4.1 Maintenance and Inspection Plan
(1) Maintenance Safety

� WARNING
• If the battery master switch is in the OFF position, but the adjacent warning light is ON
(illuminated) electrical power remains connected to the truck.
• Electrical power remains connected to the truck for 60 seconds after the battery master
switch has been selected to the OFF position.

NOTICE
• For all safety related information please refer to 2.2 General Safety on page 2-2.
• Carry out the following maintenance procedures in conjunction with the additional
procedures listed in section (1) Recommended Lubricants on page 4-16.
• Never operate the engine with the oil level below the low (L) or above the high (H) level
marks on the dipstick.
• Refer to the specific system or component in the relevant Chapter, for detailed information
on the correct maintenance procedure.

General Maintenance Safety

The instructions that follow depend upon which system is being maintained or serviced. To
enable maximum safety these instructions must be adhered to:
• Always position the machine on firm level ground.
• Always deploy the body safety prop. Refer to (a) Body Prop on page 2-26.
• Always apply the emergency park brake.
• Always block the wheels.
• Always remove the ignition key.
• Always put the battery master switch in the OFF position, unless otherwise instructed.
• Always place a warning sign on the instrument panel. This will warn other service personnel
of ongoing maintenance work.

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 Maintenance 4

(2) Maintenance Schedules

(a) Every 10 Hours of Operation
The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.1 - Every 10 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Machine – All Inspection Pre-Operating walk Refer to Operators Manual -
around check General Inspection Section.
2 Engine Check General visual and noise Refer to Note 1 , page 4-4.
check
3 Engine Check/ Oil level Refer to Note 2 , page 4-4.
Replenish
4 Engine Check Charge air cooling – Refer to 18.1 Description
Check pipe for damage on page 18-2.
5 Engine Check Air Restriction Filter Refer to 5.1 Description on
Indicator page 5-3.
6 Fuel Check/ Fuel Level Refer to (a) Functional
Replenish Description on page 15-66.
7 Transmission Check/ Oil level Refer to (2) Oil Level Check
Replenish on page 6-30.
8 Hydraulic Oil Check/ Oil level/filter Refer to Note 3 , page 4-4.
Tank Replenish/
Replace
9 Radiator Check/ Coolant level Refer to Note 4 , page 4-4.
Header Tank Replenish
10 Cooling Fan Check Fan – blades damage, Refer to Note 5 , page 4-4.
Mounting bolts security
11 Tires Check/ Tire pressures Refer to Note 6 , page 4-4.
Replenish
12 Dropbox Check/ Oil level Refer to Note 7 , page 4-4.
Replenish
13 OCDB Oil Check/ Oil level Refer to Note 8 , page 4-4.
Tank Replenish

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4 Maintenance

NOTICE
1 Visually check the engine for damage, loose or frayed belts and listen for any unusual
noises.
2 Position the machine on a level work area, apply the parking brake, shut off the engine and
wait at least five minutes (to allow the oil to drain to the oil pan) before checking the oil
level. The oil level should be between the low (L) and the high (H) marks on the dipstick.
Replenish the oil if required.
3 With the engine off and the body down the oil must be visible in the sight gauge, replenish
the oil if required. Change the oil filter if red is indicated on the filter gauge.
4 Check the coolant level when cold. Fill the radiator header tank with coolant until the
coolant level reaches the cold fill line and holds that level.
When a significant amount of coolant is added, the coolant inhibitor concentration MUST be
checked.
5 Visually inspect the fan for cracks or damaged blades. Check the fan mounting fan bolts
are secure. Tighten mounting bolts if required. Replace fan if damaged.
6 Check the tire pressures, preferably before the machine is placed in operation.
7 Engine off – Check the oil level is above the ‘COLD FULL’ mark on the dipstick. Replenish
the oil if required.
Engine running – Check the oil level is between the ‘COLD FULL’ and the ‘COLD ADD’
level on the dipstick. Replenish the oil if required.
8 Check that the oil level is between the black high level mark and the red low level mark on
the gauge. Replenish the oil if required.

(b) After First 10 Hours of Operation or Rebuilt Components

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.2 - After First 10 Hours of Operation or Rebuilt Components
Ref. Identification Task Service Instructions Remarks
1 Wheels Check Wheel rim nuts – check Refer to Note 1 , page 4-4
torque

NOTICE
1 Check and re-torque wheel rim nuts to 597 Nm (440 lbf ft.).
Torque must be applied in three stages. Nuts are to be torqued crosswise (opposing pairs).

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 Maintenance 4

(c) Every 50 Hours of Operation

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.3 - Every 50 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Wheels Check Wheel rim nuts – check Refer to Note 1 , page 4-5
torque
2 Tires Check/ Tires – check condition Refer to Note 2 , page 4-5
Replace
3 Cabin Air Filter Check/ Fresh air filter – check Refer to Note 3 , page 4-5
Clean condition and clean
4 Machine – All Lubrication Various lubrication points Refer to (2) Lubrication
Points on page 4-18

NOTICE
1 Check and torque wheel rim nuts to 597 Nm (440 lbf ft.).
Torque must be applied in three stages. Nuts are to be torqued crosswise (opposing pairs).
2 Check condition of tires, replace or repair if damaged.
3 If the fresh air filter is to be replaced, the replacement filter must comply with ISO
10263-2:2009.

(d) After First 100 Hours of Operation or Rebuilt Components

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.4 - After First 100 Hours of Operation or Rebuilt Components
Ref. Identification Task Service Instructions Remarks
1 Hydraulic Clean/ Hydraulic oil filter Refer to Note 1 , page 4-5.
Replace
2 Brake Oil Tank Clean Hydraulic oil filter Refer to Note 2 , page 4-5.

NOTICE
1 Clean the oil filter housing. Replace the oil filter element.
The element must also be replaced when the filter restriction warning light, on the right
of dashboard display illuminates.
2 Remove the brake oil tank top cover assembly. Clean the filter with a suitable solvent, and
dry with compressed air. Refit the top cover assembly.

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4 Maintenance

(e) Every 250 Hours of Operation

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.5 - Every 250 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Machine – All Inspection General inspection Refer to Note 1 , page 4-7
2 Engine Check/ Engine air intake system Refer to Note 2 , page 4-7
Replace
3 Parking Brake Check/ Parking brake pads and Refer to Note 3 , page 4-7
Adjust/ discs
Replace
4 Cooling Check/ Radiator check for Refer to Note 4 , page 4-7
Clean damage – clean
5 Cooling Check/ Charge air cooler check Refer to Note 5 , page 4-7
Clean for damage – clean
6 Transmission Check/ Oil cooler fins check for Refer to Note 6 , page 4-7
Clean damage – clean
7 Planetaries Check/ Planetaries oil level Refer to Note 7 , page 4-7
Replenish
8 Differentials Check/ Differentials oil level Refer to Note 8 , page 4-7
Replenish
9 Articulation Check/ End float/clearance Refer to Note 9 , page 4-7
and Oscillation Adjust
Pivot
10 Machine – All Lubrication Various lubrication Refer to (2) Lubrication
points Points on page 4-18

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 Maintenance 4

NOTICE
1 General inspection, check the entire machine for leaks, loose bolts and nuts or damaged
parts. Examine the machine, particularly the chassis, for cracks or broken welds. Repair
where necessary.
2 Check the air intake system for wear points or damage to piping, loose clamps and leaks.
3 Check the parking brake pads and discs for wear. Adjust or replace if required. Test for
correct function. Friction material thickness must never be allowed to wear below 3 mm
(0.12 in).
4 Check the radiator for damage, clean with a quality grease solvent such as mineral spirits
and dry with compressed air.
5 Check the charge air cooler for damage, clean with a quality grease solvent such as mineral
spirits and dry with compressed air.
6 Check the transmission oil cooler fins for damage, if necessary clean with a quality
detergent.
7 Check and replenish the oil level. The correct oil level should be at the lower bottom edge
of the thread, with the wheel hub orientated so that the oil drain plugs are positioned
horizontally in the middle of the axle.
8 Check and replenish the oil level. The correct oil level is up to the rim of the oil filler and
level-check hole.
When refilling the center axle, ensure that the 3rd differential unit is primed with 1 litre (1.75
UK pints) of oil before filling the drive head.
9 Check the end float/clearance at the thrust face of the oscillation bushes. Any clearance
found must be removed by adjustment of the thrust nut.

(f) After First 250 Hours of Operation or Rebuilt Components

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.6 - After First 250 Hours of Operation or Rebuilt Components
Ref. Identification Task Service Instructions Remarks
1 Axles Check Check for loose nuts Refer to Note 1 , page 4-7
and bolts

NOTICE
1 Check all visible nuts and bolts for loosening. Re-torque planetary fill/drain plugs to 55
Nm (40.5 lbf ft.).

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4 Maintenance

(g) Every 500 Hours of Operation

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.7 - Every 500 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Batteries Check/ Acid level Refer to Note 1 , page 4-8
Replenish
2 Engine Drain/ Engine oil – Drain and Refer to the Engine Section.
Replenish replenish with new oil
3 Engine Replace Engine lubrication oil Refer to the Engine Section.
filter
4 Engine Clean Centrifugal oil filter Refer to Note 2 , page 4-8
5 Drive Lines Check/ Universal joints Refer to Note 3 , page 4-8
Replace
6 Fuel Check/ Fuel cap strainer Refer to Note 4 , page 4-8
Replace/
Clean
7 Dropbox Drain/ Oil and oil filter Refer to Note 5 , page 4-8
Replenish/
Replace
8 Brake Check/ Accumulator gas Refer to Note 6 , page 4-8
Replace pressures

NOTICE
1 Battery acid level checks and any necessary replenishment must be conducted every 500
hours. Battery levels must be maintained at -40 mm from the surface of the battery lid.
Only distilled and deionized water can be used to top up the battery. Do not use mineral
water, as the constituent impurities are known to accelerate self-discharge and water loss.
At no point during operation or storage must the plates/separators be allowed to be
exposed, above the acid level.
Batteries must be allowed to rest for no less than 1 hour after re-charge, prior to
replenishment. This will allow the acid to stabilize in the event that it was gassing off during
re-charge.
The batteries must be topped up when fully charged, i.e. > 12.70 V or > 1.275 specific
gravity/cell. Acid expands as the state of charge increases, so there is a risk of overfilling
the battery when filled in a discharged state. If this is unavoidable and the battery is in a
discharged state, add sufficient water to cover the plates/separators. Once recharged, the
acid level must be re-assessed.
2 Clean/remove deposits from the Centrifugal Oil Cleaner. Replace paper insert.
3 Check the universal joints (front and rear) for wear. Replace if required.
4 Check the fuel cap for damage, replace if required. Clean the fuel cap and the fuel strainer
with clean fuel.
5 Drain the dropbox oil, replace the pressure filter. Replenish with new oil.
6 Check the three accumulators nitrogen pressure. Replenish if required. Refer to the
Maintenance Manual.

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 Maintenance 4

(h) After First 500 Hours of Operation or Rebuilt Components

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.8 - After First 500 Hours of Operation or Rebuilt Components
Ref. Identification Task Service Instructions Remarks
1 Engine Check/ Engine valve clearance Refer to Note 1 , page 4-9
Adjust

NOTICE
1 Valve clearance should be adjusted when the engine is cold, at least 30 minutes after shut
down.
Readings can be taken from the flywheel through the covers in the flywheel housing. Either
from above or underneath depending on access when fitting.
TDC up or TDC down is found on the flywheel. Both openings are fitted with a blanking
plate at delivery.
Intake valve clearance: 0.45 mm (0.018 in.).
Exhaust valve clearance: 0.70 mm (0.028 in.).

(i) Every 1000 Hours of Operation

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.9 - Every 1000 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Hydraulic Replace Hydraulic tank breather Refer to Note 1 , page 4-10
2 Brakes Replace OCDB Hydraulic tank Refer to Note 2 , page 4-10
breather
3 Fuel Replace Fuel filters Refer to Note 3 , page 4-10
4 Drive Shaft Check/ Bearing housing – Oil Refer to Note 5 , page 4-10
Replenish level
5 Cabin air Replace Fresh air filter Refer to Note 6 , page 4-10
6 Fuel Replace Fuel tank filler cap Refer to Note 7 , page 4-10
7 Batteries Check/ Charge Refer to the Electrical
Clean Section.
8 Engine Check Belt drive Refer To Note 8 , page 4-10
9 Hydraulic Check System pressures Refer to Note 9 , page 4-10
10 Brakes Check System/Treadle valve Refer to Note 10 , page 4-10
11 Machine – All Lubrication Various lubrication Refer to (1) Recommended
points Lubricants on page 4-16

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4 Maintenance

NOTICE
1 Hydraulic tank breather – replace. If the machine is being operated in extremely dusty
conditions, replace the hydraulic tank breather at earlier intervals.
2 OCDB hydraulic tank breather – replace. If the machine is being operated in extremely
dusty conditions, replace the hydraulic tank breather at earlier intervals.
3 There is a dual fuel filter in the form of a water separating suction filter and a pressure filter.
Clean the area around the fuel filter head and replace the fuel filter.
This service interval is dependent on fuel quality. If a lesser grade of fuel is used than
that specified within the (1) Recommended Lubricants on page 4-16, the service interval
should be decreased accordingly.
4 Remove the plug from the port, on the underside of the oscillation hub. The plug is removed
to drain the cavity of any oil that enters the cavity when replenishing. Remove the cover
plate and the level plug on the side of the oscillation hub. Replenish the oil if required.
Refit all plugs and the cover plate.
5 The replacement cabin fresh air filter must comply with ISO 10263–2:2009.
6 Replace the fuel tank filler cap, breather/filter assembly.
This service interval is dependent on fuel quality. If a lesser grade of fuel is used than that
specified within the recommended lubricants, the service interval should be decreased
accordingly.
7 Visually inspect the drive belt for damage. A correctly installed and tensioned belt will
show even pulley and belt wear. Refit the drive belt in the same direction of rotation as it
had been before removal.
8 Check all steering, body and braking system pressures.
Instructions for checking pressure, and locations of pressure check points, are contained
in the relevant maintenance manual sections. If the pressures are out with the specified
settings then the components in the relevant system should be inspected, repaired or
replaced to ensure the correct operation of the system. All safety instructions in the relevant
sections should be strictly adhered to.
9 Check the front and rear brake pressures at the remote diagnostic points. If the pressures
are not within the specified pressure range, refer to the maintenance manual, braking
system troubleshooting table and the Braking System Schematic Section.
Check all the hydraulic brake lines and fittings and the treadle valve for leaks and damage.
Tighten/replace as required.

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 Maintenance 4

(j) Every 2000 Hours of Operation

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.10 - Every 2000 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Hydraulic Drain/ Hydraulic oil tank Refer to Note 1 , page 4-12
Replenish/
Clean
2 Hydraulic Replace Oil filter Refer to Note 2 , page 4-12
3 Hydraulic Clean Magnetic oil filter Refer to Note 2 , page 4-12
4 Articulation/ Check Pivot nut Refer to Note 3 , page 4-12
Oscillation
5 Cooling Check Radiator header tank – Refer to Note 4 , page 4-12
coolant
6 Drivelines Check Low maintenance Refer to Note 5 , page 4-12
drivelines
7 Engine Check Engine – Mounting bolts Refer to Note 6 , page 4-12
8 Transmission Check Transmission – Mounting Refer to Note 7 , page 4-12
bolts
9 Engine Check/ Engine valve clearance Refer to Note 8 , page 4-12
Adjust
10 Axle – Check Axle – Mounting bolts Refer to Note 9 , page 4-12
Rear/Centre
11 Engine Replace Air cleaner filters Refer to Note 10 , page
4-12
12 Differentials Drain/Re- Differentials - Drain and
plenish replace with new oil
13 Planetaries Drain/Re- Planetaries - Drain and
plenish replace with new oil
14 OCDB Drain/Re- Hydraulic tank – Drain
plenish and replace with new oil
15 OCDB Replace Hydraulic spin on filter
16 OCDB Clean Strainer
17 OCDB Clean Hydraulic tank - Magnetic
filter

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4 Maintenance

NOTICE
1 Drain the oil, replenish the tank with new oil.
2 Remove the filter assembly from the Hydraulic Tank, remove and discard the filter element.
Clean the filter assembly, fit new element to the filter assembly. Refit the filter assembly to
the Hydraulic Tank.
The filter replacement should be completed at the same time as task number 1.
3 The Hydraulic tank magnetic filter should be cleaned or replaced if required, at the same
time as the hydraulic tank oil change. Refer to task number 1.
4 Check and re-torque Pivot Nut to 1425 Nm (1050 lbf ft.).
5 Check the coolant level, coolant condition and measure the antifreeze content. Change the
coolant if the condition is contaminated or cloudy.
6 Visually check the low maintenance drivelines for leaking or damaged seals.
Low maintenance drivelines can be identified as having plugs fitted to the spiders, not
grease nipples.
7 Check and re-torque mounting to 457 Nm (330 lbf ft.).
8 Check and re-torque mounting bolts to 790 Nm (570 lbf ft.).
9 Valve clearance should be adjusted when the engine is cold, at least 30 minutes after shut
down.
Readings can be taken from the flywheel through the covers in the flywheel housing. Either
from above or underneath depending on access when fitting.
TDC up or TDC down is found on the flywheel. Both openings are fitted with a blanking
plate at delivery.
Intake valve clearance: 0.45 mm (0.018 in.).
Exhaust valve clearance: 0.70 mm (0.028 in.).
10 Check and re-torque Control Link Assembly bolts (x 8) to 457 Nm (337 lbf ft.), Suspension
Beam bolts (x 16) to 169 Nm (125 lbf ft.).
11 Replace the primary and secondary engine air cleaner filters.
12 Clean/remove deposits from the Centrifugal Oil Cleaner. Replace paper insert.
13 Perform the oil change when the oil is warm. This task is to be carried out at the same time
as the planetaries oil change, Refer to task 14.
14 Perform the oil change when the oil is warm. This task is to be carried out at the same time
as the differentials oil change, Refer to task 13.
15 The OCDB filter should be replaced at the same time as the OCDB oil change. Refer to
task number 15.
The filter should also be replaced when the gauge indication is not green.
16 Clean the OCDB strainer with a suitable solvent and dry with compressed air. This task
should be carried out at the same time as the OCDB oil change. Refer to task number 15.
17 The OCDB tank magnetic filter should be cleaned or replaced if required, at the same time
as the OCDB oil change. Refer to task number 15.

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 Maintenance 4

(k) Every 3000 Hours of Operation

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.11 - Every 3000 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Transmission Replace Oil filters Refer to Note 1 , page 4-13

NOTICE
1 Replace the Main and Lube oil filters. Filters are supplied as a kit (Part No. 29545779).
After the filters are replaced, reset the filter life monitor.

(l) Every 4000 Hours of Operation

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.12 - Every 4000 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Air Drain/ Compressor – Refer to the Operators
Conditioning Clean/ Refrigerant oil Compartment Section.
Replenish

(m) Every 6000 Hours of Operation

The following table lists the recommended maintenance/servicing instructions. The frequency
of the maintenance/service instructions can be reduced if the machine is operated in adverse
conditions.
Table 4.13 - Every 6000 Hours of Operation
Ref. Identification Task Service Instructions Remarks
1 Transmission Drain/ Oil Refer to Note 1 , page 4-13
Replenish
2 Cooling Drain/ Coolant/Antifreeze Refer to the Cooling System
System Clean/ Section.
Replenish

NOTICE
1 Drain the transmission oil, and replenish with new oil.
When the oil is replaced the oil life monitor must be reset.

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4 Maintenance

4.2 Non-scheduled Maintenance

� WARNING
• Electrical and electronic connections, the Engine ECM and harness connections must be
protected or not directly steam cleaned when on or removed from the engine.

NOTICE
• The engine and its components that are scheduled to be checked, serviced or replaced
must be cleaned in accordance with the manufacturer's recommendations.

Seat Belts - Inspect for damage. Replace if required.

ROPS Cab - Inspect for damage. Carry out corrective action where required.
Windscreen Wipers And Washers - Inspect wiper blades and replace if damaged. Top up
washer reservoir.
Engine Air Cleaner - Replace the primary air filter when the Air Restriction Filter Indicator on
the Left of Dashboard Display illuminates, to warn of contamination.
The secondary air filter is also to be replaced every third replacement of the primary filter.
Engine - Steam clean the engine prior to performing any repair or service work on it, if heavily
contaminated due to prevailing site conditions.
Oil Cooled Disk Brakes -A squeaking noise is an indication of abnormal wear, and necessitates
an internal examination of the brakes.

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 Maintenance 4

4.3 Air Condition Commissioning Procedure

NOTICE
• If the machine has been idle overnight or for an extended period of time, the refrigerant
in the air conditioning unit converts from a gas to a liquid. This puts the compressor unit
under a great deal of strain trying to compress a liquid instead of a gas, and will cause a
failure of the air conditioning unit. The following commissioning procedure allows the air
conditioning unit to achieve normal operating parameters.

PROCEDURE
1. Start the machine and allow it to run until the engine is at a normal operating temperature
of 80° C (176° F).
2. Turn the blower control to setting 1.
3. Turn on the air conditioning unit on for 5 seconds then off for 5 seconds.
4. Repeatedly switch the air conditioning on and off for at least 1 minute. This must be at
least 12 repetitions.
5. Commissioning the air conditioning unit is complete and ready for use.

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4 Maintenance

4.4 Lubrication System

(1) Recommended Lubricants

NOTICE
Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures
are consistently above or below those listed.

Table 4.14 - Recommended Lubricants

COMPONENT LUBRICANT SPECIFICATIONS SAE GRADE
Engine Crankcase Engine Oil with 1.00% ACEA E5 / API CI-4 15W-40
(including filters) sulphated ash limit is ACEA E7 / API CI-4 + (Refer to Note 1 ,
recommended. Sulphated (Refer to Note 5 , page 4-17)
ash must not exceed 1.85% page 4-17)
limit
Transmission Engine Oil with 1.85% max. TES295 15W-40
(including cooler) sulphated ash limit (Refer to Note 6 , (Refer to Note 2 ,
page 4-17) page 4-17)
Hydraulic system Hydraulic Transmission Oil Allison C-4 10W
(including lines)
Hydraulic system Flame Retardant Hydraulic ISO 12922 Shell IRUS DU
(including lines) Oil Classification HFDU - 46
(Option) ISO 6743–4 (Refer to Note 7 ,
page 4-17
Cooling system Anti-freeze, Ethylene Glycol
Differentials Extreme Pressure Gear ZF TE-ML 05
Lubricant (Refer to Note 3 ,
page 4-17)
Planetaries Extreme Pressure Gear ZF TE-ML 05
Lubricant (Refer to Note 4 ,
page 4-17)
Dropbox Engine oil ACEA E5 / API CI-4 15W-40
ACEA E7 / API CI-4 +
Fuel tank Diesel Fuel Oil with max. DIN EN590
sulphur 0.5%
Grease nipples Extreme Pressure Lithium No.2
Grease Consistency
Drive shaft through Extreme Pressure Gear SAE J2360 80W-90
bearings Lubricant
Articulation Extreme Pressure Lithium
Bearings Complex
Hand pump tank Hydraulic Transmission Oil Allison C4 10W
Hand pump tank Flame Retardant Hydraulic ISO 12922 Shell IRUS DU
Oil Classification HFDU - 46
(Option) ISO 6743–4 (Refer to Note 7 ,
page 4-17

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 Maintenance 4

COMPONENT LUBRICANT SPECIFICATIONS SAE GRADE

Air conditioning Polyalklene Glycol (PAG) ISO46 SP 10
compressor Low Viscosity
Brake cooling UTTO (Universal Tractor ZF TE-ML 05
system Transmission Oil) (Refer to Note 4 ,
page 4-17)

NOTICE
1 The use of low viscosity oils, such as 10W-30 or 5W-30, can be used to aid in starting the
engine and providing sufficient oil flow at low ambient temperatures. Continuous use of low
viscosity oils can decrease engine life due to adverse wear.
2 Operation below the minimum temperatures listed for the oil used without proper preheat
or warmup results in greatly reduced transmission life. Proper warm-up requires 20
minutes minimum operation in neutral (with engine at part throttle) before operating the
transmission in gear.
3 ZF TE-ML 05. List of approved lubricants for ZF Axles for off-road vehicles. 05C, 05D,
05G, 05H
4 ZF TE-ML 05. List of approved lubricants for ZF Axles for off-road vehicles. 05F, 05G, 05H
5 If the engine is operated in areas of the world where lubricating oil with ACEA or API
classification is not available, the oil grade must be measured in actual operation. In this
case contact the nearest Scania workshop.
6 Only use Allison Transmission approved fluids (TES 295).
When determining whether a fluid is TES 295 approved or not look and/or ask for one of
two things - The Allison TES 295 approval number or the Allison approved logo { }. If
uncertain, consult Allison Transmission for confirmation.
7 Flame retardant hydraulic oil (option). Use Shell oil IRUS DU 46. Drain and flush the
whole mineral oil hydraulic system completely, replace all filters, before filling with new
flame retardant oil.

(a) Specific Information on Lubrication

Engine
Scania engines meet ACEA E7 Specifications.
Other grade oils can be used depending on temperatures:
SAE20W-30 = -15 deg C to +30 deg C
SAE30 = -10 deg C to +30 deg C
SAE40 = -5 deg C to >+45 deg C
SAE50 = 0 deg C to >+45 deg C
SAE5W-30W = <-40 deg C to +30 deg C
SAE10W-30 = -25 deg C to +30 deg C
SAE15W-40 = -20 deg C to >+45 deg C

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4 Maintenance

(2) Lubrication Points

Lubrication is an essential part of preventive maintenance. It is important that the instructions
regarding types of lubricants and the frequency of their application be followed to prolong the
useful life of the machine. Periodic lubrication of moving parts reduces to a minimum the
possibility of mechanical failures.
Thoroughly clean all fittings, caps, and plugs, to prevent dirt from entering the system while
servicing. Lubricants must be at operating temperature when draining.
Do not operate any system unless its oil level is within the operating range as indicated on
oil level dip stick, sight gauge or level plug.
Small circles on the following illustrations represent points at which lubrication or servicing
must take place, at the intervals indicated on the left-hand side of the lubrication chart. The
numbers on the illustrations contain reference numbers which correspond to the 'Ref. Points'
column of the chart.
All change and service periods are recommendations based on average operating conditions.
Lubricants showing evidence of excessive heat, oxidation or dirt must be changed more
frequently. Lubricant change and service periods must be established on the basis of individual
job conditions.

Figure 4.1 - Lubrication Points

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 Maintenance 4

Table 4.15 - Lubrication Chart

Interval Ref. Identification Service No. of Lubricant Service/
Hours Points Instructions Points Quantities
50 1 Oscillation Lubricate 2 EP, NLGI See Note 1 ,
Bushes page 4-19
2 Panhard Rod Lubricate 4 EP, NLGI See Note 1 ,
Bearings page 4-19
3 Body Hinge / Lubricate 2 EP, NLGI See Note 1 ,
Tailgate page 4-19
4 Suspension Lubricate 2 EP, NLGI See Note 1 ,
Beam Bushings page 4-19
5 Body Cylinder Lubricate 4 EP, NLGI See Note 1 ,
Pins page 4-19
6 Steering Cylinder Lubricate 4 EP, NLGI See Note 1 ,
Pins page 4-19
250 8 Articulation Lubricate 2 EP, NLGI See Note 1 ,
Bearings page 4-19
1000 - Door Hinges Lubricate - - -
EP, NLGI Extreme Pressure Lithium No. 2 Grease (without 'Molybdenum')

NOTICE
1 Lubricate slowly until excess lube is seen.

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4 Maintenance

Intentionally Left Blank

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 Engine 5

Table of Content
5 Engine..........................................................................................................5-1
5.1 Description ..................................................................................................... 5-3
5.2 Operation ....................................................................................................... 5-5
5.3 Removal ......................................................................................................... 5-5
5.4 Installation ...................................................................................................... 5-9
5.5 S6 Engine Management System (EMS) ...................................................... 5-11
5.6 ECU/TCU Diagnostic Screen ....................................................................... 5-12
5.7 Failure Mode Identifiers................................................................................ 5-13
5.8 List of Fault Codes ....................................................................................... 5-14
5.9 Cleaning ....................................................................................................... 5-23
5.10 Drive Belts.................................................................................................... 5-24
(1) Description............................................................................................... 5-24
(2) Maintenance ............................................................................................ 5-24
(3) Removal .................................................................................................. 5-26
(4) Installation ............................................................................................... 5-26
5.11 Starting......................................................................................................... 5-27
5.12 Stopping ....................................................................................................... 5-28
5.13 Oil – Drain/Replenish ................................................................................... 5-29
(1) Maintenance ............................................................................................ 5-29
(2) Drain ........................................................................................................ 5-29
(3) Replenish/Check ..................................................................................... 5-29
5.14 Oil Filter – Replacement............................................................................... 5-30
5.15 Centrifugal Oil Filter ..................................................................................... 5-31
(1) Maintenance ............................................................................................ 5-31
(2) Cleaning .................................................................................................. 5-31
(3) Operational Testing................................................................................. 5-34
5.16 Air Cleaner ................................................................................................... 5-35
(1) Description............................................................................................... 5-36
(2) Removal .................................................................................................. 5-37
(3) Installation ............................................................................................... 5-37
(4) Filter Removal ......................................................................................... 5-38
(5) Filter Installation ...................................................................................... 5-38
5.17 Exhaust System ........................................................................................... 5-39
(1) Exhaust and Mounting............................................................................. 5-39
(2) Description............................................................................................... 5-40
(3) Removal .................................................................................................. 5-40
(a) Exhaust Front Section Pipe ................................................................ 5-40
(b) Exhaust Rear Section Pipe ................................................................. 5-41
(c) Exhaust Middle Section Pipe .............................................................. 5-41
(d) Silencer to Diverter Box Exhaust Pipe ................................................ 5-42
(e) Stack Pipe........................................................................................... 5-42
(f) Silencer ............................................................................................... 5-43
(4) Installation ............................................................................................... 5-44
(a) Exhaust Middle Section Pipe .............................................................. 5-44
(b) Exhaust Rear Section Pipe ................................................................. 5-45
(c) Exhaust Front Section Pipe ................................................................ 5-45
(d) Stack Pipe........................................................................................... 5-46
(e) Silencer to Diverter Box Exhaust Pipe ................................................ 5-46

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5 Engine

(f) Silencer ............................................................................................... 5-47

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 Engine 5

5 Engine
5.1 Description

MOT04931

Figure 5.1 - Engine and Component Identification

1. Turbocharger 6. Coolant Pump 11. Fuel - Hand Pump
2. Oil Cooler 7. Coolant Drain 12. Starter Motor
3. Oil Filler 8. Centrifugal Oil Cleaner 13. Oil Dipstick
4. Engine Serial Number 9. Engine Data Plate 14. Oil Drain Plug
5. Oil Filter 10. Fuel Filter 15. Engine Control Unit

The Scania in-line 6 cylinder engine, with turbocharger, is designed for optimum power
generation. It is based on a robust design with a strength optimized cylinder block containing
easily exchanged wet cylinder liners. Individual cylinder heads with 4 valves per cylinder
promotes easy repair ability and fuel economy.
The engine is equipped with an Engine Management System, EMS, in order to ensure the
control of all aspects related to engine performance.
The fuel injection system is Scania’s PDE (Pumpe-Düse-Einheit).

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5 Engine

The engine is fitted with many uniquely designed accessories to enhance fuel economy and
operating performance:
• Scania Engine Management System, EMS
• Fuel injection system, PDE
• Turbocharger
• Fuel filter and extra pre-filter with water separator
• Fuel heater
• Oil filter, full flow
• Centrifugal oil cleaner
• Oil cooler, integrated in block
• Oil filler, in valve cover
• Deep front oil sump
• Oil dipstick, in block
• Magnetic drain plug for oil draining
• Starter, 1-pole 5.5 kW
• Alternator, 1-pole 100A
• Flywheel, for use with friction clutch
• Silumin flywheel housing, SAE 1 flange
• Front-mounted engine brackets
• Open crankcase ventilation

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 Engine 5

5.2 Operation
The Scania DC-13 diesel engine is an internal combustion engine that uses the heat of
compression to initiate ignition burn and burn off the fuel that has been injected into the
combustion chamber.
The engine has high thermal efficiency due to its very high compression ratio and inherent lean
burn which enables heat dissipation by the excess air. Parasitic losses from initial start-up are
compensated by the transmission torque converter as the engine’s power is transferred to
the truck’s drivelines.
Simultaneous to the fuel process is the air process which passes through the air cleaner and
turbocharger to provide greater volumes of air into the cylinders which in turn provides greater
power and fuel economy.
5.3 Removal
MOT00376

4 2

8
7

5
6
7
9
8
7

5
3
7
9

Figure 5.2 - Engine and Mounting

1. Engine Assembly 4. Oil Filter 7. Snubbing Washer
2. Fuel Filter Assembly 5. Isolation Mount 8. Hardened Washer
3. V-belt 6. Bolt 9. Nyloc Nut

Numbers in parentheses refer to Figure 5.2, unless otherwise specified.

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5 Engine

� DANGER
• 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.
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the 'OFF' position before removing any components. Remove the battery
ground cable first, and reconnect last, to avoid damaging the electrical components.
• Before disconnecting any air conditioner lines, refer to (a) Discharging the System on page
20-12. Refrigerant will rapidly freeze all objects with which it comes into contact. It can
cause serious and permanent damage to the eyes and skin.
• The fuel system should always be thought of as being highly pressurized, even when the
engine is switched off. The fuel system has extreme high pressure of up to 3,000 bar.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

NOTICE
• Tag all cables, harnesses, lines and pipes disconnected during removal to aid in installation.
• References to the powertrain relate to the combined engine and transmission.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine. Turn steering wheel several times to relieve any
pressure in the steering circuit.
2. Block all road wheels.
3. Raise the hood. Refer to (5) Raising the Hood on page 16-38.
4. Place the battery master switch in the 'OFF' position. Refer to Figure 15.102.
5. Disconnect the battery cables from the terminal posts (-ve cable first). Refer to (a) Removal
on page 15-59.
6. Locate and use the hydraulic hand pump to tilt the cab and secure. Refer (4) Tilting the
Cab on page 19-12.
7. Remove the hood from the machine. Refer to (1) Removal on page 16-34.
8. De-pressurize the fuel system.
9. Drain the cooling system. Refer to 18.1 Description on page 18-2.
10. Remove the radiator assembly from the machine. Refer to 18.1 Description on page 18-2.
11. Remove the engine air cleaner. Refer to 5.16 Air Cleaner on page 5-35.
12. Drain and remove the oil cooler system. Refer to 18.1 Description on page 18-2.
13. Gain access to the engine drain valve, through the inspection cover on the engine sump
guard.
14. Place a suitable container under the engine drain port, remove the drain plug and drain the
oil. After draining, reinstall the drain plug in the engine sump and tighten securely.

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 Engine 5

15. Gain access to the transmission drain valve, on the transmission sump.
16. Place a suitable container under the transmission drain port, remove the drain plug
protective cap, install a suitable hose to the drain plug and drain the oil. After draining,
remove the hose and reinstall the drain plug protective cap and tighten securely.
17. Evacuate the air conditioning system and disconnect the air conditioner lines at the engine
compressor. Refer to Figure 20.5.
18. Remove the charge air cooler pipes from the engine turbocharger and engine inlet manifold.
Refer to 18.1 Description on page 18-2.
19. Disconnect the exhaust piping from the engine turbocharger and the diesel oxidization
catalyst. Refer to (a) Exhaust Front Section Pipe on page 5-40.
20. Remove the radiator header tank from the air cooler bracket. Refer to 18.1 Description
on page 18-2.
21. Disconnect the air cleaner intake pipe from the air cleaner and the engine turbocharger and
remove from the engine. Refer to 5.16 Air Cleaner on page 5-35.
22. Remove the air cleaner. Refer to 5.16 Air Cleaner on page 5-35.
23. Identify, tag and with a suitable container in position, disconnect the engine heater lines
(engine in 1, 2 and engine out 1, 2). Refer to Figure 20.3.
24. Identify, tag and with a suitable container in position, disconnect the engine Air Conditioning
cooling lines (compressor - in, out). Refer to Figure 20.5.
25. Identify, tag and with a suitable container in position, disconnect the engine fuel lines
(engine feed and engine return to tank). Refer to Figure 10.2.
26. Identify, tag and disconnect the electrical connections as follows:
a. Air Clutch connection - A1.V2
b. Fuel Heater connection - A1.XHeat
c. Air Cleaner Pressure Restriction connection - B4.X
d. Fuel Level Sensor connection - B5.X
e. EMS Interface connection - A1.C4001
f. Customer Interface connection - A1.C4071
g. Scania Interface connection - A1.C4002
h. SCR Interface connection - A1.C4022 (EEC3, E67)
i. Starter Motor connection - A1.M1
j. Ground connection - M10:1- X1
Install protective caps to all connections, to prevent any ingress of dirt.
27. Identify, tag and disconnect the transmission harness at connector break A2.X. Cap all
connections to prevent ingress of dirt.
28. Remove nuts, bolts and washers securing the transmission speed sensor harness bracket,
to the chassis cross member assembly.
29. Remove the cross member assembly. Refer to Figure 16.1.
30. Identify, tag and disconnect the transmission breather and dipstick assemblies from the
support bracket (25, 26, 27, 12, 13, 14 and 15, Figure 6.1).
31. Identify, tag and with a suitable container in position, disconnect the transmission cooling
lines (transmission sump cooler - in, out and transmission retarder cooler - in, out). Refer to
18.1 Description on page 18-2.
32. Identify, tag and with a suitable container in position, disconnect the transmission breather
line. Refer to 6.1 Transmission and Mounting on page 6-2.
33. Identify, tag and with a suitable container in position, disconnect the dropbox gear pump
connections (outlet - top and inlet - bottom). Refer to Figure 7.6.

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34. Using suitable lifting equipment, disconnect and remove (if required) the front driveline (9C)
from the transmission to the transmission dropbox. Refer to 7.1 Dropbox and Mounting on
page 7-3.
35. Using suitable lifting equipment, attach to the powertrain assembly and raise to take up
the slack.
36. At the engine mounting brackets, remove the locknuts (18), snubbing washers (16), bolts
(14), washers (15) and isolation mounts (17).
37. At the transmission mounting brackets, remove the locknuts (13), washers (12), rebound
washers (11), bolts (1), washers (4), bolts (2), washers (3) bracket boss (7) and isolation
mounts (10).
38. Check to make certain that all necessary lines and electrical disconnections have been
made before lifting the powertrain.
39. Carefully lift the powertrain clear of the frame, remove to a suitable work area and mount
securely on work stands.

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5.4 Installation
Numbers in parentheses refer to Figure 5.2, unless otherwise specified.

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

NOTICE
• The Engine and the Transmission are installed together as one Powertrain Assembly.
Refer to 6.1 Transmission and Mounting on page 6-2.
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Position the powertrain assembly adjacent to the machine frame assembly.
2. Using suitable lifting equipment, attach to the powertrain assembly and raise to take up
the slack.
3. Carefully lift the powertrain assembly and locate on the front frame assembly.
4. Apply grease to the transmission mounting bolts (1)
5. Secure the powertrain assembly at the transmission mounting brackets, using the locknuts
(13), washers (12), rebound washers (11), bolts (1), washers (4), bolts (2), washers (3)
bracket boss (7) and isolation mounts (10). Torque tighten bolts (1) to 790 Nm (570 lbf ft).
6. Secure the powertrain assembly at the engine mounting brackets, using the locknuts (18),
washers (16), bolts (14), washers (15) and isolation mounts (17). Torque tighten bolts
(14) to 457 Nm (330 lbf ft).
7. Using suitable lifting equipment, install the front driveline (9C) from the transmission to the
transmission dropbox. Refer to 7.1 Dropbox and Mounting on page 7-3.
8. Identify, and connect the dropbox gear pump connections (outlet - top and inlet - bottom).
Refer to Figure 7.6.
9. Identify, and connect the transmission breather line. Refer to 6.1 Transmission and
Mounting on page 6-2.
10. Identify and connect the transmission cooling lines (transmission sump cooler - in, out
and transmission retarder cooler - in, out).
11. Identify, and connect the dipstick assemblies to the support bracket (15 and 47, Figure 6.1).
12. Install the cross member assembly (14, Figure 16.1).
13. Install the nuts, bolts and washers and secure the transmission speed sensor harness
bracket, to the chassis cross member assembly.
14. Remove protective caps, identify, and connect the transmission harness to the connector
break A2.X.

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15. Remove protective caps, identify, and connect the electrical connections as follows:
a. Ground connection - M10:1- X1
b. Starter Motor connection - A1.M1
c. SCR Interface connection - A1.C4022 (EEC3, E67)
d. Scania Interface connection - A1.C4002
e. Customer Interface connection - A1.C4071
f. EMS Interface connection - A1.C4001
g. Fuel Level Sensor connection - B5.X
h. Air Cleaner Pressure Restriction connection - B4.X
i. Fuel Heater connection - A1.XHeat
j. Air Clutch connection - A1.V2
16. Identify, and connect the engine Fuel lines (engine feed and engine return to tank). Refer
to Figure 10.2.
17. Identify, and connect the engine Air Conditioning cooling lines (compressor - in, out). Refer
to Figure 20.3.
18. Identify, and connect the engine heater lines (engine in 1, 2 and engine out 1, 2). Refer
to Figure 20.3.
19. Connect the air cleaner intake pipe to the air cleaner and the engine turbocharger and
install to the engine. Refer to 5.16 Air Cleaner on page 5-35.
20. Install the radiator header tank to the air cooler bracket. Refer to 18.1 Description on
page 18-2.
21. Connect the exhaust piping to the engine turbocharger. Refer to Figure 5.19.
22. Install the charge air cooler pipes to the engine turbocharger and engine inlet manifold.
23. Connect the air conditioner lines at the engine compressor and charge the air conditioning
system. Refer to and (b) Charging New or Completely Empty Systems on page 20-14.
24. Install the engine air cleaner. Refer to 5.16 Air Cleaner on page 5-35.
25. Install the radiator assembly to the machine. Refer to 18.1 Description on page 18-2.
26. Replenish the engine oil system. Refer to 5.13 Oil – Drain/Replenish on page 5-29.
27. Replenish the transmission oil system. Refer to 6.1 Transmission and Mounting on page
6-2.
28. Replenish the oil cooler system.
29. Bleed the fuel system. Refer to (4) Bleeding the Fuel System on page 10-13.
30. Install the hood. Refer to (2) Installation on page 16-36.
31. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
32. Connect the battery cables to the terminal posts (-ve cable last). Refer to (b) Installation
on page 15-60.
33. Place the battery master switch in the 'ON' position. Refer to Figure 15.102.
34. Lower the hood. Refer to(6) Lowering the Hood on page 16-39.
35. Start the engine and check for leaks. Tighten all fittings and top up all systems as required.
36. Check the ECU / TCU diagnostic screen for any faults, rectify any faults be fore proceeding.

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5.5 S6 Engine Management System (EMS)

NOTICE
• The engine MUST be started with foot 'OFF' the electronic foot pedal.

The S6 EMS has been introduced with improved memory addressing, and is prepared for future
demands. The EMS receives electronic inputs from the driver as well as from mounted sensors
that provide information electronically. This information is used to control both the quantity of
fuel injected and the injection timing.
(1) Electronic Foot Pedal
The electronic foot pedal provides an electrical signal to the engine's fuel control system in
proportion to the degree of pedal actuation.
Do not place the engine under full load at full speed immediately after starting. Always allow the
engine to fully circulate lubricant and warm up gradually before operating at full speed and full
load. Operate the engine at top rated speed when maximum power is needed for the load.
(2) Stop Engine Light
When the 'Stop Engine' light comes on (3, Figure 5.3), the computer has detected a major
malfunction in the engine that requires immediate attention. It is the operator’s responsibility to
shut down the engine to avoid serious damage.
(3) Check Engine Light
When the 'Check Engine' light comes on (4, Figure 5.3), the computer has detected a fault in
the engine. The fault should be diagnosed and corrected at the earliest opportunity.

Figure 5.3 - Warning Lights and Symbols - Left

1. Engine Coolant Level 4. Engine Check Light 7. Alternator Charging
2. Engine Oil Pressure 5. Engine Exhaust Brake 8. Parking Brake
3. Engine Stop Light 6. Air Restriction Filter
Indicator

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5.6 ECU/TCU Diagnostic Screen

NOTICE
• Fault Codes are displayed in Diagnostic display screen. Refer to Figure 5.4.

Figure 5.4 - Diagnostic Screen Figure 5.5 - Transmission Diagnostic

The Diagnostic Screen shows the current Fault Status of the engine and the transmission.
ENGINE DIAGNOSTICS is based on the DM1 Message sent by the ECU via CAN. The ECU
sends no more than 10 Fault Codes and the status of the Amber Warning Lamp and the
Red Stop Lamp. If there is more than 1 fault active the Suspect Parameter Number (SPN),
the Failure Mode Identifier (FMI) and the Occurrence Count (OC) is displayed cyclically in
1 second intervals.
(a) Operation
The machine is equipped with an engine protection derate system, which records fault codes
and illuminates appropriate warning lights when an out-of range condition associated with any
of the following sensors is found:
• Engine speed sensor
• Oil temperature sensor
• Boost pressure sensor
• Boost temperature sensor
The engine power and speed will be gradually reduced depending on the level of severity of the
Out of Range condition. The operator MUST shut down the engine to avoid serious damage.
The engine should not be restarted after it has been shut down after activation of the engine
protection derate system unless the problem has been diagnosed and corrected.
Whenever the 'Engine Stop' or 'Engine Check' light comes on, the EMS will determine where
the problem is and will store this information in its memory. If the malfunction is intermittent,
the lights will come on and go off as the computer senses the changing engine condition. The
fault codes are displayed in the Diagnostic screen (Figure 5.4).

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5.7 Failure Mode Identifiers

Table 5.1 - Explanation of FMI Codes.
Code Explanation
0 Data valid but above normal operational range (that is, engine overheating)
1 Data valid but below normal operational range (that is, engine oil pressure too
low)
2 Data erratic, intermittent, or incorrect
3 Voltage above normal or shorted high
4 Voltage below normal or shorted low
5 Current below normal or open circuit
6 Current above normal or grounded circuit
7 Mechanical system not responding properly
8 Abnormal frequency, pulse width, or pending
9 Abnormal update rate
10 Abnormal rate of change
11 Failure mode not identifiable
12 Bad intelligent device or component
13 Out of calibration
14 Special instructions
15 Data valid but above normal operating range - least severe level
16 Data valid but above normal operating range - moderately severe level
17 Data valid but below normal operating range - least severe level
18 Data valid but below normal operating range - moderately severe level
19 Received network data in error
20 Data drifted high
21 Data drifted low

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5.8 List of Fault Codes

Table 5.2 - List of Fault Codes
SPN SPN Name SPN Description FMIa
46 Pneumatic Supply Pressure The pneumatic pressure in the main
reservoir, sometimes referred to as the
wet tank.
51 Engine Throttle Position The position of the valve used to regulate 0,1,2,3,4,5
the supply of a fluid, usually air or fuel/air
mixture, an engine.
91 Accelerator Pedal Position 1 The ratio of actual position of the analogue
engine speed/torque request input device
(such as an accelerator pedal or throttle
lever) to the maximum position of the
input device.
94 Engine Fuel Delivery Gauge pressure of fuel in the system as 0
Pressure delivered from the supply pump to the
injection pump.
97 Water In Fuel Indicator Signal which indicates the presence of
water in the fuel.
98 Engine Oil Level Ratio of current volume of engine sump 2,3,4
oil to maximum required volume.
100 Engine Oil Pressure Gauge pressure of oil in the engine 0,1,2,3,4
lubrication system as provided by the oil
pump.
102 Engine Intake Manifold #1 The gauge pressure measurement of the 0,1,2,3,5
Pressure air intake manifold.
103 Engine Turbocharger 1 Rotational velocity of rotor in the
Speed turbocharger.
105 Engine Intake Manifold 1 Temperature of pre-combustion air found 0,2,3,4
Temperature in the intake manifold number 1 of the
engine air supply system.
107 Engine Air Filter 1 Differential Change in the engine air system pressure, 1
Pressure measured across the filter, due to the filter
and any accumulation of solid foreign
matter on or in filter.
108 Barometric Pressure Absolute air pressure of the atmosphere. 2,3,4
110 Engine Coolant Temperature Temperature of liquid found in the engine 0,1,2,3,4
cooling system.
111 Engine Coolant Level Ratio of volume of liquid found in the 1,3,4
engine cooling system to total cooling
system volume.
131 Engine Exhaust Back
Pressure
132 Engine Intake Air Mass Flow Mass flow rate of fresh air entering the
Rate engine air intake, before any EGR mixer,
if used.

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SPN SPN Name SPN Description FMIa

156 Engine Injector Timing Rail The gauge pressure of fuel in the timing 0,1,2,3,4
1 Pressure rail delivered from the supply pump to the
injector timing inlet.
167 Charging System Potential Electrical potential measured at the 2,5,6
(Voltage) charging system output. The charging
system may be device charging the
batteries. This includes alternators,
generators, solid state charger and other
charging devices.
168 Battery Potential / Power This parameter measures the first source 0, 1
Input 1 of battery potential as measured at the
input of the ECM/actuator etc. coming
from one or more batteries, irrespective
of the distance between the component
and the battery.
171 Ambient Air Temperature Temperature of air surrounding vehicle. 0,1,2
172 Engine Air Intake Temperature of air entering vehicle air
Temperature induction system.
174 Engine Fuel Temperature 1 Temperature of fuel passing through the
first fuel control system.
175 Engine Oil Temperature 1 Temperature of the engine lubricant.
188 Engine Speed At Idle, Point Stationary low idle speed of engine
1 (Engine Configuration) which includes influences due to engine
temperature (after power up) and other
stationary changes (calibration offsets,
sensor failures, etc).
190 Engine Speed Actual engine speed which is calculated 0,2
over minimum crankshaft angle of
720 degrees divided by the number of
cylinders.
234 Software Identification Software Identification of an electronic
module.
532 Engine Speed At High Engine speed of high idle of the engine
Idle, Point 6 (Engine torque map.
Configuration)
558 Accelerator Pedal 1 Low Idle Switch signal which indicates the states
Switch of the accelerator pedal 1 low idle switch.
559 Accelerator Pedal Kickdown Switch signal which indicates whether 2
Switch the accelerator pedal kickdown switch is
opened or closed.
590 Engine Idle Shutdown Timer Status signal which indicates the current
State mode of operation of the idle shutdown
timer system.
597 Brake Switch Switch signal which indicates that the
driver operated brake foot pedal is being
pressed.
598 Clutch Switch Switch signal which indicates that the
clutch pedal is being pressed.

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SPN SPN Name SPN Description FMIa

636 Engine Position Sensor
641 Engine Variable Geometry Actuator that controls the variable
Turbocharger Actuator #1 geometry turbocharger geometry.
645 Engine Tachometer Signal
Output
651 Engine Injector Cylinder #01
652 Engine Injector Cylinder #02
653 Engine Injector Cylinder #03
654 Engine Injector Cylinder #04
655 Engine Injector Cylinder #05
656 Engine Injector Cylinder #06
657 Engine Injector Cylinder #07
658 Engine Injector Cylinder #08
677 Engine Starter Motor Relay Activates the starter.
723 Engine Speed 2 The engine speed as measured by speed
sensor 2.
968 Engine Idle Increment Switch signal which indicates the position
Switch of the idle increment switch.
972 Accelerator Interlock Switch Switch signal used to disable the
accelerator and remote accelerator
inputs, causing the engine to return to
idle.
974 Remote Accelerator Pedal The ratio of actual position of the remote
Position analogue engine speed/torque request
input device (such as an accelerator
pedal or throttle lever) to the maximum
position of the input device.
986 Requested Percent Fan Fan speed as a ratio of the actual fan
Speed drive (current speed) to the fully engaged
fan drive (maximum fan speed).
1086 Parking and/or Trailer Air The pneumatic pressure in the circuit or
Pressure reservoir for the parking brake and/or the
trailer supply.
1108 Engine Protection System Status signal which indicates the status
Timer Override of the override feature of the engine
protection system timer.
1110 Engine Protection System Status signal which indicates whether
has Shutdown Engine or not the engine protection system has
shutdown the engine.
1239 Engine Fuel Leakage 1 Status signal which indicates fuel leakage
in the fuel rail of the engine. Location can
be either before or after the fuel pump.
1322 Engine Misfire for Multiple When a misfire occurs in any one ofthe
Cylinders cylinders.
1323 Engine Misfire Cylinder #1 Engine misfire detected in cylinder.

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SPN SPN Name SPN Description FMIa

1324 Engine Misfire Cylinder #2 · Engine misfire detected in cylinder.
1325 Engine Misfire Cylinder #3 Engine misfire detected in cylinder.
1326 Engine Misfire Cylinder #4 Engine misfire detected in cylinder.
1327 Engine Misfire Cylinder #5 Engine misfire detected in cylinder.
1328 Engine Misfire Cylinder #6 Engine misfire detected in cylinder.
1329 Engine Misfire Cylinder #7 Engine misfire detected in cylinder.
1330 Engine Misfire Cylinder #8 Engine misfire detected in cylinder.
1135 Engine Oil Temperature 2 Temperature of the engine lubricant.
1442 Engine Fuel Valve 1 Position The position of a gaseous fuel valve that
is metering the fuel flow to the engine.
1443 Engine Fuel Valve 2 Position The position of a gaseous fuel valve that
is metering the fuel flow to the engine.
1483 Source Address of The source address of the SAE J1939
Controlling Device for device currently controlling the engine.
Engine Control
1484 Other ECUs Have Reported
Fault Codes Affecting
Operation
1485 ECM Main Relay
1569 Engine Protection Torque Torque has been derated for protection of
Derate the engine.
1632 Engine Torque Limit Feature Torque limit rating described in the current
record.
1639 Fan Speed The speed of the fan associated with
engine coolant system.
1675 Engine Starter Mode Start cannot take place for one of several
different reasons.
1761 Aftertreatment 1 SCR A special catalyst uses a chemical 0,1,3,6,8
Catalyst Tank Level reagent to reach legal requirement for
NOX emissions. This parameter indicates
the reagent level within that catalyst tank.
2609 Cab A/C Refrigerant Gage pressure at the compressor outlet
Compressor Outlet Pressure in the cab air conditioning system.
2791 Engine Exhaust Gas Desired percentage of maximum Exhaust
Recirculation 1 (EGR 1) Gas Recirculation (EGR) valve opening.
Valve Control
2797 Engine Injector Group 1 A first collection of fuel injector circuits 2,3,4
that are grouped together.
2798 Engine Injector Group 2 A second collection of fuel injector circuits 2,3,4
that are grouped together.
2858 Machine Data There is a problem involving the
Configuration 1 parameter list for the data structure
for configuring operations within
the Controller Application being
communicated with.

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SPN SPN Name SPN Description FMIa

2859 Machine Data There is a problem involving one (or
Configuration 2 more) of the PGN(s) within the parameter
list for the data structure for configuring
operations within the Controller
Application being communicated with.
2860 Machine Data There is a problem involving the
Configuration 3 first output control list for the data
structure for configuring operations
within the Controller Application being
communicated with.
2861 Machine Data There is a problem involving the
Configuration 4 second output control list for the data
structure for configuring operations
within the Controller Application being
communicated with.
2862 Machine Data There is a problem involving the
Configuration 5 third output control list for the data
structure for configuring operations
within the Controller Application being
communicated with.
3031 Aftertreatment 1 SCR Temperature of the reagent in the storage 0,1,3,6
Catalyst Tank Temperature tank.
3216 Aftertreatment 1 Intake NOx The amount of combined NO and N02 in
the exhaust entering the a:ftertreatment
system measured by a NOx sensor at
the a:ftertreatment intake, represented in
NOx molecule parts per million non-NOx
molecules in exhaust bank 1.
3226 Aftertreatment 1 Outlet NOx The amount of combined NOx and NO2 2,3,5,6
in the exhaust entering the aftertreatment
system measured by a NOx sensor at
the aftertreatment outlet, represented in
NOx molecule parts per million non-NOx
molecules in exhaust bank 1.
3241 Aftertreatment 1 Exhaust The reading from the exhaust gas 2,3,5,6
Gas Temperature 1 temperature sensor located farthest
upstream in the aftertreatment system in
exhaust bank 1.
3242 Aftertreatment 1 Diesel Temperature of engine combustion
Particulate Filter Intake Gas by-products entering the diesel particulate
Ternperature filter in exhaust bank 1.
3245 Aftertreatment 1 Exhaust The reading from the exhaust gas
Gas Temperature 3 temperature sensor located farthest
downstream in the a:ftertreatment system
in exhaust bank 1.
3246 Aftertreatment 1 Diesel Temperature of engine combustion
Particulate Filter Outlet Gas by-products leaving the diesel particulate
Ternperature filter exhaust in exhaust bank 1.

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SPN SPN Name SPN Description FMIa

3249 Aftertreatment 1 Exhaust The reading from the exhaust gas
Gas Temperature 2 temperature sensor located midstream of
the other two temperature sensors in the
aftertreatment system in exhaust bank 1.
3251 Aftertreatment 1 Diesel Exhaust differential pressure measured
Particulate Filter Differential between the intake and exhaust of a
Pressure diesel particulate filter in exhaust bank 1.
3275 Aftertreatment 2 Exhaust The reading from the exhaust gas
Gas Temperature 1 temperature sensor located farthest
upstream in the aftertreatment systern in
exhaust bank 2.
3279 Aftertreatment 2 Exhaust The reading from the exhaust gas
Gas Temperature 3 temperature sensor located farthest
downstream in the aftertreatment system
in exhaust bank 2.
3283 Aftertreatment 2 Exhaust The reading from the exhaust gas
Gas Temperature 2 temperature sensor located midstream of
the other two temperature sensors in the
aftertreatment system in exhaust bank 2.
3340 Engine Charge Air Cooler 1 Pressure of air at intake to 1st or only
Intake Pressure charge air cooler, from multiple first stage
turbochargers being cooled and feeding
multiple second stage turbochargers.
3360 Aftertreatment 1 SCR The catalyst tank controller has the ability 2
Catalyst Tank Controller to read attributes of the catalyst reagent
such as the catalyst reagent level, catalyst
reagent temperature and catalyst reagent
quality.
3361 Aftertreatment 1 SCR The catalyst dosing unit is a device that 2,3,4,6
Catalyst Dosing Unit mixes the catalyst reagent and air, and
delivers a metered quantity of this mixture
to the exhaust stream.
3362 Aftertreatment 1 Diesel The diesel exhaust fluid dosing unit is a
Exhaust Fluid Dosing Unit device that mixes the diesel exhaust fluid
Input Lines and air, such that it contains an input line
from the air tank and an input line from
the diesel exhaust fluid tank.
3363 Aftertreatment 1 SCR Percentage of heating applied to the 2,3,5,6
Catalyst Tank Heater catalyst tank heater.
3464 Engine Throttle Actuator 1 The control command to throttle actuator
Control Command 1, normalized to percent.
3471 Aftertreatment 1 Fuel Diagnostic SPN for the actuator controlling
Pressure Control Actuator aftertreatment 1 fuel pressure.
3472 Aftertreatment 1 Air Pressure Diagnostic SPN for the actuator controlling
Control Actuator aftertreatment 1 air pressure.
3480 Aftertreatment 1 Fuel First fuel pressure measurement for the
Pressure 1 aftertreatment 1 system.
3485 Aftertreatment 1 Supply Air Pressure of the supply air for
Pressure aftertreatment 1.

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SPN SPN Name SPN Description FMIa

3515 Aftertreatment 1 Diesel Temperature of the diesel exhaust fluid
Exhaust Fluid Temperature 2 at the device measuring diesel exhaust
fluid quality.
3516 Aftertreatment 1 Diesel A measure of the concentration of urea
Exhaust Fluid Concentration in water.
3563 Engine Intake Manifold #1 The absolute pressure measurement of
Absolute Pressure the air intake manifold.
3607 Engine Emergency A signal issued by the engine control
(Immediate) Shutdown system to a user or external system
Indication indicating that it is immediately shutting
the engine down.
3673 Engine Throttle Valve 2 The sensed position feedback of the
Position valve, coming from a second electrical
actuator for a second throttle plate, used
to regulate the supply of a fluid , usually
air or fuel/air mixture.
3822 Engine Exhaust Gas The position of the second exhaust
Recirculation 1 Valve 2 gas recirculation valve expressed as a
Position percentage of full travel.
3936 Aftertreatment Diesel Non-specific failures of the aftertreatment
Particulate Filter System diesel particulate filter system.
4090 NOx limits exceeded, root Indicates that On-Board Diagnostics has 0,2
cause unknown determined that the limits for NOx in the
exhaust stream have been exceeded, but
the root cause cannot be determined by
the OBD system.
4094 NOx limits exceeded due to On-Board Diagnostics has determined
Insufficient Diesel Exhaust that the limits for NOx in the exhaust
Fluid Quality stream have been exceeded due to an
insufficient diesel exhaust fluid quality.
4095 NOx limits exceeded due to Indicates that On-Board Diagnostics has 2
Interrupted Reagent Dosing determined that the limits for NOx in the
exhaust stream have been exceeded
due to an Interruption in reagent dosing
activity.
4096 NOx limits exceeded due to Indicates that On-Board Diagnostics has 2
Empty Reagent Tank determined that the limits for NOx in the
exhaust stream have been exceeded due
to the reagent tank being empty.
4201 Engine Speed 1 The engine speed as measured by speed
sensor 1.
4202 Engine Speed 3 The engine speed as measured by speed
sensor 3 .
4225 NOx limits exceeded due On-Board Diagnostics has determined
to error in the NOx control that the limits for NOx in the exhaust
systern stream have been exceeded due to an
error in the NOx control system.

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SPN SPN Name SPN Description FMIa

4301 Aftertreatment 1 Fuel Injector Heating level that the controller is
1 Heater Control commanding the aftertreatment 1 fuel
injector 1 heater control to maintain.
4334 Aftertreatment 1 SCR Dosing The SCR dosing reagent absolute 0,1,2,3,6
Reagent Absolute Pressure pressure (measured closest to dosing
valve) for aftertreatment system 1
(exhaust bank 1).
4337 Aftertreatment 1 SCR Dosing The SCR dosing reagent temperature 2,3,6
Reagent Temperature (measured closest to dosing valve) for
aftertreatment system 1 (exhaust bank 1).
4341 Aftertreatment 1 SCR Used to identify the applicable J1939-73 2,3,5,6
Catalyst Reagent Line FMI detected in the SCR catalyst reagent
Heater 1 Preliminary FMI line heater 1, by the manufacturer’s
control software in exhaust bank 1.
4343 Aftertreatment 1 Diesel Used to identify the applicable J1939-73
Exhaust Fluid Line Heater 2 FMI detected in the diesel exhaust fluid
Preliminary FMI line heater 2, by the manufacturer's
control software in exhaust bank 1.
4345 Aftertreatment 1 Diesel Used to identify the applicable Jl939-73
Exhaust Fluid Line Heater 3 FMI detected in the diesel exhaust fluid
Preliminary FMI line heater 3, by the manufacturer's
control software in exhaust bank 1.
4347 Aftertreatment 1 Diesel Used to identify the applicable J1939-73
Exhaust Fluid Line Heater 4 FMI detected in the diesel exhaust fluid
Preliminary FMI line heater 4, by the manufacturer's
control software in exhaust bank 1.
4374 Aftertreatment 1 SCR Rotational speed of the motor driving 0,1,2,3,5,6
Catalyst Reagent Pump a pump for reagent used in an
Motor Speed aftertreatment system.
4427 Aftertreatment 2 Diesel Temperature of the diesel exhaust fluid
Exhaust Fluid Tank in the storage tank.
Temperature
4782 Diesel Particulate Filter 1 Soot density in diesel particulate filter 1.
Soot Density
4809 Aftertreatment 1 Warm Up The temperature measured at the
Diesel Oxidation Catalyst intake of the warm up oxidation catalytic
Intake Temperature converter in exhaust bank 1.
4810 Aftertreatment 1 Warm Up The temperature measured at the outlet of
Diesel Oxidation Catalyst the warm up oxidation catalytic converter
Outlet Temperature in exhaust bank 1.
4814 Engine Coolant Pump Command for a coolant pump that can be
command driven at varying output level.
5285 Engine Charge Air Cooler 1 An indication of the CAC's ability to
Efficiency reduce the temperature of the combustion
air that is being routed through the CACL
5401 Engine Turbocharger Diagnostic SPN for the actuator controlling
Turbine Bypass Actuator the engine turbocharger turbine bypass
valve.

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SPN SPN Name SPN Description FMIa

5419 Engine Throttle Actuator 1 Device used to control the flow of air or
air/fuel mix to the engine.
5421 Engine Turbocharger Device used to control the turbocharger
Wastegate Actuator 1 wastegate.
5435 Aftertreatment 1 Diesel State of Aftertreatment 1 Diesel Exhaust
Exhaust Fluid Pump State Fluid dosing pump.
5543 Engine Exhaust Brake The control command applied to the
Actuator Command engine exhaust brake actuator.
5706 Aftertreatment 1 Diesel Percentage of heating applied to the
Exhaust Fluid Pump Heater aftertreatment 1 diesel exhaust fluid pump
heater.
5743 Aftertreatment Selective Module will take temperature sensor
Catalytic Reduction inputs from the Aftertreatment Selective
Temperature Sensor Module Catalytic Reduction Temperature Sensors
and multiplex the sensor values to the
engine ECU via the J1939 network.
5745 Aftertreatment 1 Diesel Aftertreatment DEF heater internal to the
Exhaust Fluid Dosing Unit Aftertreatment Dosing Unit.
Heater
5841 Diesel Exhaust Fluid Quality The diagnostic system has determined
Malfunction that the engine has been operated with
a diesel exhaust fluid (reagent) quality
malfunction.

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5.9 Cleaning
� WARNING
• Protect all electrical, electronic components and connections. Do not directly steam clean
these components when on or removed from the engine.

NOTICE
• The engine and its components that are scheduled to be checked, serviced or replaced
must be cleaned in accordance with the manufacturer's recommendations.
• Steam clean the engine prior to performing any repair or service work. Frequent cleaning is
recommended if work site conditions create excessive dust, dirt, mud etc.

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5.10 Drive Belts

(1) Description

2
3
4
5

MOT05006

Figure 5.6 - Drive Belt Layout

1. Compressor 3. Idler Gear 5. Tension Release Point
2. Idler Gear Locking Point 4. Alternator

(2) Maintenance
1000 hour Inspection

NOTICE
• Take a note of the direction of the drive belt. Refit the drive belt with the same direction of
rotation as it had been before. Refer to Figure 5.6.
• If working close to the location of the drive belt and the drive belt has cracks or show
excessive signs of wear it must be removed and replaced.

1 Listen for 'ticking' sound - they mean interference with the belts. Visually inspect for bent
or damaged belt guards.
2 Replace all belts in a mismatched set at one time to ensure even load distribution.

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3 Periodically check tension and keep belts tight.

• The ideal tension is the lowest tension at which the belt will not slip under peak load
conditions.
• Check the belt tension frequently during the first 24 - 48 hours of run-in operation.
• Initial belt tension should be 533 N (120 lbf) dropping to 422 N (95 lbf) after the first
48 hours.
• There should be a freeplay of 10 mm in the belt.
• Do not over tension the belts.
• Keep belts free from foreign material that may cause slippage.
• Inspect the drive periodically. Re-tension the belts if they are slipping.
• Maintain sheave alignment with a strong straight edge tool while tensioning the belts.
4 Never attempt to correct the belt slippage by using a belt dressing. The dressing may
cause softening and deterioration.
5 If belt slips, even when properly tensioned, check for overload, worn sheave grooves or
oil or grease on the belts.
6 Never pry a drive belt or force it into the sheave groove. Loosen the drive belt tightener
prior to installation.
7 A belt that has operated while rolled over in the sheave groove may be damaged - replace it.
8 Store belts in a cool, dry place. If stored on a machine, relieve all belt tension by loosening
the drive belt tightener.
9 Never attempt to check or adjust belts while they are running.

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(3) Removal

NOTICE
To ease removal of the fan belt, disconnect the electrical connection to radiator fan (C4009).

Refer to Figure 5.6.

PROCEDURE
1. Loosen the bolt (M8) at idler gear locking point (2), to unlock the idler gear.
2. Position a socket wrench at idler gear (3) adjustment tension release point (5).
3. Release the tension in the belt.
4. Tighten the bolt (M8) at idler gear locking point (2), to lock the idler gear in place.
5. Remove the drive belt.

(4) Installation

NOTICE
• Take a note of the direction of the drive belt. Refit the drive belt with the same direction
of rotation as it had been before.

Refer to Figure 5.6.

PROCEDURE
1. Install the drive belt
2. Loosen the bolt (M8) at idler gear locking point (2), to unlock the idler gear.
3. Position a socket wrench at idler gear (3) adjustment tension point (5).
4. Tension the belt
5. Tighten the bolt (M8) at idler gear locking point (2), to lock the idler gear in place.
6. Re-connect the electrical connection to the radiator fan (C4009).

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5.11 Starting
� CAUTION
• Never crank the engine more than 30 seconds continuously. Allow starter at least 2 minutes
cooling time between long cranking periods to avoid overheating.
• Ensure that engine and transmission check lights extinguish. If not, do not start and
investigate.

PROCEDURE
1. Turn the battery master switch, located on the inside panel of the battery box, to the ‘ON’
position. Ensure the battery LED is illuminated.
2. Make sure the park-emergency brake lever is in 'PARK' position. (Button pushed‘IN’).
3. Make sure that the body control lever is in the 'NEUTRAL' position.
4. Make sure that the transmission gear shift control is in the 'NEUTRAL' position.
5. Insert the key into the ignition switch. Turn the key fully clockwise until it stops. Wait until
all the gauges and warning lights on the dashboard display have completed self-check
procedure. The audible warning buzzer will sound.
6. Press the service brake pedal.
7. Sound the horn twice manually for forward movement or three times for reverse movement,
to indicate that you are starting the engine and the direction you are travelling. Then press
and release the Start/Stop button to start the engine.

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5.12 Stopping
� CAUTION
• Do not start the engine when the battery master switch is in the OFF position and the
indicator light adjacent to the battery master switch is ON. The indicator light comes ON
within 5 seconds when the Battery Master Switch is selected ON. The light goes out after
60 seconds when the Battery Master Switch is selected OFF.
• Stopping a turbo charged engine immediately after high speed operation may cause
damage to the turbocharger as it will continue to turn without an oil supply to the bearings.

PROCEDURE
1. Make sure parking-emergency brake control is in 'PARK' position.
2. Make sure the transmission is in 'NEUTRAL'.
3. Allow the engine to run between idle and 1 000 rev/min. with no load for 2 minutes. This
allows the engine to cool and the turbocharger to slow down.
4. Make sure the body control lever is in 'NEUTRAL'.
5. To stop the engine press and release the Start / Stop switch.
6. Await the dashboard display to re-illuminate (reboot).
7. Turn the ignition key switch to the 'O' position (OFF) and remove the key.
8. Exit the driver’s cabin via the access steps.
9. Turn the battery master switch, located in the battery box, to the 'OFF' position. This
prevents the battery draining.

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5.13 Oil – Drain/Replenish

(1) Maintenance
Refer to Figure 5.1.

� DANGER
• Avoid direct contact of hot oil with your skin. Hot oil will cause serious personal injury.

NOTICE
• Check/Replenish every 10 hours
• Drain/Replenish every 500 hours

(2) Drain

PROCEDURE
1. Position the machine on a level work area, apply the parking brake.
2. Operate the engine until the water temperature reaches 60 °C (140 °F).
3. Gain access to the engine oil drain plug through the access hole in the engine sump guard.
4. Position a suitable container under the engine oil drain plug and drain the oil immediately to
make sure all the oil and suspended contaminants are removed from the engine.
5. Re-cycle the used engine oil in accordance with local environment laws.
6. Check and clean the engine oil drain plug threads and the seal surface. Replace the plug if
damaged.
7. Install and tighten the drain plug.

(3) Replenish/Check

PROCEDURE
1. Replenish the engine with clean lubricating oil specified in, Lubrication System. The oil level
should be between the low (L) and high (H) marks on the dipstick.
2. Engine oil pressure must be indicated on the gauge within 15 seconds after starting engine.
If oil pressure is not reached within 15 seconds, shut off the engine immediately to avoid
engine damage.
3. Confirm the correct oil level in the oil pan.
4. Start the engine and operate at idle speed to inspect for leaks at the filter and oil drain plug.
5. Shut off the engine, wait approximately ten minutes to let the oil drain back to the sump and
check the oil level again.
6. Add oil as necessary to bring the level to the high (H) mark on the dipstick. Do not overfill
the engine with oil.

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5.14 Oil Filter – Replacement

Maintenance – Replace every 500 hours
(1) Replacement

� CAUTION
• Clean the centrifugal oil cleaner when renewing the oil filter. Otherwise, the oil filter will be
blocked and resistance in the filter will increase. If this happens, an overflow valve in the
filter retainer opens and lets the oil pass without being filtered.
• Do not use an adjustable spanner or other open tool as there is risk of damaging the filter
cover.

PROCEDURE
1. Unscrew the filter cover with a socket wrench with hexagon driver e.g. 36 mm socket. For
location refer to Figure 5.1
2. Lift out the filter housing cover with filter element. The filter housing will drain automatically
once the filter has been removed. Refer to Figure 5.7.
3. Detach the old filter from the cover by holding the cover and carefully tapping the entire
filter element against something hard. Remember that there will be oil splashes. Refer
to Figure 5.8.
4. Fit the new filter and tighten the filter cover to 25 Nm (18 lbf ft).
MOT04588 MOT04589

Figure 5.7 - Engine Oil Filter Figure 5.8 - Engine Oil Filter Removal

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5.15 Centrifugal Oil Filter

(1) Maintenance

NOTICE
• The centrifugal cleaner’s rotor is caused to spin by the oil pressure. Particles of dirt are
forced against the wall. For location refer to Figure 5.1
• When cleaning the centrifugal oil cleaner there will be some dirt deposits in the rotor cover.
This indicates that the rotor is working. If it is clean and not working, the cause must be
established immediately. If the dirt deposits exceed 28 mm (1.1 in) at the recommended
intervals, the rotor cover should be cleaned more often.
• Clean inside of cover and replace paper filter every 500 hours.

(2) Cleaning

� WARNING
The oil may be hot. Carefully remove the cover from the centrifugal oil cleaner.

� CAUTION
Take care not to damage the rotor shaft. The rotor must not be put in a vice. Never strike the
rotor cover. This may cause damage resulting in imbalance.

PROCEDURE
1. Clean the outside cover and remove the securing nut.
2. Let the oil run out from the rotor.
3. Lift out the rotor. Wipe off the outside. Undo the rotor nut and unscrew it about 1.5 turns to
protect the bearing. Refer to Figure 5.9.
4. If the rotor nut is difficult to get loose, turn the rotor upside down and fasten the rotor nut
in a vice. Turn the rotor counterclockwise 1.5 turns by hand or use an M20 nut. Refer
to Figure 5.10.
MOT04562 MOT04563

M20

x 1.5
x 1.5

Figure 5.9 - Figure 5.10 -

Centrifugal Oil Filter Removal Centrifugal Oil Filter Removal

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5. Remove the rotor cover by holding the rotor in both hands and tapping the rotor nut against
the table. Never strike the rotor directly as this may damage its bearings. Refer to Figure
5.11.
6. Remove the strainer from the rotor cover. If the strainer is stuck, insert a screwdriver
between the rotor cover and strainer and carefully pries them apart. Refer to Figure 5.12.
MOT04564 MOT04565

Figure 5.11 - Figure 5.12 -

Centrifugal Oil Filter Rotor - Removal Centrifugal Oil Filter Rotor - Removal

7. Remove the paper insert and scrape away any remaining dirt deposits inside the rotor
cover. If the deposits are thicker than 28 mm, the centrifugal oil cleaner must be cleaned
more often. Refer to Figure 5.13.
8. Wash the parts.
9. Inspect the 2 nozzles on the rotor. Ensure that they are not blocked or damaged. Renew
any damaged nozzles.
10. Check that the bearings are undamaged.
11. Fit a new paper insert on the inside of the rotor cover. Refer to Figure 5.14.
MOT04566 MOT04567
1

2 3 4

Figure 5.13 - Figure 5.14 -

Centrifugal Oil Filter - Cleaning Centrifugal Paper Filter

12. Fit the strainer onto the rotor.

13. Fit a new O-ring by sliding it over the strainer. Refer to Figure 5.15.
14. Refit the rotor cover. Ensure that the O-ring is not outside the cover.
15. Screw the rotor nut back on by hand.

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16. Check that the shaft is not damaged or loose. If the shaft is damaged, it should be replaced.
Secure the shaft with thread-locking fluid if it is loose. First clean thoroughly using a suitable
solvent. Tighten the rotor shaft using a socket wrench. Torque tighten to 27 Nm (20 lbf ft.),
together with a ratchet head that is suitable for use during maintenance.
17. Refit the rotor and rotate it by hand to make sure it rotates easily.
18. Refit the oil cleaner housing. Tighten lock nut to 20 Nm (15 lbf ft.). Refer to Figure 5.16.

MOT04568 20 Nm MOT04569

Figure 5.15 - Figure 5.16 -

Centrifugal Oil Filter Assembly Centrifugal Oil Filter Assembly

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(3) Operational Testing

Operational testing need only be carried out if there is a suspicion that the centrifugal oil cleaner
is not working properly. For example, if there is an abnormally small amount of deposit in the
centrifugal oil cleaner in relation to the distance driven.
The rotor rotates very fast and should continue to turn when the engine has stopped.

PROCEDURE
1. Run the engine until it reaches normal operating temperature.
2. Stop the engine and listen for the rotor. Use your hand to feel if the filter housing is vibrating.
3. If the filter housing is not vibrating, dismantle and check the centrifugal oil cleaner.

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5.16 Air Cleaner

� CAUTION
• Do not operate the truck without the air cleaner filters fitted. Damage to the engine will occur.

NOTICE
• Keep new filter elements in storage as replacements to prevent unnecessary down time.
• All clamps should be checked frequently and tightened to prevent leakage.

MOT00193

7 5
1

2
3

Figure 5.17 - Air Cleaner Exploded View

1. Air Cleaner Assembly 4. Filter – Secondary 7. Filter – Primary
2. Valve – Vacuator 5. Cover Assembly 8. U – Clip
3. Pipe Plug 6. Latch

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(1) Description
Numbers in parentheses refer to Figure 5.17, unless otherwise specified.
The air cleaner is remotely mounted on the right side of the machine. The air cleaner prolongs
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. There is a dual dry element type air cleaner assembly fitted
to the engine, primary (7) and secondary (4). Adaptor (23, Figure 5.18) attached to the assembly
ejects grit, dust and water while the engine is running. A secondary filter assembly (4) installed
in the air cleaner assembly (1) increases the reliability of the air cleaner from airborne dirt.
An air restriction filter indicator illuminates on the left hand panel on the dashboard, inside the
cab, to warn of contamination with the air filter. If the indicator LED is visible you must replace
the filter.

23

MOT04933

Figure 5.18 - Air Cleaner Mounting Exploded View

1. Duct Air Intake 9. Bolt 17. Captive Nut
2. Lockwasher 10. Scavenge Hose 18. Mounting Bracket
3. Hose Hump 11. Clamp 19. Washer
4. Hose Air Intake 12. Air Restriction Sensor 20. Washer
5. Clamp 13. Blanking Plate 21. Bolt
6. Hose – Elbow 14. Seal 22. Gasket-Blanking
7. Clamp 15. Bolt 23. Scavenge Adaptor
8. Clamp 16. Lockwasher

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(2) Removal
Numbers in parentheses refer to Figure 5.18, unless otherwise specified.

PROCEDURE
1. Loosen clamps (11) and remove the scavenge hose (10).
2. Slacken the clamps (5) and disconnect the hose (3) from the air cleaner assembly (1,
Figure 5.17).
3. Remove the air intake duct housing assembly.
4. Detach the duct assembly (1) by removing the bolts (15), washers (16 and 19), and captive
nuts (17).
5. Remove the bolts (15, 6 off) and washers (16) securing the air cleaner to the mounting
bracket (18).

(3) Installation
Numbers in parentheses refer to Figure 5.18, unless otherwise specified.

PROCEDURE
1. Install the bolts (15, 6 off) and washers (16) securing the air cleaner to the mounting
bracket (18).
2. Attach the duct assembly (1) and secure with bolts (15), washers (16 and 19), and captive
nuts (17).
3. Install the air intake duct housing assembly.
4. Connect the hose (3) to the air cleaner assembly (1, Figure 5.17) and secure with the
clamps (5).
5. Refit the scavenge hose (10) and secure with clamps (11).

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(4) Filter Removal

NOTICE
• Replace the primary filter if the warning light on the left hand panel on the dashboard
indicates red. Replace the secondary filter every third primary filter change.
• Replace the primary filter if the warning light on the left hand panel on the dashboard
indicates red. Replace the secondary filter every third primary filter change.Replace the
primary filter if the warning light on the left hand panel on the dashboard indicates red.
Replace the secondary filter every third primary filter change.
• Replace the primary and secondary filters every 2000 hours.

Numbers in parentheses refer to Figure 5.17, unless otherwise specified.

PROCEDURE
1. Release the four latches (6) on the cover assembly (5).
2. Remove the cover assembly (5) from the body assembly.
3. Remove the primary filter assembly (7) and the secondary filter assembly (4) from the
air cleaner assembly (1).

(5) Filter Installation

Numbers in parentheses refer to Figure 5.17, unless otherwise specified.

PROCEDURE
1. Install the primary filter (7) into the body assembly.
2. Position the secondary filter (4) guide lug into the slot inside the body assembly. Press
firmly into place.
3. Install the cover assembly (5) to the body assembly.
4. Close and secure with the four latches (6).

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5.17 Exhaust System

(1) Exhaust and Mounting

22 23 49 19
49 12 7
48 44 46
50 18 7,44
18 54
37 38
55
17 7
56 52
13
26 12,41 14 15
27 20
45 36
44
28 51
45
51 9

34 49 11
12 12
53 42
6 8
25 24 29
7 21,12
31 30 13
35 39
49,12 41,12
4 40
31 30 16
5
39 43 3 9
2 32
31
33 12 30
39 48
31 1
10 47
MOT05414

Figure 5.19 - Exhaust and Mounting

1. V-Clamp 20. Exhaust Mounting Frame 39. Bolt
2. Exhaust Front Pipe 21. Bolt 40. Washer
3. Clamp 22. Silencer Cover 41. Bolt
4. V-Clamp 23. Bracket 42. Shim
5. Exhaust Middle Pipe 24. Bolt 43. Exhaust Support Bracket
6. Clamp 25. Bracket 44. Lockwasher
7. Washer 26. Heat Shield 45. Nut
8. Exhaust Rear Pipe 27. Heat Shield Bracket 46. Carbine Hook
9. V-Clamp 28. Band Clamp 47. Bolt
10. Silencer to Diverter Pipe 29. Support Bracket 48. Washer
11. Bolt 30. Locknut 49. Bolt
12. Washer 31. Washer 50. Washer
13. Gasket 32. Bolt 51. Washer
14. Blanking Plate 33. Clamp 52. Bolt
15. Exhaust Gasket 34. Guard Support Bracket 53. Exhaust Support Bracket
16. Gasket 35. Muffler Bracket 54. Spring
17. Diverter Box Assembly 36. Stack Pipe 55. Carbine Hook

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18. Bolt 37. Silencer 56. Clamp Assy

19. Collared Eyebolt 38. Bracket

(2) Description
Numbers in parentheses refer to Figure 5.19, unless otherwise specified.
The Exhaust System consists of the Exhaust Front Section Pipe (2), Exhaust Middle Section
Pipe (5) and Exhaust Rear Section Pipe (8) between the discharge of the turbocharger and
the Silencer (37); the Silencer to Diverter Box Exhaust Pipe (10) connecting between Silencer
(37) and the Diverter Box Assembly (17) and the Stack Pipe (36) mounted to the top of the
Diverter Box Assembly (17).
(3) Removal
Numbers in parentheses refer to Figure 5.19, unless otherwise specified.

� WARNING
• To prevent personal injury and property damage, be sure wheel blocks, blocking materials
and lifting equipment are correctly secured and are of adequate capacity to do the job safely.
• Do not work near or under an unblocked or unsupported cab. Use the cab safety prop at
all times.
• When the battery master switch is in the OFF position and the adjacent LED is illuminated
electrical power remains connected to the truck. Electrical power remains connected to the
truck for 60 seconds after the battery master switch has been selected to the OFF position.

(a) Exhaust Front Section Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Raise the hood. Refer to (5) Raising the Hood on page 16-38.
5. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
6. Loosen the V-clamp (1) at the turbocharger outlet.
7. Loosen the V-clamp (4) joining the exhaust front section pipe (2) to the exhaust middle
section pipe (5).
8. Separate the exhaust front section pipe (2) from the turbocharger outlet (1, Figure 5.1)
and the exhaust middle section pipe (5).
9. Loosen clamp (3).
10. If necessary, remove bolts (41) and washers (12), securing the exhaust support bracket (43).
11. Remove the exhaust front section pipe (2).
12. Move the exhaust front section pipe (2) to a clean maintenance area.

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(b) Exhaust Rear Section Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
5. Loosen the V-clamp (9) at the exhaust inlet of the silencer (37).
6. Separate the exhaust rear section pipe (8) from the exhaust inlet of the silencer (37).
7. Loosen the V-clamp (4) joining the exhaust rear section pipe (8) to the adjacent exhaust
middle section pipe (5).
8. Separate the exhaust rear section pipe (8) from the adjacent exhaust middle section
pipe (5).
9. Move the exhaust rear section pipe (8) to a clean maintenance area.

(c) Exhaust Middle Section Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
5. If necessary to gain access to remove exhaust middle section pipe (5), remove the exhaust
front section pipe (2). Refer to (a) Exhaust Front Section Pipe on page 5-40.
6. If necessary to gain access to remove exhaust middle section pipe (5), remove the exhaust
rear section pipe (8). Refer to (b) Exhaust Rear Section Pipe on page 5-41.
7. If necessary to gain access to remove exhaust middle section pipe (5), remove the cab.
Refer to (2) Removal on page 19-8
8. Loosen the V-clamps (4) joining the exhaust middle section pipe (5) to the adjacent exhaust
front section pipe (2) and exhaust rear section pipe (8).
9. Separate the exhaust middle section pipe (5) from the adjacent exhaust front section pipe
(2) and exhaust rear section pipe (8).
10. Loosen clamp (6).
11. If necessary, remove bolts (21) and washers (12), securing the exhaust support bracket (53).
12. Remove the exhaust middle section pipe (5).
13. Move the exhaust middle section pipe (5) to a clean maintenance area.

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(d) Silencer to Diverter Box Exhaust Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Gain access to the work area.
5. Loosen the V-clamp (9) at the exhaust outlet of the silencer (37).
6. Remove bolts (47), washers (48) and washers (12) attaching the silencer to diverter box
exhaust pipe (10) to the diverter box assembly (17).
7. Using standard lifting equipment, lift the silencer to diverter box exhaust pipe (10) away
from the diverter box assembly (17) and the exhaust outlet of the silencer (37).
8. Remove and discard the gasket (13).
9. Move the silencer to diverter box exhaust pipe (10) to a clean maintenance area.

(e) Stack Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Gain access to the work area.
5. Remove bolts (11) and washers (12) attaching the stack pipe (36) to the diverter box
assembly (17).
6. Using standard lifting equipment, lift the stack pipe (36) away from the diverter box
assembly (17).
7. Remove and discard the gasket (16).
8. Move the stack pipe (36) to a clean maintenance area.

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(f) Silencer

NOTICE
• When removing the heat shield (26), only remove the top and bottom rearmost nuts (45),
lockwashers (44) and washers (51). Refer to Step 13. The remaining top and bottom
forward four nuts (45), lockwashers (44) and washers (51) are removed when removing the
heat shield bracket (27) and silencer (37). Refer to Step 16.

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Gain access to the work area.
5. Remove the silencer to diverter box exhaust pipe (10). Refer to (d) Silencer to Diverter
Box Exhaust Pipe on page 5-42.
6. Loosen the V-clamp (9) at the exhaust inlet of the silencer (37).
7. Separate the exhaust rear section pipe (8) from the exhaust inlet of the silencer (37).
8. Remove bolts (49), washers (48) and washers (50) from silencer cover (22).
9. Using standard lifting equipment, lift silencer cover (22).
10. Move the silencer cover (22) to a clean maintenance area.
11. Using standard lifting equipment, support the heat shield (26).
12. Remove bolts (49) and washers (12).
13. Remove nuts (45), lockwashers (44) and washers (51).
14. Using standard lifting equipment, lift the heat shield (26) from guard support bracket (34),
bracket (25) and bracket (29).
15. Using standard lifting equipment, support the silencer (37).
16. Remove nuts (45), lockwashers (44) and washers (51).
17. Using standard lifting equipment, lift the silencer (37) with band clamps (28) still attached
and the heat shield bracket (27) away from the support bracket (29).
18. Remove the band clamps (28) from the silencer (37).
19. Move the silencer (37) and heat shield bracket (27) to a clean maintenance area.

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5 Engine

(4) Installation
Numbers in parentheses refer to Figure 5.19, unless otherwise specified.

� WARNING
• To prevent personal injury and property damage, be sure wheel blocks, blocking materials
and lifting equipment are correctly secured and are of adequate capacity to do the job safely.
• Do not work near or under an unblocked or unsupported cab. Use the cab safety prop at
all times.
• When the battery master switch is in the OFF position and the adjacent LED is illuminated
electrical power remains connected to the truck. Electrical power remains connected to the
truck for 60 seconds after the battery master switch has been selected to the OFF position.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

(a) Exhaust Middle Section Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. If necessary, install bolts (21) and washers (12) to secure the exhaust support bracket (53).
5. Torque tighten the bolts (21).
6. Fit the V-clamps (4) over the ends of the exhaust middle section pipe (5).
7. Lift the exhaust middle section pipe (5) into position between the exhaust front section pipe
(2) and the exhaust rear section pipe (8).
8. Join the exhaust middle section pipe (5) to the exhaust front section pipe (2) and the
exhaust rear section pipe (8).
9. Torque tighten the V-clamps (4) to 20 Nm (14.75 lbf ft).
10. Fit the clamp (6) securing the exhaust middle section pipe (5) to the exhaust mounting
plate (53).
11. Torque tighten the clamp (6) to 12 Nm (8.85 lbf ft).
12. If necessary, install the exhaust front section pipe (2). Refer to (c) Exhaust Front Section
Pipe on page 5-45.
13. If necessary, install the exhaust rear section pipe (18). Refer to (b) Exhaust Rear Section
Pipe on page 5-45.
14. If necessary, install the cab. Refer to(3) Installation on page 19-10.
15. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.

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 Engine 5

(b) Exhaust Rear Section Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Fit the V-clamps (9) and (4) over the ends of the exhaust rear section pipe (18).
5. Lift the exhaust rear section pipe (8) into position between the exhaust inlet of the silencer
(37) and the adjacent exhaust middle section pipe (5).
6. Join the exhaust rear section pipe (8) to the exhaust inlet of the silencer (37).
7. Join the exhaust rear section pipe (8) to the adjacent exhaust middle section pipe (5).
8. Torque tighten the V-clamps (9) and (4) to 20 Nm (14.75 lbf ft).
9. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.

(c) Exhaust Front Section Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. If necessary, install bolts (41) and washers (12), to secure the exhaust support bracket (43).
5. Torque tighten the bolts (41).
6. Fit the V-clamps (1) and (4) over the ends of the exhaust front section pipe (2).
7. Lift the exhaust front section pipe (2) into position between the turbocharger outlet and the
adjacent exhaust middle section pipe (9).
8. Join the exhaust front section pipe (2) to the turbocharger outlet.
9. Join the exhaust front section pipe (2) to the exhaust middle section pipe (9).
10. Torque tighten V-clamps (1) and (4) to 20 Nm (14.75 lbf ft).
11. Fit the clamp (3) securing the exhaust front section pipe (2) to the exhaust support bracket
(43).
12. Torque tighten the clamp (3) to 12 Nm (8.85 lbf ft).
13. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
14. Lower the hood. Refer to (6) Lowering the Hood on page 16-39.

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5 Engine

(d) Stack Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Gain access to the work area.
5. Align a new gasket (16) with the bolt holes in the top of diverter box assembly (17).
6. Using standard lifting equipment, lift the stack pipe (36) into position on the diverter box
assembly (17) and align with gasket (16) and bolt holes.
7. Install bolts (11) and washers (12).
8. Torque tighten the bolts (11).

(e) Silencer to Diverter Box Exhaust Pipe

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Gain access to the work area.
5. Align a new gasket (13) with the bolt holes in the flange of the silencer to diverter box
exhaust pipe (10).
6. Fit the v-clamp (9) over the end of the silencer to diverter box exhaust pipe (10).
7. Using standard lifting equipment, lift the silencer to diverter box exhaust pipe (10) into
position between the diverter box assembly (17) and the exhaust outlet of the silencer (37).
8. Install bolts (47), washers (48) and washers (12) to attach the silencer to diverter box
exhaust pipe (10) to the diverter box assembly (17).
9. Join the silencer to diverter box exhaust pipe (10) to the exhaust outlet of the silencer (37).
10. Torque tighten V-clamp (9) to 20 Nm (14.75 lbf ft).
11. Torque tighten the bolts (47) to 60 ± 2 Nm (44.3 ± 2.2 lbf ft).

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 Engine 5

(f) Silencer

NOTICE
• When installing the band clamps (28) on the silencer (37), ensure the band clamp studs are
to the left when looking from above the silencer (37). Refer to Step 5.
• When installing the silencer (37) and heat shield bracket (27) to support bracket (29), only
install the top and bottom forward four nuts (45), lockwasher (44) and washers (51). Refer
to Step 9.The remaining two nuts (45), lockwasher (44) and washers (51) are used when
installing the heat shield (26). Refer to Step 13.

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels.
3. Place the battery master switch in the ‘OFF’ position.
4. Gain access to the work area.
5. Install the band clamps (28) on the silencer (37).
6. Torque tighten the band clamps (28) to 70 Nm (51.63 lbf ft)
7. Using standard lifting equipment, lift the silencer (37) with band clamps (28) attached into
position with the studs of the band clamps (28) through the holes in the support bracket (29).
8. Position the heat shield bracket (27) onto the studs of the band clamps (28).
9. Install nuts (45), lockwasher (44) and washers (51).
10. Torque tighten the nuts (45) to 100 ± 3Nm (73.8 ±2.2 lbf ft).
11. Using standard lifting equipment, position the heat shield (26) with guard support bracket
(34), heat shield bracket (27) and support bracket (29).
12. Install bolts (49) and washers (12).
13. Install the top and bottom rearmost nuts (45), lockwasher (44) and washers (51).
14. Torque tighten the bolts (49) to 100 ± 3Nm (73.8 ±2.2 lbf ft).
15. Torque tighten the nuts (45) to 100 ± 3Nm (73.8 ±2.2 lbf ft).
16. Using standard lifting equipment, position the silencer cover (22) with guard support bracket
(34) and heat shield bracket (27).
17. Install bolts (49), washers (48) and washers (50).
18. Torque tighten the bolts (49) to 100 ± 3Nm (73.8 ±2.2 lbf ft).
19. Join the exhaust rear section pipe (8) to the exhaust inlet of the silencer (37).
20. Torque tighten the V-clamp (9) to 20 Nm (14.75 lbf ft).
21. Install the silencer to diverter box exhaust pipe (10). Refer to (e) Silencer to Diverter Box
Exhaust Pipe on page 5-46.
22. Place the battery master switch in the ‘ON’ position.

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5 Engine

Intentionally Left Blank

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 Transmission 6

Table of Content
6 Transmission...............................................................................................6-1
6.1 Transmission and Mounting ........................................................................... 6-2
6.2 Description ..................................................................................................... 6-3
6.3 Transmission Modules ................................................................................... 6-4
6.4 Transmission Temperatures, Pressures and Ratios....................................... 6-6
6.5 Switches, Sensors & Solenoids ..................................................................... 6-7
6.6 Operation ..................................................................................................... 6-10
(1) Allison Series 4500 Automatic Shift Transmission .................................. 6-10
(2) 5th GEN Shift Controller ........................................................................... 6-11
(3) Displaying Diagnostic Data...................................................................... 6-12
(4) Displaying Prognostic Data ..................................................................... 6-13
(5) Allison 5th Gen Diagnostic Codes ........................................................... 6-14
(6) Transmission Retarder ............................................................................ 6-18
(7) Gear Activation ........................................................................................ 6-19
6.7 Pressure Checks.......................................................................................... 6-19
6.8 Transmission TCU Connections................................................................... 6-21
6.9 General Troubleshooting.............................................................................. 6-22
6.10 Removal ....................................................................................................... 6-23
6.11 Disassembly................................................................................................. 6-24
6.12 Removal of the Control Valve Module .......................................................... 6-26
6.13 Inspection..................................................................................................... 6-27
6.14 Installation of the Control Valve Module ....................................................... 6-28
6.15 Assembly...................................................................................................... 6-29
6.16 Installation .................................................................................................... 6-29
6.17 Service Tools................................................................................................ 6-29
6.18 Special Torque Specifications ...................................................................... 6-29
6.19 Maintenance................................................................................................. 6-30
(1) Periodic Inspections ................................................................................ 6-30
(2) Oil Level Check ....................................................................................... 6-30
(3) Manual Oil Level Check........................................................................... 6-31
(4) Cold Level Check .................................................................................... 6-31
(5) Hot Level Check ...................................................................................... 6-32
(6) Oil and Filter Change............................................................................... 6-32
6.20 Transmission - Power Take Off .................................................................... 6-34
(1) Description............................................................................................... 6-35
(2) Operation................................................................................................. 6-35
(3) Removal .................................................................................................. 6-35
(4) Disassembly ............................................................................................ 6-36
(5) Inspection ................................................................................................ 6-37
(6) Assembly ................................................................................................. 6-37
(7) Installation ............................................................................................... 6-38
(8) Service Tools ........................................................................................... 6-39

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6 Transmission

6 Transmission
6.1 Transmission and Mounting

19
26
18
12 17 27
13 16 28
14 29

15 25
14 24
23
22
21

6 6

5 10
10
11
11 31 5
3 2
RH LH
20
8 9 30
9 8
29
20

1
1

4
4
5
5
7 7

MOT00623

Figure 6.1 - Exploded View of Transmission and Mounting

1. Isolation Mount 9. Lockwasher 17. Lockwasher 25. Fill Tube Seal
2. Mounting Bracket 10. Bolt 18. Bolt 26. Oil Fill Tube
3. Mounting Bracket 11. Lockwasher 19. Clamp 27. Oil Fill Tube Bracket
4. Snubbing Washer 12. Dipstick 20. Boss 28. Screw
5. Washer 13. Dipstick Tube 21. Bolt 29. Flange
6. Bolt 14. Clip 22. Retaining Plate 30. Output Yoke Slinger
7. Nut 15. Hose 23. O-ring 31. Plug
8. Bolt 16. Washer 24. O-ring

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 Transmission 6

6.2 Description

Figure 6.2 - Sectional View Of Typical 4500 Series Transmission.

1. Turbine 8. C3 Clutch 15. Electro Control Module
2. Stator 9. C4 Clutch 16. Rotating Clutch
3. Lockup 10. C5 Clutch 17. Turbine Shaft
4. Torque Converter Pump 11. P1 Module 18. Engine Speed Sensor
5. Charging Oil Pump 12. P2 Module 19. Turbine Speed Sensor
6. C1 Clutch 13. P3 Module 20. Output Speed Sensor
7. C2 Clutch 14. C5 Piston

Numbers in parentheses refer to Figure 6.1, unless otherwise specified.

For the transmission make, model and specification, refer to Transmission , page 3-13. For
additional transmission servicing and repair data refer to the transmission manufacturer's
service manual.
The transmission convertor housing module is close coupled to the engine output flywheel
housing. As the engine is secured to the chassis frame via isolation mounts at it's front, refer
to Description , page 5-3 for specific arrangement details, this ensures that the front of the
transmission is secured in place. At its rear, the transmission is secured via mounting brackets
(2 & 3) on either side of the transmission. Isolation mounts (1) provide sufficient flexibility to
absorb varying transmission vibration and torsional loads.
The transmission consists of a number of major assembly 'modules'. Integral with the
transmission assembly are the torque converter and the planetary gearing modules. There
are six forward gears, one reverse gear and a neutral position, with automatic lockup in all
speed ranges. Operation of the transmission is signalled by the electronic shift control via the
5th GEN Control system.

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6 Transmission

6.3 Transmission Modules

Numbers in parentheses refer to Figure 6.2, unless otherwise specified.
A brief description and operation of the main transmission modules follows:
Input Modules
Input modules are required to connect the transmission to the engine, an input module is
located between the engine and transmission gearbox modules. Input modules include; Torque
convertor module, Convertor housing and front support/ charging pump module.
Torque Convertor Module
The torque convertor operates hydraulically and transfers torque from the engine to
transmission. It consists of a vaned turbine (1), a vaned stator (2) and a lockup clutch/ torsional
damper assembly (3).
Convertor Housing Module
The convertor housing module connects the engine and the gearbox modules. The provision for
the Power take Off (PTO) is on the convertor housing, with the helical PTO drive gear contained
internal. The turbine shaft (17) passes through the convertor housing to the transmission
gearbox module. PTO gear hub is driven at engine speed by the torque convertor pump (4) hub
drive. In turn the PTO gear hub drives the charging pump (5).
Power takeoff at the left hand side of the transmission provides the drive for the main hydraulic
pump which supplies the braking, steering and body hoist systems. Refer to Power Take
Off section for details.
Front Support/ Charging Pump Module
The front support is bolted to the transmission main housing and contains the convertor ground
sleeve through which the turbine shaft passes to the rotating clutch assembly. The charging
pump pressurizes the transmission fluid. Charging pump rotates with engine to provide a
constant flow of pressurised fluid for the transmission hydraulic system.
Gearbox Modules
The basic gearbox modules contain five clutch assemblies and three planetary gear sets to
provide six forward speeds, neutral and one reverse.
Rotating Clutch Module
The rotating clutch (16) hub assembly is splined to the turbine shaft (17) and rotates with the
turbine (1). The rotating clutch module contains the turbine shaft assembly, rotating clutch
hub assembly, C1 and C2 (6 & 7) clutch assemblies, rotating clutch drum and sun gear drive
hub assembly for the P1 planetary gear set.
Main Housing Module
The main housing module consists of the C3, C4 and C5 clutches (8, 9 & 10), ring gear
component of the P1 planetary gear set and the transmission main housing. The clutches in the
main housing are stationary clutch assemblies and do not rotate when hydraulically applied.
The ECU signals solenoid valves in the control module to apply and release clutches based
on power and speed requirements.
P1 Planetary Gear Module (11)
P1 is the first planetary gear set assembly, consisting of a sun gear driven by the rotating
clutch drum. P1 carrier assembly containing P1 pinion gears and the P1 ring gear housed
in the C3 clutch assembly.
P2 Planetary Gear Module (12)
P2 is the second planetary gear set assembly, consisting of a sun gear splined to the main
shaft. P2 carrier assembly containing the P2 pinion gears and P2 ring gear splined to P1 carrier.

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 Transmission 6

Main Shaft Module (13)

The main shaft module passes through the centre of the transmission gearbox. The P2 and P3
sun gears are part of or splined to the main shaft, enabling it to transmit torque to the rotating
clutch module. Input torque to the main shaft is received either through rotating clutch module
or the P2 carrier. This main shaft provides the primary path for transmitting torque through the
various stages of the transmission.
Output Modules
The output modules contain components that transmit power and torque to the vehicle driveline.
The output centerline of the transmission is in line with the transmission input centreline.
Output Retarder Module
The output retarder module is to assist in stopping the vehicle and controlling the downhill
speed of the vehicle.
Electro-Hydraulic Control Module (15)
The control module houses the solenoids, sensors, valves and the regulators that control
the pressure and flow of the transmission fluid to the clutches, the torque convertor and the
lubricating/cooling hydraulic circuits. The control module also houses the transmission fluid
filters.
Transmission Control Module
Refer to Figure 6.3 and Figure 6.4, unless otherwise specified.

MOT04028
Figure 6.3 - Transmission Control Unit (TCU).
The transmission control module unit is the "brain" of the system. The independent transmission
controller unit (TCU) is configured to run off 24V. The TCU receives and processes signals
from various switches and sensors. These inputs are processed and the TCU determines the
optimum shift sequences, timing and clutch apply/release pressures. This is achieved by
controlling the transmission solenoids and valves.

TCU

MOT04027

Figure 6.4 - TCU Inputs / Outputs.

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6 Transmission

6.4 Transmission Temperatures, Pressures and Ratios

Table 6.1 - Transmission
Pressures:
Main 18.5 + 3.4 bar (269 + 50 lbf/in2)
Temperatures:
Normal 60 °C - 135° C (140 ° F- 275 °F)
Maximum 165 ° C (329 ° F)
Stall Speed 1600 – 1950 rev/min
Ratios:
Transmission Refer to Table 6.2.

Table 6.2 - Transmission Data

Low Box (1.129) High Box (0.738)
Speed Time Speed Time
Gear Gear Ratio
(km/h) (s) (km/h) (s)
1C 4.2 0.6 6.5 1.1
4.7
1L 6 0.9 9.5 1.6
2C 8 1.5 12.3 3.1
2.21
2L 11.3 2.7 16 5.7
3L 16.5 5.3 25.3 12.4 1.53
4L 25.6 12.8 39.2 35.9 1
5L 33.9 25.6 51.9 129.2 0.76
6L 41.7 46.3 63.8 231.9 0.67
Hot Engine Stall 1750 rpm
Speed (actual)
Cold Engine 1675 rpm
Stall Speed
(actual)

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 Transmission 6

6.5 Switches, Sensors & Solenoids

Figure 6.5 - Location of Transmission Switches, Sensors and Solenoids

1. Turbine Speed Sensor 5. OLS (Oil Level Sensor) 9. Output Speed Sensor
2. Engine Speed Sensor 6. OTS (Oil Temperature 10. Transmission Retarder
Sensor)
3. Transmission Filters 7. Electro-hydraulic Control
Module
4. Solenoid Locations 8. Internal Wiring Harness
Location

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6 Transmission

Numbers in parentheses refer to Figure 6.5, unless otherwise specified.

Transmission Oil Temperature
Transmission oil temperature is monitored by the temperature sensor (6), located within the
main control module (4). Oil temperature sensor (6) senses transmission oil temperature
and sends a signal back to the TCU, which in turn transmits the data on the J1939 data link.
The data is read by the instrument panel MCU and displayed on the instrument panel on the
temperature gauge.
The transmission temperature should display between 60 °C and 135 °C during normal
operating and may reach 165 °C when using the retarder. If the gauge reads above this, the
transmission should be put into neutral and engine speed increased to 1 200 - 1 500 rev/min.
Under this condition, oil temperature should drop to normal values in about 2 - 3 minutes. If oil
temperature does not drop, the cause should be investigated.
Transmission Oil Level
The transmission oil level is constantly monitored by the oil level sensor (OLS) (5) located
within the control module. The oil level can be checked and monitored via the display on the
gearshift lever. To enter the oil information sequence press the display mode button once on
the gear shift lever. A two minute countdown will begin when the following conditions of the
vehicle system are met:
1 Engine at idle.
2 Oil is at normal operating temperature - within range 82° C - 104° C.
3 Transmission is in neutral 'N'.
4 Transmission output shaft is stationary.
For further detail on displaying oil levels, refer to (2) Oil Level Check on page 6-30.
Lockup Clutch
The transmission lockup clutch (3, Figure 6.2) is automatically engaged. Engine speed is
identified by turbine speed sensor (1) which sends a signal to energise the normally closed
TCC solenoid (2, Figure 6.6) when the turbine speed reaches a predetermined level, energizing
TCC (2, Figure 6.6).
Modulated Main
5th GEN. controls include modulated main pressure for improved cooler flow and reduced
charging pump losses at low engine and output shaft speeds. The modulated main solenoid (8
Figure 6.6) is a normally closed; On/Off solenoid.
The TCU (Figure 6.3) commands the modulated main solenoid on when all of the following
conditions are met-
• Sump temperature must be between 35° C - 145° C.
• Engine RPM must be less than 1 200 RPM in all ranges (except neutral- no restriction).
• Throttle position must be less than 18% in all ranges (except neutral-no restriction)
• Transmission output speed must be below 250 rev/ min in reverse, neutral, 1st or 2nd range.
• PTO input must be off.
• A shift must not be in progress.

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 Transmission 6

Figure 6.6 - Control Valve Solenoid Designation and Internal Wiring Harness.
1. PS 1 4. PCS 2 7. PCS 4
(Pressure Switch) (Proportional Control (Proportional Control
Solenoid) Solenoid)
2. TCC 5. SS 1 8. MODULATED MAIN
(Torque Converter (Shift Solenoid) (Solenoid)
Clutch)
3. PCS 1 6. PCS 3
(Proportional Control (Proportional Control
Solenoid) Solenoid)

Shift Solenoid
Normally closed On/Off SS 1 (5, Figure 6.6) controls fluid flow to the top of the latch valves.
PCS Solenoids
PCS 1 through PCS 4 produce pressure that is proportional to the current supplied by the TCU.
• PCS 1 is normally open
• PCS 2 is normally open
• PCS 3 is normally closed
• PCS 4 is normally closed.
Diagnostic Pressure Switch
PS 1 (1, Figure 6.6) is a normally closed switch which monitors the C3 clutch pressure, verifying
the position of C1 and C2 latch valves.

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6 Transmission

6.6 Operation
(1) Allison Series 4500 Automatic Shift Transmission

NOTICE
• Before starting welding on a machine equipped with a 5th GEN control shift system, turn off
the battery master switch to isolate the batteries. Disconnect the following in this order:
battery earth cable, battery supply cable, alternator earth cables, alternator supply cables,
and electrical connections at the engine EMS, TCU, MCU, and cab bulkhead. This will avoid
damage to electrical components. After welding connect all of the above in reverse order.
• Before starting a welding process, make sure that all paint has been removed from the area
to be welded. Failure to do so will result in hazardous fumes being given off from the paint.
• Always fasten the welding machines ground cable to the piece/frame being welded if
possible.

The Allison Series 4500 transmission is equipped with a Transmission control unit (TCU)
which continually monitors the transmission and shift system electrical components. It warns
the operator when a problem develops. It also acts to prevent damage to the transmission,
and provides the serviceman with diagnostic capabilities so that problems can be corrected
quickly and easily.
When a fault occurs, a two-digit error code is displayed on the LCD display on the dash
panel. The error code is also recorded in the TCU, and can be accessible by the serviceman.
Information can be extracted by plugging in a data reader to extract the related fault. The error
code recorded in the TCU memory remains until erased by a technician.
If a major fault is detected, it is the operator’s responsibility to shut down the machine as soon
as it is safe to do so. The machine cannot be restarted until the fault has been diagnosed
and corrected.
Refer to (5) Allison 5th Gen Diagnostic Codes on page 6-14 table for a list of fault codes and
possible cause.
The Series 4500 transmission with 5th GEN control has been designed to provide the driver
with maximum operational flexibility. It allows the choice of automatic or manual gear selection
to optimize vehicle performance under all operating conditions.
The transmission provides six forward gears, one reverse gear, a neutral position, a manual
select position and a low range position. The gear positions indicate in the LCD display on the
shift control panel and on the dashboard DISPLAY screen. When the shift control lever is in the
automatic range, shifts occur automatically between 1st and 6th gear, depending on operating
requirements. When the lever is in the manual position 1st to 6th gear is achieved by the
operator manually up shifting and down shifting depending on operating conditions. Manual
selection also allows the operator to lock the transmission in a selected range.

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 Transmission 6

(2) 5th GEN Shift Controller

Figure 6.7 - 5th GEN Shift Controller

1. Display Mode Button 3. Range Selected 5. Release Button
2. Range Attained 4. Mode Button 6. Manual Select

� CAUTION
• Do not allow the machine to coast in neutral. This practice will result in severe transmission
damage.

� WARNING
• Always select Neutral and apply the parking brake before leaving the operator’s seat.

The 5th GEN shift controller has 6 forward ranges and 1 reverse as well as a neutral position
and a manual select position. The shift selector panel has a two-digit LED display that during
normal operation displays the range selected and the range attained. Refer to Figure 6.7.
Diagnostic information can be displayed on the two-digit LED display by pressing the diagnostic
mode button or on the diagnostic screen. There is a release button on the shift control lever that
must be pressed when shifting between Drive (D), Neutral (N), Reverse (R) and Low Range
(L). The button is released when the desired selector position is reached. The shift control
lever features a detent to prevent inadvertent shifting between Drive (D), Neutral (N), Reverse
(R) and Low Range (L). To release the lever from any of these positions, the detent must be
unlocked by depressing the release button on the handle.
When a forward gear range (D) has been selected the transmission upshifts and downshifts
automatically between first range and the highest range selected on the range selector (1st to
6th). In direct response to the throttle position and transmission output speed.
When reverse (R) is required and selected the 'reverse alarm' sounds. The 'reverse light'
illuminates to warn personnel at the rear of the machine and to indicate that reverse gear
has been selected.
Manually moving the shift control lever from the (D) position into the M (Manual Select) position
allows the operator to select a lower or higher forward preselected gear range
Movement of the shift control lever from the (D) position into the (M), Manual Select, position
and then with each Downshift (-) ‘bump’ decreases the range selected by one forward gear, or
with each upshift (+) ‘bump’ increases the range selected by one forward gear. Moving the lever

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6 Transmission

to (M), when a gear is attained, will set the range selected to the same forward range as the gear
currently attained, shown in the Range Monitor display. This is referred to as Express Preselect.
The ‘bump’ shifts are momentary – when the operator releases the lever, the lever will return
to the (M) position. The (M) position is accessible only from the (D) position and affects only
forward gear ranges.
Preselecting a gear range on certain applications can limit gear hunting to deliver enhanced
haul cycles, lower fuel consumption and extended transmission component life.
Moving the Gear Shift Lever to the (L) position will select 1st forward gear. The transmission
will automatically downshift to 1st gear using the preselect downshift schedule. Once attained,
the transmission will hold 1st gear on a delayed upshift schedule or until another gear range is
selected. This delayed 1st gear upshift will assist machine manoeuvrability on extreme inclines
or adverse ground conditions.
During normal operation with (D) position selected, the RANGE SELECT DISPLAY shows the
highest attainable forward range. The RANGE MONITOR DISPLAY shows the actual gear
attained by the transmission. Selection of (R) and (N) give a display in the same way.
(3) Displaying Diagnostic Data
5th Generation gear shift control levers display prognostics information in text format to provide
at-a-glance status of the transmission health.
The SERVICE INDICATOR ‘Wrench Icon’ will illuminate briefly after the engine start key is
turned to the run position. If the Wrench Icon remains on or flashes, this indicates there is a
service issue relating to the transmission clutch, filter or fluid life.
Access Diagnostic Data by pressing the Display Mode Button – (Allison Logo).
Transmission Oil Level
To access the oil level information sequence, press the Display Mode Button once. A 2-minute
countdown begins when the following conditions of the vehicle systems are met:
1 Engine at idle.
2 Oil is at operating temperature within range 82-104°C (140-220°F).
3 Transmission is in Neutral 'N'.
4 Transmission output shaft is stationary.
If the oil level is within the correct zone the display will show OK.
If the oil level is low the display will show the number of quarts the transmission oil is low and LO.
If the oil level is high the display will show the number of quarts the transmission oil is overfilled
and HI.
If the oil fluid level check can not be completed one of the following Oil Level Display Faults
will be displayed:
• SETTLING:62
• ENG RPM TOO LO
• ENG RPM TOO HI
• MUST BE IN NEUTRAL
• OIL TEMP TOO LO
• OIL TEMP TOO HI
• VEH SPEED TOO HI
• SENSOR ERROR
To exit the oil level function press the Display Mode Button once.

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 Transmission 6

(4) Displaying Prognostic Data

Oil Life Monitor
To access the oil life monitor information sequence, press the Display Mode Button twice.
When this mode has been selected a number between 100% & 0% will be displayed indicating
the percentage of life remaining in the fluid before a change is required.
To re-set the Oil Life Monitor Prognostic hold the Display Mode Button in for 10 seconds while
in Oil Life Monitor Mode.
Filter Life Mode
To access the oil filter life information sequence, press the Display Mode Button three times.
Once this mode has been selected OIL FILTERS OK or REPLACE FILTERS will be displayed.
To re-set the Filter Life Prognostic hold the Display Mode Button in for 10 seconds while in
Filter Life Mode
Transmission Health Monitor
To access the Transmission Health Monitor information sequence, press the Display Mode
Button four times.
Once this mode has been selected TRANSHEALTH OK or TRANSHEALTH LO will be
displayed. LO means clutch maintenance is required.
If LO is displayed a re-set is only possible manually using an Allison DOC ® for PC diagnostic
program after correcting a clutch system issue.
Fault Code Retrieval
To access the Fault Code Retrieval information sequence, press the Display Mode Button
five times.
This mode will display up to 5 fault codes. Code ID numbers are accompanied with ACTIVE or
INACTIVE. Press the Mode Button to advance to next fault code. Refer to table (5) Allison 5th
Gen Diagnostic Codes on page 6-14.
To exit this mode press the Display Mode Button once. Wait approximately 10 minutes and the
system will automatically return to the normal operating mode. Press the engine STOP button
and turn the ignition key to the OFF position.

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6 Transmission

(5) Allison 5th Gen Diagnostic Codes

Table 6.3 - Allison 5th Gen Diagnostic Codes
Fault Code Meaning of Code / Possible Cause of Fault
C1312 Retarder Request Sensor Failed Low
C1313 Retarder Request Sensor Failed High
P0122 Pedal Position Sensor Low Voltage
P0123 Pedal Position Sensor High Voltage
P0218 Transmission Fluid Over temperature
P0602 TCM Not Programmed
P0610 TCM Vehicle Options Error (Trans ID) Error
P0613 TCM Processor
P0614 Torque Control Mismatch (ECM/ TCM)
P0634 TCM Internal Temperature Too High
P063E Auto Configuration Throttle Input Not Present
P063F Auto Configuration Engine Coolant Temperature Input Not Present
P0658 Actuator Supply Voltage 1 (HSD1) Low
P0659 Actuator Supply Voltage 1 (HSD1) High
P0701 Transmission Control System Performance
P0702 Transmission Control System Electrical (Trans ID)
P0703 Brake Switch Circuit Malfunction
P0708 Transmission Range Sensor Circuit - High Input
P070C Transmission Fluid Level Sensor Circuit - Low Input
P070D Transmission Fluid Level Sensor Circuit - High Input
P0711 Transmission Fluid Temp. Sensor Circuit Performance
P0712 Transmission Fluid Temperature Sensor Circuit Low Input
P0713 Transmission Fluid Temperature Sensor Circuit High Input
P0716 Turbine Speed Sensor Circuit Performance
P0717 Turbine Speed Sensor Circuit No Signal
P0719 Brake Switch ABS Input Low
P071A RELS Input Failed On
P071D General Purpose Input Fault
P0721 Output Speed Sensor Circuit Performance
P0722 Output Speed Sensor Circuit No Signal
P0726 Engine Speed Input Circuit Performance
P0727 Engine Speed Input Circuit No Signal
P0729 Incorrect 6th Gear Ratio
P0731 Incorrect 1st Gear Ratio
P0732 Incorrect 2nd Gear Ratio
P0733 Incorrect 3rd Gear Ratio

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 Transmission 6

Fault Code Meaning of Code / Possible Cause of Fault

P0734 Incorrect 4th Gear Ratio
P0735 Incorrect 5th Gear Ratio
P0736 Incorrect Reverse Gear Ratio
P0741 Torque Convertor Clutch System Stuck Off
P0776 Pressure Control Solenoid 2 Stuck Off
P0777 Pressure Control Solenoid 2 Stuck On
P0796 Pressure Control Solenoid 3 Stuck Off
P0797 Pressure Control Solenoid 3 Stuck On
P0842 Transmission Pressure Switch1 Circuit Low
P0843 Transmission Pressure Switch1 Circuit High
P0880 TCM Power Input Signal
P0881 TCM Power Input Signal Performance
P0882 TCM Power Input Signal Low
P0883 TCM Power Input Signal High
P0894 Transmission Component Slipping
P0960 Pressure Control Solenoid Main Mod Control Circuit Open
P0962 Pressure Control Solenoid Main Mod Control Circuit Low
P0963 Pressure Control Solenoid Main Mod Control Circuit High
P0964 Pressure Control Solenoid 2 (PCS2) Control Circuit Open
P0966 Pressure Control Solenoid 2 (PCS2) Control Circuit Low
P0967 Pressure Control Solenoid 2 (PCS2) Control Circuit High
P0968 Pressure Control Solenoid 3 (PCS3) Control Circuit Open
P0970 Pressure Control Solenoid 3 (PCS3) Control Circuit Low
P0971 Pressure Control Solenoid 3 (PCS3) Control Circuit High
P0973 Shift Solenoid 1 (SS1) Control Circuit Low
P0974 Shift Solenoid 1 (SS1) Control Circuit High
P0975 Shift Solenoid 2 (SS2) Control Circuit Open
P0976 Shift Solenoid 2 (SS2) Control Circuit Low
P0977 Shift Solenoid 2 Control Circuit High
P0989 Retarder Pressure Sensor Failed Low
P0990 Retarder Pressure Senosr Failed High
P1739 Incorrect Low Gear Ratio
P1891 Throttle Position Sensor PWM Signal Low Input
P1892 Throttle Position Sensor PWM Signal High Input
P2184 Engine Coolant Temperature Sensor Circuit Low Input
P2185 Engine Coolant Temperature Sensor Circuit High Input
P2637 Torque Management Feedback Signal (SEM)

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6 Transmission

Fault Code Meaning of Code / Possible Cause of Fault

P2641 Torque Management Feedback Signal (LRTP)
P2670 Actuator Supply Voltage 2 (HSD2) Low
P2671 Actuator Supply Voltage 2 (HSD2) High
P2685 Actuator Supply Voltage 3 (HSD3) Low
P2686 Actuator Supply Voltage 3 (HSD3) High
P2714 Pressure Control Solenoid 4 (PCS4) Stuck Off
P2715 Pressure Control Solenoid 4 (PCS4) Stuck On
P2718 Pressure Control Solenoid 4 (PCS4) Control Circuit Open
P2720 Pressure Control Solenoid 4 (PCS4) Control Circuit Low
P2721 Pressure Control Solenoid 4 (PCS4) Control Circuit High
P2723 Pressure Control Solenoid 1 (PCS1) Stuck Off
P2724 Pressure Control Solenoid 1 (PCS1) Stuck On
P2727 Pressure Control Solenoid 1 (PCS1) Control Circuit Open
P2729 Pressure Control Solenoid 1 (PCS1) Control Circuit Low
P2730 Pressure Control Solenoid 1 (PCS1) Control Circuit High
P2736 Pressure Control Solenoid 5 (PCS5) Control Circuit Open
P2738 Pressure Control Solenoid 5 (PCS5) Control Circuit Low
P2739 Pressure Control Solenoid 5 (PCS5) Control Circuit High
P2740 Retarder Oil Temperature Hot
P2742 Retarder Oil Temperature Sensor Circuit—Low Input
P2743 Retarder Oil Temperature Sensor Circuit—High Input
P2761 TCC PCS Control Circuit Open
P2763 TCC PCS Control Circuit High
P2764 TCC PCS Control Circuit Low
P278A Kickdown Input Failed ON
P2793 Gear Shift Direction Circuit
P2808 Pressure Control Solenoid 6 (PCS6) Stuck Off
P2809 Pressure Control Solenoid 6 (PCS6) Stuck On
P2812 Pressure Control Solenoid 6 (PCS6) Control Circuit Open
P2814 Pressure Control Solenoid 6 (PCS6) Control Circuit Low
P2815 Pressure Control Solenoid 6 (PCS6) Control Circuit High
U0001 Hi Speed CAN Bus Reset Counter Overrun (IESCAN)
U0010 CAN BUS Reset Counter Overrun
U0100 Lost Communications with ECM/PCM (J1587)
U0103 Lost Communication With Gear Shift Module (Shift Selector) 1
U0115 Lost Communication With ECM
U0291 Lost Communication With Gear Shift Module (Shift Selector) 2

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 Transmission 6

Fault Code Meaning of Code / Possible Cause of Fault

U0304 Incompatible Gear Shift Module 1 (Shift Selector ID)
U0333 Incompatible Gear Shift Module 2 (Shift Selector ID)
U0404 Invalid Data Received From Gear Shift Module (Shift Selector) 1
U0592 Invalid Data Received From Gear Shift Module (Shift Selector) 2

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6 Transmission

(6) Transmission Retarder

� CAUTION
• The retarder must not be used to bring the machine to a stop. The retarder must only be
used to slow the machine down.
• The service brakes must be used for stopping the vehicle.

The transmission retarder is used to assist in stopping the vehicle and reduce the need for
service brake applications, thus reducing service brake wear and preventing overheating.
The retarder may be used at any time to slow the vehicle down. If additional braking is required
apply the service brakes.
The retarder consists of a stator, rotor, housing and control valve body assembly. The rotor
is splined to the transmission output shaft and is driven at output shaft speed. The retarder
stator, rotor and housing all have integral vanes. The rotor rotates between the stationary
stator and retarder housing.
Retardation occurs when the retarder housing is filled with transmission fluid and pressurized,
thus impeding and slowing the rotor, output shaft and vehicle.
For the retarder to engage, certain conditions must be satisfied:
1 Accelerator released.
2 Transmission 'STOP' warning light must be out.
3 Transmission must be in lockup.

Figure 6.8 - Retarder Request Switch/Percentage Lever.

1. Retarder Request Switch. 2. Retarder Lever ( 6 position)

To apply the retarder, the dashboard mounted retarder request switch must be on (1, Figure
6.8). A signal is then sent to the TCM to request retarder operation, when all conditions are met.
The amount of retardation requested is operator dependant. This is done via the six-position
lever on the right hand switch bank (2, Figure 6.8). With maximum retardation requested in
the lowest position.

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 Transmission 6

(7) Gear Activation

The following table shows the condition of the individual solenoids, switched and latch valves to
attain the full range of gears from the transmission.
Table 6.4 - Gear Activation Table
Latch Valve Main Mod Press.
Solenoid Energised PS1 position SS1
Range Position Solenoid. Clutch
Attained De- Apply
PCS1 PCS2 PCS3 PCS4 C1 C2 Open Closed Energized Energized
energized
Neutral X X X Up Up X X C5
1st X X Down Up X X C1 + C5
2nd X X Down Down X X X C1 + C4
3rd X X Down Down X X X C1 + C3
4th Down Down X X X C1 + C2
5th X X Down Down X X X C2 + C3
6th X X Up Down X X C2 + C4
Reverse X X Up Up X X C3 + C5

The main pressure modulation is checked at idle in neutral, reverse, 1st convertor and second
convertor. The main modulation pressure is checked at high speed in neutral only. RPM should
be in range of 1 780 - 1 820.
6.7 Pressure Checks

Figure 6.9 - Pressure Check Points

1. Drain Plug 3. Lube Pressure 5. Lockup Pressure Tap
2. Clutch Pressure Taps 4. Oil Filter Covers

Checking individual clutch pressures helps to determine if a transmission malfunction is

due to a mechanical or an electrical problem. Properly making these pressure checks
requires transmission and vehicle preparation, recording of data and comparing data against
specifications provided.

PROCEDURE
1. Remove the plug from the pressure tap and install a suitable hydraulic fitting and pressure
gauge at the location where the measurement is desired. Pressure gauge set J26417-A is
available.
2. Bring the transmission to the normal operating temperature of 71° C - 93° C (160° F- 200°
F). Check for fluid leaks in the circuit. Be sure that the fluid level is correct.

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6 Transmission

3. Compare the clutch pressures recorder with those given in the table. If the clutch pressures
are not within the specifications take corrective action to redeem the fault.
4. The main pressure modulation is checked in neutral, reverse, 1st and 2nd converter.
5. The main pressure modulation is checked at high speed in neutral only.

Refer to the following tables for checking pressures and troubleshooting the system.
Table 6.5 - Pressure Checks Table
Engine Clutches Main Press. Range Clutch Conv.Out Lube Press. LU Clutch
Range
RPM Applied Spec. Press. Spec* Press. Spec Spec Press. Spec*
Idle Neutral C5 218 - 319 0 - 5.8 (C5) -

Reverse C3 C5 218 - 319 0 - 5.8 (C3 & C5) 0.5 min

0 -10 (C1)
1C C1 C5 189 - 261 0.5 min
0 - 5.8 (C5)
0 - 10 (C1)
2C C1 C4 189 - 261 0.5 min
0 - 5.8 (C4)
1780 - 1820 Neutral C5 261 - 319 0 - 5.8 11 - 44 7 - 28
Reverse C3 C5 261 - 319 0 - 5.8 (C3 & C5) 25 - 44 17 - 28
0 -10 (C1)
1C C1 C5 225 - 261 25 - 44 17 - 28
0 - 5.8 (C5)
0 -10 (C1)
2C C1 C4 225 - 261 25 - 44 17 - 28
0 - 5.8 (C4)
0 - 10 (C1)
2L C1 C4 LU 152 - 203 29 - 51 20 - 28 0 - 8.7
0 - 5.8 (C4)
0 -10 (C1)
3C C1 C3 225 - 261 25 - 44 17 - 28
0 - 5.8 (C3)
0 -10 (C1)
3L C1 C3 LU 152 - 203 29 - 51 20 - 28 0 - 8.7
0 - 5.8 (C3)
0 -10 (C1)
4C C1 C2 225 - 261 19 - 36 13 - 22
0 -10 (C2)
0 -10 (C1)
4L C1 C2 LU 152 - 203 23 - 44 16 - 22 0 - 8.7
0 -10 (C2)
0 -10 (C2)
5C C2 C3 184 - 247 19 - 36 13 - 22
0 - 5.8 (C3)
0 -10 (C2)
5L C2 C3 LU 131 - 181 23 - 44 16 - 22 0 - 8.7
0 -5.8 (C3)
0 -10 (C2)
6C C2 C4 184 - 247 19 - 36 13 - 22
0 - 5.8 (C3)
0 -10 (C2)
6L C2 C4 LU 131 - 181 23 - 44 16 - 22 0 - 8.7
0 - 5.8 (C4)
Note: Pressure values are given in 'psi'
* Subtract clutch pressure from main pressure; the difference must fall within the specification given.

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 Transmission 6

6.8 Transmission TCU Connections

The transmission TCU has one 80-pin connector that provides the inputs and outputs for the
transmission functions. Refer to Figure 6.10 for specific detail.

Figure 6.10 - Transmission TCU Pin

Table 6.6 - Transmission TCU Pin Designations
No. Colour Wire# Description
1 WH 407 Range Inhibit Signal
3 WH 274 X.3 Signal Return
8 BU 242 CAN2_L
9 BN 270 Battery Ground
10 RD 273 F8 Battery Supply
11 WH 254 X.11 Trans HSD1
12 WH 246 X.12 Sensor Supply
15 WH 264 X.15 Trans Y14
16 WH 249 X.16 Oil Level Sensor Signal
18 WH 253 X.18 Trans Filter
19 WH 266 X.19 R7 22 Ohm 75Watt
20 BU 243 X.20 Turbine Speed B
21 - - .21 (Not Used)
28 YE 242 CAN2_H
31 WH 262 X.31 Trans HSD3
33 WH 260 X.33 PCS3 Solenoid Supply
34 WH 50 X.31 Direction Signal
36 WH 258 X.36 PCS1 Solenoid Supply
37 WH 265 X.37 TCC Solenoid Supply
39 BU 245 X.39 Engine Speed B
40 BU 244 X.40 Output Speed B
42 WH 282 X.42 Input 5
51 WH 261 X.51 SS1 Shift Solenoid
52 WH 259 X.52 PCS2 Solenoid
54 WH 250 X.54 Sump Temp. Signal
55 WH 255 X.55 PCS4 Solenoid

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6 Transmission

No. Colour Wire# Description

56 WH 74 X.56 Retarder Signal
58 WH 247 X.58 Analogue Return
59 YE 245 X.59 Engine Speed A
60 YE 244 X.60 Output Speed A
61 WH 411 X.58 Retarder Request
63 BK 281 F72 Ignition Battery Power
69 BN 269 Battery Ground
70 RD 272 F8 Battery Supply
71 WH 257 X.71 HSD2
74 WH 256 X.74 Modulated Main
75 WH 248 X.75 Retarder Temperature
76 WH 251 X.76 Trans ID
77 WH 252 X.76 Trans PSI
80 YE 243 X.80 Turbine Speed A

6.9 General Troubleshooting

'Check Trans' Warning Light
Refer to (8, Figure 6.11 ).
Illuminates to alert of a minor fault in the transmission control system or abnormal transmission
temperature. The light will come 'On' when the ignition key switch is turned to position '1'
to provide a bulb and system check and should go 'Off' a few seconds after the engine is
started and the transmission oil pressure rises. The check trans warning light will come 'On'
during operation, if the TCU has detected a minor fault in an electrical component or abnormal
transmission oil temperature. If transmission oil temperature is too high, stop the vehicle,
select neutral 'N', and increase engine speed to allow a greater flow of oil to the cooler until oil
temperature drops to normal operating range. In most cases, a minor fault triggering the 'check
trans' warning light will not prevent normal operation from continuing but, depending on the
nature of the problem, the TCU could take action to protect the transmission from damage,
such as preventing operating in high gear ranges. If the 'check trans' light comes 'On', have the
problem diagnosed and corrected at the earliest opportunity.

Figure 6.11 - 'Check Trans' Warning Light

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 Transmission 6

Performance Complaints
Make the following general checks before beginning specific troubleshooting.
• Are there active diagnostic codes?
• Is the shift lever in N to allow engine start?
• Is the battery properly connected and charged?
• Are all fluid levels correct?
• Is the voltage to the TCU correct?
• Is engine properly tuned?
• Is fuel flow to the engine correct?
• Is air flow to the cooler and radiator unrestricted?
• Is the driveline properly connected?
• Are there signs of fluid leakage under the vehicle?
• What is the origination point of this leak?
• Are all hydraulic connections leak free?
• Are all electrical connections correct?
After making these checks, some complaints involve diagnostic codes, so all troubleshooting
checks should involve checking the system for diagnostic codes.
6.10 Removal
The Transmission and Engine are removed as one Powertrain Assembly. Refer to 5.3
Removal on page 5-5.

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6 Transmission

6.11 Disassembly
7
6 8
4 5
1
7
3 6
5 8
2

7
6
5 8

24
23
22
17 9
10
11

12 13
20
21
18 14
19

16 15

MOT05020

Figure 6.12 - Transmission Disassembly

1. Dipstick 9. Slinger - Output Yoke 17. Porting Block Location
2. Bolt 10. Yoke 18. Nut
3. Transmission 11. O-Ring 19. Washer Hardened
4. Vent 12. O-Ring 20. O-Ring
5. O-Ring 13. Retaining Plate 21. Stud - PTO Housing
6. Speed Sensor 14. Bolt 22. Power Take Off (PTO)
7. Tab washers 15. Dropbox Gear Pump 23. Bolt
Location
8. Bolt 16. Hydraulic Pump 24. Gasket

Numbers in parentheses refer to Figure 6.12, unless otherwise specified.

PROCEDURE
1. Remove the dropbox gear pump (15), refer to 7.2 Dropbox Pump on page 7-45.
2. Remove the hydraulic pump (16), refer to (3) Removal on page 11-45.
3. If required remove the porting block (17).
4. Remove the eight mounting bolts (23) securing the power take off (PTO) to the transmission
left-hand side.
5. Remove the PTO (22) and gasket (24). Inspect the PTO studs for damage and remove
them if necessary. Refer to 6.20 Transmission - Power Take Off on page 6-34.
6. Remove the bolts (2) retaining the oil fill tube hose to the clamp over the top of the
transmission. Remove the bracket, fill tube, seal and dipstick from the transmission.

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 Transmission 6

7. Bend down the tabs of the lock washers (7) if present, and loosen the bolts (8). Remove
the speed sensors (6) and O-rings (5).
8. Remove the bolt (14), retaining plate (13) and O-rings (12 and 11).
9. Remove the yoke (10), complete with the output yoke - slinger (9).

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6.12 Removal of the Control Valve Module

2 3

12

12
4

5
1

11 6
10 7
8

9
MOT05022

Figure 6.13 - Control Valve Module - Removal

1. Control Valve Module 5. Harness Connection 9. Bolt
2. Gasket 6. O-Ring 10. Plug
3. Filters 7. Plug 11. O-Ring
4. Bolt 8. Bolt 12. Location Pin

Numbers in parentheses refer to Figure 6.13 and Figure 6.2, unless otherwise specified.

� WARNING
• Control module weighs approximately. 25 kg (55 Ib). Ensure suitable support is in place to
aid in removal.

NOTICE
• The control module or filters or both may contain residual transmission fluid. Ensure that
the external part of feed through the harness connector has been disconnected from the
external brackets before removing the control module.

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 Transmission 6

PROCEDURE
1. Remove the 43 bolts (9) and 9 bolts (8) retaining the control module (1) to the main housing
module, and also the bolts (4) retaining the filter covers.
2. Loosen the control module by applying pressure at the reinforced tabs, or use jack bolts
inserted into the control module bolt holes that bottom against the main housing module.
3. Remove the covers and filters (3) if a hand hold is needed to remove the control module.
4. Ensure that the internal wiring harness connection (5) is carefully removed from the
transmission housing during removal of the control module.
5. Remove the control module assembly (1) and gasket (2).
6. Refer to the transmission manufacturer's service manual if further transmission service
or repair is required.

6.13 Inspection
Numbers in parentheses refer to Figure 6.1, unless otherwise specified.
Periodic Inspection of the exterior of the transmission is an essential part of preventative
maintenance. The severity of service and operating conditions should be taken into account
when determining the frequency of inspection.

PROCEDURE
1. Check the mounting brackets assembly (2 & 3), for cracks and damage. Repair or renew as
required.
2. Check the condition of the engine output flywheel housing for general damage before
mating the transmission to the engine.
3. Check the general condition of the transmission assembly for wear and damage, loose
bolts, fluid leaks, or for damaged or loose hoses.
4. Check for worn or damaged driveline flanges and excessive wear on mounting holes and
isolation mounts (1).
5. Check the condition of all electrical harnesses and connections and repair/renew them as
required. Check the condition of all hydraulic lines on the transmission and renew them if
damaged.

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6.14 Installation of the Control Valve Module

Numbers in parentheses refer to Figure 6.13, unless otherwise specified.

� WARNING
• Control module weighs approximately. 25 kg (55 Ib). Ensure suitable support/lifting
equipment is in place to aid installation.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Ensure that all service and repair to the transmission has been completed.
2. Install a new gasket (3) to the control module.
3. Ensure that the location pins (12) are installed in the control module.
4. Lubricate the feedthrough hole in the main housing with oil-soluble grease.
5. Guide control module (1) onto the main housing and pass the feedthrough harness
connector through the feedthrough hole in the main housing.
6. Align the control module (1) with the transmission housing, using the location pins (12).
7. Seat the control module to the housing assembly and secure with bolts (8 and 9). Torque
tighten to 51 - 61 Nm (38 - 45 lbf ft).
8. Install new filter assemblies, O-rings and gasket (3) and secure cover assemblies with bolts
(4). Torque tighten to 51 - 61 Nm (38 - 45 lbf ft). Refer to Oil and Filter Change , page 6-32.

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 Transmission 6

6.15 Assembly
� WARNING
• Do not exceed 5 kN when fitting the output yoke - slinger.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

Numbers in parentheses refer to Figure 6.12 unless otherwise specified.

PROCEDURE
1. Install the yoke (10), complete with the output yoke - slinger (9).
2. Install the bolt (14), retaining plate (13) and O-rings (12 and 11).
3. Install the speed sensors (6) and O-rings (5). Bend up the tabs of the lock washers (7) if
present, and tighten the bolts (8).
4. Install the bracket, fill tube, seal and dipstick to the transmission. Install the bolts (2) and
secure the oil fill tube hose to the clamp over the top of the transmission.
5. Install the PTO (22). Refer to 6.20 Transmission - Power Take Off on page 6-34
6. If required install the porting block (17).
7. Install the hydraulic pump (16), refer to (7) Installation on page 11-59.
8. Install the dropbox gear pump (15), refer to 7.2 Dropbox Pump on page 7-45.

6.16 Installation
The Transmission and Engine are installed as one Powertrain Assembly. Refer to 5.4
Installation on page 5-9.
6.17 Service Tools
Refer to 22.2 Service Tools on page 22-4, for the part number of service tools which should
be used in conjunction with the procedures outlined in the transmission manufacturers service
manual, and, the general service tools required. These tools are available from your dealer.
6.18 Special Torque Specifications
Table 6.7 - Torque Specifications
TORQUE
FIG. NO. ITEM NO. ITEM NAME
Nm lbf ft
1 7 Nut 921 680
1 8 Bolt 228 - 266 168 - 196
1 10 Bolt 40 30
1 34 Bolt 921 680

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6 Transmission

6.19 Maintenance
(1) Periodic Inspections
For easier inspection, the transmission should be kept clean. Make periodic checks for loose
mounting bolts and leaking oil lines. Check the condition of the electrical harnesses and
connections regularly.
(2) Oil Level Check

Figure 6.14 - Transmission Dipstick Markings

� WARNING
• When checking the oil level, ensure that the parking brake is applied and that all road
wheels are securely blocked.

Check the transmission oil level and add oil if low, every 10 hours/daily. Use only the oil
specified in (1) Recommended Lubricants on page 4-16. Because the transmission oil cools,
lubricates and transmits hydraulic power it is important that the proper oil level is maintained
at all times. If the oil level is too low, the converter and clutches will not 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 is clean.
The oil level can be checked either manually, as described in the following text, or through
the 5th GEN gearshift lever.
Refer to (3) Displaying Diagnostic Data on page 6-12, for specific details on using the shift
lever for this purpose.

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 Transmission 6

(3) Manual Oil Level Check

NOTICE
• Clean dirt from around the end of the fluid fill tube before removing the dipstick. Do not
allow dirt or foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic
system may clog passages and cause undue transmission part failure or wear.

Always check the fluid level reading at least twice using the following procedure.
Consistent/repeatable readings are important to maintain proper fluid level. If inconsistent
readings persist, check the transmission breather to ensure it is not clogged.
(4) Cold Level Check

� WARNING
• Do NOT start the engine until the presence of sufficient transmission fluid has been
confirmed. Remove the transmission fluid dipstick and be sure that static fluid level is
near the HOT FULL mark.

Refer to Figure 6.14.

The purpose of the cold level check is to determine if the transmission has enough fluid to be
operated safely, until a hot check can be made.

PROCEDURE
1. Park the vehicle on a level surface, block all road wheels and apply the parking brake.
2. Run the engine at idle or at least one minute with the transmission in N (neutral). Move the
shift lever to D (Drive), then shift to R (reverse) to clear the hydraulic system of air. Then
move the shift lever to N (Neutral) and allow the engine to idle.
3. With the engine running, remove the dipstick from the tube and wipe clean.
4. Insert the dipstick fully into tube and then remove. Check fluid level. Repeat the check
procedure to verify the reading.
5. If the fluid level is within the "COLD RUN" band (between the cold full and cold add
markers), the transmission can be operated until the fluid is hot enough to perform a "HOT
RUN" check. If fluid level is not within the "COLD RUN" band, add or drain as necessary to
bring the fluid level to the middle of the "COLD RUN" band.
6. Perform a hot check at the first opportunity after normal operating temperature is reached,
71° C - 93° C (160° F - 200° F).

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6 Transmission

(5) Hot Level Check

� WARNING
• When checking the oil level, be sure that the parking brake is applied and all road wheels
are securely blocked.

� CAUTION
• An accurate fluid level check cannot be made unless the engine is idling (500 - 800 rev/min)
in 'N' (neutral), the transmission fluid is at the proper operating temperature and the vehicle
is on a level surface.

Refer to Figure 6.14.

PROCEDURE
1. Run the engine, and operate the transmission with the shift lever in D (Drive) range until
normal operating temperature is reached:
• Sump temperature 71° C - 93° C (160° F - 200° F)
• The converter-out temperature 82° C - 104° C (180° F - 220° F)
2. Park the vehicle on a level surface and move the shift lever to N (Neutral). Allow the
engine to idle.
3. With the engine running, remove the dipstick from the tube and wipe it clean.
4. Insert the dipstick into the tube and remove it. Check the fluid level. Repeat the check
procedure to verify the reading.
5. If the fluid level is not within the "HOT RUN" band (between the hot full and hot add
markers), add or drain as necessary to bring the fluid level within the band. The safe
operating level is within the "HOT RUN" band on the dipstick.

(6) Oil and Filter Change

� WARNING
• DO NOT spray steam, water or cleaning solution directly at the breather. Spraying steam,
water or cleaning solution directly at the breather can force water or cleaning solution into
the transmission and contaminate the transmission fluid.

NOTICE
• The interval for oil filters change is 3000 hours.
• The interval for oil change is 6000 Hours, assuming that the correct/approved oil type has
been put into the transmission unit. Refer to Lubrication System section, for recommended
lubricant details.

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 Transmission 6

Numbers in parentheses refer to Figure 6.15, unless otherwise specified.

Figure 6.15 - Transmission Oil Filters

1 Main Filter 4 O-ring 7 Filter Covers * (Not Shown)
2 Lube Filter 5 Gasket
3 O-ring 6 Gasket

1 To replace the oil filters, remove the 12 bolts and the filter covers (7).
2 Remove and discard the gaskets (5 & 6), O-rings (3 & 4), main oil filter (1) and the lube oil
filter (2).
3 Lubricate and reinstall new O-rings (3 and 4) on each cover (7). Lubricate an O-ring inside
each filter (1 & 2) and push a filter on to each cover (7).
4 Install new gaskets (5 and 6) on the respective covers and align holes in the gasket with the
holes in the cover.
5 Install the filters (1 & 2) and cover (7) assemblies into the filter compartment. Index each
filter/cover assembly to the holes in the channel of the sump. Push them in by hand to
seat the seals.
6 Install the six bolts into each cover (7) and tighten them to a torque of 51 - 61 Nm (38 -
45 Ibf ft).
7 Refill transmission oil.
The transmission breather should be checked on a regular basis, and as frequently as
necessary, depending on operating conditions. However, checking should be carried out at a
minimum of 250 hour intervals and the breather replaced where necessary. A badly corroded
or plugged breather restricts proper breathing and causes a buildup of condensation and
subsequent oil deterioration.

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6 Transmission

6.20 Transmission - Power Take Off

Figure 6.16 - Sectional View of Transmission Power Take Off

1. Drive Screw (2- Off) 11. Idler Gear 21. O-Ring (2-Off)
2. Name Plate 12. Circlip 22. Bolt
3. Bearing Housing 13. O-Ring (4-Off) 23. Ball Bearing
4. O-Ring 14. Grubscrew 24. Circlip
5. Bolt 15. Key 25. Stud
6. Idler Gear 16. Idler Gear 26. Washer
7. Circlip 17. Taper Bearing (2-Off) 27. Nut
8. Key 18. Shim 28. Adaptor Plate - Pump
9. Drive Shaft 19. Idler Shaft
10. Ball Bearing 20. PTO Case

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 Transmission 6

(1) Description
Numbers in parentheses refer to Figure 6.12, unless otherwise specified.
The power takeoff (PTO) is mounted off a machined face on the front left hand side of the
transmission.
(2) Operation
Numbers in parentheses refer to Figure 6.16, unless otherwise specified.
A idler gear (11) meshes with the transmission and rotates at transmission speed. The rotational
movement is transferred to the drive shaft (9) through a series of gears (16 & 6) which are keyed.
Mounted off the power takeoff housing is the main hydraulic pump which is driven by a drive
shaft (9). Refer to (1) Description on page 11-37.
(3) Removal

4 1
18
15 17
6 11
9 8

10

12
7

13
16
13

2 5
3 14

MOT05023

Figure 6.17 - Power Take Off (PTO) - Removal

1. Power Take Off 7. O-Ring 13. Pin Dowel
2. Drive Shaft 8. Stud 14. Shim
3. O-Ring 9. Washer 15. Access Port
4. O-Ring 10. Nut 16. Pump Adaptor Plate
5. Idler Shaft 11. Bolt 17. Bolt
6. Bolt 12. Gasket 18. Bearing Housing

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6 Transmission

Numbers in parentheses refer to Figure 6.17, unless otherwise specified.

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

NOTICE
• Identify or mark the number and thickness of the shims (14, Figure 6.17) removed. This
procedure is necessary so as to not alter the backlash of the gears during assembly.
• The gasket used at the steering pump mounting face should be discarded and replaced
at installation.

PROCEDURE
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 pressure in the steering
circuit. Block all road wheels.
3. Match mark the main hydraulic pump housing and the pump adaptor plate (16) to facilitate
assembly. Remove the main hydraulic pump following procedures outlined in (3) Removal
on page 11-45.
4. Attach a suitable lifting equipment to the power takeoff assembly and remove 10-off bolts
(11). Lift the power takeoff assembly and the shims (14) from the transmission housing.
Discard the shims (14) as a new shims must be fitted at the assembly stage. Cover the
transmission housing with a mating plate to prevent ingress of contamination.

(4) Disassembly
Numbers in parentheses refer to Figure 6.17, unless otherwise specified.

� CAUTION
• Careful removal of the pump adaptor plate is required to prevent internal component
damage.

PROCEDURE
1. Remove the main hydraulic pump to allow removal of the transmission PTO. Refer to (3)
Removal on page 11-45 for detail.
2. Remove the bolts (6) securing the pump adaptor plate (16) to the PTO case (1). Remove
the adaptor plate (16).
3. Remove and discard the O-ring (7) from the adaptor plate (16).
4. Remove the bearing (25, Figure 6.16) from the adaptor plate (16).
5. Remove the bolts (17) securing the bearing housing (18) to the PTO case (1). Carefully
remove the bearing housing (18). The bearing (10, Figure 6.16) should be removed at
this stage.
6. Remove and discard the O-ring (4) from the bearing housing (18).

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 Transmission 6

7. Remove the bearing (10, Figure 6.16) from the housing using a suitable driver, plastic
mallet or a device which will not damage the bearing.
8. Remove the circlips (7 and 24, Figure 6.16) from the drive shaft (2).
9. Carefully remove the drive shaft (2) from the idler gear (6, Figure 6.16). Remove the key
(8, Figure 6.16).
10. Remove the grubscrew (14, Figure 6.16), remove the idler shaft (19, Figure 6.16) from the
bore of the PTO case (1).
11. Discard the O-rings (3). Remove the idler gears, bearings and key (11, 16, 17 and 15,
Figure 6.16) and the shims (14) from the assembly.
12. Separate the individual components as required.

(5) Inspection
Numbers in parentheses refer to Figure 6.16, unless otherwise specified.

PROCEDURE
1. Clean all the parts, except the bearings (10, 17 and 23), in a suitable solvent and dry
with compressed air.
2. Clean the bearings (10, 17 and 23) in volatile mineral spirits, and wipe dry with a clean,
lint-free cloth. Lubricate with a light oil, and spin by hand to check for wear and roughness.
Replace with new bearings if excessively worn, or if operation is rough or noisy.
3. Check the condition of the splines and the teeth on all the gears and shafts for burrs or
signs of excessive wear.
4. The idler shaft (19) and the drive shaft (9) should not be rough, worn, cracked or damaged.
If either shaft is distorted, it should be replaced.
5. Check all the threaded parts and tapped holes for stripped or battered condition.
6. Inspect the PTO case, bearing housing and the pump adaptor plate (20, 3 and 28) for
cracks or bearing bores out-of-roundness.
7. The gear teeth should not be worn, cracked or broken.
8. Any small nicks, scratches or burrs should be smoothed up with a fine stone or crocus cloth
and part cleaned in solvent and dried with lint-free cloth.

(6) Assembly
Numbers in parentheses refer to Figure 6.17, unless otherwise specified.

NOTICE
• Orientate the idler shaft ensuring the threaded bore mates with the hole on the base
of the PTO casing.

PROCEDURE
1. If required, assemble any individual components that have been separated.
2. Sub assemble the bearing, gear and the key and secure using a circlip (17, 16, 15, and
12, Figure 6.16).
3. Locate the mating slot of the PTO case (1).

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6 Transmission

4. Fit new O-rings (3) to the idler shaft (5). Offer the shaft to the bore of the PTO casing
(refer to Figure 6.16). Tap lightly, ensure the bearings locate onto the outer diameter of
the idler shaft.
5. Once in place, secure using grubscrews (14, Figure 6.16) locking the idler shaft (5) in place.
6. Position the bearing (10, Figure 6.16) outer race on the bearing housing (18). Using a
suitable device seat the bearing fully home.
7. Fit a new O-ring (4) to the groove on the bearing housing (18).
8. Position the idler gear (6, Figure 6.16) in place to the drive shaft (2) using a key and secure
using a circlip (7 and 8, Figure 6.16).
9. Fit the bearing housing (18) to the mating surface on the PTO case (1). Fit the bolts (17)
and secure the housing to the case. Torque tighten 51–61 Nm (38–45 lbf ft)
10. Fit a circlip (24, Figure 6.16) to the drive shaft (2). Position the bearing (23, Figure 6.16)
inner race onto the drive shaft (2), seating it fully home against the circlip.
11. Fit the bearing (10, Figure 6.16) inner race to the spigot end of the driveshaft (2), ensuring
its fully home.
12. Using a suitable device, orientate the driveshaft (2) sub-assembly and tap it home until
contact is obtained with the bearing (10, Figure 6.16) inner race.

(7) Installation
Numbers in parentheses refer to Figure 6.17, unless otherwise specified.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

� CAUTION
• To prevent personal injury and property damage, be sure wheel chocks and lifting
equipment are properly secured and of adequate capacity to perform the task safely.

PROCEDURE
1. Remove 10-off setscrews from the transmission PTO cover plate located on the front
left hand side of the transmission.
2. Remove the cover plate and the existing gasket from the transmission. Clean the face to
ensure no foreign particles are present on the face.
3. Taking a stud mounting kit 15502084, screw 2-off studs into the top and bottom of the PTO
opening on the transmission, ensure a long thread portion is used for this operation.
4. Place a new gasket (12) onto the mating face of the transmission and offer a assembled
PTO onto the studs.
5. Place the nuts and washers provided onto the studs and tighten.
6. Take the bolts (11) and screw them into the remaining 8-off positions.
7. The main hydraulic pump must be fitted to the PTO assembly using the O-ring supplied in
the stud mounting kit 15502084. The O-ring should be placed on the pump spigot before

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 Transmission 6

assembly. For details of the pump, refer to the procedures outlined in Main Hydraulic
Pump section.

(8) Service Tools

NOTICE
• A stud mounting kit 15502084 is required for the installation of the PTO to the transmission.

Refer to Service Tools section for the part numbers of other tools referenced in this section and
the general service tools required. These tools are available from your dealer.

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6 Transmission

Intentionally Left Blank

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 Dropbox 7

Table of Content
7 Dropbox .......................................................................................................7-1
7.1 Dropbox and Mounting................................................................................... 7-3
(1) Description................................................................................................. 7-4
(2) Operation................................................................................................... 7-4
(3) Switches and Pressure Points................................................................... 7-5
(a) Gear Selection ...................................................................................... 7-6
(b) Diagnostic Points .................................................................................. 7-7
(4) Removal .................................................................................................... 7-9
(5) Disassembly ............................................................................................ 7-13
(a) Speed Selection Cylinder.................................................................... 7-18
(b) Yokes .................................................................................................. 7-18
(c) Casings ............................................................................................... 7-19
(d) Differential Shaft Assembly................................................................. 7-21
(e) Input Shaft and Counter Shaft Assemblies ......................................... 7-23
(f) Front Drive Gear ................................................................................. 7-25
(6) Inspection ................................................................................................ 7-26
(7) Assembly ................................................................................................. 7-27
(a) Front Drive Gear ................................................................................. 7-27
(b) Input Shaft Assembly .......................................................................... 7-28
(c) Differential Unit ................................................................................... 7-29
(d) Counter Shaft...................................................................................... 7-31
(e) Casings ............................................................................................... 7-32
(f) Final Assembly.................................................................................... 7-35
(8) Installation ............................................................................................... 7-38
(9) Maintenance ............................................................................................ 7-40
(a) Periodic Inspections............................................................................ 7-40
(b) Topping Up Oil .................................................................................... 7-40
(c) Bleeding the System ........................................................................... 7-41
(10) Service Tools ........................................................................................... 7-41
(11) Trouble Shooting ..................................................................................... 7-42
(12) Special Torque Specifications.................................................................. 7-43
(13) Dropbox Assembly Torque Specifications ............................................... 7-44
(14) Valve Block Torque Specifications ........................................................... 7-44
7.2 Dropbox Pump ............................................................................................. 7-45
(1) Description............................................................................................... 7-45
(2) Operation................................................................................................. 7-46
(3) Diagnostic Points..................................................................................... 7-46
(a) Dropbox Lubrication - Temperature/Pressure Table ........................... 7-46
(4) Removal .................................................................................................. 7-47
(5) Disassembly ............................................................................................ 7-48
(6) Inspection ................................................................................................ 7-49
(7) Assembly ................................................................................................. 7-49
(8) Installation ............................................................................................... 7-50
(9) Fault Diagnosis........................................................................................ 7-51
(10) Special Tools ........................................................................................... 7-51
7.3 Dropbox Oil Pressure Filter .......................................................................... 7-52
(1) Description............................................................................................... 7-52
(2) Removal .................................................................................................. 7-53

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7 Dropbox

(3) Installation ............................................................................................... 7-54

(4) Changing Filter Element .......................................................................... 7-54
(5) Special Tools ........................................................................................... 7-55
7.4 Dropbox Suction Filter.................................................................................. 7-56
(1) Description............................................................................................... 7-56
(2) Operation................................................................................................. 7-57
(3) Changing Filter Element .......................................................................... 7-57

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 Dropbox 7

7 Dropbox
7.1 Dropbox and Mounting

34

35
36
39 40 37
7
38
5
29
15 1 33
7
6 28
16 27
2
17 11 7
12
6
14 4 12
9 11
(IF REQUIRED)
10
18 1
1
(WELDNUTS) 4
14
1
5
8 13
8
3 18 22
(IF REQUIRED) 5
6 21 8
13
8 8
30 26
31 25
24 19 23

32 20

MOT05028

Figure 7.1 - Exploded View of Dropbox and Mounting

1. Isolation Mount 15. Guard Assembly 29. Nut
2. Mounting Bracket - Front 16. Bolt 30. Security Kit
3. Cross - Member 17. Washer 31. Lock
4. Mounting Bracket - Rear 18. Spacer (If Required) 32. Key
5. Washer - Snubbing 19. Adapter - Hose 33. Clamp
6. Washer 20. Elbow 34. Breather
7. Bolt 21. Tube - Dipstick 35. Nipple
8. Nut 22. Dipstick - Dropbox 36. Bushing
9. Washer 23. Bolt 37. Bracket
10. Screw 24. Valve - Quick Drain 38. Adapter
11. Bolt 25. Lockwasher 39. Hose
12. Washer 26. Washer 40. Adapter
13. Washer - Hardened 27. P-Clip
14. Bolt 28. Bolt

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7 Dropbox

(1) Description
Numbers in parentheses refer to Figure 7.1, unless otherwise specified.
The TEL6060 dropbox is a remote mounted two-speed, high and low, transfer gearbox taking
drive from the engine and transmission. The drive is fed to the front and centre axles via a
lockable differential.
The dropbox is supported by the front mounting bracket (2), which is bolted to the dropbox. This
in turn is secured to the frame mounted cross-member (3). Two rear mounting brackets (4)
which are bolted to the dropbox and attached to front frame mounting brackets through isolation
mounts (1) secure the rear of the dropbox. Isolation mounts (1) provide sufficient flexibility to
absorb varying dropbox vibration and torsional loads.
(2) Operation
The Dropbox has self-contained hydraulic gear selection and differential locking mechanisms.
The hydraulic supply circuits for gear activation and differential lock are separate.
Gear activation is from a supply via the main hydraulic valve assembly at port 'DL', refer to (1)
Description on page 11-3.
Differential lock supply is via a single stage gear pump which is driven off the main hydraulic
pump. This draws the sump oil from within the dropbox to satisfy locking and lubrication
requirements of the system.
Gear ratio HI - LO selection and differential lock are operated via switches (1 and 2, Figure 7.2
in the cab by continuously rated 24 V DC solenoids. These solenoids (1 and 2, Figure 7.4) are
located on the externally mounted valve block (Figure 7.4).

LO
1

HI
MOT05030

Figure 7.2 - Dropbox Switches

1. Gear HI-LO Selection 2. Differential Lock Request
Switch

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 Dropbox 7

(3) Switches and Pressure Points

Numbers in parentheses refer to Figure 7.3 and Figure 7.4, unless otherwise specified.
1 3
2
9

8
4
7

6
MOT05029

Figure 7.3 - Valve Block Detail

1. Low Range Solenoid 4. Pressure Control Valve 7. Differential Lock Solenoid
(CT2) (CT1) (CT4)
2. High Range Solenoid 5. Check Valve (CT3) 8. Temperature Switch (SW6)
(CT2)
3. Check Valve (CT6) 6. Differential Lock Relief Valve 9. Pressure Switch (SW5)
(CT5)
TP2
(12)
B

(13)
P1 GS1
(17) (4) GS2
(14)
(1)
T1
(18)
A

(15)
TP1 DL
(11) (22)
(5) TP3

(2) (7) OC1

(20)
(21)

(9)
SW5
(6) (8)
SW6 OC2
(10) (3)
SHAFT
LUBRICATION
(16)
P2

(19)

FROM
DROPBOX MOT03970
PUMP

Figure 7.4 - Dropbox Schematic Detail

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7 Dropbox

1. Range Selector Solenoid 7. Oil Cooler Feed Port - OC1 13. High Gear Range Port - GS1
(CT2)
2. Differential Lock Solenoid 8. Oil Cooler Return Port - OC2 14. Low Gear Range Port - GS2
(CT4)
3. Differential Lock Relief 9. Pressure Switch - SW5 15. Differential Lock Port - DL
Valve (CT5)
4. Pressure Control Valve 10. Temperature Switch - SW6 16. Supply Port - P2
(CT1)
5. Check Valve (CT3) 11. Differential Lock Test Point 17. Supply Port - P1
- TP1
6. Check Valve (CT6) 12. Pressure Test Point - TP2 18. Return Port - T1

(a) Gear Selection

Numbers in parentheses refer to Figure 7.4, unless otherwise specified.
During High/low change an extra transmission solenoid valve Q17 is used to inhibit the park
brake release circuit, holding the park brake on during selection. To engage high or low gear
ratio, the following steps must be adhered to:

PROCEDURE
1. Bring vehicle to a stop with the service brakes. Maintain pressure on service brakes.
2. Put the transmission shift lever in the Neutral position
» The park/emergency brake will now automatically apply.
3. Make sure that the Engine RPM is less than 750
4. Press the high / low ratio request switch into the desired gear range.
» Desired gear ratio will be activated.
5. Release the service brake pedal.
The park emergency brake will automatically disengage, when a transmission gear is
engaged.

When either high or low ratio is selected, the corresponding solenoid (1A or 1B) will be
energized. Differential lock solenoid (2) is energized to select the differential lock. The inter-axle
differential lock is a multiplate clutch device that locks the front and rear drives together (50/50
torque split) to provide more traction in arduous conditions. Request is available, provided the
vehicle speed is not greater than 5 km/hr. When the differential lock is disengaged there is
normal torque biasing of 2/3 to the rear axle and 1/3 to the front axle.

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 Dropbox 7

(b) Diagnostic Points

Numbers in parentheses refer to Figure 7.3 and Figure 7.4, unless otherwise specified.

MOT05033

Figure 7.5 - Diagnostic Pressure Check Points Left Hand Fender

1. Dropbox Difflock - 9. Pilot Raise - 18. Steering -
TP1 TPA TPO
2. Dropbox Lubrication - 10. Pilot Lower - 19. Accumulator No.1
TP3 TPB
3. Dropbox High Ratio - 11. Transmission - 20. Accumulator No.2
GS1 TS
4. Dropbox Low Ratio - 13. Parking Brake 21. Accumulator No.3
GS2
5. Cross-Axle Difflock 14. Hydraulic Pump-Front - 22. Brakes-Front
TP1
7. Body Hoist Raise - 15. Hydraulic Pump-Rear - 23. Brakes-Rear
A TP2
8. Body Hoist Lower - 16. Load Sense Pump -
B LSP

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7 Dropbox

NOTICE
• Differential lock pressure setting must be carried out with the oil temperature between 25°C
and 50°C. This can be measured using an infrared gun at the fitting on the valve block
to which the differential lock hose is fitted.
• Dropbox pressures to be measured with the throttle wide open.

Differential lock actuation pressure can be checked at the diagnostic point (1, Figure 7.5). This
is set at 34-40 bar (493-580 psi).
Lubrication circuit pressure can be checked at the diagnostic point (2, Figure 7.5). The pressure
to be 3.5 - 8.5 bar (50.8 - 123.3 psi).
Differential lock relief valve (CT5) is adjustable and may be set too low if the differential lock
pressure is not reaching the correct value. This valve is set to 23 bar (334 psi).
There may be high internal leakage, either in the clutch device or externally mounted gear pump
unit; in these cases adjustment of relief valve (CT5) will not restore or improve pressure.
Gear ratio selection actuation pressure can be checked at diagnostic points (3 and 4, Figure
7.5). This is set by pressure control valve 'CT1' (4) to 13.5 - 16.5 bar (196 - 239 psi).
Pressure will dip momentarily when the high or low solenoids are energized, as the cylinder
moves. Continued low pressure would indicate high internal leakage in the section that is
energized. Low pressure indication when no solenoids are energized would suggest the supply
to the valve from port 'DL' on the main hydraulic valve is not sufficient, or pressure control
valve 'CT1' (4) is set too low.
Indication when no solenoids are energized would suggest the supply to the valve from port 'DL'
on the main hydraulic valve is not sufficient, or pressure control valve 'CT1' (4) is set too low.

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Page 7-8 TA400 Tier2
TA400 Tier2
(4)

81 48 47
80 49
75

Maintenance Manual
79
78
76 50
77
Removal

82 4 61
1 2 3 76
91 58 60 47
41,42 29
25,28 2
1 3 13
4
39 4
57 59 9 29
43
12
44 24 29
38 59
TR
83 OC2 1 3 GS1 GS2 94 31
B2 40 TP SW5 95
OC1 SW6 LS1
39 93 LS2
11 P1 T1 P2 DL

16 35 90 92 GC2 GC1
B1
32 24 2
74 34
38
30 35

Revision 1.0
16 15
10
29
46 18 1 6 DC 41,45
32 CS3
84
DL
97 88 3

Figure 7.6 - Dropbox Lines

14 62 96
64 63 P 93 92
T
85
96
8 87
52
23 70 51 37
53 SL
DR
65,66 26 68,69 22 19
86 18 21 89
OUT
67 54
34,27 20 23 21
IN
36 73
71,69 56
17 7 55 5
33 72,69

MOT05034

Page 7-9
15-Sep-2017
Dropbox 7
7 Dropbox

1. Hose 34. Elbow 67. Bracket

2. Hose 35. Connector 68. Bolt
3. Hose 36. Plug - Dust 69. Loctite 243
4. Hose 37. Elbow 70. Washer
5. Hose 38. Adaptor 71. Bolt
6. Hose 39. Clamp 72. Screw
7. Hose 40. Clamp 73. Washer
8. Hose 41. Clamp 74. Hose
9. Hose 42. Plate 75. Hose
10. Hose 43. Screw - Stacking 76. Hose - Diagnostic
11. Hose 44. Plate - Locking 77. Adaptor
12. Hose 45. Bracket 78. Bracket
13. Hose 46. Strap 79. Bushing
14. Hose 47. Flow Divider 80. Adaptor
15. Hose 48. Bolt 81. Breather
16. Adaptor 49. Washer 82. Diagnostic Plate
17. Adaptor 50. Bracket 83. Dropbox Cooler
18. Reducer 51. Bolt 84. Main Hydraulic Valve
19. Elbow 52. Washer 85. Tank Return Tube
20. Elbow 53. Locknut 86. Dropbox Pump
21. Elbow 54. Bracket 87. Dropbox Filter
22. Adaptor - Tee 55. Bolt 88. Relief Valve
23. Elbow 56. Washer 89. Suction Filter
24. Connector 57. Adaptor - Tee 90. Control Valve
25. Bolt 58. Adaptor - Tee 91. Adaptor
26. Adaptor 59. Adaptor 92. Adaptor
27. Nipple - Diagnostic 60. Hose 93. Temperature Sensor
28. Washer 61. Hose 94. Seal
29. Adaptor 62. Adaptor 95. Pressure Switch
30. Adaptor - Bulkhead 63. Elbow 96. Adaptor
31. Connector 64. Hose 97. Pressure Sensor
32. Adaptor 65. Adaptor - Tee
33. Elbow 66. O-Ring

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 Dropbox 7

Numbers in parentheses refer to Figure 7.1, unless otherwise specified.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Do not mistake screws (10) with the bolts (11). Bolts (11) are a larger diameter and are not
interchangeable with screws (10), for the front mounting bracket (2) .

PROCEDURE
1. Position the vehicle in a level work area, ensure that the body is fully lowered, apply the
parking brake and switch off the engine. Operate the steering right and left several times to
relieve any pressure in the steering system.
2. Operate the treadle valve continuously to discharge the accumulators, block all road
wheels, place the steering lock bar in the 'Locked' position and the battery master switch
in the OFF position.
3. Remove the cab from the machine. Refer to (2) Removal on page 19-8.
4. Ensure that all connections and lines connecting to the cab are disconnected.
5. Identify, tag and disconnect the following electrical cables:
• Control Valve High Ratio - WA6.Q5 (CT2)
• Control Valve Low Ratio - WA5.Q4 (CT2)
• Control Valve Differential Lock - WA4.Q3 (CT4)
• Control Valve Pressure Switch - WA7.B19 (SW5)
• Control Valve Temperature Switch - WA3.B7 (SW6)
• Speed Selector High Ratio - B9
• Speed Selector Low Ratio - B10
• Pressure Relief Valve - WA2.B12 (PS)
• Temperature Sensor - WA1.B6 (Front Differential Case)
• Speed Sensor - B18 (RHS Rear Case)
• Cabin Bulkhead - X19
Install protective caps to all connection, to prevent ingress of dirt.
6. Place a suitable container under the dropbox drain port. Open drain plug (24) and drain oil
through hose adaptor (19) into a suitable container. After draining, close the drain plug.

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TA400 Tier2 Page 7-11
7 Dropbox

7. Identify, tag and disconnect the following hydraulic hoses:

Refer to Figure 7.6.
a. Diagnostic lines:
• DP1 (76) - Dropbox Control Valve TP1
• DP2 (76) - Dropbox Control Valve TP3
• DP3 (76) - Dropbox Control Valve GS1 (Tee)
• DP4 (76) - Dropbox Control Valve GS2 (Tee)

b. Dropbox lines:
• Breather connection (75) - Dropbox port TR
• Cooler connection ‘B2’ (11) - Dropbox Control Valve OC1 (Tee)
• Main Hydraulic Valve connection ‘DL’ (74) - Dropbox Control Valve P1
• Dropbox Filter connection (6) - Dropbox Control Valve P2 (Tee)
• Hydraulic Tank connection ‘T1’ (64) - Dropbox Control Valve T1
• Cooler connection ‘B1’ (12) (Tee on frame) - Flow Divider Port 4
• Cooler connection ‘B1’ (14) (Tee on frame) - Dropbox port CS3
• Suction Filter connection (5) - Dropbox port SL

c. Emergency Steering Valve Block lines:

Refer to Figure 12.1
• Main Hydraulic Valve connection ‘P2’ (28) - Emergency Steering Valve Block port P
• Hydraulic Tank connection (27) - Emergency Steering Valve Block port S
• Hydraulic Tank return line (Tee on Difflock Valve ‘T’) (30) - Emergency Steering Valve
Block port D

d. Emergency Steering Pump lines:

• Hydraulic Tank connection (26) - Drain hose main pump body
Install protective caps to all connections, to prevent ingress of dirt.
8. Disconnect all drivelines connected to the dropbox and secure them clear of the dropbox.
Refer to 8.1 Front Drivelines on page 8-2.
9. Attach suitable lifting equipment to the lifting bracket on the dropbox and raise the lifting
equipment to take up the slack.
10. Remove three bolts (7), locknuts (8), snubbing washers (5) and hardened washers (6)
which secure the front bracket (2) and rear bracket (4) assemblies to their respective frame
mounting positions.
11. Check to make certain that all necessary lines and electrical disconnections have been
removed before lifting the dropbox.
12. If necessary remove the isolation mounts (1) to aid removal. Carefully lift the dropbox clear
of the frame, remove it to a suitable work area and mount securely on a work stand.
13. Remove the anti-flail guard assembly (15) if necessary, by removing the two bolts (16),
with washers (17).
14. If necessary remove the front mounting bracket (2) from the dropbox, by removing the
bolts (10) with spring washers (9).
15. If necessary remove the rear mounting brackets (3) from the dropbox by removing the
bolts (11) with spring washers (12).

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TA400 Tier2
(5)

Maintenance Manual
118
103
123,109
104,132

1
Disassembly

63 51
106
113
137 122
136 4 138 99 57 96
33,111
134,133 47 121 43 49
92 86
117 116
63 32
131 14 86 11 9
59 51 2
74 95
18 47 82 87
102 39 80 48 40 81 41,42
139
20 73 88 121 49 45 112
6 5 79 138
21
58 94 122
114 51 113 139
128 64 73 19
135 100 85 70 21 114,128,135

Revision 1.0
RHS 105 10 8 67
TO REAR AXLES
FROM TRANS. 7 68
95 87 52
23,119 110 78
127 59 3 46 72
51
17 65 35
65
129
54 53
83 61
30,16 106
44 84 28 27
90 26 101
34,77 69
66 93 45 119
89 68 115
25 108 29 71 76 62
61 23 36 15

Figure 7.7 - Sectional View of Dropbox Assembly

22 78
114,128,135 38 120,125
90 13 TO FRONT AXLE 139
72 60 120,127
98 37 24 12
97 50 31 73 46
91 55
75 102 56
107 126 124
TEMP. SW.

MOT05036

Page 7-13
15-Sep-2017
Dropbox 7
7 Dropbox

1. Dropbox TEL6060 48. O-Ring 94. Wiper Seal

2. Gear - Input 28T 49. O-Ring 95. Adjustment Grubscrew
3. Gear - C Shaft 50. Taper Roller 96. Locknut
4. Gear - Input 34T 51. Taper Roller 97. Locknut
5. Gear - C Shaft 23T 52. Needle Roller 98. Lockwasher
7. Gear - C Shaft 33T 53. Friction Plate 99. Stud
8. Gear - Drop 40T 54. Plain Plate 100. Set Screw
9. Shaft - Input 55. Quad Ring 101. Key
10. Shaft - Counter 56. Quad Ring 102. Capscrew
11. Sleeve - Selector 57. Cylinder Cap 103. Self-tapping Rivet
12. Case - Front 58. O Ring 104. Washer
13. Case - Rear 59. Shim 105. Dowel
14. Bracket Lifting 60. Washer 106. Dowel
15. Housing - Bearing 61. Washer 107. Suction Tube
16. Support - Ring Diff 62. Shim 108. Capscrew
17. Cover Plate 63. Washer 109. Stud
18. Housing - Oil Seal 64. Taper Roller 110. Washer
19. Yoke - Rear 8.5C 65. Needle Roller 111. Capscrew
20. Yoke - Input 9C 66. Washer 112. Circlip
21. Plate - Retainer 67. Needle Roller 113. Plunger Switch
22. Plate - Retainer 68. Needle Roller 114. Stud
23. Baffle 69. Washer 115. Set Screw
24. Shaft 3 - Rear 70. Washer 116. Ball Detent
25. Shaft - Sun 71. Needle Roller 117. Spring Detent
26. Carrier - Planet 72. Taper Roller 118. Name Plate
27. Gear - Planet 73. Oil Seal 119. Set Screw
28. Spindle - Planet 74. Oil Seal 120. Washer
29. Annulas 75. O-Ring 121. Ball
30. Housing - Diff Lock 76. O-Ring 122. Nut
31. Piston - Diff Lock 77. O-Ring 123. Nut
32. Selector Fork 78. O-Ring 124. Washer
33. Adaptor - Pump Drive 79. Bush 125. Magnetic Plug
34. Oil Distribution Ring 80. Bush 126. Adaptor
35. Output Shaft 81. Rod Seal 127. Plug
36. Front Gear 82. Piston Seal 128. Washer - Nord Lock
37. Pressure Plate 83. O-Ring 129. Setscrew
38. Front Yoke 84. Piston Ring 130. Plug
39. Selector Rod 85. Washer 131. Bolt
40. Switch Housing 86. Washer 132. Gasket
41. Primary Piston 87. Locknut 133. Circlip

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 Dropbox 7

42. Piston (secondary) 88. Key 134. Dowel

43. Hydraulic Cylinder 89. Shim 135. Nut
44. Diff. Case 90. Flanged Bolt 136. Adaptor - Bulkhead
45. Washer 91. Flanged Bolt 137. Washer - Dowty
46. Oil Seal 92. Speedometer Sensor 138. Washer - Nord Lock
47. Needle Roller 93. Pin 139. Shim

LOW RANGE INDICATOR

SWITCH SW2
80,94 113
43

96,99

95,87 95,87
49,57
48 40, 45, 41,
79 32, 39 49 81, 42,
100 112 82
113
HIGH RANGE
INDICATOR SWITCH
SW4 MOT05094

Figure 7.8 - Speed Selector Assembly

1
2,3

4
5,6

7
8,9,10
11
12,13,14

MOT05100

Figure 7.9 - Dropbox Fittings

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TA400 Tier2 Page 7-15
7 Dropbox

1. Flow Divider 6. Washer 11. Bracket Assembly

2. Bolt 7. Relief Valve 12. Bolt
3. Washer 8. Bolt 13. Washer
4. Control Valve 9. Washer 14. Washer - Hardened
5. Bolt 10. Locknut

Numbers in parentheses refer to Figure 7.7, Figure 7.13 and Figure 7.9, unless otherwise
specified.

� DANGER
• Seals contain Viton! and produce hydrofluoric acid when subjected to high temperatures of
a fire. Hydrofluoric acid is extremely corrosive especially to living tissue. Do not attempt
repair if the unit or vehicle has been on fire.

NOTICE
• The major components of the dropbox assembly are shown in the section view Figure
7.7. This should be used for guidance only.

PROCEDURE
1. Remove the quick drain valve (24, Figure 7.1) and drain the sump oil into a suitable
container. The dropbox contains 17 litres of oil and therefore the container must have a
capacity greater than this. Retain the drain valve (24, Figure 7.1).
2. Remove and retain the dipstick assembly (21, Figure 7.1).
3. Identify, tag and disconnect the following hydraulic hoses:
Refer to Figure 7.6.
• Hi - Lo Selector connection GC1 (61) - Dropbox Control valve port GS2 (Tee)
• Hi - Lo Selector connection GC2 (60) - Dropbox Control valve port GS1 (Tee)
• Dropbox Port LS2 (9) - Flow Divider Port 1
• Dropbox Port LS1 (4) - Flow Divider Port 3
• Dropbox Lube Port (rear) (13) - Flow Divider Port 2
• Dropbox Port DC (2) - Dropbox Control Valve Port DL
• Dropbox Port DR (15) - Dropbox Control Valve Port OC2
• Dropbox Relief Valve Port P (3) - Dropbox Control Valve Port P2 (Tee)
• Dropbox Relief Valve Port T (1) - Dropbox Control Valve Port OC1 (Tee)
Install protective caps to all connection, to prevent ingress of dirt.
4. Remove the bolts and washers (2 and 3, Figure 7.9), which secure the flow divider (1,
Figure 7.9), remove the flow divider.
5. Remove the bolts and washers (5 and 6, Figure 7.9), which secure the dropbox control
valve (4, Figure 7.9), remove the dropbox control valve.
6. Remove the bolts washers and hardened washers (12, 13 and 14, Figure 7.9), which
secure the bracket assembly and the relief valve (11 and 7, Figure 7.9), remove the bracket
and relief valve.

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 Dropbox 7

7. Remove the bolts, washers and locknuts (8, 9 and 10Figure 7.9), which secure the relief
valve (7, Figure 7.9) to the bracket assembly (11, Figure 7.9), remove the relief valve.
8. Remove the emergency steering valve. Refer to (2) Removal on page 12-46.
9. Remove the emergency steering pump. Refer to (3) Removal on page 12-34.
10. Remove the following adaptors and accessories:
Refer to Figure 7.6.
a. Dropbox:
• Dipstick port - elbow (20, Figure 7.1).
• SL port - elbow (19)
• DC port - adaptor (29)
• CS3 port - adaptor (32)
• Temperature sensor and adaptor (next to port CS3) - sensor (93), adaptor (92)
• LS2 port - connector (31)
• LS1 port - adaptor (29)
• GC1 ana GC2 ports - adaptors (59)
• TR port - adaptor (76)
• DR port - elbow (37)

b. Dropbox control valve:

• OC1 port - tee (16) and adaptor (35)
• OC2 port - adaptor (24)
• TP1 port - adaptor (91)
• P1 port - elbow (34) and adaptor (32)
• T1 port - elbow (63) and adaptor (62)
• TP3 port - adaptor (91)
• DL port - adaptor (24)
• P2 port - tee (16) and adaptor (35)
• GS1 port - tee (57) and adaptor (59)
• GS2 port - tee (58) and adaptor (59)
• SW5 port - seal (95) and pressure switch (96)
• SW6 port - adaptor (94) and temperature sensor (93)

c. Flow divider:
• 1, 2, 3 and 4 port - adaptors (29)
11. Install protective caps to all ports to prevent the ingress of dirt.

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TA400 Tier2 Page 7-17
7 Dropbox

(a) Speed Selection Cylinder

PROCEDURE
1. Unscrew the switches (113) from the switch housing (40). Remove the switches (113)
complete with the Nut (122) from the switch housing (40), and retain them in a prepared
area. Be prepared for the ball (121) for the high range indicator switch to drop out of
the aperture as this switch is removed from the bottom of the switch housing (40).The
corresponding ball (121) for the low range indicator switch may remain in the aperture or be
withdrawn with the switch as it is removed.
2. Undo and remove the adjustment screws (95) with lock nuts (87) from the cylinder end
plate (57) and the front case (12).
3. Undo and remove the nuts (96) with washers (110) securing the cylinder end plate (57).
Remove the end plate (57) and retain it in a prepared area with the nuts (96) and washers
(110).
4. Withdraw the cylinder (43) and pistons (41 and 42).
5. Remove the switch housing (40).
6. Discard the 'O'-rings (48 and 49), piston seal (82) and wiper seal (81). Fit new seals on
reassembly. Retain all other components in a prepared area.

(b) Yokes
Numbers in parentheses refer to Figure 7.7, unless otherwise specified.

PROCEDURE
1. Undo and remove the screws (114 [two per yoke]) that secure the yoke retainer plates
(21 and [2x 22]).
2. Slide each of the three yokes (19, 20 and 38) off the splines on the shaft ends.
3. Discard the 'O'-rings (58 [input shaft], 78 [differential shaft and output shaft]). Fit new
'O'-rings on reassembly.
4. Discard the 'Gamma' face seal (73) for each of the three yokes. Fit new 'Gamma' seals
(73) on reassembly.

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Page 7-18 TA400 Tier2
 Dropbox 7

(c) Casings

MOT05095

Figure 7.10 - Front Case Assembly

12. Rear Case 44. Differential Case 90. Flanged Bolt
13. Front Case 59. Shim 102. Capscrew
14. Lifting Bracket 74. O-Ring 106. Dowel
17. Cover Plate 75. O-Ring 115. Flanged Screw
18. Oil Seal Housing 89. Shim 131. Flanged Bolt

Numbers in parentheses refer to Figure 7.10, unless otherwise specified.

NOTICE
• The two screws (131) at the upper end of the front case (13) also retain the dropbox
lifting bracket (14).

PROCEDURE
1. Undo and remove the six screws (102) securing the seal housing (18) to the front case (13).
Remove the seal housing (18) and discard the oil seal (74). Fit a new oil seal (74) on
reassembly. Retain the seal housing (18) in a prepared area.
2. Remove and retain the laminated shims (59) from the input shaft end of the front case (13).
3. Undo and remove the six screws (115) securing the cover plate (17) to the front case (13).
Remove the cover plate (17) to a prepared area.
4. Remove and retain the laminated shim (59) from the front case (13) where the counter
shaft locates.

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TA400 Tier2 Page 7-19
7 Dropbox

5. Undo and remove the 10 flanged bolts (90) securing the diff. case (44) to the front case
(13). Remove and discard the O-Ring (75). Fit a new O-Ring (75) on reassembly.
Remove the bearing (50, Figure 7.7) out from the diff. case (44) and remove and retain
the laminated shim (89).
6. Position the dropbox such that its front case (13) is uppermost.
7. Undo and remove the 22 screws (90) and the 2 screws (131) securing the front case (13) to
the rear case (12).
8. Attach suitable lifting equipment to the front case (13).
9. Carefully lift the front case (13) away from the dropbox assembly. The front case (13) is
located on the rear case (12) with dowels (106), and therefore some resistance may be
encountered when lifting the front case (13).
10. Remove the outer races of the counter shaft and input shaft bearings (51, Figure 7.7)
from the front case (13).
11. Transport the front case (13) to a prepared area. Remove the lifting equipment.

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 Dropbox 7

(d) Differential Shaft Assembly

MOT05098

Figure 7.11 - Differential Unit

7. Gear - Differential 45. Washer 69. Washer
8. Gear - Drop 50. Taper Roller 70. Washer
16. Differential Support Ring 52. Needle Roller 71. Needle Roller
24. Shaft - Rear 53. Friction Plate 77. O-ring
25. Gear Shaft - Sun 54. Plain Plate 84. Piston Ring
26. Planet Carrier 55. Quad Ring 85. Washer
27. Planet Gear 56. Quad Ring 91. Flanged Bolt
28. Planet Spindle 61. Washer 93. Pin
29. Annulus Gear 64. Taper Roller 97. Locknut
30. Housing - Difflock 65. Needle Roller 98. Lockwasher
31. Piston - Difflock 66. Washer 102. Capscrew
34. Oil Distribution Ring 67. Needle Roller 105. Dowel
37. Pressure Plate 68. Needle Roller 108. Capscrew

Numbers in parentheses refer to Figure 7.11, unless otherwise specified.

NOTICE
• The first 10 mm (0.4 in) of removal may be tight, as there is a possibility that there is an
interference fit between the housing (30) and the shaft (24).

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TA400 Tier2 Page 7-21
7 Dropbox

PROCEDURE
1. Attach suitable lifting equipment to the differential shaft assembly.
2. Carefully lift the differential shaft assembly and transfer it to a prepared area for further
disassembly.
3. Remove the tab washer (98) and nut (97) from the shaft end.
4. Using extracting equipment, remove the bearing (50) from the differential shaft (24).
5. Remove the differential support ring (16) from the housing (30), exposing the piston rings
(84). Remove the two O-Rings (77) from the oil distribution ring (34). Discard the O-Rings
(77). Fit new O-Rings on reassembly.
6. Remove the bolts (91), and capscrews (102) securing the housing (30) to the pressure
plate (37).
7. Remove the housing (30), complete with the assembled piston and the friction plates.
8. Using extracting equipment, remove the difflock piston (31) from the housing (30).
9. Remove the two piston rings (84) from the grooves in the housing (30).
10. Remove the quad rings (55 and 56) from the differential lock piston (31).
11. Remove the friction plates (53) and the alternate plain plates (54).
12. Remove the pressure plate (37) and the annulus gear (29) from the assembly.
13. Using extracting equipment, remove the bearing (64) from the other end of the differential
shaft (24).
14. Remove the thrust washer (70).
15. Remove the thrust washers (61) together with the roller bearing (68).
16. Using extracting equipment remove the drop gear (8) from the shaft.
17. Remove the two thrust washers (69) together with the roller bearing (68).
18. Remove the needle roller bearings (67) from the shaft.
19. Remove the differential drive gear/planet assembly as a complete unit from the sun gear
shaft (25).
20. Remove the sun gear shaft (25) from the differential drive gear/planet assembly.
21. Remove the two thrust washers (66) together with the roller bearing (65).
22. Remove the cap screws (108) securing the planet carrier (26) to the differential drive
gear (7).
23. Using extracting equipment, remove the differential drive gear (7) from the planet carrier
(26).
24. Remove the thrust washers (61 and 69) together with the roller bearing (68).
25. Carefully remove the planet gears (27) and washer (45) from the spindle/bearing
assemblies on the planet carrier (26).
26. Remove the needle roller bearings (71, 2 off), and washer (45).
27. Extract and discard the roll pins (93) from the planet carrier (26). Fit new roll pins (93)
on reassembly.
28. Remove the planet gear spindles (28).
29. If the differential drive gear (7) is being replaced by a new gear, remove the three dowels
(105) from the gear.

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 Dropbox 7

(e) Input Shaft and Counter Shaft Assemblies

MOT05096

Figure 7.12 - Input Shaft and Gearing

2. Gear - Input 47. Needle Bearing 116. Ball Detent
4. Gear - Input 51. Roller Bearing 117. Spring Detent
9. Input Shaft 63. Washer 133. Circlip
11. Sleeve Selector 86. Washer 134. Dowel
33. Pump Drive Adapter 111. Capscrew

6 5 88

51

51
10

Figure 7.13 - Counter Shaft Assembly

3. Gear - C Shaft 6. Gear - C Shaft 33T 51. Roller Bearing
5. Gear - C Shaft 23T 10. Counter Shaft 88.. Key

Numbers in parentheses refer to Figure 7.12 and Figure 7.13, unless otherwise specified.

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TA400 Tier2 Page 7-23
7 Dropbox

NOTICE
• The gears on the counter shaft (3, 5 and 6) cannot be removed, once fitted. Therefore,
if any are faulty it will be necessary to build a new counter shaft assembly, with a new
shaft, gears and bearings.
• Take care to retain the detent ball (116) and detent spring (117) which will be released from
the blind hole in the sleeve selector as it is removed.

PROCEDURE
1. Remove the dowels (100, Figure 7.7) securing the selector fork (32, Figure 7.7) to the
selector rod (39, Figure 7.7).
2. Using extracting equipment, remove the roller bearing (51) from the input shaft (9).
3. Remove the washer (63) from the input shaft (9).
4. Remove the LOW gear (2) from the input shaft (9).
5. Remove the two needle bearings (47) from the input shaft (9).
6. Remove the washer (86).
7. Attach suitable lifting equipment to the counter shaft (10) using the threaded hole in the
end of the shaft for attachment of an eyebolt. Carefully remove the counter shaft assembly
(10) from the rear case (12, Figure 7.7).
8. Attach suitable lifting equipment, to the input shaft (9), using the threaded hole in the end
of the shaft for attachment of an eyebolt. Carefully remove the input shaft assembly to
a prepared area for further disassembly.
9. Using extracting equipment, remove the roller bearing (51) from the HIGH end of the input
shaft (9).
10. Remove the washer (63).
11. Using extracting equipment, remove the HIGH gear (4) from the input shaft (9).
12. Remove the two needle bearings (47) from the HIGH end of the input shaft (9).
13. Remove the washer (86) from the HIGH end of the input shaft (9).
14. Remove the sleeve selector (11) from the middle section of the input shaft (9).
15. Remove the cap screws (111) securing the pump drive adapter (33) to the LOW end of the
input shaft (9). Remove the pump drive adapter (33).
16. If required, remove the dowel pins (134) and circlip (133) from the pump drive adapter (33).

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 Dropbox 7

(f) Front Drive Gear

MOT05097

Figure 7.14 - Front Drive Shaft Assembly in Rear Case

12. Rear Case 36. Front Gear 72. Roller Bearing
15. Bearing Housing 60. Washer 76. O-Ring
35. Ouput Shaft 62. Shim 115. Set Screw

Figure 7.15 - Front Drive Shaft Assembly

35. Output Shaft 60. Washer 101. Key
36. Front Gear 72. Roller Bearing

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7 Dropbox

Numbers in parentheses refer to Figure 7.14 and Figure 7.15, unless otherwise specified.

NOTICE
The front drive gear cannot be removed from the shaft, once fitted. Therefore, if the gear is
faulty it will be necessary to build a new front drive shaft assembly, with a new shaft, gear
and bearings.

PROCEDURE
1. Rotate the rear case (12) until the front shaft bearing housing (15) is uppermost.
2. Remove the set screws (115) securing the bearing housing (15) to the rear case (12).
3. Remove the bearing housing (15), complete with the outer race of the roller bearing (72)
4. Fit an eyebolt to the threaded hole in the upper end of the front (output) shaft (35).
5. Using suitable lifting equipment, carefully remove the front drive shaft assembly to a
prepared area.
6. Remove and discard the O-Ring (76). Fit a new O-Ring on reassembly.
7. Remove and retain the laminated shim (62).
8. Remove the outer race of the non-drive end roller bearing (72) from the bearing housing
(15).
9. Remove the outer race of the drive end roller bearing (72) from the rear case (12).

(6) Inspection
Numbers in parentheses refer to Figure 7.1, unless otherwise specified.

PROCEDURE
1. Inspect rubber isolation mounts (1) for damage and replace them if required.
2. Check front and rear mounting brackets (2 and 3) and mounting brackets of frame assembly
for cracks and/ or damage. Repair or replace as necessary.
3. Wash all machined components in high temperature cleaner for a minimum of 10 minutes.
Dry off all components and check them for cleanliness, paying particular attention to the
internal surfaces of the case castings and in particular the sump area of the rear case.

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 Dropbox 7

(7) Assembly
Numbers in parentheses refer to Figure 7.12 and Figure 7.16, unless otherwise specified.

NOTICE
• The major components of the dropbox assembly are collectively shown in the section view
Figure 7.7. This should be used for guidance only.
• Tighten all fasteners without special torques specified to standard torques listed in Table
22.1.
• Only the lubricants and proprietary sealants specified are to be used. Use 15W-40 grade
Engine Oil as an assembly lubricant for all components. Grease may be applied to oil seal
lips and hydraulic seals, but must not be used on any other components.

(a) Front Drive Gear

Numbers in parentheses refer to Figure 7.15, unless otherwise specified.

� CAUTION
• Take care to avoid injury from direct bodily contact with the preheated gear.
• Take care to avoid injury from direct bodily contact with the preheated bearings.

NOTICE
• The instructions for fitting the front drive gear to the shaft only apply to new components.
Once fitted to the shaft, the gear cannot be separated from it, and therefore will not require
to be remounted on the shaft on re-assembly, following refurbishment.

PROCEDURE
1. Ensure that the key (101) is correctly located in the keyway of the shaft (35). Heat the gear
(36) to between 140-150°C (284-302°F), then taking care to align its keyway with the key in
the shaft, carefully assemble it on the shaft until it abuts against the shaft shoulder. The
gear is not 'handed' and thus can be fitted either way round. It may be necessary to provide
a light pressing action to assist the movement of the gear along the shaft.
2. Install the spacer (60) over the shaft until it abuts against the gear.
3. Heat the bearings (72) to 120°C (248°F) and assemble them on the shaft, one on each end.
Ensure that the bearing races abut against the spacer washer (60) and shaft shoulder (35)
respectively, with no clearance.

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(b) Input Shaft Assembly

Numbers in parentheses refer to Figure 7.12 and Figure 7.13, unless otherwise specified.

� CAUTION
• Take care to avoid injury from direct bodily contact with the preheated bearings.

PROCEDURE
1. If removed, install the dowel pins (134) and circlip (133) to the pump drive adapter (33).
2. Apply Loctite 243 to capscrews (111).
3. Install the pump drive adapter (33) to the end of the input shaft (9), and secure using the
cap screws (111). Torque tighten to 45 Nm (33 lbf ft).
4. Ensure that the detent ball (116) and detent spring (117) are installed in the blind hole of the
sleeve selector (11). Depress the ball using a screwdriver then slide the sleeve selector
(11) over the splined middle section of the input shaft (9).
5. Slide a washer (86) over the HIGH end of the input shaft until it is adjacent to the shoulder
of the splined portion of the shaft.
6. Install two needle bearings (47) on the HIGH side of the input shaft (9). Lubricate the
bearings.
7. Install the HIGH gear (4) on to the input shaft (9) over the needle bearings (47), orientated
with the sleeve selector castellations on the side nearest the sleeve selector (11). Install
spacer (63) over the HIGH end of the input shaft (9).
8. Heat a roller bearing (51) to 120°C (248°F) and install it to the HIGH end of the input
shaft. Ensure that the bearing inner race is correctly located, with no clearance between
the bearing and the spacer (63).
9. Rotate the gear to ensure that there is no obstruction. DO NOT rotate an unlubricated
bearing for extended periods.

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 Dropbox 7

(c) Differential Unit

Numbers in parentheses refer to Figure 7.11, unless otherwise specified.

� CAUTION
• Take care to avoid injury from direct bodily contact with the preheated bearings.
• Take care to avoid injury from direct bodily contact with the preheated differential support
ring.

NOTICE
• Ensure that the roll pins (93) are fitted flush with the surface of the planet carrier (26).

PROCEDURE
1. Place the differential gear (7) on a work bench with the holes uppermost. Locate the three
dowels (105) in the holes of the gear (7).
2. Install the planet gear spindles (28), into the alignment holes of the planet carrier (26).
Secure each planet gear spindle (28) using a roll pin (93).
3. Assemble the needle rollers (71), two per planet gear (27), and washer (45), one per planet
gear, on the planet gear spindles (28).
4. Lubricate the needle rollers (71) with oil. Install the planet gears (27) and washers (45) over
each spindle/bearing assembly.
5. Assemble the thrust bearing (68) with the washers (61 and 69), arranged with the thicker
washer (61) adjacent to the planet gears (27).
6. Install the differential drive gear (7) on to the planet carrier (26).
7. Secure the planet carrier (26) to the differential drive gear (7) using the cap screws (108),
Torque tighten to 85 Nm (62.7 lbf ft).
8. Rotate the planet gears to ensure that there is no obstruction. DO NOT rotate any
unlubricated bearings for extended periods.
9. Install the thrust washers (66) and needle roller (65) against the shoulder on the rear shaft
(24), arranged such that the needle roller (65) is located between the two washers (66).
10. Install two off the needle roller bearings (67) over the rear shaft (24). Oil the bearings.
11. Install the sun gear shaft (25) to the installed bearings (67), then oil and insert the two
remaining needle roller bearings (67) over the rear shaft (24) and to the sun shaft (25)
12. Install the pre-assembled differential drive gear/planet assembly over the sun shaft,
engaging the planet assembly gears with the gear on the sun shaft. Ensure that the thrust
bearing elements are correctly located on assembly.
13. Lubricate the needle roller bearing (68) with oil. Install the previously assembled bearing
(68) between the differential drive gear (7) and the sun shaft (25).
14. Install a thrust washer (61) against the differential drive gear (7), and position the second
thrust bearing (68) between the thrust washer and a second thrust washer (61).
15. Fit the drop gear (8) to the rear shaft, orientated with its shoulder facing towards the
differential drive gear (7).
16. Install the thrust washers (85) against the drop gear (8), and position the thrust bearing (65)
between the thrust washer (85) and the thrust washer (70).

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17. Heat the roller bearing (64) to 120°C (248°F), then install it on to the rear shaft (24), ensuring
that the bearing race is correctly located, with no clearance between it and the washer (70).
18. Rotate the gears to ensure that there is no obstruction. DO NOT rotate any unlubricated
bearings for extended periods.
19. Install the annulus gear (29) and the pressure plate (37) over the planet gears. Lift the
annulus gear (29) slightly away from the differential drive gear (7) by a small distance,
using wedges, to prevent the first plain plate (54) from dropping off the spline on the sun
shaft during the next stage of assembly.
20. Assemble the friction plates (53) and plain plates (54) on the sun shaft, stacking them
alternately beginning with a plain plate (54) against the pressure plate (37), and finishing
with a plain plate against the differential lock piston (31). Ensure that the tangs on the
plain plates are mutually aligned.
21. Install the quad rings (55 and 56) to the differential lock piston (31). Lubricate the quad
rings (55 and 56) with oil. Install the differential lock piston (31) in the difflock housing (30).
22. Install the difflock housing (30), complete with the assembled piston (31), over the clutch
plates (53 and 54), locating the plain plate tangs in the slots in the difflock housing (30).
The final 10 mm (0.4 in) of closure may be tight, as there is a possibility that there is an
interference fit between the difflock housing (30) and the shaft (24).
23. Apply Loctite 243 to the bolts (91) and copscrews (102). Secure the difflock housing (30)
to the pressure plate (37) and the annulus gear (29).Torque tighten to 85 Nm (62.7 lbf
ft). Remove the wedges.
24. Heat the differential support ring (16) to 140-150°C (284- 302°F). Install the support ring
(16) to the rear shaft (24), tap it with a drift to engage it with the difflock housing (30).
25. Install the two piston rings (84) into the grooves in the difflock housing (30). Use a
pneumatic test rig to check the operation of the differential lock mechanism. Rectify any
faults observed.
26. Fit two O-Rings (77) to the oil distribution ring (34), then slide the oil distribution ring
assembly to the difflock housing (30), covering the piston rings (84).
27. Heat the bearing (50) to 120°C (248°F), then assemble it on the rear shaft (24), ensuring
that the bearing race is correctly located with no clearance between it and the difflock
housing (30).
28. Install the tab washer (98) and nut (97). Torque tighten to 160 Nm (118 lbf ft), turning it
clockwise to align the tab in the nut castellations.

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 Dropbox 7

(d) Counter Shaft

Numbers in parentheses refer to Figure 7.13, unless otherwise specified.

� CAUTION
• Take care to avoid injury from direct bodily contact with the preheated gear or bearings.

NOTICE
• The instructions for fitting the counter shaft gears to the shaft only apply to new components.
Once fitted to the shaft, the gears cannot be separated from it, and therefore will not require
to be remounted on the shaft on re-assembly, following refurbishment.

PROCEDURE
1. Install the key (88) in the counter shaft (10). Heat the gears (3, 5 and 6) to 140-150°C
(284-302°F).
2. Align the gears with the shaft key, then assemble them in order on the shaft, up to the
shaft shoulder. Two of the gears (3 and 6) are not handed, and can thus be fitted either
way around. The gear (5) is fitted nearest the shaft shoulder and should be fitted with
its face recess facing the shaft shoulder.
3. Heat the roller bearings (51) to 120°C (248°F) and install them on the shaft, ensuring
that the bearing races are correctly located, with no clearance against the shaft shoulder
and gears (3 and 5).

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(e) Casings

MOT05099

Figure 7.16 - Assembly of Front Case to Rear Case

4. Input Gear 47. Needle Bearing 86. Washer
32. Selector Fork 51. Roller Bearing 100. Dowel
39. Selector Rod 63. Washer

Numbers in parentheses refer to Figure 7.13, Figure 7.14 and Figure 7.16, unless otherwise
specified.

� CAUTION
• Take care to avoid injury from direct bodily contact with the preheated bearings.

NOTICE
• The inner and outer races of bearings are matched. Therefore take care to ensure that the
outer races fitted to the rear case (12) correspond to their corresponding inner races on
the shafts to be installed.

PROCEDURE
1. Mount the rear case (12) on an assembly jig. Rotate the case until it is orientated in a
horizontal attitude, with the large open end of the case pointing downwards.
2. Install the outer race of a taper roller bearing (72) in the rear case (12) and retain it with
Loctite 638. Using suitable lifting equipment, lower the front drive gear assembly into the
case (12). Locate the bearing rollers (72) in the outer race of the bearing previously fitted.

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3. Temporarily install the outer race of a taper roller bearing (72) to the bearing housing (15).
Install the bearing housing to the rear case (12) and secure it with the set screws (115).
Measure the axial end float of the shaft. Subtract 0.07 - 0.13 mm (0.003 - 0.005 in) (the
permitted end float) from the measured end float figure, this value is the correct thickness
for a laminated shim.
4. Remove the outer bearing race from the bearing housing (15), install the corrected shim
(62) then re-install the bearing race, retaining it with Loctite 638.
5. Install the O-Ring (76) into the groove on the inner face of the bearing housing (15).
6. Apply Loctite 243 to the set screws (115).
7. Fit the bearing housing (15) to the rear case, securing it with the 10 set screws (115).
Torque tighten to 147 Nm (108.4 lbf ft).
8. Rotate the rear case (12) in the assembly jig until the large orifice is horizontal and
uppermost.
9. Install the outer bearing races for the input shaft bearing (51), the differential unit shaft
bearing (64) and the counter shaft bearing (51) in the rear case (12), securing them with
Loctite 638.
10. Lower the partially assembled input shaft (9) carefully into the rear case (12). Insert the
selector rod (39) into the rear case (12) and locate the selector fork (32) over the shaft and
into the groove in the selector sleeve (11). Apply Loctite 603 to the dowels (100) and
fit them to the fork (32).
11. Using suitable lifting equipment, lower the counter shift assembly (10) into the rear case
(12).
12. Assemble the remainder of the input shaft. Install a washer (86) over the shaft until it is
adjacent to the shoulder of the splined section of the shaft (9). Oil the two needle roller
bearings (47) and install them on the shaft (9). Install the LOW gear (2) onto the shaft (9),
over the needle roller bearings (47), orientated with the castellations on the gear (2) facing
towards the fork selector (32). Install the washer (63) over the shaft. Heat the bearing (51)
to 120°C (248°F), then install it on the shaft (9), taking care to ensure that the bearing races
are correctly located, with no clearance between the races and the washer (63).
13. Rotate the gear to ensure that there is no obstruction. DO NOT spin an unlubricated
bearing for extended periods.
14. Transfer the lifting equipment to the rear shaft assembly (24), then carefully lower it into the
rear case (12). Transfer the lifting equipment to the front case (13).
15. Insert the two dowels (106, Figure 7.7) in their respective mounting holes in the rear case
(12).
16. Apply Loctite 243 to screws (90 and 131).
17. Apply a 2 mm (0.08 in) bead of Loctite 5910 to the mating face of the rear case (12). Lower
the front case (13) on to the rear case (12), taking care to locate the dowels (106), and
positioning the selector rod (39) through the hole. Secure the front case (13) to the rear
case (12) using the 22 screws (90), and the two screws (131) at the upper end of the
case, that also retain the dropbox lifting bracket (14, Figure 7.7). Tighten the screws in a
sequence working from the centre outwards, in a cross pattern, to ensure even clamping.
Torque tighten to 147 Nm (108.4 lbf ft).
18. Temporarily install the outer race of roller bearing (50) in the differential case (44). Install
the differential case (44) to the front case (13). Measure the axial end float of the shaft.
Subtract 0.07 - 0.13 mm (0.003 - 0.005 in) (the permitted end float) from the measured axial
float figure, this value is the correct thickness for a laminated shim.
19. Remove the differential case (44) and the outer race of roller bearing (50). Install the
corrected shim (89) and outer race again. Retain the outer race with Loctite 638. Install
an O-Ring (75) in the groove in the differential case (44).

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20. Install the differential case (44), complete with shim (89), outer race of bearing (50) and
O-Rring (75). Secure the differential case assembly to the front case (13) using the 10
screws (90), tighten the screws in a sequence working from the centre outwards, in a cross
pattern, to ensure even clamping. Torque tighten to 147 Nm (108.4 lbf ft).
21. Install the outer race of roller bearing (51) to the recess in the front case where the counter
shaft assembly (10) is mounted. Temporarily install a 1.0 mm (0.04 in) laminated shim (59)
over the outer face of the outer race od roller bearing (51). Install the cover plate (17) to the
front case (13) and secure it with the screws (129). The maximum thickness of shim (59)
should eliminate any axial float. Measure the gap between the cover plate (17) and the
front case (13). The required shim size is the temporary shim (1.0 mm) plus the permitted
end float 0.07 - 0.13 mm (0.003 - 0.005 in) minus the measured gap.
22. Undo the six screws (129) and the cover plate (17). Remove the required number of shims
to achieve the axial clearance calculated above. Apply Loctite 638 to the bearing outer
race (51), then fit the corrected shim (59).
23. Apply a 2 mm (0.08 in) bead of Loctite 5910 to the front case mating face where the cover
plate (17) impinges. Install the cover plate (17) to the front case (13) securing it with the six
screws (115). Torque tighten to 85 Nm (62.7 lbf ft).
24. Install the outer race of roller bearing (51) to the front case (13) and the input shaft
assembly (9). Temporarily Install a (1.0 mm) laminated shim (59) on the top of the outer
race of the roller bearing (51).
25. Install the oil seal housing (18) to the front case (13) and secure it with the six screws
(102).The maximum thickness of shim (59) should eliminate any axial float. Measure the
gap between the oil seal housing (18) and the front case (13).The required shim size is the
temporary shim (1.0 mm) plus the permitted end float 0.07 - 0.13 mm (0.003 - 0.005 in)
minus the measured gap.
26. Remove the six screws (102) and the oil seal housing (18). Remove the required number
of shims to achieve the axial clearance calculated above. Apply Loctite 638 to the roller
bearing outer race (51), install the corrected shim (59).
27. Fit the oil seal (74) to the seal housing (18).
28. Apply a 2 mm (0.08 in) bead of Loctite 5910 to the front case (13) where the seal housing
(18) impinges. Install the seal housing (18) with seal (74) to the front case (13), securing it
with the six screws (102). Torque tighten to 85 Nm (62.7 lbf ft).

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 Dropbox 7

(f) Final Assembly

Numbers in parentheses refer to Figure 7.7 and Figure 7.8, unless otherwise specified.

NOTICE
• The maximum allowed gap between the top of the input (9), rear output (24) and front
output (35) shafts and the yoke retaining plates (21 and 22), is 0.1 mm (0.004 in). Use shim
(139) to achieve correct gap between retaining plates and shafts.

PROCEDURE
1. Install a 'Gamma' oil seal (73) to each of the three drive yokes (19, 20 and 38). For each of
the three yokes, align the splines, and slide the yoke on to the shaft. Fit an O-Ring (58,
to the input shaft) and O-Rings (78, to the differential and output shafts), to the groove
of each yoke.
2. Fit the yoke retainer plates (21 and 22), securing with the screws (114), washers (128) and
gaskets (132), Torque tighten to 85 Nm (62.7 lbf ft).
3. Measure the gap between the top of the shafts and the retaining plates, use shim (139) to
achieve the correct gap. Maximum gap is to be 0.1 mm (0.004 in), re-torque tighten the
screws (114) as required.
4. Apply Loctite 575 to the speedometer probe (92) and install to the side of the rear case
(12). Torque tighten to 35 Nm (26 lbf ft).
5. Install the seal (81) over the hydraulic shift cylinder piston (41 and 42). Press the plain
bearing (121) into the switch housing (40). Install a wiper seal (82) until it locates flush
with the housing (40).
6. Install a seal (49) into the switch housing (40), ensuring that it is orientated correctly (lip
biased away from the piston). Retain the seal (49) in place using a washer (45) and circlip
(112). Install O-Rings (48 and 49) to the switch housing (40). Install the O-Ring (49) to the
cylinder end cover (57).
7. Install the four studs (99) into the rear case (12). Install the switch housing (40) into the rear
case (12), locating the selector rod (39) through the housing (40). Install the cylinder (43)
on the switch housing (40), then secure the piston (41 and 42) to the selector rod (39) and
the piston end plate, apply Loctite 603, and torque tighten 35 Nm (26 lbf ft).
8. Install the cylinder end plate (57) by passing the stud ends (99) through the holes in the end
plate. Secure with nuts (96). Torque tighten to 35 Nm (26 lbf ft).
9. Install the cylinder end stop adjustment screws (95) and lock nuts (87) to the cylinder end
plate (57). Adjustment is achieved by firstly applying pneumatic pressure to the LOW gear
engagement port, nearest the front case (13). Rotate the input shaft, if necessary, to achieve
full engagement. View the movement of the selector rod (39) through the switch mounting
holes. Screw in the grub screw (95) until resistance can be felt against the shaft end,
then screw in a further 1/2 turn, torque tighten the locknut to 20 Nm (14.75 lbf ft). Repeat
this adjustment process using the adjustment screw at the other end, and the pneumatic
pressure applied to the HIGH gear engagement port, furthest from the front case (13).
10. To install the switches (113), place a ball (121) in each aperture of the switch housing
(40), using grease to hold them in place. Apply Loctite 575 to the switch threads. Install
the switches, complete with nuts (122), into the switch housing (40). Check to ensure that
switching only occurs when the switch plunger locates on the rod selector outside 20 mm
(0.8 in) diameter, in each case. Use a hand held buzzer or a test rig using indicator lights to
identify when switching occurs.
11. Remove all port protective caps before installation.

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12. Install the following adaptors and accessories:

a. Flow divider:
• 1, 2, 3 and 4 port - adaptors (29). Torque tighten to 40 Nm (29.5 lbf ft).

b. Dropbox control valve:

• SW6 port - adaptor (94) and temperature sensor (93). Torque tighten adaptor to 40 Nm
(29.5 lbf ft) and sensor to 35 Nm (25.8 lbf ft).
• SW5 port - seal (95) and pressure switch (96). Torque tighten to 21 Nm (15.5 lbf ft).
• GS2 port - tee (58) and adaptor (59). Torque tighten adaptor to 21 Nm (15.5 lbf ft)
and tee to 24 Nm (17.7 lbf ft).
• GS1 port - tee (57) and adaptor (59). Torque tighten adaptor to 21 Nm (15.5 lbf ft)
and tee to 24 Nm (17.7 lbf ft).
• P2 port - tee (16) and adaptor (35). Torque tighten adaptor to 75 Nm (55.3 lbf ft) and
tee to 55 Nm (40.5 lbf ft).
• DL port - adaptor (24). Torque tighten to 75 Nm (55.3 lbf ft).
• TP3 port - adaptor (91). Torque tighten to 75 Nm (55.3 lbf ft).
• T1 port - elbow (63) and adaptor (62). Torque tighten adaptor to 40 Nm (29.5 lbf ft)
and elbow to 35 Nm (25.8 lbf ft).
• P1 port - elbow (34) and adaptor (32). Torque tighten adaptor to 40 Nm (29.5 lbf ft)
and elbow to 24 Nm (17.7 lbf ft).
• TP1 port - adaptor (91). Torque tighten to 75 Nm (55.3 lbf ft).
• OC2 port - adaptor (24). Torque tighten to 75 Nm (55.3 lbf ft).
• OC1 port - tee (16) and adaptor (35). Torque tighten adaptor to 75 Nm (55.3 lbf ft)
and tee to 55 Nm (40.5 lbf ft).

c. Dropbox:
• DR port - elbow (37). Torque tighten to 180 Nm (132.7 lbf ft).
• TR port - adaptor (76). Torque tighten to 40 Nm (29.5 lbf ft).
• GC1 and GC2 ports - adaptors (59). Torque tighten to 21 Nm (15.5 lbf ft).
• LS1 port - adaptor (29). Torque tighten to 40 Nm (29.5 lbf ft).
• LS2 port - connector (31). Torque tighten to 21 Nm (15.5 lbf ft).
• Temperature sensor and adaptor (next to port CS3) - sensor (93), adaptor (92). Torque
tighten adaptor to 40 Nm (29.5 lbf ft) and sensor to 35 (25.8 lbf ft).
• CS3 port - adaptor (32). Torque tighten to 40 Nm (29.5 lbf ft).
• DC port - adaptor (29). Torque tighten to 40 Nm (29.5 lbf ft).
• SL port - elbow (19). Torque tighten to 180 Nm (132.7 lbf ft).
• Dipstick port - elbow (20, Figure 7.1). Torque tighten to 125 Nm (92.2 lbf ft).
13. Install the quick drain valve (24, Figure 7.1).
14. Install the dipstick assembly (21, Figure 7.1).
15. Install the emergency steering pump. Refer to (8) Installation on page 12-42.
16. Install the emergency steering valve block. Refer to (3) Installation on page 12-47.
17. Install the bolts, washers and locknuts (8, 9 and 10Figure 7.9), and secure the relief valve
(7, Figure 7.9) to the bracket assembly (11, Figure 7.9).
18. Install the bolts washers and hardened washers (12, 13 and 14, Figure 7.9), and secure the
bracket assembly and the relief valve (11 and 7, Figure 7.9) to the dropbox.
19. Install the bolts and washers (5 and 6, Figure 7.9), and secure the dropbox control valve (4,
Figure 7.9) to the dropbox.
20. Install the bolts and washers (2 and 3, Figure 7.9), and secure the flow divider (1, Figure
7.9) to the dropbox.

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21. Identify, and connect the following hydraulic hoses:

Refer to Figure 7.6.
Remove all protective caps before installation.
• Dropbox Relief Valve Port T (1) - Dropbox Control Valve Port OC1 (Tee). Torque tighten to
55 Nm (40.5 lbf ft).
• Dropbox Relief Valve Port P (3) - Dropbox Control Valve Port P2 (Tee). Torque tighten to
55 Nm (40.5 lbf ft).
• Dropbox Port DR (15) - Dropbox Control Valve Port OC2. Torque tighten to 37 Nm (27.3
lbf ft).
• Dropbox Port DC (2) - Dropbox Control Valve Port DL. Torque tighten to 37 Nm (27.3 lbf ft).
• Dropbox Lube Port (rear) (13) - Flow Divider Port 2. Torque tighten to 37 Nm (27.3 lbf ft).
• Dropbox Port LS1 (4) - Flow Divider Port 3. Torque tighten to 37 Nm (27.3 lbf ft).
• Dropbox Port LS2 (9) - Flow Divider Port 1. Torque tighten to 37 Nm (27.3 lbf ft).
• Hi - Lo Selector connection GC2 (60) - Dropbox Control valve port GS1 (Tee). Torque
tighten to 27 Nm (20 lbf ft).
• Hi - Lo Selector connection GC1 (61) - Dropbox Control valve port GS2 (Tee). Torque
tighten to 27 Nm (20 lbf ft).
22. If this is a new installation, fit the new name plate (118) in the location shown using
self-tapping rivets (103). Hard stamp the serial number on the rear case (12).
23. Measure the torque required to turn the input shaft with the HIGH speed selected. The
reading should be below 20 Nm (14.75 lbf ft). Higher readings indicate binding of bearings
or seals. Check the bearing settings and the seal conditions, rectifying any problems
before proceeding.

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7 Dropbox

(8) Installation
Numbers in parentheses refer to Figure 7.1, unless otherwise specified.

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

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all hydraulic lines fitted with ORFS connections as described in (7) O-Ring Face
Seals (ORFS) on page 11-24. Renew all O-Rings where used.
• Orientation of snubbing washers (5) and hardened washers (6) is different for front and
rear brackets. Ensure correct orientation during installation.

PROCEDURE
1. Lightly coat bolts (11) with retaining compound (Loctite 648). Secure rear mounting
brackets (4) to either side of the dropbox using bolts (11) and washers (12). Torque tighten
to 410Nm (303 Ibf ft).
2. Lightly coat bolts (10) with retaining compound (Loctite 648). Secure front mounting bracket
(2) to dropbox using bolts (10) and washers (9). Torque tighten to 185Nm (136 Ibf ft).
3. Install isolation mounts (1) in the correct orientation to the front and rear mounting brackets
(2 and 4).
4. Attach suitable lifting equipment to dropbox lifting brackets and carefully position dropbox
assembly in the tractor frame.
5. Secure the rear mounting brackets to the front frame assembly using the snubbing washers
(5), bolts (7), hardened washers (6) and locknuts (8). Torque the locknuts (8) to a value of
921 Nm (680 Ibf ft).
6. If previously removed, orientate the cross-member (3) and secure to the front frame using
bolts (14), washers (13), and locknuts (8), and if required spacers (18). Torque tighten to
921Nm (680 Ibf ft).
7. Secure the front mounting bracket to the cross-member (3) using the snubbing washers
(5), bolts (7), hardened washers (6) and locknuts (8). Torque the locknuts (8) to a value of
921 Nm (680 Ibf ft).
8. Set the clearance between the driveline and the anti-flail guard (15) to 5 - 7 mm (0.2 - 0.3 in).
9. Install all drivelines connected to the dropbox and secure them clear of the dropbox. Refer
to 8.1 Front Drivelines on page 8-2.
10. Identify, remove protective caps and connect the following hydraulic hoses:
Refer to Figure 12.1
a. Emergency Steering Pump connection:
• Hydraulic Tank connection (26) - Drain hose main pump body. Torque tighten to 55Nm
(40.5 lbf ft).

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 Dropbox 7

b. Emergency Steering Valve Block lines:

• Hydraulic Tank return line (Tee on Difflock Valve ‘T’) (30) - Emergency Steering Valve
Block port D. Torque tighten to 27Nm (20 lbf ft).
• Main Hydraulic Valve connection ‘P2’ (28) - Emergency Steering Valve Block port
P. Torque tighten to 126 Nm (93 lbf ft).
• Hydraulic Tank connection (27) - Emergency Steering Valve Block port S. Torque
tighten to 264 Nm (195 lbf ft).

c. Dropbox lines:
Refer to Figure 7.6.
• Suction Filter connection (19) - Dropbox port SL. Torque tighten to 126 Nm (93 lbf ft).
• Cooler connection ‘B1’ (23) (Tee on frame) - Dropbox port CS3. Torque tighten to
37 Nm (27 lbf ft).
• Cooler connection ‘B1’ (11) (Tee on frame) - Flow Divider Post 4 (13). Torque tighten to
37 Nm (27 lbf ft).
• Hydraulic Tank connection ‘T1’ (24) - Dropbox Control Valve T1. Torque tighten to
37 Nm (27 lbf ft).
• Dropbox Filter connection (21) - Dropbox Control Valve P2 (Tee). Torque tighten to
55 Nm (41 lbf ft).
• Main Hydraulic Valve connection ‘DL’ (4) - Dropbox Control Valve P1. Torque tighten to
27 Nm (20 lbf ft).
• Cooler connection ‘B2’ (2) - Dropbox Control Valve OC1 (Tee). Torque tighten to 55
Nm (41 lbf ft).
• Breather connection (31) - Dropbox port TR. Torque tighten to 55 Nm (41 lbf ft).

d. Diagnostic lines:
Refer to Figure 7.6.
• DP4 (5) - Dropbox Control Valve GS2 (Tee). Torque tighten to 27 Nm (20 lbf ft).
• DP3 (5) - Dropbox Control Valve GS1 (Tee). Torque tighten to 27 Nm (20 lbf ft).
• DP2 (5) - Dropbox Control Valve TP3. Torque tighten to 27 Nm (20 lbf ft).
• DP1 (5) - Dropbox Control Valve TP1. Torque tighten to 27 Nm (20 lbf ft).
11. Identify and connect the following electrical cables:
Remove all protective caps before installation.
• Cabin Bulkhead - X19
• Speed Sensor - B18 (RHS Rear Case)
• Temperature Sensor - WA1.B6 (Front Differential Case)
• Pressure Relief Valve - WA2.B12 (PS)
• Speed Selector Low Ratio - B10
• Speed Selector High Ratio - B9
• Control Valve Temperature Switch - WA3.B7 (SW6)
• Control Valve Pressure Switch - WA7.B19 (SW5)
• Control Valve Differential Lock - WA4.Q3 (CT4)
• Control Valve Low Ratio - WA5.Q4 (CT2)
• Control Valve High Ratio - WA6.Q5 (CT2)
12. Fill and bleed the dropbox oil system. Refer to (c) Bleeding the System on page 7-41.

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(9) Maintenance
(a) Periodic Inspections

� WARNING
• When checking the oil level, be sure that the parking brake is applied and all road wheels
are securely blocked.

For easier inspection, the dropbox should be kept clean. Make periodic checks for loose
mounting bolts and leaking oil lines. Check the condition of electrical harnesses and
connections regularly. Because the dropbox oil cools, lubricates and transmits hydraulic power
it is important that the proper oil level be maintained at all times. It is absolutely necessary that
the oil put into the dropbox is clean.

HOT COLD
RUNNING RUNNING

MOT05101

Figure 7.17 - Dropbox Oil Dipstick

1. Cold Running Oil level 2. Hot Running Oil level

(b) Topping Up Oil

Oil Level Check- Engine Off
This check should be made to determine if the dropbox contains sufficient oil for safe starting.
Oil should be well above the 'cold running' mark on the dipstick (Figure 7.17). If there is a deficit
of oil, this must be replenished until it is up to the correct level
Oil Level Check- Engine Running
1 Position the vehicle on a level work area, apply the parking brake and block all road wheels
securely.
2 With the transmission in neutral and the engine running, allow the vehicle to run for 1
minute (vehicle stationary). This allows for oil to distribute itself round the circuits.
3 Check the oil levels in the dropbox. Oil should be within the 'cold running' and 'hot running'
level marks (Figure 7.17) on the dipstick. If there is a deficit of oil or indeed an excess of
oil this must be rectified untill it is within the correct band.
Oil and Filter Change
The dropbox oil and oil filter cartridge should be changed every 500 hours. Clean oil filter head
when replacing the filter cartridge. Replace the oil filter.
The system requires approximately 8 liters of oil. Refer to Table 4.14
Drop box suction screen filter is housed internally within the transmission body and it filters and
cleans the hydraulic oil of debris, metal flashing, filing from the gears, dirt, rust and other junk.

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 Dropbox 7

It should be checked daily. The element should be changed immediately when the indicator
registers in the yellow area, or every 1000 hours, whichever occurs first. Refer to Figure 7.21
Oil must be changed whenever there are traces of dirt or evidence of high temperature
indicated by discolouring or strong residue; in certain operating conditions filter and oil change
periods may need to be more frequent. Consult the relevant manufacturer with any queries
regarding change intervals.
(c) Bleeding the System
Following draining for repair or replacement, the system should be bled to remove any air
that has become trapped.

PROCEDURE
1. Position the vehicle on a level work area, apply the parking brake and securely block
all road wheels.
2. Replenish the oil in the dropbox to the correct level (Figure 7.17).
3. Fill the dropbox filter to the required level.
4. Install a hose to the pressure test point.
5. Place a suitable container under the hose.
6. Start the engine.
7. Make sure that the Low Pressure Alarm, on the dashboard, is in the off position.
8. Make sure that oil is seen in the container and no air is audible.
9. Switch off the engine.
10. Remove the hose from the test point and the remove the container.
11. Check the level of oil in the dropbox (Figure 7.17).

(10) Service Tools

Refer to Service Tools section, for service tools which should be used in conjuction with
procedures outlined in the dropbox manufacturer's service manual and general service tools
required. These tools are available from your dealer.

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(11) Trouble Shooting

Table 7.1 - Trouble Shooting
Problem Possible Cause Corrective Action
Low Pressure Indication Wiring or Pressure Switch Check pressure at diagnostic test point
(Engine Running). failure. - Pressure at DP3 and DP4 should be
15 bar (217 psi). If OK check wiring
and switch.
Partial/ Full blockage of Check and replace filter element.
valve block filter.
Failure of main hydraulic Check flow and pressure to dropbox
system. from main hydraulic valve port 'DL'.
Failure/wear in dropbox Replace pump unit- checks must be
pump unit. made to establish primary cause i.e.
contaminated oil.
High Temperature Low oil level Check oil level and unit for leaks.
Warning.
Vehicle cooler circuit Check oil cooler circuit for failure,
failure. damage or radiator blockage.
Differential lock Wiring or solenoid failure. Check for power to solenoid and that
Inoperative solenoid energises when differential
lock switch activated replace or repair
as necessary.
Low pressure Check oil pressure at pressure point
DP1 on dropbox valve block - should be
34-40 bar (493-580 psi) on activation
of differential lock switch (measured
with oil between 25°C and 50°C). Low
pressure indicates either worn pump
unit, leaking valve (CT3) in the valve
block or worn differential piston and/
or shaft seals. Check and replace as
necessary. Verify and rectify primary
cause i.e. contaminated oil.
Clutch plate wear If pressure is within specification check
oil line for blockage. If oil flow is
present examine and replace clutch
plates in the differential.
Squeal from differential Differential lock partially Check oil pressure at pressure point
with differential lock not engaged. DP1 on dropbox valve block- should
engaged. be 0 bar with Differential. lock off. If
pressure is indicated, ensure solenoid
(CT4) is not being energized, check
solenoid valve for leakage. Replace as
necessary
Clutch plates warped or Examine and replace clutch plates in
damaged differential.
Cannot change gear Wiring or solenoid failure Check pressure on dropbox valve
range block- Pressure at DP3 and DP4
should be 15 ± 2.5 bar (217 ± 36 psi).
If OK check wiring and switch.

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 Dropbox 7

Problem Possible Cause Corrective Action

Fail To Engage Range - Low pressure Check pressure on dropbox valve
No Drive block- pressure at DP3 and DP4
should be 15 ± 2.5 bar (217 ± 36 psi).
Check that pressure control valve (4)
is not faulty.
Ensure supply from main hydraulic
valve is correct.
Gear selector mechanism Test selector mechanism manually by
damage/wear removing hydraulic selector cylinder
and push and pull on the selector rod.

NOTICE
• Full gear selection will require some rotation of the input shaft to align dog selector. Check
for bent or broken shaft or selector fork. Strip dropbox and replace where necessary.

(12) Special Torque Specifications

Table 7.2 - Special Torque Specifications
TORQUE
FIG. NO. ITEM NO. ITEM NAME
Nm lbf ft
Figure 7.1 7 Bolt 921 680
Figure 7.1 8 Locknut 921 680
Figure 7.1 10 Bolt 185 156
Figure 7.1 11 Bolt 410 303
Figure 7.1 14 Bolt 921 680

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7 Dropbox

(13) Dropbox Assembly Torque Specifications

Table 7.3 - Dropbox Assembly Torque Specifications
TORQUE
FIG. NO. ITEM NO. ITEM NAME
Nm lbf ft
Figure 7.7 97 Differential Locking Ring 160 118
Figure 7.7 90, 131 Case Bolts 147 108.4
Figure 7.7 90 Differential Case Bolts 147 108.4
Figure 7.7 115 Bearing Housing Bolts 85 62.7
Figure 7.7 135 Yoke Stud Nuts 85 62.7
Figure 7.7 92 Speed Sender Unit 35 26
Figure 7.7 125,126 Drain and Level Plugs 70 52
Figure 7.7 108 Differential Planet Carrier Bolts 85 62.7
Figure 7.7 91, 102 Annulus/Differential Housing Screws 85 62.7
Figure 7.7 17 Bearing Cover Plate Screws 85 62.7
Figure 7.7 111 Pump Drive Adapter Screw 45 33
Figure 7.7 102 Oil Seal Housing Screws 85 62.7
Figure 7.7 96 Cylinder Stud Nuts 35 26
Figure 7.7 95 Cylinder Stroke Lock Nut 20 14.75

(14) Valve Block Torque Specifications

Table 7.4 - Valve Block Torque Specifications
TORQUE
FIG. NO. ITEM NO. ITEM NAME
Nm lbf ft
CT2 20 14.75
Figure 7.3 1, 2
Coil 3.4 2.5
Figure 7.3 3 CT6 45 33
Figure 7.3 4 CT1 60 44.25
Figure 7.3 5 CT3 45 33
Figure 7.3 6 CT5 45 33
CT4 30 22
Figure 7.3 7
Coil 3.4 3.4
SW6 - Sensor 35 25.8
Figure 7.3 8
Adaptor 40 29.5
Figure 7.3 9 SW5 21 15.5

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 Dropbox 7

7.2 Dropbox Pump

Figure 7.18 - Exploded View of Dropbox Pump

1. Housing 6. Centering Pin 11. Shaft Seal
2. Bolt 7. Bearing 12. Retaining ring
3. Lock Washer 8. Gear 13. Front cover
4. End Cover 9. Centering Pin 14. Friction Gear
5. Seal Kit 10. Plain Bearing

(1) Description
Numbers in parentheses refer to Figure 7.18, unless otherwise specified.
The dropbox pump is mounted on, and operates in unison with, the main hydraulic pump.
The main hydraulic pump assembly is mounted on the transmission power take off (PTO) on
the left-hand side of the transmission. The dropbox, pump, mounted at the rear of the main
hydraulic pump assembly, draws oil from the dropbox sump, and delivers it to the dropbox
differential lock circuit and the dropbox shaft lubrication galleries via the dropbox control valve.
The dropbox delivers oil at 35 bar (507 psi) to the control valve, which reduces the delivery
pressure for shaft lubrication to 4.5-8.5 bar (65- 123 psi), the dropbox high/low ratio actuation
pressure to 15 bar (217 psi) and the differential lock pressure to 34-50 bar (493-725 psi). The
shaft lubrication oil passes through the dropbox oil cooler before being supplied to the dropbox
shafts. A two-stage temperature switch (SW6), fitted to the dropbox control valve, starts the
cooler fan when the oil temperature rises to 60°C and illuminates a warning indicator on the
dashboard display, when the oil temperature reaches 120°C. A further (secondary) temperature
switch, fitted in the shaft lubrication line local to the dropbox, also illuminates the dashboard
display warning indicator when the oil temperature at the dropbox (shaft 3) reaches 120°C. A
pressure switch (SW5) fitted to the dropbox control valve illuminates a warning indicator on the
dashboard display when the oil pressure drops below 0.8 bar (11 psi).

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7 Dropbox

(2) Operation
Numbers in parentheses refer toFigure 7.4, unless otherwise specified.

NOTICE
• Direction of rotation is clockwise as viewed from the shaft end, and is indicated by an
arrow on the pump housing.

The dropbox pump is a gear pump, driven from an extension of the main hydraulic pump
common drive shaft; at the rear end of the rear main hydraulic pump, via a splined fitting. The
pump draws oil from the dropbox sump, through a suction filter, and discharges the pressurized
oil though a pressure filter, to the dropbox control valve.
Valve CT6 (6) limits the oil pressure to the dropbox shaft bearings to 4.5-8.5 bar (65-123 psi).
Similarly, valve CT1 (4) limits the oil pressure to the dropbox high/low actuation section of
the circuit to 15 bar.
The differential lock actuation system is subject to the full pump discharge pressure of 34-50 bar
(391-725 psi). A by-pass relief valve, set at 60 bar (870 psi), protects the circuit from excessive
pressures that may occur when starting the machine in cold ambient temperatures.
(3) Diagnostic Points
Numbers in parentheses refer to Figure 7.5, unless otherwise specified.
Dropbox lubrication pressure should be checked at 'wide open throttle', and the readings
obtained should be considered in conjunction with reference to Table 7.5, as the pressure
ranges vary with changing oil temperature. Lubrication pressure is checked at the diagnostic
point TP3 (2), while temperature is measured using an infrared gun at the filter hose fitting on
the rear right-hand side of the sump.
(a) Dropbox Lubrication - Temperature/Pressure Table
Table 7.5 - Temperature/Pressure Table
TEMPERATURE PRESSURE
°C °F bar psi
5 41 6.8-8.9 99-129
10 50 6.4-8.5 93-123
15 59 5.9-8.0 86-116
20 68 5.4-7.4 78-107
25 77 5.2-7.2 75-104
30 86 4.9-7.0 71-102
35 95 4.9-7.0 71-102
40 104 4.9-7.0 71-102
45 113 4.8-6.9 70-100
50 122 4.8-6.9 70-100
55 131 4.8-6.9 70-100

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 Dropbox 7

(4) Removal

1, 2

6 MOT05125

Figure 7.19 - Dropbox Pump Mounting

1. Bolt 3. Mounting Bracket 5. Dropbox Pump
2. Washer 4. Bolt 6. Hexagon Socket

Numbers in parentheses refer to Figure 7.19, unless otherwise specified.

� WARNING
• Ensure that wheel chocks, blocking materials and lifting equipment are properly secured
and of adequate capacity to do the job safely. This will prevent personal injury and property
damage.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.

PROCEDURE
1. Position the vehicle in a level work area, apply the parking brake and switch OFF the engine.
2. Raise the cab. Refer to (4) Tilting the Cab on page 19-12.
3. Turn steering wheel in both directions several times to relieve pressure in accumulator
and steering system.
4. Block all road wheels and place the battery master switch in the 'OFF' position.
5. Place the steering lock bar in the 'Locked' position.
6. Clean the dropbox pump assembly (5) and the surrounding area with a suitable solvent.

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7 Dropbox

7. Identify and tag the inlet (7, Figure 7.6) and the outlet (8, Figure 7.6) hydraulic hose lines
connected to the pump.
8. With a suitable container in position, remove drain plug from bottom of hydraulic tank and
drain the oil. Reinstall the drain plug and tighten securely.
9. With a suitable container in position, disconnect the following hydraulic hoses:
• Outlet connection (8, Figure 7.6) – Dropbox pressure filter ‘IN’.
• Inlet connection (7, Figure 7.6) – Dropbox suction filter ‘OUT’.
10. Fit blanking caps and plugs to all hydraulic lines and ports.
11. Remove the two bolts (1) and washers (2) securing the mounting bracket (3) to the
transmission. Retain the plastic bushes and spacers.
12. Support the dropbox pump (5) and remove bolt (4) and hexagon socket (6) securing the
dropbox pump (5) and bracket (3) to the main hydraulic pump.
13. Remove the dropbox pump (5) and the mounting bracket (3).
14. Retain the gasket from the mating faces of the dropbox pump (5) and the main hydraulic
pump.

(5) Disassembly
Numbers in parentheses refer to Figure 7.18, unless otherwise specified.

� CAUTION
• Do not clamp the vice on the machined surfaces of the assembly at any time.
• Do not attempt to pry the pump assembly apart with a large screwdriver or pry bar. The
machined surfaces of the assembly may be damaged.

PROCEDURE
1. Place the pump assembly in a soft-jawed vice, and apply the vice clamp to the body. Match
mark the pump covers and body to aid in re-assembly.
2. Remove the elbow and adaptor (23 and 26, Figure 7.6) from the OUT port on the dropbox
pump.
3. Remove the elbow and adaptor (33 and 17, Figure 7.6) from the IN port on the dropbox
pump.
4. Remove the four bolts (2) and washers (3), and remove the end cover (4) from the pump
assembly.
5. Remove the constituent parts of the pump assembly.
6. Remove and discard the seals that are to be replaced with new seals in the kits (5).

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 Dropbox 7

(6) Inspection
Numbers in parentheses refer to Figure 7.18, unless otherwise specified.

PROCEDURE
1. Clean all of the parts in a suitable solvent and dry them with compressed air.
2. Check the port threads and ensure that they are not damaged or stripped.

(7) Assembly
Numbers in parentheses refer to Figure 7.18, unless otherwise specified.

PROCEDURE
1. Replace the seals kits (5) on both ends of the pump, prior to re-assembly.
2. Lightly lubricate internal parts prior to re-assembly.
3. Assemble the pump internal components and secure them with the bolts (2) and washers
(3). Torque tighten the bolts (2) to 50 Nm (37 lbf ft).
4. Install the adaptor and elbow (17 and 33, Figure 7.6) to the ‘IN’ port on the dropbox pump.
Torque tighten adaptor to 110 Nm (81.1 lbf ft) and elbow to 125 Nm (92.2 lbf ft).
5. Install the adaptor and elbow (26 and 23, Figure 7.6) to the ‘OUT’ port on the dropbox
pump. Torque tighten adaptor to 110 Nm (81.1 lbf ft) and elbow to 55 Nm (40.5 lbf ft).

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(8) Installation
Numbers in parentheses refer to Figure 7.19, unless otherwise specified.

� WARNING
• Ensure that wheel chocks, blocking materials and lifting equipment are properly secured
and of adequate capacity to do the job safely. This will prevent personal injury and property
damage.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Clean the dropbox pump assembly (5) and the surrounding area with a suitable solvent.
2. Apply Vaseline to the mating face of the main hydraulic pump.
3. Check that the main hydraulic pump O-Ring is in position.
4. Install gasket to the mating surface of the hydraulic pump.
5. Install the dropbox pump (5) to the hydraulic pump, ensure that the holes on the pump (5)
align with the holes on the hydraulic pump.
6. Ensure that the plastic bushes and spacers are in position in the holes of the mounting
bracket (3).
7. Apply Loctite 243 to bolts (1).
8. Secure the mounting bracket (3) to the transmission with bolts (1) and washers (2).
9. Torque tighten bolts (1) to 102 Nm (75.2 lbf ft).
10. Apply Loctite 243 to bolt (4) and hexagon socket (6).
11. Secure the dropbox pump assembly (5) and the bracket (3) to the main hydraulic pump,
with bolt (4) and hexagon socket (6). Torque tighten to 45 Nm (33 lbf).
12. Remove the blanking plugs and install the following hydraulic hoses:
• Outlet connection (8, Figure 7.6) – Dropbox pressure filter ‘IN’. Torque tighten to 55 Nm
(40.5 lbf ft).
• Inlet connection (7, Figure 7.6) – Dropbox suction filter ‘OUT’. Torque tighten to 125 Nm
(92.2 lbf ft).
13. Fill and bleed the dropbox oil system. Refer to (c) Bleeding the System on page 7-41.
14. Place the battery master switch in the 'ON' position.
15. Start the engine.
16. Bring the hydraulic oil to operating temperature.
17. Check the dropbox pump and the hydraulic hose connections for leaks, tighten if required.
18. Lower the cab. Refer to(5) Lowering the Cab on page 19-14.

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 Dropbox 7

19. Remove all blocking from the road wheels and place the steering lock bar in the 'Stowed'
position.
20. Check the dropbox pressures at D1, D2, D3 and D4, on the diagnostic plate. Refer to (b)
Diagnostic Points on page 7-7.

(9) Fault Diagnosis

With the exception of the seals any damage to the pump internal components would necessitate
renewal of the complete pump assembly.
(10) Special Tools
There are no special tools required for the procedures outlined in this section. Refer to 22.2
Service Tools on page 22-4, for part numbers of general service tools required. These tools are
available from your dealer.

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7 Dropbox

7.3 Dropbox Oil Pressure Filter

6
5

2
3

MOT05102

Figure 7.20 - Dropbox Oil Pressure Filter

1. 10 Micron Filter Assembly 4. Indicator - 5 Bar 7. Bolt
2. Element 5. Washer
3. O Ring 6. Lockwasher

(1) Description
Numbers in parentheses refer to Figure 7.20, unless otherwise specified.
The dropbox pressure filter assembly is installed in the ouput line from the dropbox pump, and
removes any solid contaminants from the dropbox oil (sump), to minimize wear, and thus
contribute to maximum service life for the dropbox. The filter assembly (1) is bolted directly to
the exhaust mounting cradle, adjacent to the tractor/trailer pivot point.
A by-pass valve in the filter housing ensures an adequate flow of oil to the dropbox if the
element (2) becomes blocked, and cannot pass oil through adequately enough to satisfy
demand. The by-pass valve opens at a differential pressure of 8 bar (116 psi).
A visual restriction indicator (4) is fitted to the filter, and indicates that the filter element is
becoming blocked at a differential pressure of 5 bar (72.5 psi).
Oil is drawn from the dropbox sump by the dropbox pump, which is mounted on the rear end
of the main hydraulic pump, and is supplied to the inlet side of filter housing where the oil will
then take one of two routes:
• If the oil is cold and thick, or the filter element (2) is blocked, oil pressure increases and
opens the bypass valve allowing the oil to by-pass the filter element and flow through the
filter housing and exit at the outlet port to the dropbox.
• If the oil is warm and the filter element (2) is not blocked, oil will flow through the element
before returning to the dropbox.

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 Dropbox 7

A two-stage temperature switch is fitted to the dropbox control valve (SW6, (3) Switches and
Pressure Points on page 7-5), which starts the cooling fan when the oil temperature rises to
60°C, and illuminates a warning indicator on the dashboard display, when the oil temperature
reaches 120°C
(2) Removal
Numbers in parentheses refer to Figure 7.20, unless otherwise specified.
For additional reference refer to Figure 7.6.

� WARNING
• Ensure that wheel chocks and blocking materials are properly secured and of adequate
capacity to do the job safely. This will prevent personal injury and property damage.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.

NOTICE
• If the filter element (2) is being replaced, disassemble the filter assembly (1) and replace
the element as described in (4) Changing Filter Element on page 7-54. It is not necessary
to remove the entire filter assembly to renew the filter element.

PROCEDURE
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 the pressure in the
steering system.
3. Operate the treadle valve continuously to discharge the brake accumulators.
4. Block all road wheels.
5. With a suitable container in position tag the filter inlet and outlet hoses (6 and 8), to aid in
installation. Refer to Figure 7.6.
6. Disconnect hoses (6 and 8) from them from the filter housing elbow (20) and tee-piece
(22). Refer toFigure 7.6.
7. Fit blanking caps and plugs to both hydraulic lines, the elbow and the tee-piece to prevent
ingress of contaminants.
8. Support the filter assembly. Remove the bolts (7) and washers (5 and 6) securing the filter
assembly to the exhaust cradle. Remove the filter assembly to a prepared area and drain
the oil from the assembly into a suitable container.

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7 Dropbox

(3) Installation
Numbers in parentheses refer to Figure 7.20, unless otherwise specified.

� WARNING
• Ensure that wheel chocks and blocking materials are properly secured and of adequate
capacity to do the job safely. This will prevent personal injury and property damage.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.

NOTICE
• Tighten all hydraulic lines fitted with ORFS connections, as described in Steering System
Schematic section.

PROCEDURE
1. Position the filter assembly on the exhaust cradle and secure it with the bolts (7) and
washers (5 and 6) retained at Removal. Take care to mount the filter assembly in the
correct orientation, with the retriction indicator outermost.
2. Remove the blanking caps from the inlet and outlet hoses, and from the inlet and outlet
ports on the filter housing, all as tagged on Removal.
3. Start the engine and check for leaks. Tighten the hose fittings as required.
4. Check the dropbox oil level and add oil if required. Refer to Dropbox and Mounting section
for the correct fill level and Lubricants, Oils and Fluids Chapter, for the oil specification.
5. Ensure that the parking brake is applied. Remove the wheel blocks from all road wheels.

(4) Changing Filter Element

Numbers in parentheses refer to Figure 7.20, unless otherwise specified.

� WARNING
• Ensure that wheel chocks and blocking materials are properly secured and of adequate
capacity to do the job safely. This will prevent personal injury and property damage.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.
• Turning the steering wheel several times in each direction relieves pressure in the system.
Failure to release pressure as stated can result in personal injury and property damage.

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 Dropbox 7

NOTICE
• Each new filter element is supplied complete with a replacement O-ring for the filter body.
• Change the filter element (2) at intervals specified in Lubricants, Oils and Fluids Chapter.
The element (2) should also be changed whenever a dropbox overhaul is performed, or
other internal servicing is carried out.

PROCEDURE
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 pressure in the steering
system.
3. Operate the treadle valve continuously to discharge the brake accumulators. Block all
road wheels.
4. With a suitable container under the filter assembly (1) to catch draining oil, unscrew the
external tubular cover and remove complete with O-ring (3) and element (2). Discard
the element (2).
5. Discard element (2) and O-ring (3).
6. Clean the external tubular cover with solvent and dry it with a clean, lint free cloth. Lubricate
the new 'O' ring and install it on the filter body (7) . Lubricate the threads of the filter body (7).
7. Lubricate the new 'O' ring and install it on external tubular cover. Lubricate the threads of
the external tubular cover.
8. Install the new element (2) in the external tubular cover . Fill the external tubular cover with
a charge of new oil, taking care to keep it in a vertical attitude to avoid spillage.
9. Fit the external tubular cover, complete with the new O-ring (3) and element (2), to the
filter housing.
10. Start the engine and check for leaks. Tighten lines and fittings where required.
11. Check transmission oil level and add oil if required. Refer to Dropbox and Mounting section
for correct fill level and Lubricants, Oils and Fluids Chapter for oil specification.
12. Ensure that the parking brake is applied. Remove the wheel blocks from all road wheels.

(5) Special Tools

There are no special tools required for procedures outlined in this section. Refer to Service
Tools section, for part numbers of general service tools required. These tools are available
from your dealer.

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7 Dropbox

7.4 Dropbox Suction Filter

3 4

OUT

IN
2
6

MOT05127

Figure 7.21 - Dropbox Suction Filter

1. Filter Element 4. Washer 7. Filter Housing
2. Indicator Gauge 5. Bolt
3. Welded Bracket 6. Front Frame Cross Member

(1) Description
Numbers in parentheses refer to Figure 7.21, unless otherwise specified.
The dropbox suction filter is mounted on a bracket (3) on the front frame cross member (6)
immediately forward of the dropbox. It is connected in the line between the dropbox sump and
the dropbox pump. The dropbox pump is shaft-mounted on one end of the main hydraulic pump.
The main components of the suction filter are: filter element (1), restriction indicator gauge (2),
and a filter housing (7). The filter housing (7) features a single inlet and outlet port. Refer to
Figure 7.6.

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 Dropbox 7

(2) Operation
Numbers in parentheses refer to Figure 7.21, unless otherwise specified.

� CAUTION
• Operating the truck with a blocked dropbox suction filter can lead to failure of the dropbox
pump and ultimately a catastrophic failure of the dropbox. Regular checking of the indicator
gauge is vital to protect the dropbox and the filtration system.

The dropbox oil is drawn from the dropbox sump and it passes through the suction filter before
entering the dropbox pump ‘IN’ port. The dropbox pump then passes the pressurized oil through
a pressure filter, refer to Figure 7.6.
The pressure drop across the suction filter assembly is minimal when element (1) is clean.
Contaminants (dirt) build up across the element (1) as the dropbox sump oil passes through
the filter assembly. The pressure drop across the filter increases, as dirt build up increases,
and is applied to an integral by-pass valve within the filter housing (7). The by-pass valve is
mechanically linked to the indicator gauge (2).
Movement of the piston in the by-pass valve is reflected on the indicator gauge (2). As dirt
build up increases, the pointer of the indicator gauge (2) will move from the green area into
the yellow area. The element (1) should be changed immediately when the pointer registers in
the yellow 'Needs Cleaning' area.
The internal by-pass valve starts to open when the pointer passes from the yellow area into the
red area on the indicator gauge (2), which will occur at a differential pressure of approximately
0.25 bar (3.6 psi) across the element. If the indicator gauge (2) is in the red 'Bypass' area, the
by-pass valve is open. This allows a certain amount of hydraulic oil to by-pass the blocked
element (1). The element must be changed immediately.
(3) Changing Filter Element
Numbers in parentheses refer to Figure 7.21, unless otherwise specified.

� WARNING
• Turning the steering wheel several times in each direction relieves pressure in the system.
Failure to release pressure as stated can result in personal injury and property damage.
• To prevent personal injury and property damage, ensure that wheel blocks are properly
secured and of adequate capacity to do the job safely.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.
• Change the filter element (1) when the indicator gauge (3) is in the yellow or the red position
and when a dropbox overhaul is performed.

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7 Dropbox

PROCEDURE
1. Position the vehicle in a level work area, apply the parking brake and switch OFF the engine.
2. Turn steering wheel in both directions several times to relieve any pressure in the steering
system.
3. Operate the treadle valve continuously to discharge the brake accumulators. Block all
road wheels.
4. Install and secure the steering lock bar in the ‘locked’ position.
5. With a suitable container under the filter assembly to catch draining oil, unscrew the filter
element and remove. Discard the element (1).
6. Clean the housing (7) thoroughly with a suitable solvent and dry it with a clean, lint free
cloth, prior to installation of a new filter element (1).
7. Screw a new filter element (1) into the housing (7).
8. Remove wheel blocks and disconnect the steering lock bar and place it in the ‘stowed’
position. Start the engine, check for correct dropbox operation in both high and low ratios
and check for leaks. Tighten all lines and fittings, as required.

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 Drivelines 8

Table of Content
8 Drivelines.....................................................................................................8-1
8.1 Front Drivelines .............................................................................................. 8-2
(1) Description................................................................................................. 8-3
(2) Removal .................................................................................................... 8-3
(3) Universal Joint Disassembly...................................................................... 8-5
(4) Inspection .................................................................................................. 8-6
(5) Universal Joint Assembly .......................................................................... 8-7
(6) Installation ................................................................................................. 8-8
(7) Special Tools ............................................................................................. 8-9
(8) Driveline Diagnosis Chart .......................................................................... 8-9
(9) Special Torque Specifications.................................................................... 8-9
8.2 Rear Drivelines............................................................................................. 8-10
(1) Description............................................................................................... 8-10
(2) Removal .................................................................................................. 8-11
(3) Universal Joint Disassembly.................................................................... 8-12
(4) Inspection ................................................................................................ 8-13
(5) Universal Joint Assembly ........................................................................ 8-13
(6) Installation ............................................................................................... 8-14
(7) Special Tools ........................................................................................... 8-15
(8) Driveline Diagnosis Chart ........................................................................ 8-15

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8 Drivelines

8 Drivelines
8.1 Front Drivelines

1, 2, 3

10

4, 5, 6

7, 8, 9
11

10
MOT05108

Figure 8.1 - Front Drivelines

1. Driveline 9 C 5. Universal Joint 9. Screw
2. Universal Joint 6. Bolts 10. Cap Screw
3. Screw 7. Driveline 8.5 C 11. Bolt
4. Driveline 8.5 C 8. Universal Joint

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 Drivelines 8

(1) Description

� CAUTION
• Extra care must be taken when handling drivelines. Carelessness can result in premature
failure of the components. Chips, dents, burrs, or any other deformity of universal joints will
prevent accurate alignment. Misalignment will result in vibration and excessive wear.

Numbers in parentheses refer to Figure 8.1, unless otherwise specified.

The function of the driveline is to transmit rotating power from one point to another in a
smooth and continuous action while allowing a degree of movement or misalignment of the
components it connects.
The drivelines must operate through constantly changing relative angles between the
components they are mounted to and must also be capable of changing length while
transmitting torque.
A typical driveline consists of universal joints which allow some misalignment and permit the
driveline to pivot in any direction, and, a light rigid hollow slip yoke and splined shaft assembly
forming a slip joint.
The slip joint accommodates length variations generated during operation, preventing tension
or compression loads from causing serious damage to the components.
There are three driveline assemblies installed between various components in the tractor
frame as follows:
Driveline assembly (1) is connected between the transmission final drive and the dropbox
input drive.
Driveline assembly (4) connects the rear axle drive of the dropbox to the articulation and
oscillation pivot.
Driveline assembly (7) is connected between the front axle drive flange and the dropbox final
drive.
(2) Removal
Numbers in parentheses refer to Figure 8.1, unless otherwise specified.

� DANGER
• To prevent serious injury or death, DO NOT go under the vehicle when the engine is
running. Rotating shafts are dangerous. You can snag clothes, skin, hair, hands, etc.

� WARNING
• Ensure that wheel chocks, blocking materials and lifting equipment are properly secured
and of adequate capacity to do the job safely. This will prevent personal injury and property
damage.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.

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8 Drivelines

� CAUTION
• Extra care must be taken when handling drivelines. Carelessness can result in premature
failure of the components. Chips, dents, burrs, or any other deformity of universal joints will
prevent accurate alignment. Misalignment will result in vibration and excessive wear.
• Access to driveline assembly (1) can be obtained from underneath the vehicle.

NOTICE
• The driveline from the dropbox to the oscillation pivot is secured to the respective flanges
with hexagon head bolts. This is to ensure that the driveline achieves the maximum
operating angle of 25°.
• The driveline from the dropbox to the oscillation pivot is secured to the respective flanges
with hexagon head bolts. This is to ensure that the driveline achieves the maximum
operating angle of 25°.

PROCEDURE
1. Position the vehicle in a level work area.
2. Apply the parking brake and switch off the engine.
3. Depress the brake pedal continuously to relieve any pressure in the braking circuit. Turn
the steering wheel several times to relieve any pressure in the steering circuit.
4. Block all road wheels and place the battery master switch in the OFF position.
5. Remove support plate and anti-flail guard assembly (15, Figure 7.1).
6. Match mark universal joints and their mating surfaces to ensure correct mating alignment
when re-installing driveline assembly (1).
7. Use suitable lifting equipment to support driveline (1).
8. Remove cap screws (10) securing universal joints to their mating components and remove
driveline assembly (1). If necessary tap driveline assembly (1) from its mating components
with a soft faced hammer.
9. Match mark universal joints and their mating surfaces to ensure correct mating alignment
when re-installing driveline assemblies (4 and 7).
10. Use suitable lifting equipment to support driveline (4.)
11. Remove bolts (11) securing universal joints (5) to their mating components and remove
driveline assembly (4). If necessary tap driveline assembly (4) from its mating components
with a soft faced hammer.
12. Use suitable lifting equipment to support driveline (7).
13. Remove cap screws (10) securing universal joints (8) to their mating components and
remove driveline assembly (7). If necessary tap driveline assembly (7) from its mating
components with a soft faced hammer.

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 Drivelines 8

(3) Universal Joint Disassembly

MOT05109

Figure 8.2 - Universal Joint Removal

1. Capscrew

Numbers in parenthesis refer to Figure 8.1, unless otherwise specified.

� CAUTION
• Do not use excessive force when clamping the tube of the driveshaft. Excessive force
will result in damage to the tube.

PROCEDURE
1. Place the yoke end of driveline assembly (1) in a soft jawed vice, clamping on the tube of
the shaft.
2. Remove cap screws (1, Figure 8.2) and universal joint from driveline assembly (1).
3. Place the shaft end of driveline assembly (1) in a soft jawed vice.
4. Remove cap screws (1, Figure 8.2) and universal joint from driveline assembly (1).
5. Repeat steps 1 to 4 for drivelines (4 and 7).

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8 Drivelines

(4) Inspection

Figure 8.3 - Checking Parallelism

1 Clean all metal parts in a suitable solvent, and dry all parts with compressed air.
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 file or medium India
stone.
3 Check the surfaces of the components that universal joints mate against for parallelism.
Refer to Figure 8.3.
4 Check condition of mounting cap screws and replace if required.
5 Check that the anti-flail guard assembly (15, refer to Figure 7.1, is not damaged prior
to re-assembly.

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 Drivelines 8

(5) Universal Joint Assembly

� CAUTION
• Do not use excessive force when clamping the tube of the driveshaft. Excessive force
will result in damage to the tube.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

Numbers in parentheses refer to Figure 8.1, unless otherwise specified.

PROCEDURE
1. Place the yoke end of driveline assembly (1) in a soft jawed vice, clamping on the tube of
shaft.
2. Install universal joint to yoke end of driveline assembly (1) and secure with cap screws
(1, Figure 8.2).
3. Place the shaft end of driveline assembly (1) in a soft jawed vice.
4. Install universal joint to shaft end of driveline assembly (1) and secure with cap screws
(1, Figure 8.2).
5. Repeat steps 1 to 4 for drivelines (4 & 7).

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8 Drivelines

(6) Installation
Numbers in parentheses refer to Figure 8.1, unless otherwise specified.

� DANGER
• To prevent serious injury or death, DO NOT go under the vehicle when the engine is
running. Rotating shafts are dangerous. You can snag clothes, skin, hair, hands, etc.

� WARNING
• To prevent personal injury and property damage, be sure wheel chocks, blocking materials
and lifting equipment are properly secured and of adequate capacity to do the job safely.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.

� CAUTION
• Extra care must be taken when handling drivelines. Carelessness can result in premature
failure of the components. Chips, dents, burrs, or any other deformity of universal joints will
prevent accurate alignment. Misalignment will result in vibration and excessive wear.
• Access to driveline assembly (1) can be obtained from underneath the vehicle.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Use suitable lifting equipment to support driveline (1).
2. Position driveline assembly (1) on the vehicle and align match marks on universal joints
with those on their mating surfaces.
3. Apply Loctite 648 to the threads of cap screws (10). Secure universal joints to their mating
surfaces with capscrews (10) and torque tighten to 153 Nm (113 lbf ft).
4. Use suitable lifting equipment to support driveline (4).
5. Position driveline assembly (4) on the vehicle and align match marks on universal joints
with those on their mating surfaces.
6. Apply Loctite 648 to the threads of bolts (11). Secure universal joints to their mating
surfaces with bolts (11) and torque tighten to 153 Nm (113 lbf ft).
7. Use suitable lifting equipment to support driveline (7).
8. Position driveline assembly (7) on the vehicle and align match marks on universal joints
with those on their mating surfaces.
9. Apply Loctite 648 to the threads of cap screws (10). Secure universal joints to their mating
surfaces with cap screws (10) and torque tighten to 153 Nm (113 lbf ft).

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 Drivelines 8

10. Install anti-flail guard assembly to the crossmember (15, Figure 7.1). Torque tighten bolts
(16, Figure 7.1) to 185 Nm (136 Ibf ft).
11. Ensure the parking brake is applied and remove wheel chocks from all road wheels.

(7) Special Tools

There are no special tools required for procedures outlined in this section. Refer to 22.2 Service
Tools on page 22-4, for part numbers of general service tools and adhesives required. These
tools and adhesives are available from your dealer.
(8) Driveline Diagnosis Chart
Table 8.1 - Driveline Diagnosis Chart
CONDITION REASON REMEDY
Vibration or noise Driveline bent or out of Clean driveline in a suitable
balance 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 and bolts for
tightness. If loose, replace
and torque tighten to the
proper specification.
Excessive wear of Poor yoke/flange alignment Check yoke/flange for
and/or run-out alignment, run-out and
universal joints
balance. Repair or replace
as required.
Driveline imbalance Check to see if balance
weights are missing or if
driveline is distorted. If
driveline is distorted, replace;
if weights are missing,
check balance of driveline
dynamically and rebalance.

(9) Special Torque Specifications

Table 8.2 - Special Torque Specifications
FIG. NO. ITEM NO. ITEM NAME TORQUE
Nm lbf ft
Figure 8.1 10 Cap Screw 153 113
Figure 8.1 11 Bolt 153 113
Figure 7.1 16 Bolt 185 136

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8 Drivelines

8.2 Rear Drivelines

2 3
3 2 5 6 7 5 6
4
MOT05111

Figure 8.4 - Rear Drivelines

1. Driveline - 8.5 C Pivot 4. Centre Axle 7. Driveline - 7 C Centre Axle
Point to Centre Axle to Rear Axle
2. Universal Joint 5. Universal Joint 8. Rear Axle
3. Bolt 6. Bolt

(1) Description

� CAUTION
• Extra care must be taken when handling drivelines. Carelessness can result in premature
failure of the components. Chips, dents, burrs, or any other deformity of universal joints will
prevent accurate alignment. Misalignment will result in vibration and excessive wear.

Numbers in parentheses refer to Figure 8.4, unless otherwise specified.

The function of the driveline is to transmit rotating power from one point to another in a
smooth and continuous action while allowing a degree of movement or misalignment of the
components it connects.
The drivelines must operate through constantly changing relative angles between the
components they are mounted to and must also be capable of changing length while
transmitting torque.
A typical driveline consists of universal joints which allow some misalignment and permit the
driveline to pivot in any direction and a light rigid hollow slip yoke and splined shaft assembly
forming a slip joint.
The slip joint accommodates length variations generated during operation, preventing tension
or compression loads from causing serious damage to the components.
There are two driveline assemblies connecting the centre and rear axles to the drive supplied
from the transmission, through the pivot drive arrangement, as follows:
Driveline assembly (1) is connected between the articulation and oscillation pivot and the
centre axle.
Driveline assembly (7) is connected between the centre axle and the rear axle.

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 Drivelines 8

(2) Removal
Numbers in parentheses refer to Figure 8.4, unless otherwise specified.

� DANGER
• To prevent serious injury or death, DO NOT go under the vehicle when the engine is
running. Rotating shafts are dangerous. You can snag clothes, skin, hair, hands, etc.

� WARNING
• Ensure that wheel chocks, blocking materials and lifting equipment are properly secured
and of adequate capacity to do the job safely. This will prevent personal injury and property
damage.

� CAUTION
• Disconnecting or removing any of the rear drivelines will make the parking brake ineffective.
• When the Battery Master Switch is selected OFF the red light adjacent to the switch
remains ON for 60 seconds. Be aware that when the light is ON electrical power is still
connected to the truck.
• Extra care should be taken when handling drivelines since carelessness can result in
premature failure of the components. Chips, dents, burrs, or any other deformity of
universal joints will prevent accurate mating. This will cause misalignment which is
accompanied by vibration and excessive wear.
• Access to driveline assemblies (1 and 7) can be obtained from underneath the vehicle.

PROCEDURE
1. Position the vehicle in a level work area, apply the parking brake and switch off the engine.
Depress the brake pedal continuously to relieve any pressure in the braking circuit. Turn
the steering wheel several times to relieve any pressure in the steering circuit.
2. Block all road wheels and place the battery master switch in the OFF position.
3. Match mark universal joints and their mating surfaces to ensure correct mating alignment
when installing driveline assembly (1).
4. Remove bolts (3) securing universal joints (2) to their mating components and remove
driveline assembly (1). If necessary tap driveline assembly (1) from its mating components
with a soft faced hammer.
5. Use suitable lifting equipment to support driveline (1).
6. Match mark universal joints and their mating surfaces to ensure correct mating alignment
when installing driveline assembly (7).
7. Use suitable lifting equipment to support driveline (7)
8. Remove bolts (6) securing universal joints (5) to their mating components and remove
driveline assembly (7). If necessary tap driveline assembly (7) from its mating components
with a soft faced hammer.

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8 Drivelines

(3) Universal Joint Disassembly

MOT05109

Figure 8.5 - Universal Joint Removal

1. Capscrew

Numbers in parenthesis refer to Figure 8.4, unless otherwise specified.

� CAUTION
• Do not use excessive force when clamping the tube of the driveshaft. Excessive force
will result in damage to the tube.

NOTICE
• The capscrews that secure drivelines (1) and (7) are not interchangeable.

PROCEDURE
1. Place the yoke end of driveline assembly (1) in a soft jawed vice, clamping on the tube of
the shaft.
2. Remove capscrews (1, Figure 8.5) and universal joint from driveline assembly (1).
3. Place the shaft end of driveline assembly (1) in a soft jawed vice.
4. Remove capscrews (1, Figure 8.5) and universal joint from driveline assembly (1).
5. Repeat steps 1 to 4 for driveline (7).

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 Drivelines 8

(4) Inspection

PROCEDURE
1. Clean all metal parts in a suitable solvent, and dry all parts with compressed air.
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 file or medium India
stone.
3. Check the surfaces of the components that universal joints mate against for parallelism.
Refer to Figure 8.3.
4. Check condition of mounting capscrews and replace if required.

(5) Universal Joint Assembly

Numbers in parentheses refer to Figure 8.4, unless otherwise specified.

� CAUTION
• Do not use excessive force when clamping the tube of the driveshaft. Excessive force
will result in damage to the tube.

PROCEDURE
1. Place the yoke end of driveline assembly (1) in a soft jawed vice, clamping on the tube of
shaft.
2. Install universal joint to yoke end of driveline assembly (1) and secure with screws (3)
and bolts (8).
3. Place the shaft end of driveline assembly (1) in a soft jawed vice.
4. Install universal joint to shaft end of driveline assembly (1) and secure with screws (3)
and bolts (8).
5. Repeat steps 1 to 4 for driveline (4).

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8 Drivelines

(6) Installation
Numbers in parentheses refer to Figure 8.4, unless otherwise specified.

� DANGER
• To prevent serious injury or death, DO NOT go under the vehicle when the engine is
running. Rotating shafts are dangerous. You can snag clothes, skin, hair, hands, etc.

� CAUTION
• 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.
• Disconnecting or removing any of the rear drivelines will make the parking brake ineffective.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in Section,
Standard Bolt and Nut Torque Specifications.
• Extra care should be taken when handling drivelines since carelessness can result in
premature failure of the components. Chips, dents, burrs, or any other deformity of
universal joints will prevent accurate mating. This will cause misalignment which is
accompanied by vibration and excessive wear.
• Access to driveline assemblies (1 and 7) can be obtained from underneath the vehicle.

PROCEDURE
1. Use suitable lifting equipment to support driveline (1).
2. Position driveline assembly (1) on the vehicle as shown in Figure 8.4 and align match
marks on universal joints with those on their mating surfaces.
3. Apply Loctite 648 to the threads of bolts (3). Secure universal joints (2) to their mating
surfaces with bolts (3) and torque tighten to 153 Nm (113 lbf ft).
4. Use suitable lifting equipment to support driveline (7).
5. Position driveline assembly (7) on the vehicle as shown in Figure 8.4 and align match
marks on universal joints with those on their mating surfaces.
6. Apply Loctite 648 to the threads of bolts (6). Secure universal joints (5) to their mating
surfaces with bolts (6) and torque tighten to 153 Nm (113 lbf ft).
7. Ensure the parking brake is applied and remove wheel blocks from all road wheels.

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 Drivelines 8

(7) Special Tools

There are no special tools required for procedures outlined in this section. Refer to 22.2 Service
Tools on page 22-4, for part numbers of general service tools and adhesives required. These
tools and adhesives are available from your dealer.
(8) Driveline Diagnosis Chart
Table 8.3 - Driveline Diagnosis Chart
CONDITION REASON REMEDY
Vibration or noise Driveline bent or out of Clean driveline in a suitable
balance solvent. Inspect for contact
with adjacent parts. If
driveline is distorted or
sprung, replace. If driveline
does not run smoothly, and
vibration is felt, remove
driveline and dynamically
balance the assembly.
Driveline loose at yoke/flange Check driveline mounting
capscrews for tightness. If
loose, replace capscrews
and torque tighten to the
proper specification.
Excessive wear of Poor yoke/flange alignment Check yoke/flange for
alignment, run-out and
universal joints and/or run-out
balance. Repair or replace
as required.
Driveline imbalance Check to see if balance
weights are missing or if
driveline is distorted. If
driveline is distorted, replace;
if weights are missing,
check balance of driveline
dynamically and rebalance.

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8 Drivelines

Intentionally Left Blank

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 Axle Group 9

Table of Content
9 Axle Group ..................................................................................................9-1
9.1 Differential Lock Controls ............................................................................... 9-3
(1) Description and Operation......................................................................... 9-3
(2) Removal and Disassembly ........................................................................ 9-5
(3) Assembly and Installation.......................................................................... 9-7
(4) Pressure Checks ....................................................................................... 9-8
(5) Maintenance .............................................................................................. 9-9
(6) Special Tools ............................................................................................. 9-9
9.2 Front Axle Group.......................................................................................... 9-10
(1) Front Axle ................................................................................................ 9-10
(a) Description .......................................................................................... 9-11
(b) Removal.............................................................................................. 9-12
(c) Installation........................................................................................... 9-13
(2) Differential Drive Head ............................................................................ 9-14
(a) Description .......................................................................................... 9-14
(b) Operation ............................................................................................ 9-15
(c) Removal.............................................................................................. 9-16
(d) Disassembly........................................................................................ 9-17
(e) Inspection............................................................................................ 9-19
(f) Assembly ............................................................................................ 9-19
(g) Installation........................................................................................... 9-29
(h) Gleason Gear Tooth System............................................................... 9-29
(i) Maintenance ....................................................................................... 9-31
(j) Special Tools....................................................................................... 9-31
(k) Diagnosis ............................................................................................ 9-31
(l) Diagnosis Chart .................................................................................. 9-32
(m) Special Torque Specifications ............................................................. 9-32
9.3 Centre Axle Group ....................................................................................... 9-33
(1) Centre Axle.............................................................................................. 9-33
(2) Removal .................................................................................................. 9-35
(3) Installation ............................................................................................... 9-37
(4) Differential Drive Head ............................................................................ 9-38
(a) Description .......................................................................................... 9-38
(b) Removal.............................................................................................. 9-41
(c) Disassembly........................................................................................ 9-42
(d) Inspection............................................................................................ 9-49
(e) Assembly ............................................................................................ 9-50
(f) Installation........................................................................................... 9-69
(g) Gleason Gear Tooth System............................................................... 9-70
(h) Maintenance ....................................................................................... 9-71
(i) Special Tools....................................................................................... 9-71
(j) Diagnosis ............................................................................................ 9-71
(k) Diagnosis Chart .................................................................................. 9-72
(l) Special Torque Specifications ............................................................. 9-73
9.4 Rear Axle Group .......................................................................................... 9-74
(1) Rear Axle................................................................................................. 9-74
(2) Removal .................................................................................................. 9-76
(3) Installation ............................................................................................... 9-77

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9 Axle Group

(4) Differential Drive Head ............................................................................ 9-78

(a) Description .......................................................................................... 9-78
(b) Operation ............................................................................................ 9-80
(c) Removal.............................................................................................. 9-80
(d) Disassembly........................................................................................ 9-82
(e) Inspection............................................................................................ 9-88
(f) Assembly ............................................................................................ 9-89
(g) Installation......................................................................................... 9-104
(h) Gleason Gear Tooth System............................................................. 9-105
(i) Maintenance ..................................................................................... 9-106
(j) Special Tools..................................................................................... 9-106
(k) Diagnosis .......................................................................................... 9-107
(l) Diagnosis Chart ................................................................................ 9-107
(m) Special Torque Specifications ........................................................... 9-108
9.5 Axle Group/Hub.......................................................................................... 9-109
(1) Operation............................................................................................... 9-109
(2) Removal and Disassembly .................................................................... 9-110
(3) Inspection .............................................................................................. 9-114
(4) Assembly and Installation...................................................................... 9-114
(5) Maintenance .......................................................................................... 9-121
(6) Special Tools ......................................................................................... 9-121
(7) Axle Diagnosis....................................................................................... 9-122
(8) Diagnosis Chart ..................................................................................... 9-122
(9) Special Torque Specifications................................................................ 9-122
9.6 Wheel Rim and Tire.................................................................................... 9-123
(1) Description and Operation..................................................................... 9-123
(2) Preparation for Servicing ....................................................................... 9-124
(3) Removing Tire and Rim Assembly from Machine.................................. 9-125
(4) Dismounting Tire from Rim .................................................................... 9-126
(5) Inspection .............................................................................................. 9-128
(6) Mounting Tire on Rim ............................................................................ 9-128
(7) Mounting Tire and Rim Assembly on Machine ...................................... 9-129
(8) Air Tire Inflation...................................................................................... 9-130
(9) Nitrogen Tire Inflation ............................................................................ 9-131
(10) Tire Explosion Hazard ........................................................................... 9-133
(11) Maintenance .......................................................................................... 9-134
(12) Tire Care................................................................................................ 9-135
(13) Service Tools ......................................................................................... 9-136
(14) Tire Pressures ....................................................................................... 9-136
(15) Tubeless Tire Leak Diagnosis ............................................................... 9-137
(16) Special Torque Specification ................................................................. 9-137

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 Axle Group 9

9 Axle Group
9.1 Differential Lock Controls

4
MOT04165

Figure 9.1 - Differential Lock Valve Assembly

1. Solenoid (CT1) 3. Elbow - Port P 5. Port T T–piece
2. Diff Lock Valve 4. Elbow - Port B

(1) Description and Operation

Numbers in parentheses refer to Figure 9.1, unless otherwise specified.
The Differential Lock Valve is mounted on a bracket on the exhaust mounting cradle. The
purpose of the valve is to, when actuated, allow hydraulic pressure to flow to each axle to
activate the cross axle differential locks.
The dropbox incorporates a torque splitting cross-axle (Fore / Aft) differential lock that is applied
by the operator when operating conditions are severe and maximum torque to all drive axles is
required to maintain momentum. The application of this device shall lock front and rear axles to
a 1:1 torque that will maximize traction until the machine has exited the severe condition.
The cross-axle differential locks can be selected at any time (Figure 9.2). Engagement will
happen when machine speed is <less than 5 km/h. Differential locks will disengage when the
machine speed is >greater than 15 km/h. This safeguards the machine’s drivetrain at high
speeds engagement. The warning lamp on the main display will illuminate when differential
lock is engaged (Figure 9.3).

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9 Axle Group

MOT05131 MOT05132

Figure 9.2 - Dropbox Differential Lock Figure 9.3 - Dropbox Differential Lock
Request Switch Warning

MOT04167

Figure 9.4 - Differential Lock Schematic

1. Main Hydraulic Valve 4. Tank Return Line 7. Center Axle
Port ‘DL’ Diff Lock Port
2. Dropbox Control Valve 5. Diagnostic Plate
Port ‘P1’ ’DP5’
3. Emergency Steering Valve 6. Manifold Plate
Port ‘D’

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 Axle Group 9

(2) Removal and Disassembly

13
9

10

28
23

18
19
29

24
25
8

11

17
22

14
15
16
21
7

12
26
20

27
5
6

MOT05133

Figure 9.5 - Differential Lock Hoses

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9 Axle Group

1. Hose Assembly 11. Dropbox Control Valve 21. Elbow

2. Hose Assembly 12. Manifold Plate 22. Elbow
3. Hose Assembly 13. Diagnostic Plate 23. O-Ring
4. Hose Assembly 14. Washer 24. Elbow
5. Hose Assembly 15. Lockwasher 25. Adaptor
6. Emergency Steering Valve 16. Bolt 26. Tee
Block
7. Differential Lock Valve 17. Diagnostic Hose 27. Adaptor
8. Exhaust Cradle 18. Diagnostic Hose 28. Tee
9. Tank Return Tube 19. Diagnostic Hose 29. Adaptor
10. Main Hydraulic Valve 20. Tee

Numbers in parentheses refer to Figure 9.5, unless otherwise specified.

� 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 perform the task
safely.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains on for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

NOTICE
• On dismantling, clean all parts in paraffin or suitable cleaner, place on a clean work surface.

PROCEDURE
1. Apply the parking brake and switch off the engine.
2. Block the appropriate road wheels, place the steering lock bar in the 'Locked' position and
the battery master switch in the 'OFF‘ position.
3. Turn steering wheel in both directions several times to relieve pressure in accumulator
and steering system. Block all road wheels.
4. With a suitable container in position, remove drain plug from bottom of hydraulic tank and
drain the oil. Reinstall the drain plug and tighten securely.
5. Identify, tag and remove the following hydraulic hoses:
a. Main Hydraulic Valve connection ‘DL’ (3) - Differential Valve port ‘P’
b. Tank Return Line connection (1) - Differential Valve port ‘T’ (Tee, 20)
c. Emergency Steering Valve Block port ‘D’ (5) - Differential Valve port ‘T’ (Tee, 20)
d. Rear Axle connection, Manifold Plate (12, Tee, 26) (2) - Differential Valve port ‘B’
6. Ensure all hoses are capped and valve ports are plugged.
7. Disconnect electrical harness connection WA4.Q29.X1 - Differential Valve connection ‘CT1’.
Cap both electrical connectors, to prevent ingress of dirt.

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 Axle Group 9

8. Note the orientation of the valve on the machine and the corresponding hose/elbow
connections to aid in installation.
9. Remove bolts (16), lockwashers (15) and washers (14) securing the differential lock valve
(7) to the exhaust cradle assembly (8).
10. Remove the differential lock valve (7).
11. Remove Tee (20) and Elbow’s (21 and 22).
12. Thoroughly clean all parts with a suitable solvent and dry with compressed air.
13. Inspect all parts for damage or excessive wear and replace where necessary.
14. O-rings should be replaced with new when reinstalling the valve block to the machine.

(3) Assembly and Installation

Numbers in parentheses refer to Figure 9.5, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure wheel blocks, blocking materials
and lifting equipment are properly secured and of adequate capacity to perform the task
safely.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Install Elbow’s (21 and 22) and Tee (20), ensure correct orientation to the differential valve
(7). Torque tighten to 20 Nm (15 lbf ft).
2. Install bolts (16), lockwashers (15) and washers (14) and secure the differential lock valve
to the exhaust cradle (8).
3. Remove caps and connect electrical harness connection WA4.Q29.X1 - Differential Valve
connection ‘CT1’.
4. Remove all caps from the hydraulic hoses, valve ports and adaptors.
5. Install the following hydraulic hoses:
a. Rear Axle connection, Manifold Plate (12, Tee, 26) (2) - Differential Valve port ‘B’.
Torque tighten to 27 Nm (20 lbf ft).
b. Emergency Steering Valve connection ‘D’ (5) - Differential Valve port ‘T’ (Tee, 20).
Torque tighten to 37 Nm (27 lbf ft).
c. Tank Return Line connection (1) - Differential Valve port ‘T’ (Tee, 20).
Torque tighten to 37 Nm (27 lbf ft).
d. Main Hydraulic Valve connection ‘DL’ (3) - Differential Valve port ‘P’.
Torque tighten to 27 Nm (20 lbf ft).
6. Fill the steering and brake control tank with clean hydraulic oil specified in (1) Recommended
Lubricants on page 4-16. Refer to (1) Checking Oil Level on page 11-70 for correct oil level.
7. Once installed, check the integrity of the circuit, ensuring that there are no leaks or
problems.

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9 Axle Group

8. Ensure the system is working to the correct pressures. Where appropriate, carry out
pressure adjustments. Refer to (4) Pressure Checks on page 9-8.

(4) Pressure Checks

MOT05033

Figure 9.6 - Diagnostic Pressure Check Points Left Hand Fender

1. Dropbox Difflock - 9. Pilot Raise - 18. Steering -
TP1 TPA TPO
2. Dropbox Lubrication - 10. Pilot Lower - 19. Accumulator No.1
TP3 TPB
3. Dropbox High Ratio - 11. Transmission - 20. Accumulator No.2
GS1 TS
4. Dropbox Low Ratio - 13. Parking Brake 21. Accumulator No.3
GS2
5. Cross-Axle Difflock 14. Hydraulic Pump-Front - 22. Brakes-Front
TP1
7. Body Hoist Raise - 15. Hydraulic Pump-Rear - 23. Brakes-Rear
A TP2
8. Body Hoist Lower - 16. Load Sense Pump -
B LSP

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 Axle Group 9

NOTICE
• Differential lock pressure can only be checked with the differential lock NOT actuated.
While the differential lock is actuated, the diagnostic point is vented to the tank via hose
(1, Figure 9.5).

The dropbox differential lock actuation pressure, 35 - 42 bar (500 - 609 psi), is set on the main
hydraulic valve. Refer to (1) Description on page 11-3.
Differential lock pressure can be checked at the diagnostic plate (DP1) (refer to, Figure 9.6).
Install a pressure gauge capable of reading at least 240 bar (3 500 psi).
The axle differential lock pressure, 25 bar (362 psi), is maintained set by ‘CT21’ on the main
hydraulic valve. Refer to (1) Description on page 11-3.
Axle differential lock pressure can be checked at the diagnostic plate (DP5) (refer to, Figure
9.6). Install a pressure gauge capable of reading at least 240 bar (3 500 psi).
(5) Maintenance
Limited maintenance of the valve block is available. Ensure pressures are set correctly
periodically. Refer to Figure 9.6.
(6) Special Tools
The special tools referenced throughout this section are available from your dealer. Refer to
Service Tools section, for part numbers of general service tools and sealants required.

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9 Axle Group

9.2 Front Axle Group

(1) Front Axle

1 3 4 TO FRAME

8
9
7
10
12
11

6
5 MOT05135

Figure 9.7 - Front Axle

1. Front Axle Complete 5. Oil Drain - Plug (Hub) 9. OCDB Pump - Plug
2. Adaptor 6. Oil Fill - Plug (Hub) 10. Brake Actuation
3. Hose - Breather 7. Oil Drain - Plug (Axle) 11. OCDB Pump - Plug
4. Adaptor 8. Oil Fill - Plug (Axle) 12. Breather - Plug (Hub)

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 Axle Group 9

27

MOT05146

Figure 9.8 - Front Axle Casing

1. Screw 10. Plug Assembly 19. Shaft - Stub 1294 MM
2. Washer 11. Plug 20. Scraper Plate - LH
3. Pin 12. O-Ring 21. Scraper Plate - RH
4. Pin 13. Plug 22. Bolt
5. Screw 14. Seal 23. Washer
6. Plug 15. Plate 24. Plug - Button
7. O-Ring 16. Valve - Vent 25. Loctite
8. Plug - Screw 17. Axle Casing 26. Loctite - 243
9. O-Ring 18. Shaft - Stub 1384 MM 27. Hub Carrier

(a) Description
The front axle is in permanent all-wheel drive, with a differential coupling between the forward
and rear drivelines.
The front axle also includes an automatic limited slip differential, this splits the required torque
across the axle to each wheel limiting the risk of wheel spin.
The front axle assembly is installed at the front frame assembly in conjunction with the front
suspension assembly. Refer to 16.1 Frames on page 16-3 and 17.1 Front Suspension on
page 17-2.

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9 Axle Group

(b) Removal
Numbers in parentheses refer to Figure 9.7, unless otherwise specified.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

� 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.

PROCEDURE
1. Position the vehicle in a level work area, ensure the body is fully lowered, apply the parking
brake and switch off the engine. Turn steering wheel several times to relieve any pressure
in the steering system.
2. Block rear road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'Off' position.
3. Whilst the front road wheels are still on the ground, loosen the wheel nuts. Refer to 9.6
Wheel Rim and Tire on page 9-123.
4. Using suitable lifting equipment, raise the machine until both front tires are off the ground.
Support the vehicle with suitable stands and blocking at the tractor frame and articulation
pivot area.
5. Support one tire and rim assembly with suitable lifting equipment and remove wheel nuts
securing the rim to the axle. Remove tire and rim assembly. Repeat for the opposite tire.
Refer to 9.6 Wheel Rim and Tire on page 9-123.
6. Remove sump guards from front frame assembly if necessary. Refer to 16.1 Frames on
page 16-3.
7. Using a suitable container to catch any oil, identify, tag and remove the following hydraulic
hoses:
Brake Lines
Refer to (5) Hose Removal on page 14-42.
a. OCDB Manifold connection ‘C1’(18) - Brake Hub LH actuation line ‘RH’ port.
b. Axle Bracket connection (62) - Brake Hub LH bleed line ‘LH’ port
c. OCDB Manifold connection ‘C2’(18) - Brake Hub RH actuation line ‘RH’ port.
d. Axle Bracket connection (62) - Brake Hub LH bleed line ‘RH’ port
Brake Cooling Lines
a. OCDB Manifold connection ‘X’(6) - Brake Hub LH cooling line ‘Bottom’ port.
b. OCDB Manifold connection ‘Y’(7) - Brake Hub LH cooling line ‘Top’ port.
c. OCDB Manifold connection ‘B1’(6) - Brake Hub RH cooling line ‘Bottom’ port.
d. OCDB Manifold connection ‘B2’(7) - Brake Hub RH cooling line ‘Top’ port.
Axle Bleed Line
a. Front Frame connection (3) - Axle bleed line ‘Axle differential port’.
Install protective caps to all connections and ports to prevent ingress of dirt.
8. Using suitable lifting equipment, support the axle.

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 Axle Group 9

9. Remove the front driveline (7, Figure 8.1). Refer to (2) Removal on page 8-3.
10. Remove the Axle and Suspension assembly from the front frame assembly. Refer to 17.1
Front Suspension on page 17-2.

(c) Installation
Numbers in parentheses refer to Figure 9.7, unless otherwise specified.

� 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.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Using suitable lifting equipment, support the axle assembly.
2. Install the Axle and Suspension assembly to the front frame assembly. Refer to 17.1 Front
Suspension on page 17-2.
3. Install the front driveline (7, Figure 8.1). Refer to (6) Installation on page 8-8.
4. Identify, remove protective caps and install the following hydraulic hoses:
Axle Bleed Line
a. Front Frame connection (3) - Axle bleed line ‘Axle differential port’.
Torque tighten to 22 Nm (16.2 lbf ft).
Brake Cooling Lines
Refer to 18.1 Description on page 18-2.
a. OCDB Manifold connection ‘B2’(7) - Brake Hub RH cooling line ‘Top’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
b. OCDB Manifold connection ‘B1’(6) - Brake Hub RH cooling line ‘Bottom’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
c. OCDB Manifold connection ‘Y’(7) - Brake Hub LH cooling line ‘Top’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
d. OCDB Manifold connection ‘X’(6) - Brake Hub LH cooling line ‘Bottom’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
Brake Lines
Refer to (6) Hose Installation on page 14-51.
a. Axle Bracket connection (62) - Brake Hub LH bleed line ‘RH’ port.
Torque tighten to 35 Nm (25.8 lbf ft).
b. OCDB Manifold connection ‘C2’(18) - Brake Hub RH actuation line ‘RH’ port.
Torque tighten to 55 Nm (40.6 lbf ft).
c. Axle Bracket connection (62) - Brake Hub LH bleed line ‘LH’ port.
Torque tighten to 35 Nm (25.8 lbf ft).
d. OCDB Manifold connection ‘C1’(18) - Brake Hub LH actuation line ‘RH’ port.
Torque tighten to 55 Nm (40.6 lbf ft).

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9 Axle Group

5. Install sump guards to front frame assembly if necessary. Refer to Figure 16.1.
6. Fill and bleed the brake system. Refer to (1) Checking Oil Level on page 11-70.
7. Fill, bleed and test the OCDB cooling system. Refer to 14.1 Description on page 14-4.
8. Support one tire and rim assembly with suitable lifting equipment and install the wheel and
rim assembly to the axle. Secure the tire and rim assembly. Repeat for the opposite tire.
Refer to 9.6 Wheel Rim and Tire on page 9-123.
9. Lower the machine until both front tires are on the ground. Remove lifting equipment,
stands and blocking at the tractor frame and articulation pivot area.
10. Torque tighten the wheel nuts. Refer to 9.6 Wheel Rim and Tire on page 9-123.

(2) Differential Drive Head

Figure 9.9 - Sectional View of Typical Differential

1. Bearing Adjuster 5. Ring Gear A. Spider Differential
2. Housing 6. Spider (Pinion) Gear B. Limited Slip Differential
3. Pinion Gear (Drive) 7. Side Gear
4. Drive Flange 8. Differential Case Assembly

(a) Description
Numbers in parentheses refer to Figure 9.9, unless otherwise specified.
Figure 9.9 illustrates both a standard pinion gear and spider differential (A) and a limited slip
type (B). Basically the differential consists of pinion gear (3) and ring gear (5). The differential is
a spiral bevel ring gear type with an automatically operating limited slip element (B).
The differential is mounted to the axle housing. The driveline yoke attaches directly to
differential flange (4) which is splined to the shaft of pinion gear (3).

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 Axle Group 9

Limited Slip Assembly

Numbers in parentheses refer to Figure 9.10, unless otherwise specified.
The limited slip assembly consists of housing (1), thrust washers (2 & 11), externally splined
discs (3), internally splined discs (4), thrust ring (5), side gears (6), pinion gears (7), differential
axle (8) and cover (9).

Figure 9.10 - Exploded View of Limited Slip Assembly

1. Cover 5. Thrust Ring 9. Housing
2. Thrust Washers (Steel) 6. Side Gears 10. Bolts
3. Externally Splined Discs 7. Pinion Gears 11. Thrust Washers (Brass)
4. Internally Splined Discs 8. Differential Axle 12. Capscrews

(b) Operation
Numbers in parentheses refer to Figure 9.10, unless otherwise specified.
Pinion gear (3, Figure 9.9) is mated with ring gear (5, Figure 9.9) which is bolted to differential
case assembly (8, Figure 9.9).
When both drive wheels are free to turn under equal resistance loads, ring gear (5, Figure 9.9)
and four small pinion (spider) gears (6, Figure 9.9) act as one rigid unit, transmitting torque to
both splined side gears (6). Side gears (6), being splined to the axle shafts, then drive each
rear wheel with the same amount of torque at identical rates of speed. In this instance, pinion
gears (7) do not rotate on their axis, therefore, side gears (6) rotate at the same rev/min as
ring gear (5, Figure 9.9).

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9 Axle Group

When resistance on one drive wheel exceeds the resistance on the other, or when the vehicle
makes a turn creating the same effect, one gear continues to revolve but pinion gears (7) cease
to act rigidly with it. Pinion gears (7) now rotate on their own axis, permitting one drive wheel to
rotate at a different speed from the other. Since the ratio of the pinion and side gear assembly is
approximately 2 to 1, the result is that as one drive wheel slows down, the speed of the other
proportionately increases. This prohibits the application of a torsional load to either axle, which
is greater than that existing during normal operation.
Thus pinion gears (7) serve a dual purpose:
• They allow a differential in speed between the two drive wheels, permitting maximum
manoeuvrability.
• They prohibit the application of all torque to one axle shaft.
(c) Removal
Numbers in parentheses refer to Figure 9.11, unless otherwise specified.

� 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.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

PROCEDURE
1. Before attempting to remove the front axle differential, drive the vehicle onto a level, solid
concrete floor, preferably after a short run to warm the oil.
2. Apply the parking brake and switch off the engine.
3. Block all road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'OFF‘ position.
4. Remove the front axle. Refer to (b) Removal on page 9-12.
5. Drain the gear oil out of the axle housing and both planetaries into a suitable container.
6. Remove the planetary assemblies and axle shafts from the axle housing. Note from which
side the long and short axle shafts (18 and 19, Figure 9.8) are removed. Refer to 9.5
Axle Group/Hub on page 9-109.
7. Index mark differential housing (2) and the axle housing to ensure that differential housing
(2) is installed in the same position.
8. Remove bolts (1) from the differential and axle housings. Thread in three puller bolts to
break the seal between the differential and axle housings and to partially pull the differential
assembly out of the axle housing.
9. Using suitable lifting equipment, support the weight of the differential assembly.
10. Remove the differential assembly and transport to a suitable clean maintenance area.

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 Axle Group 9

(d) Disassembly
Numbers in parentheses refer to Figure 9.11 and Figure 9.12, unless otherwise specified.

16

6
2 7 9
10

10
9 8
4
5
11
15
14

12
13

MOT05145

Figure 9.11 - Exploded View of Front Differential

26 26
24

17

25
26
23
29
22
21
22
21

20
18
19 28
A
B
19
27
20

21
22
21
22

23

25
MOT05197

Figure 9.12 - Exploded View of Limited Slip Differential

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9 Axle Group

1. Bolt 11. Seal - Shaft 21. Clutch Disc

2. Axle Housing 12. Washer 22. Disc
3. Roller Bearing 13. Nut 23. Ring
4. Washer - Shim 14. Flange - Input 24. Differential Axle
5. Roller Bearing 15. Protector - Dust 25. Bevel Gear
6. Washer - Shim 16. Bevel Gear - Set 26. Bevel Gear - Differential
7. Bearing 17. Limited Slip Differential 27. Cover - Housing
8. Roller Bearing 18. Differential Housing 28. Capscrew
9. Nut -Adjusting 19. Washer - Thrust 29. Screw
10. Pin - Slot 20. Washer - Thrust

� 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.

NOTICE
• The following removal procedure assumes the complete axle assembly was removed
from the vehicle.

PROCEDURE
1. Ensure oil is drained from the axle casing. Refer to Figure 9.7.
2. Ensure both planetary assemblies and axle shafts have been removed. Refer to 9.5 Axle
Group/Hub on page 9-109.
3. Ensure the differential assembly has been removed from the axle housing. Refer to (c)
Removal on page 9-16.
4. Loosen ring gear (16) bolts as shown in Figure 9.13.
5. Remove slotted pins (10) before loosening adjusting nuts (9) as shown in Figure 9.14.

SM2951 SM2952 SM2953

Figure 9.13 - Removing Figure 9.14 - Removing Figure 9.15 - Removing

Ring Gear Bolts Adjusting Nuts Bearing Caps

6. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
the area around the threaded holes and loosen bolts securing bearing caps. Remove
bearing caps. Refer to Figure 9.15.
7. Lift the differential assembly out of differential housing (2) with the special tool (15269929
Lifting Pliers) as shown in Figure 9.16.

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 Axle Group 9

SM858

Figure 9.16 - Removing Figure 9.17 - Removing Figure 9.18 - Differential

Differential Bearing Inner Rings Components

8. Remove both bearings (8 and 7) inner rings using special tools (15272560 Puller, 15500887
Gripping Insert, 15500888 Gripping Insert and 15500889 Reducer) as shown in Figure 9.17.
9. Remove capscrews (28) and separate housing (18) from cover (27). Remove single
components as shown in Figure 9.18.
10. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
the slotted nut (13) to around 120°C before loosening using special tool (15500890 Socket).
Remove slotted nut (13), washer (12) and drive flange (14).
11. Remove plate (15) and seal (11).
12. With the special tool (15269946 Puller Set), press the bevel gear (16) out of the bearing (5).
13. Pull off the bearing (3) inner race from the gear (16) using special tools (15500892 Gripping
Insert and 15272560 Bearing Puller).
14. Remove washer - shims (4) and spacing washer (6).

(e) Inspection

NOTICE
• If either ring gear or bevel gear is defective, both gears must be replaced, because they
are serviced only as a matched set. Make sure the ring gear and pinion gear have the
same mating numbers.

1 Clean all parts with a suitable solvent. Dry all parts, except bearings, with compressed air or
with soft, clean lint free cloths. DO NOT spin bearings with compressed air. Place bearings
on a clean surface, cover with lint free cloths and allow to dry.
2 Coat cleaned, dried parts immediately with light oil to prevent corrosion. If parts are not to
be assembled immediately, treat them with a good quality rust preventive and wrap them
with treated paper or suitable material designed to prevent corrosion.
3 Before installing the differential assembly into the axle housing, clean the inside and outside
of the axle housing to remove any debris or dirt.
4 Inspect all gears, pinions and splines for cracked or broken teeth, excessive wear, and
pitted or scored surfaces. Repair or replace as necessary.
5 Check for pitted, scored or worn thrust surfaces of differential case halves.
6 During assembly and installation, make sure that mated, punch marked or otherwise
identified parts are returned to their original positions, if still serviceable.
(f) Assembly
Numbers in parentheses refer to Figure 9.11 and Figure 9.12, unless otherwise specified.

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9 Axle Group

� 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.

� CAUTION
• To prevent personal injury, wear protective gloves when handling bearings.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.
• When tightening nut (13), rotate the pinion gear (16) in both directions several times.
• If necessary to change the outer externally splined discs (21) to obtain correct clearance,
these should be changed so that the overall thickness of disc sets A and B are identical. If
installing new discs, the lower clearance should be aimed for.
• Bearing adjusting nuts (9) have two basic functions: pre-loading the bearings and
positioning ring gear (16) to obtain the correct backlash between it and pinion gear (16).

PROCEDURE
1. Press bearing (5) outer race into housing (2) bore.
2. At this stage in the assembly procedure the thickness of spacing washer (6) must be
determined to ensure correct contact pattern between bevel gear (16) and ring gear (16).
As shown in Figure 9.19, measure Dimension 'A' from the mounting face of housing (22) to
the locating face of the bearing (5) outer ring, using special tools (15270113 Gauge Blocks,
15269948 Straight Edge and 15270114 Digital Depth Gauge).
3. As shown in Figure 9.20, use special tools (15500893 Shims, 15500894 Shims and
15269934 Measuring Shaft) and place shims into the bores of differential housing (2)
and assemble the measuring shaft.

SM2973
MOT05149 MOT05198

Figure 9.19 - Measuring Figure 9.20 - Assembling Figure 9.21 - Measuring

Dimension 'A' The Measuring Shaft Dimension 'B'

Eg. Dimension 'A' = 29.70 Eg. Dimension 'B' = 196.75

mm mm

4. Measure Dimension 'B' from mounting face of housing (2) to Measuring Shaft (see Figure
9.19).

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 Axle Group 9

Table 9.1 - Measuring Dimension 'B'

Example:
Dimension 'A' 29.70 mm
Dimension 'B' 196.75 mm
Dimension 'C' (1/2 diameter of 15.00 mm
Measuring Shaft)
Dimension 'X' = (A + B + C) 241.45 mm

5. Measure thickness of bearing (3) as shown in Figure 9.22 using special tools (15270113
Gauge Blocks and 15270114 Digital Depth Gauge). Record as Dimension 'D'.
6. The arrow in Figure 9.23 is pointing to a dimension stamped on the face of pinion gear
(16). Record as Dimension 'E'.

SM868 SM2975

Figure 9.22 - Measuring Bearing Thickness Figure 9.23 - Dimension On Pinion Face
Eg. Dimension 'D' = 42.70 mm Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm

Table 9.2 - Dimension On Pinion Face

Example:
Dimension 'D' 42.70 mm
Dimension 'E' 197.90 mm
Dimension 'Y' = (D + E) 240.60 mm

7. Calculate spacing washer (6) thickness by subtracting Dimension 'Y' from Dimension 'X'.
Install spacing washer (6). Refer to Figure 9.24.
Table 9.3 - Spacing Washer Thickness
Example:
Dimension 'X' 241.45 mm
Dimension 'Y' 240.60 mm
Required thickness = (X - Y) 0.85 mm

8. Freeze bearing (3) outer race and install in housing (2), ensuring it is firmly home. Refer
to Figure 9.25.

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9 Axle Group

Figure 9.24 - Installing Spacing Washer Figure 9.25 - Installing Bearing Outer Race

9. Heat inner race of bearing (3) to approximately 90 °C (190 °F) and press it on to the
shaft of pinion gear (16). Be sure it is firmly seated against the shaft shoulder as shown
in Figure 9.26.
10. Install assembled pinion gear (16) in housing (2) using special tool (15269946 Puller Set)
as shown in Figure 9.27. Do not remove special tool at this point.

SM873 SM2978

Figure 9.26 - Installing Bearing Inner Race Figure 9.27 - Installing Pinion Gear

11. The adjusting ring (11) is used to obtain the rolling resistance of the pinion bearing. Rolling
resistance should be 3.5 - 4.0 Nm (2.6 - 2.9 lbf ft). This rolling resistance is checked once
pinion gear (16) is secured in housing (2) (Step 17). Install adjusting ring (11).
12. Heat inner race of bearing (5) to approximately 90 °C (190 °F) and press it on to the shaft
of pinion gear (16) until it is firmly home as shown in Figure 9.28. After bearing (23) inner
race has cooled, remove special tool installed in Step 13.
13. Coat threads of slotted nut (13) with Loctite 649. Install drive flange (14) washer (12) and
slotted nut (13). Using special tool (15500891 Socket) tighten slotted nut (13) to a torque
of 750 Nm (553 lbf ft). Refer to Figure 9.29. When tightening nut (13), rotate the pinion
gear (16) in both directions several times.

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 Axle Group 9

Figure 9.28 - Installing Bearing Figure 9.29 - Tightening Slotted Nut

14. Check the rolling resistance of the pinion bearing as shown in Figure 9.30 by using special
tool (15500895 Torque Spanner). If the rolling resistance is out with range (3.5 - 4.0 Nm),
adjusting ring (11) thickness must be changed.
15. Heat ring gear (16) and install it on the differential housing (18) until it is firmly home as
shown in Figure 9.31.

Figure 9.30 - Checking Rolling Resistance Figure 9.31 - Installing Ring Gear
Record this torque as Tpinion e.g. 3.5 Nm.

16. Prior to assembly, coat components with gear oil as specified in (1) Recommended
Lubricants on page 4-16. Place both thrust washers (19 and 20) in the housing (18),
installing steel thrust washer (19) first as shown in Figure 9.32.
17. Install disc set A in housing (18), beginning with externally splined disc (21) as shown
in Figure 9.32.

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9 Axle Group

20
19

SM3000
SM2999

Figure 9.32 - Installing Thrust Washers Figure 9.33 - Installing Disc Set A

18. Install thrust ring (23) as shown in Figure 9.34.

19. Install side gear (25) as shown in Figure 9.35. Ensure both internally splined discs (22) of
set A are located on side gear (25).

Figure 9.34 - Installing Thrust Ring Figure 9.35 - Installing Side Gear

20. Sub-assemble pinion gears (26) and differential axles (24). Install sub-assembly as shown
in Figure 9.36.
21. Install second side gear (25) as shown in Figure 9.37.

Figure 9.36 - Installing Differential Pinion Gears Figure 9.37 - Installing Side Gear

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 Axle Group 9

22. Install second thrust ring (23) as shown in Figure 9.34.

23. Install disc set B beginning with internally splined disc (22 as shown in Figure 9.39.

Figure 9.38 - Installing Thrust Ring Figure 9.39 - Installing Disc Set B

24. The clearance between the assembled differential housing and the cover (27) should be
0.2 - 0.6 mm. Press outer externally splined disc (21) evenly on and measure Dimension
'A' from the mounting face of housing (18) to the outer disc (21) as shown on Figure 9.40,
using special tool 15270114 Digital Depth Gauge).
25. Measure Dimension 'B' from the contact face to the mounting face of housing cover (27)
using special tool (15270114 Digital Depth Gauge) as shown in Figure 9.41.

Figure 9.40 - Measuring Differential Housing Figure 9.41 - Measuring Housing Cover
Clearance
Eg. Dimension 'A' = 4.30 mm Eg. Dimension 'B' = 4.00 mm

26. Calculate clearance as shown in the example below.

Table 9.4 - Clearance
Example:
Dimension 'A' 4.30 mm
Dimension 'B' 4.00 mm
Results in clearance = (A - B) 0.30 mm

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9 Axle Group

If clearance falls out with specification (0.2 - 0.6 mm), then thicker or thinner outer externally
splined discs (21) should be installed.
If necessary to change the outer externally splined discs (21) to obtain correct clearance,
these should be changed so that the overall thickness of disc sets A and B are identical.
If installing new discs, the lower clearance should be aimed for.
27. Place both thrust washers (19 and 20) in the cover (27), installing steel thrust washer
(19) first as shown in Figure 9.42.

Figure 9.42 - Installing Thrust Washers

28. Secure cover (27) to housing (18) with two capscrews (28). Torque capscrews to 46 Nm
(34 lbf ft).
29. Heat bearings (7 and 8) inner races and install on assembled differential, as shown in
Figure 9.43.
30. Using suitable lifting equipment, position the assembled differential in the differential
housing (2) and install bearings (7 and 8) outer rings, as shown in Figure 9.44.

Figure 9.43 - Installing Bearing Inner Race Figure 9.44 - Installing Differential

31. Install adjusting nuts (9) and locate bearing caps using bolts and washers as shown
in Figure 9.45. Coat thread of bearing cap bolts with Loctite 649. Torque bolts to 390
Nm (288 lbf ft).
Bearing adjusting nuts (10) have two basic functions: preloading the bearings and
positioning ring gear (16) to obtain the correct backlash between it and pinion gear (16).
32. Install new bolts (29) in differential assembly and torque bolts to 390 Nm (288 lbf ft) as
shown in Figure 9.46.

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 Axle Group 9

Figure 9.45 - Installing Bearing Caps Figure 9.46 - Tightening Differential Bolts

33. Check the backlash between ring gear and pinion gear (16). Mount special tools (15500897
Magnetic Stands and 15500898 Dial Indicator) at right angles to the outer diameter of the
ring gear tooth flank as shown in Figure 9.47. Establish the backlash by alternately setting
both adjusting nuts (9). Rock the ring gear back and forth being careful not to move the
pinion gear. Backlash should be 0.27 - 0.33 mm.
34. Determine the bearing (7 and 8) rolling resistance and bracket dimension by further
tightening of both adjusting nuts (9). The bearing rolling resistance should be 3 - 4 Nm
(2.2 - 2.9 lbf ft). Measure bracket dimension as shown in Figure 9.48 using 15500899
Micrometer. Dimension should be 358-0.1 mm.

Figure 9.47 - Measuring Backlash Figure 9.48 - Measuring Bracket Dimension

35. To check the tooth pattern of ring gear (16), coat about twelve ring gear teeth with prussian
blue, oiled red lead or some other easily removed print or 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 as shown in Figure 9.49.
Compare the contact pattern obtained with the Gear tooth patterns for the (h) Gleason
Gear Tooth System on page 9-29.
36. Fasten adjusting nuts (9) with slotted pins (10) as shown in Figure 9.50.

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9 Axle Group

SM891 SM3016

Figure 9.49 - Checking Contact Pattern Figure 9.50 - Installing Slotted Pin

37. Apply Loctite 574 to axle casing mounting face. Using suitable lifting equipment, install
differential assembly in axle casing and secure using new bolts (1). Torque bolts to 375 Nm
(277 lbf ft). Refer to Figure 9.252.

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 Axle Group 9

(g) Installation
Numbers in parentheses refer to Figure 9.11, unless otherwise specified.

� 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.

NOTICE
• Tighten all fasteners without specified torques to standard torques listed in 22.3 Standard
Bolt and Nut Torque Specifications on page 22-5.
• Use sealing compound (Loctite 574) between the axle housing and differential housing
mounting faces.

PROCEDURE
1. Using suitable lifting equipment, support the weight of the differential assembly.
2. Apply Loctite 574 to the mating surfaces of the differential and axle housings.
3. Position the differential assembly adjacent to the axle housing. Align the index marks on
the differential and axle housings and carefully install the differential assembly.
4. Apply Loctite 243 (26, Figure 9.8) to screws (1).
5. Install screws (1) and secure the differential assembly to the axle housing. Torque tighten
screws to 375 Nm (277 lbf ft).
6. Install the planetary assemblies and axle shafts to the axle housing. Note from which side
the long and short axle shafts are installed. Refer to Figure 9.261.
7. Fill the axle casing with gear oil of the type specified in (1) Recommended Lubricants on
page 4-16, through the differential filler/level hole (8, Figure 9.7) until the oil is level with
the bottom of the filler/level hole.
8. Check oil level after a few minutes to ensure level remains constant.

(h) Gleason Gear Tooth System

Ideal tooth-contact pattern shown in Figure 9.51 and Figure 9.52 indicating the pinion distance
is correct.

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9 Axle Group

Figure 9.51 - Coast Side (Concave) Figure 9.52 - Drive Side (Convex)

If the patterns obtained are the same as that shown in Figure 9.53 and Figure 9.54 then
decrease the pinion distance (Figure 9.55).

Figure 9.53 - Coast Side (Concave) Figure 9.54 - Drive Side (Convex)

Figure 9.55 - Pinion Distance must be Decreased

If the patterns obtained are the same as that shown in Figure 9.56 and Figure 9.57 then
increase the pinion distance (Figure 9.58).

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 Axle Group 9

Figure 9.56 - Coast Side (Concave) Figure 9.57 - Drive Side (Convex)

Figure 9.58 - Pinion Distance must be Increased

(i) Maintenance
Proper lubrication of the differential assembly is essential if the differentials are to deliver the
service intended. (1) Recommended Lubricants on page 4-16 section gives full information on
the proper lubrication intervals and the lubricant which should be used.
(j) Special Tools
The special tools referenced in this section are available from your dealer. Refer to 22.2 Service
Tools on page 22-4 section, for part numbers of general service tools and sealants required.
(k) Diagnosis

� WARNING
• Removing the axle shafts or drivelines will make the parking brake ineffective.
• 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.

Noises and vibrations originating in the tires, transmission, planetaries and drivelines are easily
transmitted and may be erroneously attributed to the differential. Therefore, all possible sources
of noise should be investigated before the differential is taken apart.
Whenever noises such as a grating or rattle are heard coming from the differential, stop the
unit immediately. One tooth from a gear can cause damage to all gears and bearings. When

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9 Axle Group

the differential is definitely at fault, remove the axle shafts and disconnect the driveline before
moving the vehicle.
(l) Diagnosis Chart
Table 9.5 - Diagnosis Chart
CONDITION REASON REMEDY
Vibration Broken gear teeth Replace damaged gear
Excessive run-out of pinion Disassemble, correct or
or flanged case replace faulty part
Continual noise Bearing worn Replace worn parts
Gears damaged or worn Replace gears
Noise on drive Ring or pinion gear adjustment Adjust
tight
Noise on coast Bearings damaged Replace bearings
loose Ring and pinion gear Adjust
adjustment
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential Use an EP oil with limited
operation slip additives. Refer to (1)
Recommended Lubricants
on page 4-16
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to
correct torque
Cracked housing/case Repair or replace housing/case

(m) Special Torque Specifications

Table 9.6 - Special Torque Specifications
FIG. NO. ITEM NO. PART NAME TORQUE
Nm lbf ft
Figure 9.12 28 Capscrew 46 34
Figure 9.12 29 Bolt 390 288
Figure 9.11 13 Slotted Nut 750 553
Figure 9.45 - Bearing Cap Bolt 390 288
Figure 9.11 1 Axle Casing Bolts 375 277

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 Axle Group 9

9.3 Centre Axle Group

(1) Centre Axle

AXLE CENTRE FRAME RAIL

3
4
2 3

2
4
3

MOT05150

Figure 9.59 - Centre Axle

1. Centre Axle Complete 2. Adaptor 3. Hose - Breather
4. Adaptor

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9 Axle Group

24
ONLY FOR 21
TRANSPORT 22
19 18
20
12 6
11 4 10
23 9

8 7
13
6 5

5 6
15
14
1 3
17
16
4 6
2

MOT05151

Figure 9.60 - Centre Axle Casing

1. Axle Casing 9. Pin 17. O-Ring
2. Shaft - Stub 1380 MM 10. Pin 18. Plug Assembly
3. Shaft - Stub 1290 MM 11. Stud M16 x 35 19. Plug
4. Bracket 12. Nut 20. O-Ring
5. Bracket 13. Screw 21. Plug
6. Screw 14. Plug 22. Seal
7. Screw 15. O-Ring 23. Plate
8. Washer 16. Plug 24. Valve - Vent

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 Axle Group 9

(2) Removal
Numbers in parentheses refer to Figure 9.59, unless otherwise specified.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

� 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.

PROCEDURE
1. Position the vehicle in a level work area, ensure the body is fully lowered, apply the parking
brake and switch off the engine. Turn steering wheel several times to relieve any pressure
in the steering system.
2. Block front road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'Off' position.
3. Whilst the rear centre road wheels are still on the ground, loosen the wheel nuts. Refer
to 9.6 Wheel Rim and Tire on page 9-123.
4. Using suitable lifting equipment, raise the machine until both rear centre tires are off the
ground. Support the vehicle (trailer) with suitable stands and blocking at the trailer frame
and articulation pivot area.
5. Support one tire and rim assembly with suitable lifting equipment and remove wheel nuts
securing the rim to the axle. Remove tire and rim assembly. Repeat for the opposite tire.
Refer to 9.6 Wheel Rim and Tire on page 9-123.
6. Using a suitable container to catch any oil, identify, tag and remove the following hydraulic
hoses:
Brake Lines
Refer to Figure 14.2.
a. OCDB Manifold connection ‘C1’(1) - Brake Hub LH actuation line ‘RH’ port. (If required).
b. OCDB Manifold connection ‘C2’(2) - Brake Hub RH actuation line ‘RH’ port. (If required).
c. OCDB Manifold connection ‘B3’ tee (3 and 7) - Rear OCDB manifold ‘B3’ and Manifold
tube (10).
d. Differential lock connection (5) - Manifold tube (11).
Brake Cooling Lines
a. OCDB Manifold connection ‘X’(18) - Brake Hub LH cooling line ‘Bottom’ port.
b. OCDB Manifold connection ‘Y’(21) - Brake Hub LH cooling line ‘Top’ port.
c. OCDB Manifold connection ‘B1’(20) - Brake Hub RH cooling line ‘Bottom’ port.
d. OCDB Manifold connection ‘B2’(22) - Brake Hub RH cooling line ‘Top’ port.
e. OCDB Manifold connection ‘T’ tee (27 and 28) - Manifold tube (8) and Rear OCDB
manifold connection ‘T’.
f. OCDB Manifold connection ‘A1’(24) - Manifold tube (6).
g. OCDB Manifold connection ‘A2’(26) - Tee, Manifold tube (7).
Axle Bleed Line
a. Rear Frame connection (3) - Axle bleed line ‘Axle casing port’.

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9 Axle Group

Install protective caps to all connections and ports to prevent ingress of dirt.
7. Tag, identify and disconnect electrical connection ‘B31.X’ , axle differential lock. Install
protective caps to all connections to prevent ingress of dirt.
8. Using suitable lifting equipment, support the axle.
9. Remove the rear drivelines (1 and 7, Figure 8.4). Refer to (2) Removal on page 8-11.
10. Remove the Axle and Suspension assembly from the rear frame assembly. Refer to (2)
Removal on page 17-15.

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 Axle Group 9

(3) Installation
Numbers in parentheses refer to Figure 9.59, unless otherwise specified.

� 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.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Install the Axle and Suspension assembly to the rear frame assembly.
2. Using suitable lifting equipment, support the axle assembly.
3. Install the rear drivelines (1 and 7, Figure 8.4). Refer to (6) Installation on page 8-14.
4. Remove protective caps, identify and connect electrical connection ‘B31.X’ , axle differential
lock.
5. Identify, remove protective caps and install the following hydraulic hoses:
Axle Bleed Line
a. Rear Frame connection (3) - Axle bleed line ‘Axle casing port’.
Torque tighten to 22 Nm (16.2 lbf ft).
Brake Cooling Lines.
a. OCDB Manifold connection ‘T’ tee (27 and 28) - Manifold tube (8) and Rear OCDB
manifold connection ‘T’.
Torque tighten to 160 Nm (118 lbf ft).
b. OCDB Manifold connection ‘A1’(24) - Manifold tube (6).
Torque tighten to 160 Nm (118 lbf ft).
c. OCDB Manifold connection ‘A2’(26) - Tee, Manifold tube (7).
Torque tighten to 160 Nm (118 lbf ft).
d. OCDB Manifold connection ‘B2’(20) - Brake Hub RH cooling line ‘Top’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
e. OCDB Manifold connection ‘B1’(22) - Brake Hub RH cooling line ‘Bottom’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
f. OCDB Manifold connection ‘Y’(21) - Brake Hub LH cooling line ‘Top’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
g. OCDB Manifold connection ‘X’(18) - Brake Hub LH cooling line ‘Bottom’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).

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Brake Lines
Refer to Figure 14.2.
a. Differential lock connection (5) - Manifold tube (11).
Torque Tighten to 27 Nm (20 lbf ft).
b. OCDB Manifold connection ‘B3’ tee (3 and 7) - Rear OCDB manifold ‘B3’ and Manifold
tube (10).
Torque tighten to 55 Nm (40.6 lbf ft).
c. OCDB Manifold connection ‘C2’(2) - Brake Hub RH actuation line ‘RH’ port. (If required).
Torque Tighten to 125 Nm (92.2 lbf ft).
d. OCDB Manifold connection ‘C1’(1) - Brake Hub LH actuation line ‘RH’ port. (If required).
Torque Tighten to 125 Nm (92.2 lbf ft).
6. Fill the brake system.
7. Bleed the brake system. Refer to (7) Bleeding the Service Brakes on page 14-61.
8. Fill, bleed and test the OCDB cooling system.
9. Support one tire and rim assembly with suitable lifting equipment and install the wheel and
rim assembly to the axle. Secure the tire and rim assembly. Repeat for the opposite tire.
Refer to 9.6 Wheel Rim and Tire on page 9-123.
10. Lower the machine until both centre tires are on the ground. Remove lifting equipment,
stands and blocking at the trailer frame and articulation pivot area.
11. Torque tighten the wheel nuts. Refer to 9.6 Wheel Rim and Tire on page 9-123.

(4) Differential Drive Head

(a) Description

� CAUTION
• Never engage or disengage the Differential Lock when moving or when the wheels are
spinning.

The differential assembly is mounted to the axle housing. It comprises of two differentials; one
for the normal cross-axle drive function; the other for the thrudrive.
The differential is a spiral bevel ring gear type with an automatically limited slip element (See
Figure 9.62).
The thrudrive differential is lockable by the operator.

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Figure 9.61 - Exploded View Of Centre Differential

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Figure 9.62 - Exploded View of Limited Slip Cross-axle Differential

1. Adjusting Nut 34. O-Ring 67. Slotted Nut
2. Differential Housing 35. Plug 68. Sliding Dog
3. Layshaft Housing 36. O-Ring 69. Shifter Fork Assembly
4. Plug 37. Differential Case Half 70. Thrust Block
5. O-Ring 38. Thrust Washer 71. Shifter Fork Lock Pin
6. Plug 39. Pin 72. Bolt
7. O-Ring 40. Quill Shaft 73. Seal
8. Plate 41. Side Gear 74. Piston
9. Pin 42. Pinion Gear 75. U-Ring
10. Bushing 43. Thrust Washer 76. Spring
11. Capscrew 44. Spider 77. Centering Ring
12. Bearing 45. Flange 78. Cylinder
13. Bush Spacer 46. Ring Gear 79. Bolt
14. Adjusting Ring 47. Differential Housing 80. Filter Element
15. Bearing 48. Externally Splined Disc 81. Adjusting Bolt
16. Shim 49. Internally Splined Disc 82. Nut
17. Bearing 50. Thrust Ring 83. Disc
18. Bearing 51. Side Gear 84. Contact Pin
19. Adjusting Nut 52. Thrust Washer 85. Seal Ring
20. Slotted Pin 53. Pinion Gear 86. Contact Switch
21. Washer 54. Thrust Washer 87. Drive Shaft Flange

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22. Slotted Nut 55. Differential Axle 88. Flange

23. Bearing 56. Bolt 89. Shaft Seal
24. Bearing 57. Housing Cover 90. Bearing
25. Adjusting Ring 58. Capscrew 91. Shim
26. Spacer Ring 59. Bearing 92. Retaining Ring
27. Slotted Nut 60. Shim 93. Bolt
28. Bolt 61. Shaft Seal 94. Drive Flange
29. Bolt 62. Flange 95. Dust Cap
30. Slotted Pin 63. Bolt 96. Pinion Gear
31. Differential Housing 64. Bolt 97. Spur Gear
32. Slotted Pin 65. Bolt 98. Spur Gear
33. Plug 66. Washer 99. Shim

(b) Removal
Numbers in parentheses refer to Figure 9.61, unless otherwise specified.

� 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.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

PROCEDURE
1. Position the vehicle in a level work area, raise the body and install the body safety prop to
secure the body in the partially raised position.
2. Apply the parking brake and switch off the engine.
3. Block all road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'Off' position.
4. Remove the centre axle. Refer to (2) Removal on page 9-35.
5. Drain the gear oil out of the axle housing and both planetaries into a suitable container.
6. Remove the planetary assemblies and axle shafts from the axle housing. Note from which
side the long and short axle shafts are removed. Refer to 9.5 Axle Group/Hub on page
9-109.
7. Support the weight of differential housings (2 & 31) and layshaft housing (3) with suitable
lifting equipment. Remove bolts (13, Figure 9.60) securing differential housing (2) to axle
casing and carefully remove differential assembly clear of axle casing.

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(c) Disassembly
Numbers in parentheses refer to Figure 9.61 and Figure 9.62, unless otherwise specified.

� 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.

NOTICE
• The following removal procedure assumes the complete axle assembly was removed
from the vehicle.

PROCEDURE
1. Ensure oil is drained from planetaries, axle casing, differential housings (2 & 31) and
layshaft housing (3).
2. Remove bolts (93) securing flange (88) to axle casing. Using special tools (15271101
Back-up Tool and 15500905 Extractor) remove drive shaft flange (87) as shown in Figure
9.63.
3. Remove retaining ring (92) and shim (91) from drive shaft flange (87). Press off flange (88)
and bearing (90) from drive shaft flange (87).
4. Press shaft seal (89) out of flange (88).
5. Ensure both planetary assemblies and axle shafts are removed, by following the procedure
in 9.5 Axle Group/Hub on page 9-109. Using suitable lifting equipment, support differential
assembly. If not done already, remove nuts and bolts and remove the differential assembly
from the axle casing as shown in Figure 9.64.

Figure 9.63 - Removing Drive Shaft Flange Figure 9.64 - Removing Differential Assembly

6. Loosen ring gear bolts (56) as shown in Figure 9.65.

7. Remove slotted pins (20) before loosening adjusting nuts (1 & 19) as shown in Figure 9.66.

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Figure 9.65 - Removing Ring Gear Bolts Figure 9.66 - Removing Adjusting Nuts

8. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
the area around the threaded holes and loosen bolts securing bearing caps. Remove
bearing caps. Refer Figure 9.67
9. Lift the differential assembly out of differential housing (2) with the special tool (15269929
Lifting Pliers) as shown in Figure 9.68.

Figure 9.67 - Removing Bearing Caps Figure 9.68 - Removing Differential

10. Remove both bearings (17 & 18) inner rings using special tools (15272560 Puller, 15500887
Gripping Insert, 15500888 Gripping Insert and 15500889 Reducer) as shown in Figure 9.69.
11. Remove capscrews (58) and separate housing (47) from cover (57). Remove single
components as shown in Figure 9.70.

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Figure 9.69 - Removing Bearing Inner Rings Figure 9.70 - Removing Components

12. Using suitable lifting equipment, remove bolts (28 & 29) and separate layshaft housing (3)
and differential housing (31) from differential housing (2) as shown in Figure 9.71.
13. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower)
heat the slotted nut (67) to around 120 °C before loosening using special tools (15500890
Socket and 15270120 Clamping Yoke) as shown in Figure 9.72. Do not remove nut (67) at
this point.

Figure 9.71 - Separating Differential Figure 9.72 - Loosening Nut

14. Remove bolts (65) and using suitable lifting equipment, separate the inter-axle differential
with flanges (45 & 62) from housing (31) as shown in Figure 9.73.
15. Remove slotted nut (67), washer (66) and drive flange (94). Press the inter-axle differential
out of flanges (45 & 62) as shown in Figure 9.74.

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Figure 9.73 - Separating Housing Figure 9.74 - Pressing Differential

16. Separate flanges (45 & 62) and press out bearing (59). Shims (60 & 99) should also be
removed at this stage.
17. Pull off bearing inner race from differential case (37) using special tool (15500906 Puller)
as shown in Figure 9.75.
18. Remove capscrews (11) and separate inter-axle differential as shown in Figure 9.76.

Figure 9.75 - Removing Bearing Figure 9.76 - Inter-axle Differential

19. Loosen bolts (79) evenly and separate cylinder (78) from the housing (31) as shown
in Figure 9.77.
20. Remove switch (86), seal ring (85) and contact pin(84) from housing (31) as shown in
Figure 9.78. Remove both shifter fork lock pins (71).

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Figure 9.77 - Removing Cylinder Figure 9.78 - Removing Contact Switch

21. Remove shifter fork assembly (69) and piston (74) assembly as shown in Figure 9.79.
22. Remove adjusting bolt (81) and nut (82) from housing (31).
23. Using special tool (15500907 Fixture) lock quill shaft (40) as shown in Figure 9.80.

Figure 9.79 - Removing Shifter Fork And Piston Figure 9.80 - Locking Shaft

24. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
slotted nut (27) to around 120°C before removing using special tool (15500908 Socket).
Remove fixture installed in Step 23.
25. Press out quill shaft (40) using special tool (15269946 Puller Set) as shown in Figure 9.81.
26. Remove adjusting ring (25) from shaft (40). Support shaft (40) on sliding dog (68) and
press off bearing (24) inner race as shown in Figure 9.82.

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Figure 9.81 - Pressing Shaft Figure 9.82 - Pressing Bearing Inner Race

27. Remove bearing (23) inner race and spacer ring (26) from housing (3) as shown in Figure
9.83.
28. Remove bolts (64) securing differential housing (31) to layshaft housing (3) and separate
housings using suitable lifting equipment as shown in Figure 9.84. Remove spur gear (97).

Figure 9.83 - Removing Bearing Inner Race Figure 9.84 - Separating Housings

29. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
slotted nut (22) to around 120 oC before removing using special tool (15500891 Socket).
Block spur gear (98) with wooden block, as shown in Figure 9.85.
30. Press pinion gear (96) out of bearing (12) using special tool (15269946 Puller Set) as
shown in Figure 9.86. Remove bearing (12) inner race from housing (3).

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Figure 9.85 - Removing Slotted Nut Figure 9.86 - Pressing Out Pinion Gear

31. Pull off the bearing (15) inner race from the pinion gear (96) using special tools (15500892
Gripping Insert and 15272560 Bearing Puller). Refer Figure 9.87
32. Remove bush spacer (13) and adjusting ring (14) from layshaft housing (3). Using special
tool (15269946 Puller Set) press out bushing (10) as shown in Figure 9.88.
33. Press out the bearing (15) outer ring from the bushing (10) and remove the shim (16).

Figure 9.87 - Removing Bearing From Pinion Figure 9.88 - Pressing Out Components
Gear

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(d) Inspection

NOTICE
• If either ring gear or pinion gear is defective, both gears must be replaced, because they
are serviced only as a matched set. Make sure the ring gear and pinion gear have the
same mating numbers.

The importance of careful and thorough inspection cannot be overstressed. Thorough inspection
and necessary replacement of parts now may eliminate costly and avoidable trouble later.
1 Clean all parts in petroleum base solvent.
2 Immediately after cleaning, dry all parts, except bearings, with compressed air, or with
a soft, clean lint free wiping cloth. Compressed air has a corrosive effect on bearings,
therefore, they must be wiped dry with a cloth.
3 Coat cleaned, dried parts immediately with light oil to prevent corrosion. If parts are not
to be assembled immediately, treat them with a good rust preventive and wrap them with
treated paper or other suitable material designed to prevent corrosion.
4 Before installing the differential assembly to the machine, clean the inside and outside of
the axle housing to remove any foreign material.
5 Inspect all gears, pinions, and splines for cracked or broken teeth, excessive wear, and
pitted or scored surfaces. Repair or replace as necessary.
6 Check for pitted, scored or worn thrust surfaces of differential case halves.

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(e) Assembly
Numbers in parentheses refer to Figure 9.61 & Figure 9.62 unless otherwise specified.

� 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.
• To prevent personal injury, wear protective gloves when handling frozen or heated bearings.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.
• During assembly and installation, make sure that mated, punch marked, or otherwise
identified parts are returned to their original positions, if still serviceable.
• When tightening nut (22), rotate the pinion gear (96) in both directions several times.
• When tightening nut (27), rotate the shaft (40) in both directions several times.

PROCEDURE
1. Press bearing (12) outer race into housing (3) bore as shown in Figure 9.89.
2. Press bearing (23) outer race into housing (3) bore as shown in Figure 9.90.

Figure 9.89 - Pressing Bearing Outer Race in Figure 9.90 - Pressing Bearing Outer Race in
Housing Housing

3. Insert spur gear (98) into housing (3) bore, ensuring that inner diameter (85 mm) is facing
down, as shown in Figure 9.91.
4. Press the bushing (10) into housing (3) bore and ensure it is firmly home, as shown
in Figure 9.92.

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Figure 9.91 - Installing Spur Gear Figure 9.92 - Installing Bushing

5. At this stage in the assembly procedure the thickness of shim (16) must be determined to
ensure correct contact pattern between pinion gear (96) and ring gear (46). As shown in
Figure 9.93, measure Dimension 'A' from the mounting face of housing (3) to the locating
face of the bearing (15) outer ring, using special tools (15270113 Gauge Blocks, 15269948
Straight Edge and 15270114 Digital Depth Gauge).
6. As shown in Figure 9.94, use special tools (15500893 Shims, 15500894 Shims and
15269934 Measuring Shaft) and place shims into the bores of differential housing (2)
and assemble the measuring shaft.

Figure 9.93 - Measuring Dimension 'A' Figure 9.94 - Assembling The Measuring Shaft
Eg. Dimension 'A' = 29.70 mm.

7. Measure Dimension 'B' from mounting face of housing (2) to Measuring Shaft (see Figure
9.95).

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Figure 9.95 - Measuring Dimension ‘B’

Eg. Dimension ‘B’ = 1965.75 mm
Table 9.7 - Measuring Dimension ‘B’
Example:
Dimension 'A' 29.70 mm
Dimension 'B' 196.75 mm
Dimension 'C' (1/2 diameter of Measuring 15.00 mm
Shaft)
Dimension 'X' = (A + B + C) 241.45 mm

8. Measure thickness of bearing (15) as shown in Figure 9.96 using special tools (15270113
Gauge Blocks and 15270114 Digital Depth Gauge). Record as Dimension 'D'.
9. The arrow in Figure 9.97 is pointing to a dimension stamped on the face of pinion gear
(96). Record as Dimension 'E'.

Figure 9.96 - Measuring Bearing Thickness Figure 9.97 - Dimension On Pinion Face
Eg. Dimension 'D' = 42.70 mm Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm

Table 9.8 - Dimension On Pinion Face

Example:
Dimension 'D' 42.70 mm
Dimension 'E' 197.90 mm
Dimension 'Y' = (D + E) 240.60 mm

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10. Calculate shim (16) thickness by subtracting Dimension 'Y' from Dimension 'X'.

Figure 9.98 - Installing Spacing Washer

Table 9.9 - Installing Spacing Washer
Example:
Dimension 'X' 241.45 mm
Dimension 'Y' 240.60 mm
Required thickness = (X - Y) 0.85 mm

Install shim (16) of required thickness into the bushing (10) as shown in Figure 9.98.
11. Freeze bearing (15) outer race and install in bushing (10), ensuring it is firmly home.
Refer Figure 9.99.
12. Heat inner race of bearing (15) to approximately 90 °C (190 °F) and press it on to the shaft
of pinion gear (96). Be sure it is firmly seated against the shaft shoulder as shown in
Figure 9.100.

Figure 9.99 - Installing Bearing Outer Race Figure 9.100 - Installing Bearing Inner Race

13. Install assembled pinion gear (96) in layshaft housing (3) using special tool (15269946
Puller Set) as shown in Figure 9.101. Do not remove special tool at this point.
14. The adjusting ring (14) is used to obtain the rolling resistance of the pinion bearing. Rolling
resistance should be 3.5 - 4.0 Nm (2.6 - 2.9 lbf ft). This rolling resistance is checked once
pinion gear (96) is secured in housing (3) (Step 17.).
As shown in Figure 9.102, install bush spacer (13) with the small collar showing up (ref.
arrow) into the bore of the spur gear (98) and install adjusting ring (14).

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Figure 9.101 - Installing Pinion Gear Figure 9.102 - Installing Spacer Bush and
Adjusting Ring

15. Heat inner race of bearing (12) to approximately 90 °C (190 °F) and press it on to the shaft
of pinion gear (96) until it is firmly home as shown in Figure 9.103.
After bearing (12) inner race has cooled, remove special tool installed in Step 13.
16. Coat threads of slotted nut (22) with Loctite 649. Locate washer (21) and install slotted nut
(22). Using special tool (15500891 Socket) tighten slotted nut (22) to a torque of 1200 Nm
(885 lbf ft). Refer Figure 9.104.

Figure 9.103 - Installing Bearing Figure 9.104 - Tightening Slotted Nut

17. Check the rolling resistance of the pinion bearing as shown in Figure 9.105 by using special
tool (15500895 Torque Spanner). If the rolling resistance is out-with range (3.5 - 4.0 Nm),
adjusting ring (14) thickness must be changed.
18. Install spur gear (97) in housing (3) as shown in Figure 9.106.

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Figure 9.105 - Checking Rolling Resistance Figure 9.106 - Installing Spur Gear
Record this torque as Tpinion e.g. 3.5 Nm.

19. Install bearing (24) outer race into bore of differential housing (31) as shown in Figure 9.107.
20. Apply Loctite 574 to mounting face of layshaft housing (3). Using suitable lifting equipment,
install the differential housing (31) to layshaft housing (3) as shown in Figure 9.108.

Figure 9.107 - Installing Bearing Outer Race Figure 9.108 - Installing Differential Housing

21. Insert the slotted pin (32) (ref. arrow) and new bolts (64) as shown in Figure 9.109. Torque
bolts (64) to 155 Nm (114 lbf ft).
22. Install sliding dog (68) on quill shaft (40) with the gearing showing downwards as shown in
Figure 9.110.

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Figure 9.109 - Tightening Bolts Figure 9.110 - Installing Sliding Dog

23. Press bearing (24) inner race onto quill shaft (40) until it is firmly home as shown in Figure
9.111.
24. Install adjusting ring (25) in housing (31) before installing sub assembled quill shaft (40)
as shown in Figure 9.112.

Figure 9.111 - Installing Bearing Inner Race Figure 9.112 - Installing Shaft

25. Using special tool (15500907 Fixture) lock quill shaft (40) as shown in Figure 9.113.
26. The spacer ring (26) is used to obtain the rolling resistance of the shaft (40) bearing.
Rolling resistance should be 0.5 - 2.0 Nm (0.37 - 1.48 lbf ft). This rolling resistance (THo) is
calculated once shaft (40) is secured in housing (Step 29). As shown in Figure 9.114, install
spacer ring (26) on shaft (40) with the collar facing down.

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Figure 9.113 - Locking Shaft Figure 9.114 - Installing Sliding Dog

27. Heat inner race of bearing (23) to approximately 90 °C (190 °F) and press it on to the shaft
(40) until it is firmly home as shown in Figure 9.115.
28. Allow bearing (23) to cool, then coat threads of slotted nut (27) with Loctite 649. Assemble
slotted nut (27) on shaft (40) and tighten using special tool (15500908 Socket). Torque
slotted nut (27) to 1 200 Nm (885 lbf ft) as shown in Figure 9.116.

Figure 9.115 - Installing Bearing Figure 9.116 - Tightening Slotted Nut

29. Remove special tool (15500908 Fixture) installed at Step 25. As shown in Figure 9.117,
check total rolling resistance of pinion gear (96) and shaft (40) by using special tool
(15500895 Torque Spanner). Record this torque as T tot e.g. 4.5 Nm.

Figure 9.117 - Checking Rolling Resistance

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Table 9.10 - Checking Rolling Resistance

Example:
T tot e.g. 4.5 Nm
T pinion e.g. 3.5 Nm
Results in T Ho 1.0 Nm

30. Attach thrust blocks (70) to shifter fork assembly (69) and install in differential housing (31)
as shown in Figure 9.118. Thrust blocks (70) fit into sliding dog (68) groove.
31. Place 'U' section ring (75) on piston (74) with sealing lip towards outside. Slide spring (76)
on the piston stem. Locate the centering ring (77) in the recess as denoted by arrow in
Figure 9.119. Insert the assembled piston into its bore in differential housing (31). Be sure
the piston stem makes contact with shifter fork (69).

Figure 9.118 - Installing Fork Assembly Figure 9.119 - Installing Piston

Shifter fork assembly is not symmetrical, 'X'
denotes short side.

32. Place new seals (73) on shifter fork lock pins (71). Position the shifter fork assembly (69)
and fix in place with shifter fork lock pins (71) as shown in Figure 9.120. Secure lock pins
(71) with bolts (72) and torque to 45 Nm (33 lbf ft).
33. Apply Loctite 574 to mounting face of cylinder (78) and secure to differential housing (31)
using bolts (79). Ensure port is at top, as shown in Figure 9.121. Tighten bolts to 23 Nm
(17 lbf ft).

Figure 9.120 - Installing Lock Pins Figure 9.121 - Installing Cylinder

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34. Sub-assemble inter-axle differential by installing thrust washer (38) in differential case half
(37), with lubrication groove facing up. Secure thrust washer with pins (39). Refer Figure
9.120
35. Install side gear (41) in differential case half (37).
36. Sub-assemble differential spider (44), pinion gears (42) and thrust washers (43), ensuring
thrust washers are correctly fitted. Install sub-assembly as shown in Figure 9.123.

Figure 9.122 - Installing Thrust Washer Figure 9.123 - Installing Spider Assembly
Ensure pins do not protrude above contact
face of thrust washer.

37. Install differential case half (37) and fasten with capscrews (11). Tighten capscrews to
115 Nm (85 lbf ft).
38. Install the pre-assembled inter-axle differential in differential housing (31).
To meet required differential end float (0.18 - 0.23 mm) shim (99) dimension should be
calculated. Initially measure Dimension 'A' from the housing (31) mounting face to inter-axle
differential locating face as shown in Figure 9.125.

Figure 9.124 - Assembling Differential Figure 9.125 - Measuring Dimension 'A'

Eg. Dimension 'A' = 5.00 mm.
Use part number stamped on differential cage Measure at several points and determine
halves (37) to ensure correct alignment. average dimension.

39. On flange (45) measure Dimension 'B' from the mounting face to the locating face as
shown in Figure 9.126.

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Figure 9.126 - Measuring Dimension 'B'

Eg. Dimension 'B' = 6.70 mm
Table 9.11 - Measuring Dimension 'B'
Example:
Dimension 'B' 241.45 mm
Dimension 'A' 240.60 mm
Difference (B-A) 1.70 mm
Required End Float + 0.20 mm
Shim (99) Dimension = (B - A+ Required End 1.90 mm
Float)

40. Press bearing (59) into flange (45) until firmly home.
41. Install both bearing (59) inner rings. Refer Figure 9.127. Place pre-assembled flange (45)
on inter-axle differential and press until firmly home as shown in Figure 9.128.

Figure 9.127 - Installing Bearing Figure 9.128 - Installing Flange to Differential

42. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
housing (31) bore and coat mounting face with sealing compound Loctite 574. Carry out
following steps (43 - 46) promptly before sealing compound hardens.
43. Install flange (62) on housing (31) as shown in Figure 9.129. Use guide screws if necessary.
44. To remove bearing (59) backlash, initially measure Dimension 'X' from the bearing (59) face
to the flange (62) mounting face as shown in Figure 9.130.

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Figure 9.129 - Installing Flange Figure 9.130 - Measuring Dimension 'X'

Eg. Dimension 'X' = 10.40 mm

45. Remove flange (62) and measure Dimension 'Y' from mounting face to bearing contact
face as shown in Figure 9.131.

Figure 9.131 - Measuring Dimension 'Y'

Eg. Dimension 'Y' = 11.10 mm
Example:
Dimension 'Y' 11.10 mm
Dimension 'X' 10.40 mm
Shim (60) Dimension (Y - X) 0.70 mm

Place calculated shim (60) into the flange (62).

46. Again coat mounting face with sealing compound Loctite 574. Assemble flange (62)
complete with shim (60) on housing (31) and secure with bolts (65). Tighten bolts to 155
Nm (114 lbf ft).
47. Using special tool (15500896 Driver) install shaft seal (61) as shown in Figure 9.132.
48. Press dust cap (95) onto drive flange (94) using special tools (15500909 Driver and
15270121 Handle).
49. Install drive flange (94) and secure with washer (66) and slotted nut (67). Using special
tools (15500890 Socket and 15270120 Clamping Yoke) tighten nut to 1 000 Nm (738 lbf
ft). Refer to Figure 9.133.

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9 Axle Group

Figure 9.132 - Installing Shaft Seal Figure 9.133 - Installing Drive Flange
If seal outer diameter is rubber coated, coat Coat threads of slotted nut (67) with Loctite
with spirit. If seal outer diameter is metallic, 649.
coat with Loctite 574.

50. Set inter-axle differential lock by installing special tool (15500910 Compressed Air
Connection) and pressurising piston with compressed air (maximum 10 bar (145 lbf/in2)) as
shown in Figure 9.134. Ensure differential lock is engaged by turning the drive flange (94).
51. Coat threads of adjusting bolt (81) with sealing compound Loctite 574 and hand tighten
until bolt contacts piston (74). Tighten adjusting bolt (81) a further 1/3 of a turn, and lock
with nut (82).
52. Install contact pin (84), seal ring (85) and contact switch (86). Connect special tool
(15500911 Indicator) as shown in Figure 9.135.

Figure 9.134 - Compressing Diff-lock Figure 9.135 - Installing Indicator

53. Pressurise piston with compressed air (maximum 10 bar (145 psi)) as shown in Figure
9.136. Ensure differential lock is engaged by turning the drive flange (94). The warning
lamp on the Indicator should illuminate when the sliding dog (68) is fully engaged.
54. Install disc (83) and filter element (80) in bore arrowed in Figure 9.137. Cover port until
final installation of hose.

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Figure 9.136 - Checking Contact Switch Figure 9.137 - Installing Filter

55. Coat mounting face of differential housing (2) with sealing compound Loctite 574. Using
suitable lifting equipment, install pre-assembled layshaft housing on the differential housing
(2). Install new bolts (28 & 29) and slotted pins (30) in correct locations (arrowed in Figure
9.138). Tighten bolts to 155 Nm (114 lbf ft).
56. Heat ring gear (46) and install it on the differential housing (47) until it is firmly home as
shown in Figure 9.139.

Figure 9.138 - Installing Pre-assembled Layshaft Figure 9.139 - Installing Ring Gear
Housing

57. Prior to assembly, coat components with gear oil as specified in Lubricants, Oils and Fluids
Chapter. Place both thrust washers (52 & 54) in the housing (47), installing steel thrust
washer (52) first as shown in Figure 9.140.
58. Install disc set A (Figure 9.62) in housing (47), beginning with externally splined disc (48)
as shown in Figure 9.141.

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Figure 9.140 - Installing Thrust Washers Figure 9.141 - Installing Disc Set A

59. Install thrust ring (50) as shown in Figure 9.142.

60. Install side gear (51) as shown in Figure 9.143. Ensure both internally splined discs (49) of
set A are located on side gear (51).

Figure 9.142 - Installing Thrust Ring Figure 9.143 - Installing Side Gear

61. Sub-assemble pinion gears (53) and differential axles (55). Install sub-assembly as shown
in Figure 9.144.
62. Install second side gear (51) as shown in Figure 9.145.

Figure 9.144 - Installing Differential Pinion Gears Figure 9.145 - Installing Side Gear

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63. Install second thrust ring (50) as shown in Figure 9.146.

64. Install disc set B (Figure 9.62) beginning with internally splined disc (49) as shown in
Figure 9.147.

Figure 9.146 - Installing Thrust Ring Figure 9.147 - Installing Disc Set B

65. The clearance between the assembled differential housing and the cover (57) should be 0.2
- 0.6 mm. Press outer externally splined disc (48) evenly on and measure Dimension 'A'
from the mounting face of housing (47) to the outer disc (48) as shown on Figure 9.148,
using special tool (15270114 Digital Depth Gauge).
66. Measure Dimension 'B' from the contact face to the mounting face of housing cover (57)
using special tool (15270114 Digital Depth Gauge) as shown in Figure 9.149.

Figure 9.148 - Measuring Differential Housing Figure 9.149 - Measuring Housing Cover
Clearance
Eg. Dimension 'B' = 4.00 mm
Eg. Dimension 'A' = 4.30 mm

67. With reference to Steps 65 - 66, calculate clearance as shown in the example below.
Table 9.12 - Clearance
Example:
Dimension 'A' 4.30 mm
Dimension 'B' 4.00 mm
Results in clearance = (A - B) 0.30 mm

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If clearance falls out with specification (0.2 - 0.6 mm), then thicker or thinner outer externally
splined discs (48) should be installed.
If necessary to change the outer externally splined discs (48) to obtain correct clearance,
these should be changed so that the overall thickness of disc sets A and B (Figure 9.62)
are identical.
If installing new discs, the lower clearance should be aimed for.
68. Place both thrust washers (52 & 54) in the cover (57), installing steel thrust washer (52) first
as shown in Figure 9.150.
69. Secure cover (57) to housing (47) with two capscrews (58). Torque capscrews to 46 Nm
(34 lbf ft).
70. Heat bearings (17 & 18) inner races and install on assembled differential, as shown in
Figure 9.151.

Figure 9.150 - Installing Thrust Washers Figure 9.151 - Installing Bearing Inner Race

71. Using suitable lifting equipment, position the assembled differential in the differential
housing (2) and install bearings (17 & 18) outer rings, as shown in Figure 9.152.
72. Install adjusting nuts (1 & 19) and locate bearing caps using bolts and washers as shown
in Figure 9.153. Coat thread of bearing cap bolts with Loctite 649. Torque bolts to 390
Nm (288 lbf ft).

Figure 9.152 - Installing Differential Figure 9.153 - Installing Bearing Caps

Bearing adjusting nuts (1 & 19) have two
basic functions: pre-loading the bearings and
positioning ring gear (46) to obtain the correct
backlash between it and pinion gear (96).

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73. Install new bolts (56) in differential assembly and torque bolts to 390 Nm (288 lbf ft) as
shown in Figure 9.154.
74. Check the backlash between ring gear (46) and pinion gear (96). Mount special tools
(15500897 Magnetic Stands and 15500898 Dial Indicator) at right angles to the outer
diameter of the ring gear tooth flank as shown in Figure 9.155. Establish the backlash by
alternately setting both adjusting nuts (1 & 19). Rock the ring gear back and forth being
careful not to move the pinion gear. Backlash should be 0.27 - 0.33 mm.

Figure 9.154 - Tightening Differential Bolts Figure 9.155 - Measuring Backlash

75. Determine the bearing (17 & 18) rolling resistance and bracket dimension by further
tightening of both adjusting nuts (1 & 19). The bearing rolling resistance should be 3 - 4 Nm
(2.2 - 2.9 lbf ft). Measure bracket dimension as shown in Figure 9.156 using 15500899
Micrometer. Dimension should be 358-0.1 mm.
76. To check the tooth pattern of ring gear (46), coat about twelve ring gear teeth with prussian
blue, oiled red lead or some other easily removed print or 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 as shown in Figure 9.157.

Figure 9.156 - Measuring Bracket Dimension Figure 9.157 - Checking Contact Pattern

Compare the contact pattern obtained with the Gear tooth patterns for the Gleason Gear
Tooth system shown on the following pages.
77. Fasten adjusting nuts (1 & 19) with slotted pins (20) as shown in Figure 9.158.
78. Install studs in positions shown by arrows in Figure 9.159. Apply Loctite 262 to studs
and torque to 55 Nm (40 lbf ft).

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Figure 9.158 - Installing Slotted Pin Figure 9.159 - Installing Studs

79. Apply Loctite 574 to axle casing mounting face. Using suitable lifting equipment, install
differential assembly in axle casing and secure using new bolts and nuts as shown in Figure
9.160. Torque bolts to 375 Nm (277 lbf ft) and nuts to 280 Nm (206 lbf ft).
80. Install shaft seal (89) into flange (88) using special tool (15500912 Driver) as shown in
Figure 9.161.

Figure 9.160 - Installing Differential Figure 9.161 - Installing Shaft Seal

If seal outer diameter is rubber coated, coat
with spirit. If seal outer diameter is metallic,
coat with Loctite 574.

81. Install flange (88) on drive flange shaft (87). Heat bearing (90) to approximately 90 °C (190
°F) and press it on to the drive flange shaft (87) and locate it on the collar as shown in
Figure 9.162.
Install shim (91) and retaining ring (92) to secure bearing on shaft.
82. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
axle housing bore and coat mounting face with sealing compound Loctite 574.
83. Install pre-assembled flange shaft (87) and secure with bolts (93). Tighten bolts to 23
Nm (17 lbf ft) as shown in Figure 9.163.

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Figure 9.162 - Installing Bearing Figure 9.163 - Tightening Bolts

84. Install axle shafts as noted on removal. Refer to Axle Group (Hub) section.

(f) Installation
Numbers in parentheses refer to Figure 9.61, unless otherwise specified.

� 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.

NOTICE
• Tighten all fasteners without specified torques to standard torques. Refer to Table 22.1.
• Use sealing compound (Loctite 574) between the axle housing and differential housing
mounting faces.

PROCEDURE
1. Using suitable lifting equipment, support the weight of the differential assembly.
2. Apply Loctite 574 to the mating surfaces of the differential and axle housings.
3. Position the differential assembly adjacent to the axle housing. Align the index marks on
the differential and axle housings and carefully install the differential assembly.
4. Apply Loctite 243 to screws (28 and 29).
5. Install screws (28 and 29) and secure the differential assembly to the axle housing. Torque
tighten screws to 375 Nm (277 lbf ft).
6. Install the planetary assemblies and axle shafts to the axle housing. Note from which side
the long and short axle shafts are installed. Refer to Figure 9.261.
7. Fill the axle casing with gear oil of the type specified in (1) Recommended Lubricants on
page 4-16, through the differential filler/level hole (14, Figure 9.60) until the oil is level with
the bottom of the filler/level hole.
8. Check oil level after a few minutes to ensure level remains constant.

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(g) Gleason Gear Tooth System

Ideal tooth-contact patterns are shown in Figure 9.164 & Figure 9.165 indicating the pinion
distance is correct.

Figure 9.164 - Coast Side (Concave) Figure 9.165 - Drive Side (Convex)

If the patterns obtained are the same as that shown in Figure 9.166 & Figure 9.167 then
decrease the pinion distance. Refer to Figure 9.168.

Figure 9.166 - Coast Side (Concave) Figure 9.167 - Drive Side (Convex)

Figure 9.168 - Pinion Distance must be Decreased

If the patterns obtained are the same as that shown in Figure 9.169 & Figure 9.170 then
increase the pinion distance. Refer to Figure 9.171.

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Figure 9.169 - Coast Side (Concave) Figure 9.170 - Drive Side (Convex)

Figure 9.171 - Pinion Distance must be Increased

(h) Maintenance
Proper lubrication of the differential assembly is essential if the differentials are to deliver the
service intended. Refer to (1) Recommended Lubricants on page 4-16.
(i) Special Tools
The special tools referenced in this section are available from your dealer. Refer to 22.2 Service
Tools on page 22-4, for part numbers of general service tools and sealants required.
(j) Diagnosis

� CAUTION
• 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.

� WARNING
• Removing the axle shafts or drivelines will make the parking brake ineffective.
• 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.

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Noises and vibrations originating in the tires, transmission, planetaries and drivelines are easily
transmitted and may be erroneously attributed to the differential. Therefore, all possible sources
of noise should be investigated before the differential is taken apart.
Whenever noises such as a grating or rattle are heard coming from the differential, stop the
unit immediately. One tooth from a gear can cause damage to all gears and bearings. When
the differential is definitely at fault, remove the axle shafts and disconnect the driveline before
moving the vehicle.
(k) Diagnosis Chart
Table 9.13 - Diagnosis Chart
CONDITION REASON REMEDY
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Gears damaged or worn Replace gears
Noise on drive Ring or pinion gear adjustment Adjust
tight
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear Adjust
adjustment loose
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential Use an EP oil with limited
operation slip additives. Refer to (1)
Recommended Lubricants
on page 4-16
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to
correct torque
Cracked housing/case Repair or replace housing/case

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(l) Special Torque Specifications

Table 9.14 - Special Torque Specifications
FIG. NO. ITEM NO. PART NAME TORQUE
Nm lbf ft
Figure 9.61 22 Slotted Nut 1 200 885
Figure 9.61 64 Bolt 155 114
Figure 9.61 27 Slotted Nut 1 200 885
Figure 9.61 72 Bolt 45 33
Figure 9.61 79 Bolt 23 17
Figure 9.61 11 Capscrew 115 85
Figure 9.61 65 Bolt 155 114
Figure 9.61 67 Slotted Nut 1 000 738
Figure 9.61 28/29 Bolt 155 114
Figure 9.62 58 Capscrew 46 34
Figure 9.153 - Bearing Cap Bolt 390 288
Figure 9.62 56 Bolt 390 288
Figure 9.60 13 Stud 55 40
Figure 9.60 13 Axle Casing Bolts 375 277
Figure 9.60 12 Axle Casing Nuts 280 206
Figure 9.61 93 Bolts 25 17

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9.4 Rear Axle Group

(1) Rear Axle

FRAME RAIL AXLE REAR

3
4
3 2

4 2

3
1

MOT05173

Figure 9.172 - Rear Axle

1. Rear Axle Complete 3. Breather Hose
2. Elbow 4. Adaptor

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 Axle Group 9

24
21
22
19 18
20
12 6
11 4 10
23 9

8 7
13
6 5

5 6
15
14
1 3
17
16
4 6
2

MOT05172

Figure 9.173 - Rear Axle Casing

1. Axle Casing 9. Pin 17. O-Ring
2. Shaft - Stub 1380 MM 10. Pin 18. Plug Assembly
3. Shaft - Stub 1290 MM 11. Stud M16 x 35 19. Plug
4. Bracket 12. Nut 20. O-Ring
5. Bracket 13. Screw 21. Plug
6. Screw 14. Plug 22. Seal
7. Screw 15. O-Ring 23. Plate
8. Washer 16. Plug 24. Valve - Vent

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9 Axle Group

(2) Removal
Numbers in parentheses refer to Figure 9.172, unless otherwise specified.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

� 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.

PROCEDURE
1. Position the vehicle in a level work area, ensure the body is fully lowered, apply the parking
brake and switch off the engine. Turn steering wheel several times to relieve any pressure
in the steering system.
2. Block front road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'Off' position.
3. Whilst the rear road wheels are still on the ground, loosen the wheel nuts. Refer to 9.6
Wheel Rim and Tire on page 9-123.
4. Using suitable lifting equipment, raise the machine until both rear tires are off the ground.
Support the vehicle (trailer) with suitable stands and blocking at the trailer frame and
articulation pivot area.
5. Support one tire and rim assembly with suitable lifting equipment and remove wheel nuts
securing the rim to the axle. Remove tire and rim assembly. Repeat for the opposite tire.
Refer to 9.6 Wheel Rim and Tire on page 9-123.
6. Using a suitable container to catch any oil, identify, tag and remove the following hydraulic
hoses:
Brake Lines
Refer to Figure 14.2.
a. OCDB Manifold connection ‘C1’(4) - Brake Hub RH actuation line ‘RH’ port. (If required).
b. OCDB Manifold connection ‘C2’(2) - Brake Hub LH actuation line ‘RH’ port. (If required).
c. OCDB Manifold connection ‘B3’(3) - Centre OCDB manifold ‘B3’ (tee).
Brake Cooling Lines
Refer to Figure 18.3
a. OCDB Manifold connection ‘X’(19) - Brake Hub RH cooling line ‘Bottom’ port.
b. OCDB Manifold connection ‘Y’(17) - Brake Hub RH cooling line ‘Top’ port.
c. OCDB Manifold connection ‘B1’(20) - Brake Hub LH cooling line ‘Bottom’ port.
d. OCDB Manifold connection ‘B2’(22) - Brake Hub LH cooling line ‘Top’ port.
e. OCDB Manifold connection ‘T’(28) - Centre OCDB manifold connection ‘T’(tee).
f. OCDB Manifold connection ‘A1’(23) - Manifold tube (9).
g. OCDB Manifold connection ‘A2’(25) - Tee, Manifold tube (7).
Axle Bleed Line
a. Rear Frame connection (3) - Axle bleed line ‘Axle casing port’.
Install protective caps to all connections and ports to prevent ingress of dirt.

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 Axle Group 9

7. Using suitable lifting equipment, support the axle.

8. Remove the rear driveline (1, Figure 8.4). Refer to (2) Removal on page 8-11.
9. Remove the Axle and Suspension assembly from the rear frame assembly. Refer to (2)
Removal on page 17-15.

(3) Installation
Numbers in parentheses refer to Figure 9.172, unless otherwise specified.

� 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.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Install the Axle and Suspension assembly to the rear frame assembly. Refer to (3)
Installation on page 17-18.
2. Using suitable lifting equipment, support the axle assembly.
3. Install the rear drivelines (1, Figure 8.4). Refer to (6) Installation on page 8-14.
4. Identify, remove protective caps and install the following hydraulic hoses:
Axle Bleed Line
a. Rear Frame connection (3) - Axle bleed line ‘Axle casing port’.
Torque tighten to 22 Nm (16.2 lbf ft).
Brake Cooling Lines
a. OCDB Manifold connection ‘T’ tee (28) - Centre OCDB manifold connection ‘T’(tee).
Torque tighten to 160 Nm (118 lbf ft).
b. OCDB Manifold connection ‘A1’(23) - Manifold tube (9).
Torque tighten to 160 Nm (118 lbf ft).
c. OCDB Manifold connection ‘A2’(25) - Tee, Manifold tube (7).
Torque tighten to 160 Nm (118 lbf ft).
d. OCDB Manifold connection ‘B2’(20) - Brake Hub LH cooling line ‘Top’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
e. OCDB Manifold connection ‘B1’(22) - Brake Hub LH cooling line ‘Bottom’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
f. OCDB Manifold connection ‘Y’(17) - Brake Hub RH cooling line ‘Top’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
g. OCDB Manifold connection ‘X’(19) - Brake Hub RH cooling line ‘Bottom’ port.
Torque Tighten to 125 Nm (92.2 lbf ft).
Brake Lines
Refer to Figure 14.2.
a. OCDB Manifold connection ‘B3’ (3) - Rear OCDB manifold ‘B3’ and Manifold tube (10).
Torque tighten to 55 Nm (40.6 lbf ft).

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b. OCDB Manifold connection ‘C2’(4) - Brake Hub RH actuation line ‘RH’ port. (If required).
Torque Tighten to 125 Nm (92.2 lbf ft).
c. OCDB Manifold connection ‘C1’(2) - Brake Hub LH actuation line ‘RH’ port. (If required).
Torque Tighten to 125 Nm (92.2 lbf ft).
5. Fill and bleed the brake system. Refer to (1) Checking Oil Level on page 11-70.
6. Fill, bleed and test the OCDB cooling system. Refer to 14.1 Description on page 14-4.
7. Support one tire and rim assembly with suitable lifting equipment and install the wheel and
rim assembly to the axle. Secure the tire and rim assembly. Repeat for the opposite tire.
Refer to 9.6 Wheel Rim and Tire on page 9-123.
8. Lower the machine until both centre tires are on the ground. Remove lifting equipment,
stands and blocking at the trailer frame and articulation pivot area.
9. Torque tighten the wheel nuts. Refer to 9.6 Wheel Rim and Tire on page 9-123.

(4) Differential Drive Head

Figure 9.174 - Sectional View of Typical Differential

1. Bearing Adjuster 5. Ring Gear A. Spider Differential
2. Housing 6. Spider (Pinion) Gear B. Limited Slip Differential
3. Pinion Gear (Drive) 7. Side Gear
4. Drive Flange 8. Differential Case Assembly

(a) Description
Numbers in parentheses refer to Figure 9.174, unless otherwise specified.
Figure 9.174 illustrates both a standard pinion gear and spider differential (A) and a limited slip
type (B). Basically the differential consists of pinion gear (3) and ring gear (5). The differential is
a spiral bevel ring gear type with an automatically operating limited slip element (B).

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The differential is mounted to the axle housing. The driveline yoke attaches directly to
differential flange (4) which is splined to the shaft of pinion gear (3).
Limited Slip Assembly
Numbers in parentheses refer to Figure 9.175, unless otherwise specified.
The limited slip assembly consists of housing (1), thrust washers (2 & 11), externally splined
discs (3), internally splined discs (4), thrust ring (5), side gears (6), pinion gears (7), differential
axle (8) and cover (9).

Figure 9.175 - Exploded View of Limited Slip Assembly

1. Cover 5. Thrust Ring 9. Housing
2. Thrust Washers (Steel) 6. Side Gears 10. Bolts
3. Externally Splined Discs 7. Pinion Gears 11. Thrust Washers (Brass)
4. Internally Splined Discs 8. Differential Axle 12. Capscrews

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(b) Operation
Numbers in parentheses refer to Figure 9.175, unless otherwise specified.
Pinion gear (3, Figure 9.174) is mated with ring gear (5, Figure 9.174) which is bolted to
differential case assembly (8, Figure 9.174).
When both drive wheels are free to turn under equal resistance loads, ring gear (5, Figure
9.174) and four small pinion (spider) gears (6, Figure 9.174) act as one rigid unit, transmitting
torque to both splined side gears (6). Side gears (6), being splined to the axle shafts, then drive
each rear wheel with the same amount of torque at identical rates of speed. In this instance,
pinion gears (7) do not rotate on their axis, therefore, side gears (6) rotate at the same rev/min
as ring gear (5, Figure 9.174).
When resistance on one drive wheel exceeds the resistance on the other, or when the vehicle
makes a turn creating the same effect, one gear continues to revolve but pinion gears (7) cease
to act rigidly with it. Pinion gears (7) now rotate on their own axis, permitting one drive wheel to
rotate at a different speed from the other. Since the ratio of the pinion and side gear assembly is
approximately 2 to 1, the result is that as one drive wheel slows down, the speed of the other
proportionately increases. This prohibits the application of a torsional load to either axle, which
is greater than that existing during normal operation.
Thus pinion gears (7) serve a dual purpose:
• They allow a differential in speed between the two drive wheels, permitting maximum
manoeuvrability.
• They prohibit the application of all torque to one axle shaft.
(c) Removal
Numbers in parentheses refer to Figure 9.176, unless otherwise specified.

� 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.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

NOTICE
• If the rear differential is being removed, raise the body and fit the body prop.

PROCEDURE
1. Before attempting to remove the road wheels, drive the vehicle onto a level, solid concrete
floor, preferably after a short run to warm the oil.
2. Apply the parking brake and switch off the engine.
3. Block all road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'Off' position.
4. Remove the rear axle. Refer to (2) Removal on page 9-76.
5. Drain the gear oil out of the axle housing and both planetaries into a suitable container.

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 Axle Group 9

6. Remove the planetary assemblies and axle shafts from the axle housing. Note from which
side the long and short axle shafts are removed. Refer to Figure 9.261.
7. Identify the relationship of the driveline flange and differential pinion flange with punch
marks.
8. Disconnect the driveline from the differential drive flange. The driveline can be removed if it
is convenient to do so. Refer to 8.1 Front Drivelines on page 8-2.
9. Index mark differential housing (1) and the axle housing to ensure that differential housing
(1) is installed in the same position.
10. Remove bolts (40) and nuts (41) from the differential and axle housings. Thread in three
puller bolts to break the seal between the differential and axle housings and to partially pull
the differential assembly out of the axle housing.
11. Using suitable lifting equipment, support the weight of the differential assembly.
12. Pull out the differential assembly until it clears the axle housing, then carefully lower it to the
floor. Slide the differential assembly out from beneath the vehicle.

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(d) Disassembly
Numbers in parentheses refer to Figure 9.176 and Figure 9.177, unless otherwise specified.

2 9
39 8
29,30
38

35 19
18
24
25
34 1
17
19
20

45
42
41
40

3
32
33 22
43 21 26
44 12 23
37 14 27
13 28

4 5

6,7
31 36

10
16
15
11 45
MOT05174

Figure 9.176 - Exploded View of Rear Differential

46

A
B

MOT05175

Figure 9.177 - Exploded View of Limited Slip Differential

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1. Differential Carrier 21. Washer 41. Washer

2. Housing - Differential 22. Nut 42. Nut
3. Housing - Layshaft 23. Bearing - Roller 43. Flange - Input
4. Plug 24. Bearing - Roller 44. Cap - Dust
5. O-Ring 25. Spacer 45. Crown Wheel
6. Plug - Screw 26. Spacer 46. Limited Slip Differential
7. O-Ring 27. Support - Shim 47. Housing - Slip Diff.
8. Type Plate 28. Retainer 48. Clutch Disc
9. Pin - Grooved 29. Screw - Locking 49. Disc
10. Bushing 30. Screw - Locking 50. Ring
11. N/A 31. Pin 51. Bevel Gear
12. Bearing - Roller 32. Cover 52. Washer - Thrust
13. Spacer - Bush 33. Pin 53. Bevel Gear - Diff.
14. Washer - Shim 34. Spur Gear 54. Washer - Thrust
15. Bearing 35. Quill Shaft 55. Differential - Axle
16. Washer - Shim 36. Spur Gear 56. Screw
17. Bearing - Roller 37. Seal - Shaft 57. Housing - Cover
18. Bearing 38. Sealing Holder 58. Capscrew
19. Nut - Adjusting 39. Screw
20. Pin - Slotted 40. Screw

� 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.

NOTICE
• The following removal procedure assumes the complete axle assembly was removed
from the vehicle.

PROCEDURE
1. Ensure oil is drained from both axle casing and layshaft housing as shown in Figure 9.178.
2. Remove both planetary assemblies and axle shafts by following the procedure in 9.5 Axle
Group/Hub on page 9-109 section. Using suitable lifting equipment, support differential
assembly. Remove nuts and bolts (12 and 13, Figure 9.173) and remove the differential
assembly from the axle casing as shown in Figure 9.179.

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Figure 9.178 - Removing Drain Plugs Figure 9.179 - Removing Differential Assembly

3. Loosen ring gear (45) bolts as shown in Figure 9.181.

4. Remove slotted pins (20) before loosening adjusting nuts (19) as shown in Figure 9.181.

SM2951 SM2952

Figure 9.180 - Removing Ring Gear Bolts Figure 9.181 - Removing Adjusting Nuts

5. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
the area around the threaded holes and loosen bolts securing bearing caps. Remove
bearing caps. Refer to Figure 9.182.
6. Lift the differential assembly out of differential housing (2) with the special tool (15269929
Lifting Pliers) as shown in Figure 9.183.

SM2953 SM858

Figure 9.182 - Removing Bearing Caps Figure 9.183 - Removing Differential

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 Axle Group 9

7. Remove both bearings (17 & 18) inner rings using special tools (15272560 Puller,
15500887 Gripping Insert, 15500888 Gripping Insert and 15500889 Reducer) as shown in
Figure 9.184.
8. Remove capscrews (58) and separate housing (47) from cover (57). Remove single
components as shown in Figure 9.185.

Figure 9.184 - Removing Bearing Inner Rings Figure 9.185 - Differential Components

9. Remove bolts (40 & 41) securing layshaft housing (26) to differential housing (1). Separate
the housings using suitable lifting equipment, and secure layshaft housing to a suitable
fixture. Refer to Figure 9.186.
10. Using special tool (15269899 220V Hot Air Blower or 15269900 110V Hot Air Blower) heat
the slotted nut (42) to around 120°C before loosening using special tool (15500890 Socket)
as shown in Figure 9.187. Remove slotted nut (42), washer (41) and drive flange (43).

Figure 9.186 - Separating Layshaft Housing Figure 9.187 - Removing Slotted Nut

11. Remove bolts (39) and seal holder (38) from cover (32) as shown in Figure 9.188.
12. Remove retainer (28) and shim support (27) from layshaft housing (3) as shown in Figure
9.189.

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Figure 9.188 - Removing Seal Holder Figure 9.189 - Removing Retainer

13. As shown in Figure 9.190 use special tool (15269946 Puller Set) to press quill shaft (35)
out of the bearing.
14. Remove spacer (25) and press the bearing (24) inner race from the shaft (35). Refer to
Figure 9.191.

Figure 9.190 - Pressing Out Shaft Figure 9.191 - Pressing Inner Race of Bearing

15. Remove bearing (23) inner race and spacer (26) from housing (3). Refer to Figure 9.192.
16. Remove bolts (40) and separate cover (32) from layshaft housing (3) as shown in Figure
9.193. Remove spur gear (34) at this time.

Figure 9.192 - Removing Inner Race of Bearing Figure 9.193 - Separating Cover From Housing

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17. Using special tool (15269899 220 V Hot Air Blower or 15269900 110 V Hot Air Blower)
heat slotted nut (22) before removing using special tool (15500891 Socket) as shown in
Figure 9.194.
18. With the special tool (15269946 Puller Set) shown in Figure 9.195, press the pinion gear
(45) out of the bearing (12).

Figure 9.194 - Removing Slotted Nut Figure 9.195 - Pressing Out Pinion Gear

19. Pull off the bearing (15) inner race from the pinion gear (45) using special tools (15500892
Gripping Insert and 15272560 Bearing Puller).
20. Remove adjusting ring (14) and spacer bush (13) from housing (3). Using special tool
(15269946 Puller Set) press out bushing (10) and spacing washer (16).

Figure 9.196 - Removing Bearing From Pinion Figure 9.197 - Pressing Out Components
Gear

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(e) Inspection

NOTICE
• If either ring gear or pinion gear is defective, both gears must be replaced, because they
are serviced only as a matched set.

PROCEDURE
1. Clean all parts with a suitable solvent. Dry all parts, except bearings, with compressed air or
with soft, clean lint free cloths. DO NOT spin bearings with compressed air. Place bearings
on a clean surface, cover with lint free cloths and allow to dry.
2. Coat cleaned, dried parts immediately with light oil to prevent corrosion. If parts are not to
be assembled immediately, treat them with a good quality rust preventive and wrap them
with treated paper or suitable material designed to prevent corrosion.
3. Before installing the differential assembly into the axle housing, clean the inside and outside
of the axle housing to remove any debris or dirt.
4. Inspect all gears, pinions and splines for cracked or broken teeth, excessive wear, and
pitted or scored surfaces. Repair or replace as necessary.
5. Check for pitted, scored or worn thrust surfaces of differential case halves.
6. During assembly and installation, make sure that mated, punch marked or otherwise
identified parts are returned to their original positions, if still serviceable.

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(f) Assembly
Numbers in parentheses refer to Figure 9.176 and Figure 9.177, unless otherwise specified.

� 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.

� CAUTION
• To prevent personal injury, wear protective gloves when handling bearings.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.
• When tightening nut (13), rotate the pinion gear (16) in both directions several times.
• If necessary to change the outer externally splined discs (21) to obtain correct clearance,
these should be changed so that the overall thickness of disc sets A and B are identical. If
installing new discs, the lower clearance should be aimed for.
• Bearing adjusting nuts (9) have two basic functions: pre-loading the bearings and
positioning ring gear (16) to obtain the correct backlash between it and pinion gear (16).

PROCEDURE
1. Press bearing (12) outer race into housing (3) bore as shown in Figure 9.198.
2. Press bearing (23) outer race into housing (3) bore as shown in Figure 9.199.

Figure 9.198 - Pressing Bearing Figure 9.199 - Pressing Bearing

Outer Race in Housing Outer Race in Housing

3. Insert spur gear (36) into housing (3) bore, ensuring that inner diameter 85 mm (3.35 in)
is facing down, as shown in Figure 9.200.
4. Press the bushing (10) into housing (3) bore and ensure it is firmly home, as shown in
Figure 9.201.

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Figure 9.200 - Installing Spur Gear Figure 9.201 - Installing Bushing

5. At this stage in the assembly procedure the thickness of spacing washer (16) must be
determined to ensure correct contact pattern between pinion and ring gear (45). As shown
in Figure 9.202, measure Dimension 'A' from the mounting face of housing (3) to the
locating face of the bearing (15) outer ring, using special tools (15270113 Gauge Blocks,
15269948 Straight Edge and 15270114 Digital Depth Gauge).
6. As shown in Figure 9.203, use special tools (15500893 Shims, 15500894 Shims and
15269934 Measuring Shaft) and place shims into the bores of differential housing (2)
and assemble the measuring shaft.

Figure 9.202 - Measuring Dimension 'A' Figure 9.203 - Assembling The Measuring Shaft
Eg. Dimension 'A' = 29.70 mm

7. Measure Dimension 'B' from mounting face of housing (2) to Measuring Shaft (see Figure
9.204).

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Figure 9.204 - Measuring Dimension 'B'

Eg. Dimension 'B' = 196.75 mm
Table 9.15 - Measuring Dimension 'B'
Example:
Dimension 'A' 29.70 mm
Dimension 'B' 196.75 mm
Dimension 'C' (1/2 diameter of 15.00 mm
Measuring Shaft)
Dimension 'X' = (A + B + C) 241.45 mm

8. Measure thickness of bearing (15) as shown in Figure 9.205 using special tools (15270113
Gauge Blocks and 15270114 Digital Depth Gauge). Record as Dimension 'D'.
9. The arrow in Figure 9.206 is pointing to a dimension stamped on the face of pinion gear
(45). Record as Dimension 'E'.

SM2975
SM868

Figure 9.205 - Measuring Bearing Thickness Figure 9.206 - Dimension On Pinion Face
Eg. Dimension 'D' = 42.70 mm Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm

Table 9.16 - Dimension On Pinion Face

Example:
Dimension 'D' 42.70 mm
Dimension 'E' 197.90 mm
Dimension 'Y' = (D + E) 240.60 mm

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10. Calculate spacing washer (15) thickness by subtracting Dimension 'Y' from Dimension
'X'. Refer to Figure 9.207.

Figure 9.207 - Installing Spacing Washer

Table 9.17 - Spacing Washer Thickness
Example:
Dimension 'X' 241.45 mm
Dimension 'Y' 240.60 mm
Required thickness = (X-Y) 0.85 mm

11. Freeze bearing (15) outer race and install in bushing (10), ensuring it is firmly home. Refer
to Figure 9.208.
12. Heat inner race of bearing (15) to approximately 90 °C (190 °F) and press it on to the shaft
of pinion gear (45). Be sure it is firmly seated against the shaft shoulder as shown in
Figure 9.209.

SM873

Figure 9.208 - Installing Bearing Outer Race Figure 9.209 - Installing Bearing Inner Race

13. Install assembled pinion gear (45) in layshaft housing (3) using special tool (15269946
Puller Set) as shown in Figure 9.210. Do not remove special tool at this point.
14. The adjusting ring (14) is used to obtain the rolling resistance of the pinion bearing. Rolling
resistance should be 3.5 - 4.0 Nm (2.6 - 2.9 lbf ft). This rolling resistance is checked once
pinion gear (45) is secured in housing (3) (Step 17.).
As shown in Figure 9.211, install spacer bush (13) with the small collar showing up (ref.
arrow) into the bore of the spur gear (36) and install adjusting ring (14).

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Figure 9.210 - Installing Pinion Gear Figure 9.211 - Installing Spacer Bush and
Adjusting Ring

15. Heat inner race of bearing (12) to approximately 90 °C (190 °F) and press it on to the shaft
of pinion gear (45) until it is firmly home as shown in Figure 9.212.
After bearing (12) inner race has cooled, remove special tool installed in Step 13..
16. Coat threads of slotted nut (22) with Loctite 649. Locate washer (21) and install slotted nut
(22). Using special tool (15500891 Socket) tighten slotted nut (22) to a torque of 1200 Nm
(885 lbf ft). Refer to Figure 9.213.

Figure 9.212 - Installing Bearing Figure 9.213 - Tightening Slotted Nut

17. Check the rolling resistance of the pinion bearing as shown in Figure 9.214 by using special
tool (15500895 Torque Spanner). If the rolling resistance is out with range (3.5 - 4.0 Nm),
adjusting ring (14) thickness must be changed.
18. Install spur gear (34) in housing (3) as shown in Figure 9.215.

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Figure 9.214 - Checking Rolling Resistance Figure 9.215 - Installing Spur Gear
Record this torque as Tpinion e.g. 3.5 Nm.

19. Install quill shaft (35) into housing (3) using special tool (15269946 Puller Set) as shown
in Figure 9.216. Do not remove special tool at this point.
20. On the other side of shaft (35), install spacer (26) with the collar facing down as shown in
Figure 9.217.

Figure 9.216 - Installing Quill Shaft Figure 9.217 - Installing Spacer

21. Heat inner race of bearing (23) to approximately 90 °C (190 °F) and press it on to the shaft
(35) until it is firmly home as shown in Figure 9.218.
22. Install shim support (27) and snap in the retainer (28) as shown in Figure 9.219.

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Figure 9.218 - Installing Bearing Inner Race Figure 9.219 - Installing Shim Support and
Retainer

23. Remove special tool (15269946 Puller Set) installed in Step 19., and install it to the retainer
(28) end of shaft (35). Press the shaft (35) until the shim support (27) is located on retainer
(28). Refer to Figure 9.220.
Do not remove special tool at this point.
24. Press bearing (24) outer race into cover (32) until firmly home, as shown in Figure 9.221.

Figure 9.220 - Pressing Shaft Figure 9.221 - Pressing Bearing Outer Race

25. Apply Loctite 574 to mounting face of housing (3) as shown in Figure 9.222. Place the
housing cover (32) on housing (3) and secure using pin (33) and new bolts (40). Torque
bolts (40) to 155 Nm (114 lbf ft).
26. The spacer (25) is used to obtain the rolling resistance of the shaft (35) bearing. Rolling
resistance should be 1.5 - 3.0 Nm (1.1 - 2.2 lbf ft). This rolling resistance (TAn) is calculated
once shaft (35) is secured in housing (3) (Step 32.). As shown in Figure 9.223, install
spacer (25) on shaft (35).

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Figure 9.222 - Applying Loctite 574 Figure 9.223 - Installing Spacer

27. Heat inner race of bearing (24) to approximately 90 °C (190 °F) and press it on to the shaft
(35) until it is firmly home as shown in Figure 9.224.
Once the bearing (24) has cooled, remove special tool (15269946 Puller Set) installed in
Step 23..
28. Apply Loctite 574 to mounting face of cover (32). Place the seal holder (38) on cover (32)
and secure using new bolts (39). Torque bolts (39) to 155 Nm (114 lbf ft) as shown on
Figure 9.225.

Figure 9.224 - Installing Bearing Inner Race Figure 9.225 - Tightening Seal Holder Bolts

29. Coat outer diameter of shaft seal (37) with Loctite 574 and install in seal holder (38) using
special tool (15500896 Driver). Ensure sealing lip faces inboard. Refer to Figure 9.226.
30. Press dust shield (44) over drive flange (43) as shown in Figure 9.227.

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Figure 9.226 - Installing Shaft Seal Figure 9.227 - Installing Dust Shield

31. Coat threads of slotted nut (42) with Loctite 649. Coat faces of washer (41) with Loctite
574. Assemble drive flange (43), washer (41) and slotted nut (42) on shaft (35). Using
special tools (15500890 Socket and 15270120 Clamping Yoke) torque slotted nut (42) to
750 Nm (553 lbf ft) as shown in Figure 9.228.
32. As shown in Figure 9.229, check total rolling resistance of pinion gear (45) and shaft (35)
using by using special tool (15500895 Torque Spanner). Record this torque as Ttot e.g.
5.5 Nm.

Figure 9.228 - Tightening Slotted Nut Figure 9.229 - Checking Rolling Resistance

Table 9.18 - Rolling Resistance of Pinion Gear

Example:
Ttot e.g. 5.5 Nm
Tpinion e.g. 3.5 Nm
Results in THo 2.0 Nm

As specified in Step 26., rolling resistance (TAn) of shaft (35) should be 1.5 - 3.0 Nm. If out
with this range, spacer (25) thickness must be changed.
33. Coat mounting face of differential housing (2) with Loctite 574. Using suitable lifting
equipment, install the pre-assembled layshaft housing (3) to the differential housing (2).
34. As shown in Figure 9.230, secure the pre-assembled layshaft housing to the differential
housing (2) with pins (refer to arrows) and new bolts (29 and 30). Torque bolts (29 and
30) to 155 Nm (114 lbf ft).

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9 Axle Group

35. Heat ring gear (45) and install it on the differential housing (47) until it is firmly home as
shown in Figure 9.231.

Figure 9.230 - Installing Pre-assembled Layshaft Figure 9.231 - Installing Ring Gear
Housing

36. Prior to assembly, coat components with gear oil as specified in (1) Recommended
Lubricants on page 4-16. Place both thrust washers (49 and 54) in the housing (47),
installing steel thrust washer (52) first as shown in Figure 9.232.
37. Install disc set A in housing (47), beginning with externally splined disc (48) as shown in
Figure 9.233.

Figure 9.232 - Installing Thrust Washers Figure 9.233 - Installing Disc Set A

38. Install thrust ring (50) as shown in Figure 9.234.

39. Install side gear (51) as shown in Figure 9.235. Ensure both internally splined discs (49) of
set A are located on side gear (51).

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Figure 9.234 - Installing Thrust Ring Figure 9.235 - Installing Side Gear

40. Sub-assemble pinion gears (53) and differential axles (55). Install sub-assembly as shown
in Figure 9.236.
41. Install second side gear (51) as shown in Figure 9.237.

Figure 9.236 - Installing Differential Pinion Gears Figure 9.237 - Installing Side Gear

42. Install second thrust ring (50) as shown in Figure 9.238.

43. Install disc set B beginning with internally splined disc (49) as shown in Figure 9.239.

Figure 9.238 - Installing Thrust Ring Figure 9.239 - Installing Disc Set B

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44. The clearance between the assembled differential housing and the cover (57) should be 0.2
- 0.6 mm. Press outer externally splined disc (48) evenly on and measure Dimension 'A'
from the mounting face of housing (47) to the outer disc (48) as shown on Figure 9.240,
using special tool 15270114 Digital Depth Gauge).
45. Measure Dimension 'B' from the contact face to the mounting face of housing cover (57)
using special tool (15270114 Digital Depth Gauge) as shown in Figure 9.241.

Figure 9.240 - Measuring Differential Housing Figure 9.241 - Measuring Housing Cover
Clearance
Eg. Dimension 'A' = 4.30 mm Eg. Dimension 'B' = 4.00 mm

46. With reference to Step 44. and Step 45. , calculate clearance as shown in the example
below.
Table 9.19 - Clearance
Example:
Dimension 'A' 4.30 mm
Dimension 'B' 4.00 mm
Results in clearance = (A - B) 0.30 mm

If clearance falls out with specification (0.2 - 0.6 mm), then thicker or thinner outer externally
splined discs (48) should be installed.
47. Place both thrust washers (52 and 54) in the cover (57), installing steel thrust washer
(52) first as shown in Figure 9.242.
48. Secure cover (57) to housing (47) with two capscrews (58). Torque capscrews to 46 Nm
(34 lbf ft).
49. Heat bearings (12 & 44) inner races and install on assembled differential, as shown in
Figure 9.243.

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Figure 9.242 - Installing Thrust Washers Figure 9.243 - Installing Bearing Inner Race

50. Using suitable lifting equipment, position the assembled differential in the differential
housing (2) and install bearings (17 and 18) outer rings, as shown in Figure 9.244.
51. Install adjusting nuts (19) and locate bearing caps using bolts and washers as shown in
Figure 9.245. Coat thread of bearing cap bolts with Loctite 649. Torque bolts to 390 Nm
(288 lbf ft).

Figure 9.244 - Installing Differential Figure 9.245 - Installing Bearing Caps

52. Install new bolts (56) in differential assembly and torque bolts to 390 Nm (288 lbf ft) as
shown in Figure 9.246.
53. Check the backlash between ring gear (45) and pinion gear (45). Mount special tools
(15500897 Magnetic Stands and 15500898 Dial Indicator) at right angles to the outer
diameter of the ring gear tooth flank as shown in Figure 9.247. Establish the backlash by
alternately setting both adjusting nuts (19). Rock the ring gear back and forth being careful
not to move the pinion gear. Backlash should be 0.27 - 0.33 mm.

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Figure 9.246 - Tightening Differential Bolts Figure 9.247 - Measuring Backlash

54. Determine the bearing (17 and 18) rolling resistance and bracket dimension by further
tightening of both adjusting nuts (19). The bearing rolling resistance should be 3 - 4 Nm
(2.2 - 2.9 lbf ft). Measure bracket dimension as shown in Figure 9.248 using 15500899
Micrometer. Dimension should be 358-0.1 mm.
55. To check the tooth pattern of ring gear (45), coat about twelve ring gear teeth with prussian
blue, oiled red lead or some other easily removed print or 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 as shown in Figure 9.249.
Compare the contact pattern obtained with the Gear tooth patterns for the Gleason Gear
Tooth system. Refer to (h) Gleason Gear Tooth System on page 9-105.

SM891

Figure 9.248 - Measuring Bracket Dimension Figure 9.249 - Checking Contact Pattern

56. Fasten adjusting nuts (19) with slotted pins (20) as shown in Figure 9.250.
57. Install studs (11, Figure 9.173) in positions shown by arrows in Figure 9.251. Apply Loctite
262 to studs.

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Figure 9.250 - Installing Slotted Pin Figure 9.251 - Installing Studs

58. Apply Loctite 574 to axle casing mounting face. Using suitable lifting equipment, install
differential assembly in axle casing and secure using new bolts and nuts (13 and 12, Figure
9.173). Torque bolts to 375 Nm (277 lbf ft) and nuts to 280 Nm (206 lbf ft). Refer to
Figure 9.252.
Install axle shafts as noted on removal. Refer to 9.5 Axle Group/Hub on page 9-109.

Figure 9.252 - Installing Differential

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(g) Installation

NOTICE
• Tighten all fasteners without specified torques to standard torques listed in 22.3 Standard
Bolt and Nut Torque Specifications on page 22-5.
• Use sealing compound (Loctite 574) between the axle housing and differential housing
mounting faces.

Tighten bolts securing differential assembly to axle housing to 375 Nm (277 lbf ft). Tighten
nuts to 280 Nm (207 lbf ft).
Fill the layshaft housing (3) with 1.5 litres (0.4 US gallon) of gear oil of the type specified
in Lubricants, Oils and Fluids Chapter, through the differential filler/level hole. Fill the axle
casing with gear oil of the type specified in Lubricants, Oils and Fluids Chapter, through the
differential filler/level hole until the oil is level with the bottom of the filler/level hole. Fill the
planetary assemblies up to the 'Oil Level Check Line'. Check oil levels after a few minutes
to ensure level remains constant.

PROCEDURE
1. Apply Loctite 262 to studs (11, Figure 9.173), install studs in axle casing. Refer to Figure
9.251.
2. Apply Loctite 574 to the mating surfaces of the differential and axle housings.
3. Using suitable lifting equipment, support the weight of the differential assembly.
4. Position the differential assembly adjacent to the axle housing. Align the index marks on
the differential and axle housings and carefully install the differential assembly.
5. Install new screws and nuts (13 and 12, Figure 9.173) and secure the differential assembly
to the axle casing. Torque tighten screws to 375 Nm (277 lbf ft) and nuts to 280 Nm (206
lbf ft).

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(h) Gleason Gear Tooth System

Ideal tooth-contact pattern shown in Figure 9.253 and Figure 9.254 indicating the pinion
distance is correct.

Figure 9.253 - Coast Side (Concave) Figure 9.254 - Drive Side (Convex)

If the patterns obtained are the same as that shown in Figure 9.255 and Figure 9.256 then
decrease the pinion distance (Figure 9.257).

Figure 9.255 - Coast Side (Concave) Figure 9.256 - Drive Side (Convex)

Figure 9.257 - Pinion Distance must be Decreased

If the patterns obtained are the same as that shown in Figure 9.258 and Figure 9.259 then
increase the pinion distance (Figure 9.260).

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Figure 9.258 - Coast Side (Concave) Figure 9.259 - Drive Side (Convex)

Figure 9.260 - Pinion Distance Must Be Increased

(i) Maintenance
Proper lubrication of the differential assembly is essential if the differentials are to deliver the
service intended. Refer to (1) Recommended Lubricants on page 4-16.
(j) Special Tools
The special tools referenced in this section are available from your dealer. Refer to Service
Tools section, for part numbers of general service tools and sealants required.

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(k) Diagnosis

� WARNING
• Removing the axle shafts or drivelines will make the parking brake ineffective.
• 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.

� CAUTION
• 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.

Noises and vibrations originating in the tires, transmission, planetaries and drivelines are easily
transmitted and may be erroneously attributed to the differential. Therefore, all possible sources
of noise should be investigated before the differential is taken apart.
Whenever noises such as a grating or rattle are heard coming from the differential, stop the
unit immediately. One tooth from a gear can cause damage to all gears and bearings. When
the differential is definitely at fault, remove the axle shafts and disconnect the driveline before
moving the vehicle.
(l) Diagnosis Chart
Table 9.20 - Diagnosis Chart
CONDITION REASON REMEDY
Vibration Broken gear teeth Replace damaged gear
Excessive run-out of pinion Disassemble, correct or
or flanged case replace faulty part
Continual noise Bearing worn Replace worn parts
Gears damaged or worn Replace gears
Noise on drive Ring or pinion gear adjustment Adjust
tight
Noise on coast Bearings damaged Replace bearings
loose Ring and pinion gear Adjust
adjustment
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential Use an EP oil with limited
operation slip additives. Refer to (1)
Recommended Lubricants
on page 4-16
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to
correct torque
Cracked housing/case Repair or replace housing/case

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(m) Special Torque Specifications

Table 9.21 - Special Torque Specifications
FIG. NO. ITEM NO. PART NAME TORQUE
Nm lbf ft
Figure 9.177 58 Capscrew 46 34
Figure 9.177 56 Bolt 390 288
Figure 9.176 42 Slotted Nut 750 553
Figure 9.176 40 Bolt 155 114
Figure 9.176 22 Slotted Nut 1 200 885
Figure 9.176 39 Bolt 155 114
Figure 9.176 29 and 30 Bolt 155 114
Figure 9.245 - Bearing Cap Bolt 390 288
Figure 9.173 13 Axle Casing Bolts 375 277
Figure 9.173 12 Axle Casing Nuts 280 206

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 Axle Group 9

9.5 Axle Group/Hub

30 29

6
28

7
5
4

8 24

18 17

1
19
12
13

27 26
25
23
14 16
15
2

20
10 22 21
9
11 MOT05144

Figure 9.261 - Axle Group/Hub

1. Hub Carrier 11. Ring - Snap 21. Roller Bearing
2. Nut - Slotted 12. Washer - Tab 22. Ring - Snap
3. Ring - Shim 13. Screw 23. Shim
4. Seal - Shaft 14. Shaft - Sun Gear 24. Screw
5. Ring 15. Washer 25. Capscrew
6. Roller Bearing 16. Planet Carrier 26. Plug
7. Roller Bearing 17. Plug - Screw 27. O-Ring
8. Hub 18. O-Ring 28. Bolt - Wheel
9. Ring Gear - Carrier 19. O-Ring 29. Nut - Wheel
10. Ring Gear 20. Planet Gear 30. Lockwasher

(1) Operation
Numbers and letters in parentheses refer to Figure 9.261, unless otherwise specified.
Power from the differential is transmitted through a fully floating axle shaft connected to sun
gear shaft (14). As sun gear shaft (14) rotates in a clockwise direction, the three planet gears
(20) meshed with sun gear shaft (14) rotate anticlockwise. Ring gear carrier (9) is splined to
hub carrier (1) and does not rotate but causes planet gears (20), which are meshed with ring
gear (10), to move around it in a clockwise direction. As planet carrier (16) is bolted to wheel
hub (8) the wheel then rotates in a clockwise direction.

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(2) Removal and Disassembly

Numbers in parentheses refer to Figure 9.261, unless otherwise specified.

� WARNING
• Apply pressure to the brake before removing the hub, to ensure that the brake plate
is secure.

� CAUTION
• To prevent personal injury and property damage, be sure wheel blocks, blocking materials
and lifting equipment are properly secured and of adequate capacity to do the job safely.
• To prevent personal injury and property damage, the procedure for removing tire and rim
assembly described in 9.6 Wheel Rim and Tire on page 9-123, must be strictly followed.
• When necessary to drive out components during disassembly, be sure to use a soft drift to
prevent property damage and personal injury.

NOTICE
• On dismantling, clean all parts in paraffin or other suitable cleaning agent and place on a
clean work surface.
• Roller bearings (21) within the planetary gear (20) are fixed with a circlip and these
components are destroyed at separation. Planetary gear and roller bearing must be
replaced together at reassembly.

PROCEDURE
1. Before attempting to remove the road wheels, drive the vehicle onto a level, solid concrete
floor, preferably after a short run to warm the oil.
2. Apply the parking brake and switch off the engine.
3. Block the appropriate road wheels, place the steering lock bar in the 'Locked' position and
the battery master switch in the 'Off' position.
4. Whilst road wheels are still on the ground, loosen wheel nuts (29).
5. Jack up the axle and support with suitably placed stands or timbers.
6. Support tire and rim assembly with a suitable sling and lifting device. Remove wheel nuts
(28) and washers (30) and remove tire and rim assembly from the machine. Remove
opposite road wheel in the same way. Refer to 9.6 Wheel Rim and Tire on page 9-123.
7. Place suitable containers under the differential and both hubs (8). Remove differential
drain plug (e.g. 16, Figure 9.173) and drain oil from the differential. Refer to individual
axle sections.
8. Rotate hubs (8) until plug screw (26) and the cap screw (25) are at their lowest points.
Remove cap screw (25), plug screw (26) and O-Ring (27), drain the oil from hubs. Remove
cap screw (A). Refer to Figure 9.262.
9. Remove drain plug and drain cooling oil from brake packs into a clean container. Refit
drain plug. Refer to Figure 9.263.

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 Axle Group 9

26

25

MOT05182 MOT05181

Figure 9.262 - Oil Drain Axle Hub Figure 9.263 - Oil Drain Axle Brake

10. Index mark planet carrier (16) and hub (8) to aid in installation. Refer to Figure 9.264.
11. Loosen bolts (24) and install adjusting screws (B, 15502331) to aid in removal of planet
carrier (16) sub assembly as shown in Figure 9.264. Remove bolts (24) then prise planet
carrier (16) from hub (8) and remove with suitable lifting equipment (15501178) as shown in
Figure 9.265.

24
8

16
SM3450

Figure 9.264 - Install Adjusting Screws. Figure 9.265 - Removing Planet Carrier Assembly

12. Place on the floor with planet gears (20) facing upwards. Remove O-Ring (19) as shown in
Figure 9.266.
13. Unsnap retaining rings (22) from planet gears (20) using suitable pliers 15270145. Extract
planet gears (20) from the planet carrier (16) using extractor tool 15271107 as shown in
Figure 9.267.

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9 Axle Group

22

19

20

SM3452 SM3453

Figure 9.266 - Removing O-ring. Figure 9.267 - Extracting Planet Gears.

14. Remove thrust washer (23).

15. Remove sun gear shaft (14) as shown in Figure 9.268.

2/3

14

SM3455

Figure 9.268 - Removing Sungear Shaft Figure 9.269 - Remove Driveshaft

16. Remove drive shaft (e.g. 2 or 3, Figure 9.173) as shown in Figure 9.269. Note that left and
right driveshafts are of a different length.
17. Remove two lock screws (13) and remove locking plate (12) from the ring gear (10) as
shown in Figure 9.270.

13, 12

SM3456

Figure 9.270 - Remove Lock Screws / Plate. Figure 9.271 - Removing Slotted Nut.

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 Axle Group 9

18. Remove slotted nut (2) from hub carrier (1) with the special tools (15500882, Socket and
15500883 Centering Bracket) as shown in Figure 9.271.
19. Using lifting tackle 15501170 and suitable pry bar 15270131, separate hub (8) assembly
from the hub carrier (1) as shown in Figure 9.272.
20. Remove the hub Figure 9.273. Ensure that the released ring gear carrier (9) and the ring
gear (10) are secure.

Figure 9.272 - Removing Hub from Carrier Figure 9.273 - Removing Hub

21. Remove ring gear (10) from hub (8) as shown inFigure 9.274.
22. Remove snap ring (11) and separate the ring gear carrier (9) from the ring gear (10) as
shown in Figure 9.275.

Figure 9.274 - Removing Hub from Carrier Figure 9.275 - Removing Ring

23. Using a suitable pry bar 15270131, lever and press shaft seal (4) out of the hub carrier (8)
bore and remove U-Ring (5). If required remove both bearings (6 and 7) outer races from
the bore of the hub (8). Refer to Figure 9.276.
24. By means of lever action press the slide ring seal out of the hub (8), as shown in Figure
9.277.

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6, 7

MOT05186 MOT05187

Figure 9.276 - Remove Shaft Seal, U-Ring Figure 9.277 - Remove Slide Ring Seal

25. For further disassembly of the service brakes refer to (2) Removal and Disassembly on
page 14-29.

(3) Inspection
Numbers in parentheses refer to Figure 9.261, unless otherwise specified.
Thoroughly clean all parts with a suitable solvent and dry with compressed air. Inspect all parts
for damage or excessive wear and replace where necessary. Inspect thrust washer (23) to
make sure it is free of burrs and is absolutely flat. Replace all O-Rings.
(4) Assembly and Installation
Numbers in parentheses refer to Figure 9.261, unless otherwise specified.

� 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.

� CAUTION
• To prevent personal injury, wear protective gloves when handling bearings.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.
• To prevent personal injury and property damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job safely.
• Shim (3) will be used to adjust the rolling moment to the desired value.
• Ensure correct orientation of planet gears (20) in planet carrier (19).

PROCEDURE
1. Install brake pack on axle as described in 14.1 Description on page 14-4.

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 Axle Group 9

2. Apply white spirit to the new O-Ring of the slide ring and insert into the slide ring guide.
Refer to Figure 9.278.
3. Snap the new slide ring seal into the seal ring guide. Refer to Figure 9.279.

MOT05189 MOT05190

Figure 9.278 - Slide Ring Seal Figure 9.279 - Install Slide Ring Seal

4. Before clamping the slide ring seal to installation clean the sliding surfaces (see arrows)
and apply an oil film, with a leather soaked cloth. For the installation position of the slide
ring seal, refer to Figure 9.280.
5. Grease sealing lips and wet outer diameter of shaft seal (4) to aid in installation of
components.
6. Insert roller bearing (7), U-ring (5) and shaft seal (4) into hub (8). Refer to Figure 9.281.

2 5
1 4
3
7

MOT05191 MOT05192

Figure 9.280 - Slide Ring Seal Install Position Figure 9.281 - Install Shaft Seal, U-Ring
1. Slide Ring Seal 3. Sealing Holder
2. Brake Housing 4. Hub

7. Shaft seal (4) should be inserted with care, using special tools; mounting tool 15501177 and
handle 15269898. Refer to Figure 9.282.
8. Mount inner installer 15502336 on hub carrier (1) as shown in Figure 9.283.

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Figure 9.282 - Inserting Shaft Seal Figure 9.283 - Mounting Installer

9. Using suitable lifting tackle 15501170 and chain 15501178, mount hub (8) over the inner
installer. Ensure care is taken not to damage shaft seal (4) during this process. Before fully
seating sealing elements in place, apply a thin film of oil onto sliding surfaces. Refer to
Figure 9.284.
10. Use centering bracket 15500883 to centre hub (8) on the inner installer. Mount hub (8) in
the brake pack. Ensure hub is free to rotate. Refer to Figure 9.285.

SM3463
Figure 9.284 - Mounting Hub Figure 9.285 - Centering Hub

11. Push hub (8) until contact is obtained, now remove centering bracket and inner installer
tools. Refer to Figure 9.286.
12. Heat inner race of roller bearing (5) using a suitable hot air blower 15269899 or 15269900.
Refer to Figure 9.287.

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Figure 9.286 - Remove Installer / Bracket Figure 9.287 - Heating Bearing

13. Mount shim (3) and roller bearing (6) inner race onto hub carrier (1) until contact is
obtained. Refer to Figure 9.288.
14. Pre-assemble ring gear (10), ring gear carrier (9) and snap ring (11). Insert ring gear sub
assembly and screw on slotted nut (2). Ensure chamfer on Slotted Nut (2) is showing to
outside. Refer to Figure 9.289.

Figure 9.288 - Shim Detail Figure 9.289 - Insert Slotted Nut

15. Using centering bracket 15500883 and slotted nut wrench 15500882, torque slotted nut
(28) to a value of 2 000 - 2 200 Nm (1 475 - 1 622 Ibf ft). Refer to Figure 9.290.
16. Install locking plate (12), securing in place with 2-off new lock screws (13). Torque lock
screws (13) to a value of 86 Nm (63.5 Ibf ft). Refer to Figure 9.291.

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Figure 9.290 - Torque Slotted Nut Figure 9.291 - Secure Lock Plate

17. Insert driveshaft (2/3, Figure 9.173) into the unit until contact is obtained. Ensure correct
shaft is fitted, as left and right shafts are of differing length. Refer to Figure 9.292.
18. Mount sun gear shaft (14) until contact is obtained as shown in Figure 9.293.

2/3

14

SM3455

Figure 9.292 - Insert Drive Shaft Figure 9.293 - Mounting Sun Gear Shaft

19. Press roller bearing (21) into bore of planet gear (20) until the circlip has snapped into place
in planet gear (20). Refer to Figure 9.294.
20. Heat inner diameter of roller bearing (21), mount planetary gears (20) onto planet carrier
(16) and secure in place by means of retaining ring (22). Refer to Figure 9.294 and Figure
9.295.
21. Mount Planet gears (20) until fully home and secure in place using retaining rings (22).
Refer to Figure 9.295.

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 Axle Group 9

22
21

20
20

16

SM3473 MOT05194

Figure 9.294 - Planetary Gear Detail Figure 9.295 - Planetary Gear Install

22. Adjust the axial float of the sun gear shaft (14); this should be within the range of 0.3
mm to 0.8 mm, as follows:
a. Insert sun gear shaft (14) until seated. Determine the depth from the mounting face of the
hub (8) to the top face of the sun gear (14) using a straight edge 15269948 and digital depth
gauge 15270114. Call this dimension 'A'. Refer to Figure 9.296.
b. Measure dimension from mounting face of planet gear (20) to contact surface of thrust
washer (22) using measuring equipment used in previous step, including block gauges
15502404. Call this dimension 'B'. Refer to Figure 9.297.

Figure 9.296 - Measurement Figure 9.297 - Measurement

Table 9.22 - Axial Float Measurement

Example:
Dimension ‘A’ 9.4 mm
Dimension ‘B’ 4.0 mm
Difference ‘C’ (A - B) 5.4 mm
Axial Float Required e.g. ‘D’ 0.4 mm
Thrust Washer (23), (C - D) 4.0 mm

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9 Axle Group

23. Once correct thrust washer (23) has been determined, grease washer and locate in place in
planet carrier (16). Refer to Figure 9.298.
24. Insert sun gear shaft (14) into position over thrust washer (23) as shown in Figure 9.299.
Ensure O-Ring (19) is greased and fitted at this time as well.

23

SM3477

Figure 9.298 - Fit Thrust Washer Figure 9.299 - Fit Sun Gear

25. Using suitable lifting tackle 15502405 and adjusting screws 15502331 to aid in location,
insert planet carrier (16) sub-assembly into ring gear (10) bore and locate it in the hub (8) till
fully home. Refer to Figure 9.300. Ensure that planet carrier (16) is aligned to in correct
orientation with hub (index marks), so that drain and fill holes are in the correct position
as shown in Figure 9.301.

Figure 9.300 - Locate Planet assembly Figure 9.301 - Alignment

26. Apply loctite 574 to threads of cap screw (25) and secure planet carrier (16) in place to hub
(8); tightening screw as shown in Figure 9.302. Taking bolts (24), secure carrier in place,
torque bolts (24) to a value of 280 Nm (207 Ibf ft).
27. Secure plug screw (17), O-Ring (18) and plug (26), O-Ring (27) in place on planet carrier
(16) face as shown in Figure 9.303. Torque plug (17) to a value of 40 Nm (29.5 Ibf ft) and
torque plug (26) to a value of 150 Nm (111 Ibf ft).

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 Axle Group 9

24
17

26

25
SM3481 SM3482

Figure 9.302 - Torque Bolts Figure 9.303 - Torque Plugs

28. Install differential drain plug. Add gear oil of the type specified in (1) Recommended
Lubricants on page 4-16, through the differential filler/level hole until the oil is level with
the bottom of the filler/level hole.
29. Fill the planetary assemblies up to the 'Oil Level Check Line' with gear oil of the type
specified in (1) Recommended Lubricants on page 4-16.
30. Fill the brake coolant tank with oil as specified in (1) Recommended Lubricants on page
4-16. Fill until oil is halfway up sight glass. Install filler cap on brake coolant tank filler
neck. Once engine has been started, oil level will drop as brake packs are filled. Top
up oil as necessary.
31. Refit road wheels, securing with wheel nuts (29) and washers (30). Remove stands
or timber supports and lower the machine to the ground. Fully tighten wheel nuts to a
torque of 600 Nm (442 lbf ft). Refer to 9.6 Wheel Rim and Tire on page 9-123. Remove
blocks from the wheels.

(5) Maintenance
Proper lubrication of the axle group is essential if axles are to deliver the service intended.
Lubrication System section gives full information on the proper lubrication intervals and the
lubricant which should be used.
(6) Special Tools
The special tools referenced throughout this section are available from your dealer. Refer to
22.2 Service Tools on page 22-4 section, for part numbers of general service tools and sealants
required.

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(7) Axle Diagnosis

� CAUTION
• 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.

Noises originating in the tires, transmission, brakes or drivelines might be attributed by mistake
to the axle components, therefore, all possible sources of noise should be investigated before
deciding the axle is at fault.
True axle noises may be located by lifting or jacking the machine up until all tires are clear of
the floor or ground. Securely block the machine in this position. Run power train at moderate
speed. Ensure all tires are off the ground to prevent damage to the differential and make
sure that there is no brake drag.
(8) Diagnosis Chart
Table 9.23 - Diagnosis Chart
CONDITION REASON REMEDY
Noises Insufficient or incorrect lubricant Check level. Fill or replace with
correct lubricant.
Wheel bearings scored or rough Replace wheel bearings
Gear teeth in planetary chipped Replace gear
Loss of lubricant Lubricant foams excessively Drain and fill with correct lubricant
Worn or broken oil seal Replace oil seal
Loose nuts or bolts Tighten nuts or bolts
Gain of lubricant Incorrect lubricant Drain and fill with correct lubricant
Planetaries running hot Bearings seized Replace bearings

(9) Special Torque Specifications

Table 9.24 - Special Torque Specifications
TORQUE
FIG. NO. ITEM NO. ITEM NAME
Nm lbf ft
Figure 9.261 28 Wheel Nut 600 442
Figure 9.261 13 Lock Screw 86 63.5
Figure 9.261 24 Bolt 280 207
Figure 9.261 26 Plug Screw 150 111
Figure 9.261 17 Plug Screw 40 29.5
Figure 9.261 28 Slotted Nut 2 000 - 2 200 1 475 - 1 622

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9.6 Wheel Rim and Tire

(1) Description and Operation
1

10 9 5
11

7
8 12

MOT05195

Figure 9.304 - Wheel Rim and Tire

1. Rim and Disc Assembly 5. O-ring 9. Tire
2. Flange 6. Valve Assembly 10. Adaptor
3. Lock Ring 7. Core 11. Valve Cap
4. Driver 8. Cap 12. Stud Assembly

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� CAUTION
• Never mix components of one manufacturer’s rims with those of another. Using the rim
base of one manufacturer with the lock ring of another or vice versa is dangerous. The
lock ring of one may not fully engage with the lock ring groove of the other. Always consult
the rim manufacturers for proper matching, assembly and safety instructions. Also, use
and servicing of damaged, worn out or improperly assembled rim assemblies is a very
dangerous practice. Failure to comply with the above warnings could result in an explosion
from tire pressure causing serious property damage and serious personnel injury or death.
• Tires on this machine are factory inflated with dry nitrogen. It is recommended that
dry nitrogen be used exclusively for all tire pressure adjustments as well as inflation of
replacement tires.
• Nitrogen gas improves tire pressure retention, increases tire life by reducing carcass
oxidation from within, minimizes rim rust, and has no known detrimental effect on the tire. It
also reduces the potential of a tire explosion because it is an inert gas and will not support
combustion inside the tire. The same tire inflation pressure used for air inflation must be
used for nitrogen inflation. Refer to Maintenance Manual for recommended procedures for
inflating and pressure adjusting types with dry nitrogen gas. Only proper nitrogen charging
equipment operated by personnel trained in its use must be used.

Wheel Assembly
The wheels are 3–piece earthmover rims with 19 stud fixings
The wheel assembly is designed to allow the tire and rim assembly to be replaced with a
pre-assembled tire and rim. The tire and rim may be removed from the machine as an assembly
and transported to a more suitable location for removing the tire from the rim.
Procedures for removing the tire and rim assembly from the machine, dismounting the tire from
rim and the use of hand and special tools, are described in this section.
The rim assembly consists of the following: wheel rim, inner and outer flange, O-ring, bead seat
band, driver and lock ring.
When removing a tire and rim assembly from the machine, special equipment and careful
handling are required because of the size and weight of the tires.
One of the following pieces of hoisting equipment should be used to lift the tire and rim: chain
block and tackle, overhead crane, fork lift truck, boom truck, or tripod tire changing tool.
(2) Preparation for Servicing

� DANGER
• Before performing any service on the tires or rim components, to prevent personal injury
and property damage, completely deflate the tire by removing the valve cap and core.
Insert a thin wire through the valve to be sure the valve is not plugged. Even a flat tire, in
some cases, will retain sufficient air pressure to blow off a rim component with enough force
to cause bodily injury or death.

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(3) Removing Tire and Rim Assembly from Machine

Numbers in parentheses refer to Figure 9.304, unless otherwise specified.

� CAUTION
• 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.

NOTICE
• If the tire and rim assembly is to be replaced pre-assembled, it is not necessary to remove
the tire from the rim. It may be removed as an assembly.

PROCEDURE
1. Position the vehicle in a level work area, apply the parking brake and shutdown the engine.
Turn the steering wheel in both directions several times to relieve pressure in the steering
system.
2. Block all road wheels, except the one to be raised, and place the battery master switch in
the 'OFF' position.
3. Brake wheel nuts (29, Figure 9.261) loose with tire still on the ground, but do not remove
from wheel studs.
4. Jack up the axle to the height required to allow removal of the tire and rim assembly.
5. Place suitable supports under the axle.
6. Support tire and rim assembly with a suitable sling and attach a suitable lifting device.
7. Remove wheel nuts (29, Figure 9.261) securing wheel rim (1).
8. Using the lifting device, remove tire and rim assembly from wheel and lift clear of machine.

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(4) Dismounting Tire from Rim

Numbers in parentheses refer to Figure 9.305, unless otherwise specified.

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

NOTICE
• The following instructions apply to use of hand tools. For procedures and tooling required to
dismount the tire from the rim using hydraulic tools, contact the relevant tire manufacturer.

Figure 9.305 - Typical Tire and Rim Assembly

1. Outer Flange 3. Bead Seat Band 5. Wheel Rim
2. Driver 4. Lock Ring 6. Inner Flange

PROCEDURE
1. Remove valve cap and valve core and leave valve open to prevent trapping of air in tire.
Tape valve threads for protection.
2. Remove driver (2) from bead seat band (3) and wheel rim (5).
3. Break outer tire bead loose with pry bar shown in Figure 9.306.
4. Insert flat hooked end of pry bar into breaking slots between bead seat band (3) and outer
flange (1) (See Figure 9.307). A pipe over the straight end of the pry bar will increase
leverage.

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Figure 9.306 - Pry Bar Figure 9.307 - Breaking Typical Tire Bead

5. Twist bar toward tire to break bead.

6. A second bar may be inserted in space between bead seat band (3) and outer flange (1).
Twist second bar to maintain space gained by the first bar.
7. Move the first bar around the rim, twisting and following with the second bar, until the
outer tire bead is loose.
8. Pry bead seat band (3) away from lock ring (4) by placing hooked end of pry bar in groove
of wheel rim (5), between ends of lock ring (4), and prying up with bar. Using two bars, as in
Step 7, work completely around wheel rim (5).
9. Pry lock ring (4) out in same manner by starting at prying notch in rim assembly and work
all the way around rim with two pry bars.
10. Remove and discard 'O' ring (5, Figure 9.304).
11. Remove lock ring (4), pry out and remove bead seat band (3).
12. Breaking slots are provided inside the rims. The inner bead may be broken as described in
Steps 4 through 8. If tire and rim assembly are on the machine, the following procedure
may be used for breaking the inner bead.
13. Place jack between inner flange (6) and machine frame. Extend jack until tire bead is
broken. Continue around rim until tire bead is broken at all points.
14. Using suitable lifting equipment, remove tire from rim. This completes the removal of the
tubeless tire.
15. If necessary, remove inner flange (6).
16. If tire rim is on the machine, and no tire lifting equipment is available, 'walk' the tire off
the rim as follows:
a. Force bottom of tire outward as far as possible; lower jack enough to allow weight of
tire to rest on ground; force top of tire out as far as possible; raise jack to original height
and repeat the above until the tire is off the rim.

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(5) Inspection
Tire
Check the interior surface of the tire to determine its condition. Inspect for cuts or fabric breaks
that have penetrated the tire body. The casing should be inspected closely for any sharp,
pointed object that may have penetrated the tire body but is invisible from the outside. All dust,
dirt, water or other foreign matter should be cleaned from the inside of tire.
Rim Assembly

� WARNING
• Never mix components of one manufacturer's rims with those of another. Using the rim
base of one manufacturer with the lock ring of another or vice versa is dangerous. The lock
ring of one may not fully engage with the lock ring groove of the other. Always consult the
rim manufacturer for proper matching and assembly instructions. Also, use and servicing of
damaged, worn out, or improperly assembled rim assemblies is a very dangerous practice.
Failure to comply with the above warnings could result in explosions from tire pressure
causing serious personal injury and property damage.
• Handle O-rings carefully, as damage will prevent an airtight seal for tire inflation.

Overloading, improper tire inflation, rough terrain, high speed, accidents, dirt accumulation, and
corrosion all tend to reduce the service life of rims and rim components. It is recommended that
rims be inspected, as below, not less often than at every tire change and that, as the warranty
limit approaches, consideration be given to periodic replacement.
The rim and its components are designed with built-in safety factors, to prevent the components
from flying off with killing force during inflation. Check components for cracks, bends, distortion,
or other damage. If damage is found, the component must be replaced.
Clean all rust and dirt from the rim parts and wheel and apply a coat of good grade primer paint.
Allow the paint to dry thoroughly before remounting tire.
The rim parts used with tubeless tires form an important part of the air chamber. Therefore,
they should be carefully checked for distortion or mutilation that would prevent an effective air
seal when the tire and rim are reassembled.
Rubber O-rings are air seals for tubeless tire and rim assemblies and therefore should be
carefully handled to provide an airtight seal when the tire is remounted on the rim. Always use
new O-rings when mounting a tubeless tire.
(6) Mounting Tire on Rim
Numbers in parentheses refer to Figure 9.305, unless otherwise specified.

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

For mounting a tire with rim on or off machine, the procedure is basically the same.

PROCEDURE
1. For off-machine installation, lay rim on blocks or mounting stand with O-ring groove up. Rim
should be off floor enough to allow tire to rest on rim and not on floor. Blocks are not to
extend more than 13 mm (0.50 in) beyond rim base.
2. If removed, install inner flange (6) over wheel rim (5).

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3. Lubricate tire beads and O-ring, with a thin solution of vegetable base soap and water.
4. Using suitable lifting equipment, lower tire onto rim. Seat tire firmly against inner flange (6).
5. Install outer flange (1) on rim (5).
6. Align lock ring driver notch in bead seat band (3) with notch in wheel rim (5) and install
bead seat band on rim.
7. Install lock ring (4) in groove of wheel rim (5) so that lock ring lug engages both notches.
Notches and lock ring lug must line up correctly. If necessary, use only a soft hammer to
rotate lug. Use bar for installing lock ring, as illustrated in Figure 9.308.

4 2 A

SM207

Figure 9.308 - Installing Typical Lock Ring

A. Notches 2. Drive Lug 4. Lock Ring

8. Force bead seat band (3) past O-ring groove in wheel rim (5) by prying, or with lift truck
forks. Use blocking between the forks and tire to prevent damage. Insert a new O-ring (5,
Figure 9.304) in groove of the rim behind lock ring (4). Lubricate area of front taper of bead
seat band adjacent to O-ring, with a thin solution of soap and water or another approved
lubricant which is not harmful to rubber. Avoid using an excessive amount of lubricant.
9. Install driver (2). Make sure all rim components are correctly assembled.
10. Lift the tire upwards to effect a seal between bead seat band (3) and O-ring (5, Figure
9.304). In some cases the tire will automatically spring out, making this step unnecessary.
11. Refer to (8) Air Tire Inflation on page 9-130 for the proper procedure for inflating the tire.

(7) Mounting Tire and Rim Assembly on Machine

Numbers in parentheses refer to (1) Description and Operation on page 9-123, unless
otherwise specified.

� WARNING
• When jacking, lifting, or blocking the machine, be sure the equipment is of sufficient
capacity to do the job safely.

PROCEDURE
1. Support tire and rim assembly with a chain, or rope sling. Attach sling to overhead lifting
device. Slide assembly on to wheel of machine, with lock ring (4) facing outward.
2. Install wheel nuts and washers (29 and 30, Figure 9.308) on wheel studs. Gradually tighten
nuts opposite each other until all nuts are snug. Torque tighten wheel nuts to 600 Nm (442
lbf ft). Check and torque tighten wheel nuts again, after 2 hours of machine operation.

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(8) Air Tire Inflation

� CAUTION
• To prevent personal injury and property damage, the tire and rim assembly should be
placed in a safety cage before inflating. If no safety cage is available or tire is on the
machine, the tire and rim assembly should be wrapped with safety chains or with lash
cables before inflating.
Even with these precautions remember that air-blast is a potential hazard. Tire inflation
should be carried out away from busy working areas.
• To avoid personal injury and property damage, never stand or sit in front of a mounted tire
during tire inflation. Use a clip-on air chuck with a long hose and stand to one side while
the tire is being inflated.
• To prevent personal injury and property damage, always prevent flammable vapors that
could produce tire explosions, from being pumped into tires during inflation, by observing
the following precautions:
• 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 outside temperatures.
• Make sure that paints, lacquers, paint thinners, or similar materials that produce volatile,
flammable vapors are not used or stored near the air intake of the compressor that supplies
the air for inflating tires. The compressor should be isolated from all such sources of
flammable vapors.
• Be sure to thoroughly flush and blow off all flammable solvents used for cleaning the air
compressor inlet screen before using the compressor for tire inflation, or any other purpose.
• Do not charge batteries, either in or out of a machine, near the air inlet of a compressor
used for inflating tires. Charging batteries produces highly explosive hydrogen gas which
can be readily drawn into a nearby compressor inlet and pumped into the tire.
• Never exceed the specified concentration of alcohol when adjusting the alcohol vaporizer,
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 vapors that will be pumped into a
tire when this air supply is used for tire inflation if the tire 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 tire inflation.
• Another source of hazardous flammable vapors in tires is the tire bead lubricant. Always
use bead lubricants that do not introduce flammable vapors into the tire.

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NOTICE
• Always use tire inflation equipment with an air filter that removes moisture from the air
supply, when available, to prevent moisture corrosion of internal rim parts.
• Inflate tire to 1 bar (15 psi) initially to seat components and tap lock ring lightly to ensure
correct seating. Visually check that all components are in place, then continue inflation
observing all safety precautions. (See Step 2 ).
• If the tire is off the machine, place it in a safety cage after initially inflating to 1 bar (15 psi) to
seat components. See (9) Nitrogen Tire Inflation on page 9-131.
• Inflate tires to 5.2 bar (75 psi) to seat beads and seal the O-ring, then adjust to the
recommended inflation pressure.
• For recommended operating pressure, refer to the (14) Tire Pressures on page 9-136.

(9) Nitrogen Tire Inflation

NOTICE
• All Warnings and procedures in (8) Air Tire Inflation on page 9-130 apply, except for
differences covered by this section.

In certain environments it is recommended that tires be inflated with dry nitrogen gas, and that
the resulting oxygen content of the inflation does not exceed 5%. All machines whose tires are
factory inflated with dry nitrogen gas will be identified by a decal on the body or frame.
Nitrogen gas improves tire pressure retention, increases tire life by reducing carcass oxidation
from within, minimizes rim rust and has no detrimental effects on the tire. It also reduces
the potential of a tire explosion because it is an inert gas and will not support combustion
inside the tire.
The same tire inflation pressure used for air inflation should be used for nitrogen inflation. tire
valves formerly used with air inflation are entirely satisfactory for use with nitrogen gas.
Nitrogen Tire Inflation Kit

� WARNING
• DO NOT USE charging assembly, Part No. 9359489, for tire inflation because this
assembly does not include a pressure regulator, safety relief valve, and adequate pressure
gauging which is mandatory for tire inflation purposes. tire volume is as much as 90 times
greater than the average accumulator volume and hence it takes very much longer to
inflate a tire - up to 40 minutes or more for very large tires.
• Nitrogen gas cylinders used to inflate tires are generally charged to approximately 152
bar (2 200 psi). A tire blowout and/or rim failure could occur if inflation equipment is not
properly used. Proper nitrogen charging equipment and personnel training for its use
is a must to avoid over inflation.

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Figure 9.309 - Typical Safety Cage Figure 9.310 - Nitrogen Tire Inflation Kit

1 A nitrogen tire inflation kit is available from your dealer and consists of the following. Refer
to Figure 9.310.
a Pressure regulator, 0 - 13 bar (0 - 200 psi), with two dual pressure gauges.
b Safety relief valve, 8.6 bar (125 psi), that will assure an upper limit to the pressure
available for tire inflation.
c A 15.2 m (50 ft) length of flexible hose with interconnecting fittings. On the tire end of
the hose is a large bore quick connect/disconnect clip-on chuck.
2 The pressure regulator is connected to a nitrogen compressed gas cylinder available from
local suppliers.
3 The usual procedure for using this type of equipment is as follows:
a Connect nitrogen tire inflation kit to nitrogen compressed gas supply. DO NOT connect
clip-on chuck to the tire valve at this time.
b Open valve on nitrogen supply
c With flexible hose and clip-on chuck connected to nitrogen tire inflation kit assembly but
not connected to the tire, adjust pressure regulator so that its output pressure is not
more than 1.4 bar (20 psi) higher than the desired tire inflation pressure.
d Connect clip-on chuck to the tire valve. The tire will now inflate. Tire pressure can
be monitored by observing the gauge at the pressure regulator. STAY AWAY FROM
THE Tire.
e When desired inflation pressure has been achieved, back off the regulator or close the
valve on the compressed gas cylinder.
f Remove the clip-on chuck and adjust the tire pressure with the tire gauge in the usual
manner.
Re-inflation of a Mounted Tire
To re-inflate a tire with dry nitrogen gas which is now inflated with air, proceed as follows:
1 Exhaust the tire until only air at atmospheric pressure remains in the tire.
2 Re-inflate the tire using only dry nitrogen gas to 4.15 bar (60 psi) gauge as a minimum, or
to bead seating pressure as a maximum.
3 Adjust to the service inflation pressure required:
a If the required service inflation pressure is LESS than 4.1 bar (60 psi), remove the
clip-on chuck and adjust the pressure with the tire gauge in the usual manner.
b If the required service inflation pressure is greater than 4.1 bar (60 psi), further inflate,
with dry nitrogen gas only, to the pressure level required.

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New Tire Mounts and Remounts

NOTICE
• To newly mount or remount a tire to its rim, use only dry nitrogen gas; this includes the
pressure required to seat the beads. After seating the tire beads, remove the clip-on chuck
and adjust the pressure with the tire gauge in the usual manner.
• Although a little more nitrogen gas is used to seat beads than that used for re-inflation of
a mounted tire, refer to Re-inflation of a Mounted Tire on page9-132, its cost is generally
negligible in comparison to the time and labour saving and, longer tire life achievable with
the reduced oxygen content which results.

(10) Tire Explosion Hazard

� WARNING
• Whenever a machines tire(s) is (are) exposed to excessive heat such as a machine fire or
extremely hot brakes the hazard of a subsequent violent tire explosion must be recognized.
All persons must avoid approaching the machine so as not to be physically endangered
in the event of an explosion of the tire and rim parts. The machine should be moved to a
remote area, but only when this can be done with complete safety to the operator operating
or towing the machine. All other persons should stay clear of the machine. The fire or
overheated brakes, wheel, etc. should be extinguished or cooled from a safe distance. Do
not attempt to extinguish the fire or cool the machine by use of hand-held fire extinguishers.
• If it is absolutely necessary to approach a machine with a suspect tire, approach only from
the front or the back. Stay at least 15 m (50 ft) from the tread area. Keep observers out of
the area and at least 460 m (1 500 ft) from the tire sidewall. Refer to Figure 9.311. The
tire(s) should be allowed at least eight (8) hours cooling time after the machine is shut down
or the fire extinguished before approaching closer.
• There is always a possibility of a tire explosion whenever the smell of burning rubber
or excessively hot brakes is detected. The danger is also present when a fire on the
machine reaches the tire and wheel area. Under such conditions, all personnel must avoid
approaching the machine in a manner that could result in injury should an explosion actually
occur. Move the machine to a remote area only if it can be done without endangering
the operator or other personnel in the area.
• DO NOT WELD ON OR HEAT RIM COMPONENTS. For several years the company and
tire and rim manufacturers have warned users never to weld rim components with the tire
mounted on the rim. The gases that build up inside the tire during arc welding or heating
on rim components can ignite, resulting in one of these explosive-like failures of the tire
and rim. This warning also applies to nitrogen inflated tires. Ignition will not occur in the
nitrogen atmosphere, but the pressure buildup from the heat of welding may be sufficient to
cause a blowout severe enough to injure or kill. It is recommended to scrap the part if heat
is necessary to repair any rim component.

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Figure 9.311 - Warning – Tire Explosion

(11) Maintenance
Tire Repairs
Prompt repair of tire injuries will prevent small injuries from enlarging and causing tire failure.
Use the best tire facilities available. If good repair facilities are not available, have the nearest
dealer make the necessary repairs.
Minor cuts, snags, or punctures should be repaired upon discovery. Skive with a sharp pointed
knife around any cut in the tire tread area that is of sufficient depth or shape to hold pebbles or
dirt. The angle of the skive should be no more than sufficient to expel all foreign material and
should extend no deeper than the breaker. The skive should go to the bottom of the hole. tires
with shallow cuts, if treated promptly, may be allowed to continue in service. If the cut extends
deeper into the tire carcass, the tire should be removed for repair.
The tire must be removed from the rim to repair larger punctures or cuts. Irregular shaped
punctures or cuts less than 13 mm (0.50 in) in size can be repaired with a plug and hot patch.
Insert a repair plug into the hole to keep out moisture and to back up the hot patch. Trim
the plug off flush with the inside of the casing, buff, and apply the hot patch according to the
instructions supplied with the hot patch equipment.
Punctures 13 mm (0.50 in) or larger, large cuts, or bruise breaks require sectional or reinforced
vulcanized repair. Cover the repair patch with a layer of cushion gum after application to the
tubeless tire to ensure an airtight repair. Any cords of the inside ply that are exposed in buffing
and are not covered with repair patch must be coated with cushion gum to prevent air leakage
into the carcass plies on tubeless tires.
Recapping and Retreading
There are two general methods employed in restoring the tread surface of off-the-highway tires:
recapping and retreading.
A recapped tire has a new tread cured right over the old tread surface.
A retreaded tire has the old tread removed entirely and a new tread cured directly onto the body
of the tire. A tire can be recapped or retreaded if the cord body is free of cuts, bruises and
separation, and is thoroughly sound, including previous repairs.

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(12) Tire Care

To obtain maximum service from off-highway tires, the following common-sense precautions
should be followed.
Maintain Correct Inflation
The most common cause of tire damage is improper inflation. Both over-inflation and
under-inflation are detrimental to tire life. Tire pressure should be checked daily, preferably
before the machine is placed in operation. Refer to (14) Tire Pressures on page 9-136.
The valve cores should be checked for leaks. Keep in mind that valve cores are delicate
mechanisms that wear out in service; therefore, they should be replaced with new ones when
they become worn. Each tire should be equipped with a valve cap to prevent dirt from damaging
the valve core and causing air leakage.
Maintain Good Haul Roads
Because haul roads are considered temporary roads they are frequently neglected. The better
the haul road, the longer the tire and machine life of off highway machines.
Although it takes time and effort to maintain good haul roads, the delay and cost of tires and
machine breakdowns caused by poor haul roads is many times greater.
Inspect Tires Regularly
A systematic plan for tire inspection will more than pay for itself in lowered tire costs per hour of
operation. All tires should be checked regularly for cuts, bruises, ply material breaks, excessive
or uneven wear, embedded foreign matter, and any other damage which can be repaired. A
considerable increase in tire service can be realized if tire injuries are repaired before they have
progressed to the irreparable stage.
The rim mounting nuts should also be checked periodically and tightened to the torque specified.
Prevent Overloading
Off-highway machines are designed to carry a maximum allowable payload. Excessive loading
will overstress both the machine and tires and shorten the life of both.
Prevent Contact with Oil
Prevent tire contact with petroleum products. Rubber that is exposed to oil, gasoline, or grease
becomes soft and spongy and deteriorates rapidly. Always avoid driving machine through a
puddle of gasoline, fuel oil, lubricating oil, or grease. Never let a tire stand in an oil or grease
spot overnight.
Store Tires Properly
The best of care given to tires in service by operators and maintenance personnel can be
completely nullified by careless storage. Time is not the only contributing factor to the
deterioration of rubber products. Therefore, tires that are to be stored must be protected from
light, heat, oils, dirt, moisture, and ozone. Stored tires should be carefully covered with a
tarpaulin or some other suitable material, such as opaque plastic sheets, to prevent contact
with the contaminants listed above.
Proper Handling of Tires and Wheel Rim Parts
Tires should be stored vertically. Horizontal stacking may compress the tire walls, making
inflation difficult. If tires are stored in racks, the lower supporting members should provide as
broad a surface as possible to the tire tread to avoid a concentration of load.
The beads of tubeless tires must be protected from damage or a faulty air seal will result.
Do not use hooks, cables, or chains in contact with the tire beads when lifting these tires. If
forklift trucks are used for handling, they should be equipped with broad, well-rounded arms
to distribute the load and prevent damage to the tire bead. When handling tires with the fork
truck do not scrape the fork across the bead.

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Tubeless tire rims perform an important function as part of the assembly air seal. Proper care,
therefore, must be taken not to distort or mutilate the rim parts because they must mate properly
to form part of the basic air chamber. Since the rim base and bead seat band are mating
surfaces, distortion may prevent easy assembly as well as possibly resulting in no seal.
Never drop, tumble, or roll rim parts.
If rim parts are stored outdoors, they should be given a protective coat of a good commercial
primer.
Similar parts should be stacked neatly to prevent distortion.
Babbitt or lead hammers, not sledge hammers, should be used in assembling rim parts.
O-Rings are seals and should be carefully stored in a cool, dry place where they will not be
injured or damaged.
Valve cores should also be stored in a cool, dry and clean place.
(13) Service Tools
Refer to 22.2 Service Tools on page 22-4 section for part numbers of the nitrogen tire inflation
kit shown in Figure 9.310 and general service tools required.
(14) Tire Pressures
Table 9.25 - Tire Pressures
Front Centre & Rear
Model Brand Tire Size Tread bar psi bar psi
Bridgestone 29.5 R 25 VLT 4.0 58 5.0 73
Bridgestone 29.5 R 25 VMT 4.0 58 5.0 73
Michelin 29.5 R 25 XADN 2.8 40 3.8 55
Triangle 29.5 R 25 TB516 4.0 58 4.9 71
TA400 Magna 29.5 R 25 MA04 5.2 75 5.2 75
Techking 29.5 R 25 ET6A 2.8 41 4.5 65
Maxam 29.5 R 25 MS302 3.2 46 3.2 46
BKT 29.5 R 25 SR40 4.5 65 4.5 65
Michelin 29.5 R 25 XADN+ 3.25 47 4.5 65

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(15) Tubeless Tire Leak Diagnosis

Diagnostics

� WARNING
• Do not attempt repair of wheel components.

NOTICE
• Weld trim should follow rim contour.

Table 9.26 - Tubeless Tire Leak Diagnosis

Occasionally a tubeless off highway tire/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 tire 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
Twisted or damaged O-Ring Replace O-Ring (lubricate)
Tire cuts and snags Repair tire damage
Bead area awl holes Repair inner liner (preferred)
Leakage between tire bead trim With tire removed from rim:
• Clean tire 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).
• Mount tire using a lubricant such as
Murphy's Tire and tube Mounting
Compound, or equivalent, on tire beads
and rim bead seat area.

(16) Special Torque Specification

Table 9.27 - Special Torque Specification
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
Figure 9.261 29 Wheel Nut 600 442

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Intentionally Left Blank

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 Fuel System 10

Table of Content
10 Fuel System...............................................................................................10-1
10.1 Description ................................................................................................... 10-2
10.2 Operation ..................................................................................................... 10-4
10.3 Cleanliness Requirement ............................................................................. 10-5
10.4 Fuel Tank...................................................................................................... 10-6
(1) Removal .................................................................................................. 10-6
(2) Disassembly ............................................................................................ 10-8
(3) Assembly ................................................................................................. 10-8
(4) Installation ............................................................................................... 10-9
10.5 Maintenance............................................................................................... 10-10
(1) Fuel Filter............................................................................................... 10-10
(a) Removal............................................................................................ 10-10
(b) Installation......................................................................................... 10-10
(2) Fuel Filter - Water Separator ................................................................. 10-11
(3) Fuel Filler Cap ....................................................................................... 10-12
(a) Removal............................................................................................ 10-12
(b) Installation......................................................................................... 10-12
(4) Bleeding the Fuel System...................................................................... 10-13
(5) Special Tools ......................................................................................... 10-14
10.6 Troubleshooting.......................................................................................... 10-15
(1) SDP3 Fuel System Tests....................................................................... 10-19
10.7 Electronic Foot Pedal ................................................................................. 10-20
(1) Description............................................................................................. 10-20
(2) Removal ................................................................................................ 10-21
(3) Installation ............................................................................................. 10-22
(4) Maintenance .......................................................................................... 10-22

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10 Fuel System

10 Fuel System
10.1 Description

Figure 10.1 - Fuel Flow Schematic

1. Feed Pump 5. Cylinders B. Feed Pump
2. Hand Pump 6. Fuel Tank C. Safety Valve
3. Control Unit 7. Return Pipe D. Overflow Valve
4. Fuel Filter A. Check Valve E. Drain Nipple

NOTICE
• Before removing injectors, the fuel passages must be blown out to prevent the fuel flow
from entering the cylinder head.

Numbers in parentheses refer to Figure 10.1, unless otherwise specified.

The fuel system consists of the fuel filter (4), fuel pump (2, 1 and B), control unit (3), PDE fuel
injectors, fuel tank (6) and the necessary connecting fuel lines.
The fuel filter (4) is alongside the fuel pump. Refer to Figure 10.5 for location of the engine
fuel filter.
Fuel pump (2) transfers the fuel from the fuel tank (6), via fuel filter (4), to the fuel injectors.
The PDE fuel injection (high pressure injection) system makes continual, precise adjustments to
ensure optimal fuel delivery in all conditions. It is able to vary the volume and timing of injection,
thus minimizing fuel consumption and harmful emissions without restricting torque build-up.
The benefits achieved from the PDE fuel injection system are:

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 Fuel System 10

• Lower emission and higher outputs due to high pressure injection in all usage ranges.
• Reduction in noise and emission due to injection rate control.
• Improved performance due to increased flexibility in injection timing setting.
• Independent control of injection pressure in response to rotation and load.

12 13
14 8
20
21
17
9 2 8
19

16
ENGINE 1 15
FUEL FILTER

18
6
TANK REAR PORT
11
7

TANK FRONT PORT

10
7
17 5
3,4,5,6
6 3 4
6
MOT02150

Figure 10.2 - Fuel Lines

1. Fuel-Water Separator 8. Adaptor 15. Bolt
2. Fuel Shut Off Valve 9. Hose Assembly 16. Washer
3. Bracket Assembly 10. Hose Assembly 17. Elbow
4. Bolt 11. Hose Assembly 18. Clamp
5. Washer 12. Bracket 19. Washer
6. Clamp 13. Bolt 20. Plate
7. Adaptor 14. Washer 21. Adaptor

Flexible fuel lines (9, 10 and 11), refer to Figure 10.2, are used to facilitate connection of
lines leading to and from the fuel tank (1), and to minimize the effects of any vibration in the
installation.
When installing the fuel lines, it is recommended that connections be tightened only sufficiently
to prevent leakage of fuel; thus flared ends of the fuel lines will not become twisted or fractured
because of excessive tightening.
A fuel tank breather/filter assembly is incorporated into the fuel cap (3,(1) Removal on page
10-6), allowing fuel tank (6) to vent to atmosphere, preventing pressure from building up within
the fuel tank (6) assembly.

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10.2 Operation
Numbers in parentheses refer to Figure 10.3, unless otherwise specified.
The basic operation can be described as a sequence of four separate phases: the filling phase,
the spill phase, the injection phase, and the pressure reduction phase.
A low pressure fuel delivery pump supplies filtered diesel fuel into the cylinder head fuel ducts,
and into each injector fuel port of constant stroke pump plunger injector, which is overhead
camshaft operated
During the filling phase, pump plunger (2) moves up to it’s highest position. Fuel valve (1) is in
it’s open position and fuel can flow in to the barrel from the fuel duct, (3)
The spill phase begins when the camshaft starts to press pump plunger (2). The fuel can flow
through fuel valve (1) through the hole in the unit injector and out through fuel duct (3).
The injection phase begins when the fuel valve (1) closes. The fuel valve closes when voltage
is applied to the solenoid valve. The injection phase continues as long as fuel valve (1) is
remains closed.
Injection stops when the fuel valve (1) opens and the pressure in the unit injector drops
below the nozzle’s opening pressure. It’s the closed or open position of the fuel valve which
determines when injection should begin and end
The fuel injector for each cylinder is constantly fed with high-pressure fuel from the rail. Fuel is
injected into the combustion chamber through the injector nozzle.

Figure 10.3 - Fuel Injector System

1. Fuel Valve 2. Pump Plunger 3. Fuel Duct

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10.3 Cleanliness Requirement

� CAUTION
• Many internal parts in the fuel system are extremely sensitive to dirt and water droplets.
This is because the dimensions are very small, the surface finish requirements are high
and the pressures are very high.

Cleanliness is more important than ever when working on fuel system components. Hence it is
necessary to follow certain pre-requisites for maintaining cleanliness, as follows:
• Do not use compressed air for cleaning purposes.
• Only use lint free cloths when cleaning , fitting or removing fuel system components.
• When removing and fitting components, do not use materials like cardboard or wood.
• Only use undamaged tools (not with split chrome surfaces).
• Do not remove parts from their original enclosure until immediately before assembly.
• If any part needs to be sent somewhere: use a new plastic bag and seal it properly. If
possible, use the original packing of the new part.

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10.4 Fuel Tank

(1) Removal

18
19 11
16 12
23 17
10
24
14,15 22

12
21
1

6 20
7
3
4

4
5

8
MOT04524
9

Figure 10.4 - Fuel Tank Installation

1. Fuel Tank Assembly 10. Cover Plate 19. Washer
2. Tube Assembly - Strainer 11. Bolt 20. Cover Plate
3. Bolt 12. Washer 21. Bolt
4. Washer - Hardened 13. Nitrile Gasket 22. Bracket
5. Nut 14. Cap Assembly - Fuel 23. Bolt
6. Bolt 15. Cartridge - Filter Kit 24. Washer
7. Washer 16. Fuel Level Sender 25. Lock
8. Bonded Seal 17. Gasket 26. Key
9. Drain Valve - Magnetic 18. Bolt

Numbers in parentheses refer to Figure 10.4, unless otherwise specified.

� WARNING
• To prevent personal injury and property damage, be sure wheel blocks, blocking materials
and lifting equipment are correctly secured and are of adequate capacity to do the job safely.
• Do not work near or under an unblocked or unsupported cab. Use the cab safety prop at
all times.
• When the battery master switch is in the OFF position and the adjacent LED is illuminated
electrical power remains connected to the truck. Electrical power remains connected to the
truck for 60 seconds after the battery master switch has been selected to the OFF position.

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 Fuel System 10

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the
engine. Block all road wheels.
2. Raise the hood using the hood raise switch next to the master switch. Refer to Figure
15.102.
3. Place the battery master switch in the 'OFF' position.
4. Remove the padlock (25) and remove the fuel cap (14) from the fuel tank (1).
5. Remove the fuel filler assembly (2) from the fuel tank (1) and clean with clean diesel fuel.
6. With a suitable container in position, remove the drain plug (9) from the fuel tank (1) and
drain the fuel from the fuel tank (1). Reinstall the drain plug (9) and tighten securely when
the fuel tank (1) is completely drained.
7. Identify and tag fuel lines (9, 10 and 11, Figure 10.2) and with a suitable container available
to catch leakage, disconnect the fuel lines (9, 10 and 11, Figure 10.2). Cap open line
ends and adaptors to prevent entry of dirt.
8. Identify and tag the electrical connection (B5) fuel sender unit (16). Disconnect connector
(B5), cap both connections to prevent the ingress of dirt.
9. Remove the right hand side fender assembly, as required. Refer to (1) Removal on page
16-51.
10. Remove the right hand front wheel rim and tire. Refer to 9.6 Wheel Rim and Tire on page
9-123.
11. Using suitable lifting equipment, support the fuel tank (1) assembly.
12. Remove the bolts (6) and washers (7) securing the fuel tank (1) assembly to the front
frame rail.
13. Remove bolts (3), washers (4) and nuts (5).
14. Manoeuvre the tank rearwards to clear the front frame bracket, lift the tank and secure
to a suitable maintenance area.

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10 Fuel System

(2) Disassembly
Numbers in parentheses refer to (1) Removal on page 10-6, unless otherwise specified.

PROCEDURE
1. Remove the bolts (18) and washers (19) securing the fuel sender (16) to the fuel tank (1).
Remove the fuel sender (16) and gasket (17).
2. Remove the bolts (21) and washers (12) securing the cover plate (20) to the fuel tank
(1). Remove the cover plate (20).
3. If required, remove bolts (11) and washers (12) securing the tank access plate (10).
Remove the tank access plate (10) and the gasket (13).
4. If required, remove bolts (23) and washers (24) securing the brackets (22). Remove the
brackets (22).

(3) Assembly
Numbers in parentheses refer to Figure 10.4, unless otherwise specified.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. If removed, install brackets (22) and secure with bolts (23) and washers (24).
2. If removed, install tank access plate (10) with new gasket (13) and secure with bolts (11)
and washers (12).
3. Install cover plate (20) and secure with bolts (21) and washers (12).
4. Install the fuel sender (16) with new gasket (17), secure with bolts (18) and washers (19).

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 Fuel System 10

(4) Installation
Numbers in parentheses refer to Figure 10.4, unless otherwise specified.

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

NOTICE
• Tighten all fasteners to standard torques specified in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Using suitable lifting equipment, position the fuel tank (1) assembly to the front frame.
2. Secure the front of the fuel tank (1) assembly to the front frame rail with bolts (6) and
washers (7). Torque tighten bolts (6).
3. Install the bolts (3) washers (4) and nuts (5) and secure the tank to the front frame. Torque
tighten bolts (3) and nuts (5) to 500 ± 30 Nm (369 ± 22 lbf ft).
4. Install the right hand front wheel rim and tire. Refer to 9.6 Wheel Rim and Tire on page
9-123.
5. Install the right fender assembly. Refer to (2) Installation on page 16-57
6. Remove the blanking caps from the electrical connections (B5), Connect and secure to
the fuel sender unit (16).
7. Remove the blanking caps and secure the fuel lines (9, 10 and 11, Figure 10.2) to the
adaptors. Torque tighten fuel lines to 55 Nm (40.5 lbf ft).
8. Install the fuel filler assembly (2) in the fuel tank (1).
9. Replace the fuel filter assemblies. Refer to (1) Fuel Filter on page 10-10.
10. Fill the fuel tank (1) assembly with clean diesel fuel as specified in (1) Recommended
Lubricants on page 4-16.
11. Install the fuel filler cap (3) assembly on the fuel tank filler neck. Tighten the fuel cap (3)
securely and secure in place with padlock.
12. Place the battery master switch in the 'ON' position, start the engine and run for a few
minutes to ensure fuel is being supplied to the engine. Check for leaks at the fuel lines (9,
10 and 11, Figure 10.2) and tighten if required.
13. Remove wheel blocks from all road wheels.

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10 Fuel System

10.5 Maintenance
(1) Fuel Filter

� CAUTION
• Fit the filter elements in the filter covers before placing them in the fuel filter housings. If you
do not do this you will damage the filter elements.

Numbers in parentheses refer to Figure 10.6, unless otherwise specified.

(a) Removal

PROCEDURE
1. Unscrew the filter cap (1), using 36 mm socket 3 to 4 turns.
2. Wait for two minutes for the fuel to drain out of the filter housing.
3. Unscrew the filter cap (1), remove the cap with filter attached.
4. Remove the filter element (3) from the cap (1), by carefully bending it to one side.
5. Discard the element (3) in accordance with local environmental instructions.

MOT04922 MOT04923

Figure 10.5 - Fuel Filter Installation Figure 10.6 - Fuel Filter Assembly
1. Filter Lid 2. O-Ring
3. Filter Element

(b) Installation

PROCEDURE
1. Replace the O-ring (2), lubricate new O-ring with suitable grease.
2. Ensure that the filter housing is drained of fuel.
3. Install new filter element (3), by pressing the element into the snap fastener in the filter
lid (1).
4. Install the filter lid (1) with new element (3) to the filter housing. Torque tighten to 25 ± 5
Nm (18 ± 3 lbf ft).
5. Bleed the fuel system. Refer to (4) Bleeding the Fuel System on page 10-13.

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 Fuel System 10

(2) Fuel Filter - Water Separator

� CAUTION
• Fit the filter elements in the filter covers before placing them in the fuel filter housings. If you
do not do this you will damage the filter elements.

Numbers in parentheses refer to Figure 10.7, unless otherwise specified.

MOT05370

Figure 10.7 - Fuel Filter - Water Separator

1. Drain Tap 2. Shut Off Valve

PROCEDURE
1. Ensure that the fuel shut off valve (2) is closed, and that a suitable container is placed
under the filter.
2. Open the drain tap (1) on the filter cover and let the fluid run down into the container.
3. Unscrew the filter cover.
4. Unscrew the filter from the filter head.
5. Discard the old filter and use a new filter.
6. Lubricate the O-ring in the filter cover with engine oil.
7. Screw the filter cover onto the new filter by hand. Make sure that the drain tap (1) is fully
closed.
8. Lubricate the O-ring on the filter with engine.
9. Fill the width of the filter with clean fuel.
10. Screw the filter into position until the O-ring rests against the filter head. Tighten the filter
another 1/2 to 3/4 turn by hand.
11. Open the shut-off valve (2) and check the system for leaks.
12. Bleed the fuel system. Refer to (4) Bleeding the Fuel System on page 10-13.

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10 Fuel System

(3) Fuel Filler Cap

Numbers in parentheses refer to Figure 10.8, unless otherwise specified.
(a) Removal

PROCEDURE
1. If required, unlock and remove the padlock securing the fuel filler cap (1).
2. Lift and rotate the fuel cap handle (2), remove the fuel filler cap (1).
3. Remove the three screws securing the fuel strainer to the fuel filler tube (2, (a) Removal
on page 10-12). Remove the fuel strainer.
4. On the underside of the fuel filler cap, remove the two screws securing the cartridge valve
(3) to the cap.
5. Remove the cartridge valve from the cap.
6. Discard the cartridge valve, screws and O-rings.
7. Clean the top of the fuel filler cap and valve cartridge cavity.
8. Clean the fuel strainer.

MOT04689
2
Figure 10.8 - Fuel Filler Cap
1. Fuel Filler Cap 2. Fuel Cap Handle 3. Cartridge Valve

(b) Installation

PROCEDURE
1. Install the fuel strainer to the fuel filler tube (2, (b) Installation on page 10-12), tighten the
three screws.
2. Install new O-rings to the new screws supplied in the cartridge valve kit.
3. Install new O-rings to the new cartridge valve (3), supplied.
4. Install the new cartridge valve (3) to the fuel filler cap (1).
5. Torque tighten the screws to 1.1-1.5 Nm (0.8-1.1 lbf ft).
6. Install the fuel filler cap (1), rotate and push down the handle (2).
7. If removed, install the padlock.

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 Fuel System 10

(4) Bleeding the Fuel System

Numbers in parentheses refer to Figure 10.9, unless otherwise specified.

2
4
3

MOT04924

Figure 10.9 - Fuel Filter

1. Filter Bleed Nipple 2. Hand Pump 3. Manifold Bleed Nipple
4. Overflow Valve

PROCEDURE
1. Attach a clear plastic hose to the filter bleed nipple (1), and to a fuel container to catch
the bled fuel.
2. Loosen the hand pump (2) handle.
3. Open the filter bleed nipple (1).
4. Operate the pump by hand until the fuel comes out of the hose. This may take around 100
pump strokes depending on the installation.
5. Continue to pump until fuel without air bubbles comes out of the hose (approximately 20
strokes).
6. Close the bleed nipple (1) and remove the hose.
7. Attach the plastic hose to the manifold bleed nipple (3).
8. Open the manifold bleed nipple (3).
9. Operate the pump by hand until fuel without air bubbles comes out of the hose
(approximately 50 strokes).
10. Close the manifold bleed nipple (3) and remove the plastic hose.
11. Operate the pump by hand until the overflow valve (4) opens (approximately 20 strokes). A
creaking sound is heard when the overflow valve (4) opens.

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10 Fuel System

12. Tighten the hand pump handle.

13. Start the engine and check for leaks. Refer to 5.11 Starting on page 5-27.
14. If the engine fails to start, repeat Step 8.

(5) Special Tools

NOTICE
Pressure is displayed in Mpa. 0.1 MPa = 1 bar

Scania SDP3 software, communication interface to vehicle (VCI) Scania VCI2 and adaptor
cable (Part number 1862924).
Scania pressure measurement kit (Part Number 99 362) or another suitable sensor and
multimeter are required.

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 Fuel System 10

10.6 Troubleshooting
(1) Preparation
Text in Italics refers to a test or procedure using SPD3 or Scania troubleshooting SAIL
03:14–01 manual.
The following basic checks should always be carried out before troubleshooting is started:
• Check that there is no water in the fuel.
• Check that there is no external leakage from the high or low pressure circuit.
• Check fault codes in SDP3.
• Use SDP3 to check that the high pressure section can build up and retain pressure. Use
Fuel leak test for help in making decisions on further troubleshooting.
Determining whether the high pressure circuit has leaks or not is the most important factor for
further troubleshooting. Different faults that could occur and which tests can be used to locate
the reason for the fault are found in the following tables:
(2) Internal Leak in the High Pressure Circuit
Table 10.1 - Injectors Leak Into Cylinder
Component/Fault Test/Procedure SDP3 SAIL
03:14–01
Injectors leak into cylinder Fuel leak test X
• Usually possible to locate • Check for internal leaks
using SDP3 test.
• Cylinder balancing
• If a fault occurs in several
• Cylinder output test
injectors simultaneously, the
SDP3 tests do not work as Cylinder Shut-off X
well.
Activating injector solenoid X
• Increased fuel consump- valves
tion/black smoke. H5, H6
Verification of a faulty injector
• Raised emission levels. (plugging the injector)

Table 10.2 - Injectors Leak Into The Return Fuel Manifold

Component/Fault Test/Procedure SDP3 SAIL
03:14–01
Injectors leak into the return fuel Fuel leak test X
manifold
• Check for internal leaks
• SDP3 tests can help to find
• Cylinder balancing
the suspected injector.
• Cylinder output test
• Large leakage produces
increased flow/pressure at the Cylinder Shut-off X
fuel manifold test connection.
Activating injector solenoid X
• Small leakage is only found valves
by ruling out injectors through Verification of a faulty injector H5, H6
plugging. (plugging the injector)
Checking return fuel pressure H2, H7
(does not identify which cylinder)

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10 Fuel System

Table 10.3 - Leaking High Pressure Connection

Component/Fault Test/Procedure SDP3 SAIL
03:14–01
Leaking high pressure connection Detach and visually inspect
• Leaks into the fuel manifold. Verification of a faulty injector H5, H6
(plugging the injector)
• Not indicated in SPD3.
Checking return fuel pressure H2, H7
• Checking the torque on the
(does not identify which cylinder)
high pressure connections
may be enough to eliminate
leakage.

Table 10.4 - Leaking Safety Valve

Component/Fault Test/Procedure SDP3 SAIL
03:14–01
Leaking safety valve Feel whether the return pipe
becomes hot within 15 seconds at
• Leaks into the fuel manifold.
idling.
• Does not produce increased
Checking the safety valve H3, H8
flow/pressure at the fuel
manifold test connection.
• Large leakage due to triggered
safety valve makes the return
pipe hot and limits the
pressure to about 1 000 bar
(14 500 psi)
• If the safety valve is triggered,
a check is required to
determine whether the
problem is a defective safety
valve or the fuel inlet metering
valve being in the open
position.
• A small leak requires a visual
check to see whether fuel is
coming out.

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 Fuel System 10

Table 10.5 - Leaking Cylinder Head on High Pressure Pump

Component/Fault Test/Procedure SDP3 SAIL
03:14–01
Leaking cylinder head on high Verification of a faulty injector H5, H6
pressure pump (entire accumulator plugged)
• Leaks into the return line to Quick test: Carry out Checking H2, H7
the tank. return fuel pressure and
Checking for internal leaks
• Does not produce increased
simultaneously. Check whether
flow/pressure at the fuel
the return pipe from the safety
manifold test connection.
valve gets hot. Also check whether
• Usually larger leakage at the return flow/pressure at the fuel
higher pressure and smaller at manifold test connection is high.
lower pressure. If the return pipe does not get hot
and the return flow/pressure is not
• The troubleshooting method
high when there is large leakage
Checking for internal leaks
in the high pressure circuit, then
is often unable to raise the
the pump head may be leaking.
pressure to 2 400 bar (34 800
psi)

(3) No Internal Leak in the High Pressure Circuit

Table 10.6 - Fuel Inlet Metering Valve Jammed
Component/Fault Fault Result on Test/Procedure SDP3 SAIL
the Engine 03:14–01
The fuel inlet Poor control of the Checking of the fuel inlet X
metering valve is pressure in the high metering valve
jammed. pressure circuit.
Checking the fuel X
pressure in the
accumulator

Table 10.7 - Blocked Filters

Component/Fault Fault Result on Test/Procedure SDP3 SAIL
the Engine 03:14–01
Blocked filters due Engine loses power Low pressure check L1
to dirt/paraffin or under load or has
Checking the suction L2
pinched/damaged starting difficulties.
filter
fuel lines result in
suction resistance. Checking the supply L6
pressure at test
connection on high
pressure pump

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10 Fuel System

Table 10.8 - Suction Leakage

Component/Fault Fault Result on Test/Procedure SDP3 SAIL
the Engine 03:14–01
Suction leakage on Engine loses Low pressure check L1
tank pick-up unit, pressure in
Checking the suction L2
couplings, fuel lines low pressure
filter
or feed pump. circuit or has
starting difficulties. Checking the supply L6
Recurring air in pressure at test
suction filter or connection on high
pressure filter. pressure pump

Table 10.9 - Low Pressure

Component/Fault Fault Result on Test/Procedure SDP3 SAIL
the Engine 03:14–01
Inner leakage in Low/no pressure Checking supply L6
filter housing due in low pressure pressure at test
to defective safety circuit. connection on high
valve in pressure pressure pump
filter housing or
defective seal on
pressure filter.

Table 10.10 - High/Low Pressure

Component/Fault Fault Result on Test/Procedure SDP3 SAIL
the Engine 03:14–01
Defective pressure High or low/no Checking supply L6
regulator or pressure in low pressure at test
mechanical damage pressure circuit. connection on high
on feed pump Low/no supply pressure pump
pressure.
Checking the feed pump L3
Checking the feed pump L5
drive

Table 10.11 - High Pressure Pump

Component/Fault Fault Result on Test/Procedure SDP3 SAIL
the Engine 03:14–01
Mechanical damage Pump element is Checking the high H9
on the high pressure stuck/damaged. pressure pump
pump. Worn roller tappet,
or worn or broken
camshaft.

Table 10.12 - High Pressure Pump Drive

Component/Fault Fault Result on Test/Procedure SDP3 SAIL
the Engine 03:14–01
Mechanical damage Drove damaged Checking the high L5
on the high pressure gear wheel in pressure pump drive
pump drive. timing gear or loose
pump gear.

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 Fuel System 10

(1) SDP3 Fuel System Tests

The SDP3 system diagnostic tool is used to help troubleshoot the engine fuel system.
The following parameters can be checked using the SDP3 diagnostic tool:
• Cylinder balancing
• Cylinder shut-off
• Leak testing the safety valve
• Checking the fuel inlet metering valve
• Cylinder output test
• Checking fuel pressure in the accumulator
• Checking internal leakage.
Refer to the Scania engine maintenance manual.

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10 Fuel System

10.7 Electronic Foot Pedal

(1) Description

3
2

6
1

SM3607

Figure 10.10 - Electronic Foot Pedal

1. Accelerator Assembly 3. Washer 5. Gasket
2. Bolt 4. Harness 6. Connector - Potentiometer

Numbers in parentheses refer to Figure 10.10, unless otherwise specified.

NOTICE
• The engine MUST be started with foot 'OFF' pedal assembly (1).

The electronic foot pedal assembly provides an electrical signal to the engine's fuel control
system in proportion to the degree of pedal actuation. Maximum and minimum stops are built
into the pedal assembly during manufacture. The pedal assembly comes preset and therefore
no adjustment is necessary.
Refer to Figure 10.11.
The foot pedal receives a 5V (VREF) supply from the MCU via the vehicle Dash harness
connection at wire W184. The return line is via wire W166. The signal to determine the level of
acceleration requested by the operator (throttle pedal position) is received at the engine ECU
via the MCU, wire W167.
For safety there is an idle activation switch arrangement to determine that the pedal is at the idle
position. When at idle, the switch is closed and the signal is sent back to the engine ECU via the
MCU, wire W168 (black connector). Should there be a throttle signal problem, the engine ECU
(via the MCU) will be able to determine this via the idle validation side of the circuit, wire W419.

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 Fuel System 10

The kickdown facility is not operational with the Alison transmission. B2.X3 (grey connector)
however remains electrically connected.
MCU (K18) Throttle Pedal (B2)
VREF 5V - XL.51 WH - W184 B2.X1.D
Pedal Position - XL.22 WH - W167 B2.X1.E
Idle/Deactivated - XL.34 WH - W168 B2.X2.B
Idle/Activated - XL.34 WH - W419 B2.X2.C

Dashboard Panel (K20)

Kickdown_OFF - XK.26 WH - W219 B2.X3.B
Kickdown_ON - XK.26 WH - W172 B2.X3.C
PCB/Fuse Panel
Rocker Switches - F30 BK - W180 B2.X2.A
BK - W218 B2.X3.A
XGND3 BN - W166 B2.X1.C SM3608

Figure 10.11 - Electronic Foot Pedal Wiring Detail

(2) Removal
Numbers in parentheses refer to Figure 10.10, unless otherwise specified.

� WARNING
• To prevent personal injury and property damage, ensure that wheel blocks are properly
secured and of adequate capacity to do the job safely.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

PROCEDURE
1. Position the vehicle in a level work area, ensure the body is fully lowered, apply the parking
brake and switch off the engine. Turn steering wheel in both directions several times to
relieve any pressure in the steering circuit.
2. Block all road wheels and place the battery master switch in the OFF position.
3. Remove front cab floor mat to clear the pedal assembly (1) and mounting plates.
4. Identify and tag the electrical connections.
5. Disconnect the following electrical connections:
a. Idle/Activation connection B2.X2 - Dash harness
b. Kickdown connection B2.X3 - Dash harness (not operational)
c. Potentiometer connection B2.X1 - Dash harness
6. Install protective caps to all connections to prevent ingress of dirt.
7. Remove bolts (2) and washers (3) from pedal assembly (1) and remove pedal from the cab.
8. Remove gasket (5) from the pedal assembly (1).

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10 Fuel System

(3) Installation
Numbers in parentheses refer to Figure 10.10, unless otherwise specified.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.
• The engine MUST be started with foot 'OFF' pedal assembly (1).

PROCEDURE
1. Install gasket (5) to the pedal assembly (1).
2. Position pedal assembly (1) in position and secure with bolts (2) and washers (3).
3. Remove protective caps from electrical connections.
4. Identify and connect the following electrical connections:
a. Potentiometer connection B2.X1 - Dash harness
b. Kickdown connection B2.X3 - Dash harness (not operational)
c. Idle/Activation connection B2.X2 - Dash harness
5. Install the front floor mat on cab floor and ensure that pedal assembly (1) is free to operate.
6. Place the battery master switch in the 'ON' position, remove wheel blocks and start the
engine.
7. Ensure that pedal assembly (1) operates correctly.

(4) Maintenance
Numbers in parentheses refer to Figure 10.11, unless otherwise specified.
Limited repair of the electronic foot pedal assembly is by replacement of parts only. Refer to
vehicle Illustrated Parts Catalogue for spare part numbers.
A number of checks can be made to determine correct voltages are being seen at the pedal,
which can help in diagnosis of problems. These are follows:
Voltages range which should be seen assuming correct operation.
Check Wire Identification Percentage Expected Voltage
Input W184 - 4.95 V - 5.05 V
Idle W167 10 - 20% of Input 0.5 V to 1.0 V
Full Throttle W167 70 - 85% of Input 3.5 V to 4.25 V

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 Hydraulic System 11

Table of Content
11 Hydraulic System...................................................................................... 11-1
11.1 Description ................................................................................................... 11-3
11.2 Main Hydraulic Valve.................................................................................... 11-3
(1) Description............................................................................................... 11-3
(a) System Relief...................................................................................... 11-7
(b) System Priority.................................................................................... 11-7
(c) Steering............................................................................................... 11-8
(d) Emergency Steering ........................................................................... 11-8
(e) Brake Charging ................................................................................... 11-8
(f) Service Brake...................................................................................... 11-8
(g) Park/Emergency Brake ....................................................................... 11-9
(h) Body Control ....................................................................................... 11-9
(i) Cooling Fan Drive System .................................................................. 11-9
(j) Cold Start .......................................................................................... 11-10
(2) Removal ................................................................................................ 11-12
(3) Disassembly .......................................................................................... 11-15
(4) Assembly ............................................................................................... 11-17
(5) Installation ............................................................................................. 11-19
(6) Integral Valve Torque Values ................................................................. 11-22
(7) O-Ring Face Seals (ORFS)................................................................... 11-24
11.3 Hydraulic Tank............................................................................................ 11-25
(1) Description............................................................................................. 11-25
(2) Operation............................................................................................... 11-27
(3) Removal ................................................................................................ 11-29
(4) Disassembly and Inspection.................................................................. 11-32
(5) Assembly ............................................................................................... 11-34
(6) Installation ............................................................................................. 11-36
11.4 Main Hydraulic Pump ................................................................................. 11-37
(1) Description............................................................................................. 11-37
(2) Operation............................................................................................... 11-42
(3) Removal ................................................................................................ 11-45
(4) Disassembly .......................................................................................... 11-46
(a) Rear Pump........................................................................................ 11-46
(b) Front Pump ....................................................................................... 11-49
(c) Control Valve..................................................................................... 11-52
(5) Inspection .............................................................................................. 11-52
(a) Rotating Group.................................................................................. 11-52
(b) Pump Housing and Associated Parts ............................................... 11-53
(c) Driveshaft and Associated Parts....................................................... 11-53
(6) Assembly ............................................................................................... 11-54
(a) Front and Rear Pumps...................................................................... 11-54
(b) Control Valve..................................................................................... 11-59
(7) Installation ............................................................................................. 11-59
(8) Filling and Bleeding ............................................................................... 11-60
(9) Starting .................................................................................................. 11-62
(10) Pressure Checks ................................................................................... 11-62
(11) Troubleshooting ..................................................................................... 11-64
(12) Pump Settings ....................................................................................... 11-65

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11 Hydraulic System

(a) Differential Pressure Setting ............................................................. 11-65

(b) Delivery Pressure Setting ................................................................. 11-66
(13) Adjustable O-Ring Seal Hydraulic Pipe Fittings .................................... 11-68
(14) Recommended Periodic Oil Change Periods and Oil
Specifications ........................................................................................ 11-70
(15) Wear Limits............................................................................................ 11-70
11.5 Maintenance............................................................................................... 11-70
(1) Checking Oil Level................................................................................. 11-70
(2) Replacing Filter Element ....................................................................... 11-71
(3) Transmission Cooler Fan Drive Troubleshooting .................................. 11-72

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 Hydraulic System 11

11 Hydraulic System
11.1 Description
NOTICE
• Recommended oil cleanliness level to ISO 4406 18/16/13.

The hydraulic system consists of the following sub systems:

• Brake Circuit including Cooling
• Steering Circuit including Emergency
• Body Circuit
• Fan Drive Circuit
• Dropbox Control Circuit
• Axle Differential Lock Circuit
For hydraulic system schematics, refer to Appendix B Hydraulic System Schematic Diagram on
page B-1.
11.2 Main Hydraulic Valve
(1) Description
Numbers in parentheses refer to Figure 11.1 , Figure 11.2 and Figure 11.3, unless otherwise
specified.
The Main Hydraulic Valve Assembly is mounted on the left hand side of the tractor frame
next to the dropbox.
The Main Hydraulic Valve Assembly controls the following functions:
• System relief protection for main pump.
• System priority
• Steering
• Brake charging
• Service brake
• Park/emergency brake
• Body control
• Transmission cooler fan drive
• Cold start
Valves that control all the above functions are integrated into the Main Hydraulic Valve Assembly
and are identified in Figure 11.1 , Figure 11.2 and Figure 11.3.

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11 Hydraulic System

MOT05218

Figure 11.1 - Main Hydraulic Valve Assembly Schematic

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 Hydraulic System 11

CT25

CT30

84

CT27
CT1
CT28

CT39
CT19

CT10
CT3A CT38
CT6
CT3

CT17

CT34
81

CT15
CT18

CT33

CT35
CT26
CT8

CT10
CT21
MOT05021A/B

Figure 11.2 - Main Hydraulic Valve Assembly

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11 Hydraulic System

CT7

CT5

CT4

CT22

CT16

CT13 CT23
CT37
CT29
CT11

CT14

CT31
CT32

CT12

CT36

CT20

CT2

CT24

CT42

CT34

CT43
CT41

MOT05021C/D

Figure 11.3 - Main Hydraulic Valve Assembly

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 Hydraulic System 11

Cartridge and Valve Positions - CT Numbers

1. Main Relief Valve 15. Load Sense Orifice 30. Hoist LS Orifice Plug
Plug
2. Ground Pump Relief 16. Steering/Unload 31. Park Brake Solenoid Valve
Valve Shuttle
3. Ground Pump Unload 17. Load Sense Shuttle 32. Main Brake Solenoid Valve
Cartridge
3A. Ground Pump Unload 18. Steering Orifice Plug 33. Pilot Valve Orifice Plug
Orifice
4. Ground Pump Check 19. Pump LS Orifice Plug 34. Hoist Shuttle
Cartridge
5. Steering Check 20. Hoist LS Relief Plug 35. Accumulator Orifice Plug
Cartridge
6. Ground Pump 21. DC Pilot Control 36. Hoist LS Pilot Cartridge
Reverse Flow Check Reducer
7. Priority Valve 22. Fan Speed Solenoid 37. Cavity Plug
Cartridge
8. Pilot/Brake Check 23. Fan Speed Solenoid 38. Check Cartridge
Cartridge Cartridge
9. Brake Pressure 24. Dual Check 39. Fan Orifice Plug
Reducer
10. Accumulator Check 25. Hoist Pilot Shuttle 41. Hoist DC Valve
Cartridge - ACC1
11. Accumulator Check 26. Hoist/Fan Shuttle 42. Anti-Cavity Check
Cartridge - ACC2
12. Unloader Pilot 27. DC Pilot Control 43. Hoist Relief Valve
Cartridge Reducer
13. Unload Orifice Plug 28. DC Pilot Control
Reducer
14. Cold Start Solenoid 29. Body Float Solenoid
Cartridge

(a) System Relief

The main relief valve (CT1) protects the main hydraulic valve assembly components against
pressure spikes. This system relief valve is pre-set at 260 bar (3 770 psi) and is non-adjustable.
(b) System Priority
This function automatically ensures that the steering and brake charging circuits are given
preference over the fan and body tipping functions.
When the pump is not running, the priority valve (CT7) is closed. As the main pump starts
rotating it builds up residual pressure and the priority valve opens, feeding the main pump
pressure through to the fan drive (CT22 and CT23) and body control (CT27 and CT28)
solenoids/valves.
During body lift/lower operations and whilst the fan is running, if the demand pressure at the
brake charging or the steering circuit is less than these functions, the priority valve (CT7)
remains open, the oil will always meet the reduced requirements of the charging or steering
circuit.

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If the demand pressure for charging or steering is higher than that demanded by the fan drive
and/or body lift/lower function, this higher pressure will be fed to the main pump load sense
line via the shuttle valves (CT16 and CT17) and therefore enable the main pump to meet the
charging or steering pressure requirements. At the same time the higher load sense pressure
assists the spring in the priority valve (CT7), the priority valve will then close to reduce the flow
to the fan or body lift/lower circuit and therefore making sure the brake charging & steering
functions always have priority over the other functions.
If the demand pressure for fan drive or body lift/lower function is higher than that demanded by
the charging and/or steering function, this higher pressure will be fed to the main pump load
sense line via the shuttle valves (CT26 and CT17) and therefore enable the main pump to meet
the fan drive or body pressure requirements. At the same time this higher load sense pressure
releases the spring in the priority valve (CT7), the priority valve will then open to increase the
flow to the fan or body tipping circuit.
(c) Steering
Refer to 12.1 Description on page 12-3.
Steering actuation pressure is controlled by steering load sense orifice (CT15).The steering
load sense orifice (CT15) controls main pump pressure in the steering load sense line. As
pressure increases, via rate reducing orifice (CT18) through steering load sense orifice (CT15),
main pump pressure increases lifting steering check valve (CT5) allowing steering actuation
pressure to access the steering orbital control valve. Check valve (CT4) isolates the main
steering flow from the emergency steering flow.
Electrical connection ‘port P1S’ sends the steering system pressure value to the MCU. A
warning light will illuminate if the value is low.
(d) Emergency Steering
Refer to 12.1 Description on page 12-3.
The emergency valve (CT3) forms part of the emergency steering system. It is connected to the
main output line of the wheel driven Emergency Steering Pump mounted on the dropbox. Relief
Valve (CT2) limits the pressure at the emergency steering pump to 260 bar (3 770 psi).
(e) Brake Charging
Refer to 14.1 Description on page 14-4.
Brake charge valve (CT12) and brake pressure reducer valve (CT9) are integral valves that
form part of the brake charging function. Brake charge valve (CT12) ensures that there is
sufficient load sense pressure (accumulator No. 3, min. 165 bar (2 392 psi) max. 210 Bar (3
046 psi) at the main pump to allow the charge pressure to be generated. Brake pressure
reducer valve (CT9) maintains a safe operating pressure (max. 160 bar (2 320 psi) within the
front No. 1 and rear No. 2 brake accumulators.
Orifice (CT13) reduces the control flow within the brake charging system, orifice (CT35) controls
the rate of charge to the accumulators.
Check valves (CT10 and CT11) isolate the system from accumulators No. 1 and No. 2. Check
valve (CT8) isolates the system from accumulator No. 3.
Electrical connections ‘ports ACC1S & ACC2S’ send the accumulator pressure values to the
MCU. A warning light will illuminate, and a buzzer will sound if the value is low.
(f) Service Brake
Refer to 14.1 Description on page 14-4.
Brake control valve (CT32) is the integral valve that directs pressure to the remote hydraulic
port of the brake modulating valve, to select the service brakes on when the engine is running
and when the parking brake is selected. Orifice (CT33) reduces the rate of pressure rise to and
from the remote hydraulic port of the brake modulating valve.

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 Hydraulic System 11

(g) Park/Emergency Brake

Refer to 14.1 Description on page 14-4.
Park/Emergency brake solenoid (CT31) is the integral valve that controls hydraulic pressure to
the park and emergency brake function of the truck.
(h) Body Control
Refer to 13.1 Description on page 13-2.
Proportional pressure control valve (CT27) is the integral valve that controls the body lift
function. This valve is operated via the body control lever located in the operators cab. The
body control lever sends an electrical signal to the MCU. Refer to (1) Description on page 15-9.
The MCU processes this signal and delivers an actuating electrical signal to the proportional
pressure control valve (CT27). The proportional pressure control valve (CT27) converts this
electrical signal into a pilot pressure, that then is allowed to operate the body control spool
(CT41) to the lift position.
Relief valve (CT20) limits the raise load sense circuit to a maximum pressure of 210 bar (3
045 psi).
Proportional pressure control valve (CT28) is the integral valve that controls the body lower
function. This valve is operated via the body control lever located in the operators cab. The
body control lever sends an electrical signal to the MCU. Refer to (1) Description on page 15-9.
The MCU processes this signal and delivers an actuating electrical signal to the proportional
pressure control valve (CT28). The proportional pressure control valve (CT28) converts this
electrical signal into a pilot pressure, that then is allowed to operate the body control spool
(CT41) to the lower position.
Hoist valve (CT36) drains the load sense line when a lowering body reaches the proximity
switch on the chassis, body control spool (CT41) returns to the neutral position. Check valve
(CT42) allows for a controlled flow to the lower end of the tip cylinder when the body reaches
the proximity switch. The cylinder will receive oil when the body control spool (CT41) defaults
to the neutral position during float thus enabling the body to travel onto the chassis frame
rails without interruption.
When the body reaches the proximity switch on the chassis, solenoid (CT29) opens to enable
the raise load sense circuit.
Pressure control valve (CT12) maintains a pilot pressure of 40 bar (580 psi) for control valve
(CT27) and the axle differential lock.
Body relief valve (CT43) is located on the raise side of the circuit and prevents pressure spikes
at maximum extension of the cylinders when the body is raised at maximum engine speed.
Relief valve (CT43) is set at 250 bar (3 625 lbf/in²).
(i) Cooling Fan Drive System
Refer to Figure 11.4.
The cooling fan speed is modulated by proportionally controlling the pressure at the fan motor.
Fan speed is a function of the pressure at the fan motor.
On a cold start, the cooling fan will not rotate. A fan stop solenoid valve, mounted on the
left hand forward frame, will remain closed, blocking actuating pressure until the engine oil
temperature reaches 90 °C (195 °F).
The fan stop solenoid valve will remain energized until any of the pre programmed temperature
values are seen by the MCU. Refer to (1) Description on page 15-9.
When any of the following temperature conditions are seen, a signal to de-energize the fan
stop solenoid valve will be initiated and oil flow will be allowed to the fan motor. Refer to (1)
Description on page 15-9

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Table 11.1 - MCU Inputs - Fan Stop Solenoid Valve

MCU Inputs - Fan Stop Solenoid Valve
Input Source Temp Route
Engine Coolant ECU > 85 °C (185 °F) Via CAN 2
Engine Oil ECU > 108 °C (226 °F) Via CAN 2
Air Intake ECU > 54 °C (129 °F) Via CAN 2
Transmission Oil TCU > 80 °C (176 °F) Via CAN 2
Transmission Retarder Oil TCU > 90 °C (194 °F) Via CAN 2
Dropbox Coolant Sensor (Dropbox) > 60 °C (140 °F) B6
Hydraulic Oil Sensor (Main tank) - B29
Air Conditioning ‘ON’ GIGA Panel - Via CAN 3

The fan stop solenoid valve speed pressure is controlled by the Electro-Hydraulic Proportional
Control Valves (CT22 and CT23). A varying current input into these valves is between 0 mA
to 400 mA and controls the pressure proportional to the electrical input. This pressure then
acts upon the Shuttle Valve (CT26) and onto the main pump load sense connection via Shuttle
Valve (CT17). This pressure acts upon the spring chamber of the Dual Check Valve (CT24)
that controls the pressure at the fan.
The fan stop solenoid valve will remain de-energized until the transmission oil temperature falls
to 87 °C (188 °F). At this point the oil flow to the cooling fan will stop.
Orifice (CT39) controls the flow rate in the transmission oil cooler load sense circuit to the
main tank.

MOT05221

Figure 11.4 - Fan Stop Solenoid Valve

1. Port 1 - Fan Motor 2. Port 2 - Main Hydraulic 3. Solenoid Valve (Q12) - MCU
(Port A) Valve (DF1 and DF2) (Via X15)

(j) Cold Start

Cold Start Solenoid (CT14) is the integral valve that controls the cold start function of the main
hydraulic valve assembly.
Cold start solenoid (CT14) energizes when starter motor signal is high, this dumps all load
sense pressure from the main hydraulic pump, rendering the pump off-load. This reduces
parasitic losses during engine cranking procedure.
There is about a 2 second delay before de-energizing cold start solenoid (CT14) (starter motor
signal low). This function prevents brake charging during engine start up, which is particularly
important in cold climates.

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A starter motor high signal is received by the MCU. The MCU converts this high signal into
digital output signal, energizing the cold start solenoid (CT14). The signal to energies the cold
start solenoid (CT14) will remain on until a starter motor low signal is received by the MCU, this
will negate the digital output signal from the MCU .

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11 Hydraulic System

(2) Removal
Numbers in parenthesis refer to Figure 11.1, Figure 11.2 and Figure 11.3; unless otherwise
specified.

� 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.
• Never work under or near an unsupported raised operator cab assembly. Always ensure
cab safety prop is in correct position.

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the hydraulic system has been dissipated.
5. Discharge the pressure in the accumulators. Refer to (7) Discharging on page 14-72.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Tilt the operator’s cab. Refer to (4) Tilting the Cab on page 19-12.
9. Clean outer area of the main hydraulic valve assembly with a suitable cleaning solvent.
10. Disconnect the electrical harness connection:
a. Tag and identify the electrical harness connection, hydraulic valve X18.
b. Disconnect connector X18.
c. Cap both connections to prevent ingress of dirt.
11. Ensure all hydraulic lines connected to the main hydraulic valve assembly are identified for
ease of installation.
12. Disconnect the body system hoses as follows:
a. Identify and tag all body system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Disconnect the Diagnostic hose connections DP7 at port A.
d. Disconnect the Diagnostic hose connections DP8 at port B.
e. Disconnect the Body Raise hose at port A. Refer to (a) Main Hydraulic Valve Body
Raise Hose on page 13-5.
f. Disconnect the Body Lower hose at port B. Refer to (b) Main Hydraulic Valve Body
Lower Hose on page 13-6.
g. Disconnect the Hydraulic Tank Return hose at port T2 (C). Refer to (c) Main Hydraulic
Valve Body Return Hose on page 13-6.
h. Install caps to all disconnected hose ends.
i. Install plugs to all disconnected valve ports.

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 Hydraulic System 11

13. Disconnect the cooling system hoses as follows:

a. Identify and tag all cooling system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Disconnect the Main Hydraulic Pump hose at port P1.
d. Disconnect the Fan cooling system hose at port DF1.
e. Disconnect the Fan cooling system hose at port DF2.
f. Disconnect the Diagnostic line DP13 at port TS T-piece.
g. Disconnect the Transmission pressure hose at port TS T-piece.
h. Disconnect the Hydraulic pump hose at port LSP T-piece.
i. Disconnect the Diagnostic line DP16 at port LSP T-piece.
j. Install caps to all disconnected hose ends.
k. Install plugs to all disconnected valve ports.
14. Disconnect the braking system hoses as follows:
a. Identify and tag all braking system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Disconnect the Treadle Valve hose at port B1. Refer to (b) Main Hydraulic Valve to
Treadle Valve Pedal Assembly Hoses on page 14-23.
d. Disconnect the Treadle Valve hose at port B2. Refer to (b) Main Hydraulic Valve to
Treadle Valve Pedal Assembly Hoses on page 14-23.
e. Disconnect the Tank Return hose at port T1.
f. Disconnect the Interlock Solenoid Valve hose at port PBP. Refer to (a) Main Hydraulic
Valve to Interlock Solenoid Valve Hose on page 14-87.
g. Disconnect the Parking Brake hose at port PB. Refer to (a) Parking Brake Tractor
Supply Hose on page 14-102.
h. Disconnect the Diagnostic line DP19 at port ACC1.
i. Disconnect the Accumulator 1 hose at port ACC1 T-piece. Refer to (a) Accumulator to
Main Hydraulic Valve Hoses on page 14-80.
j. Disconnect the Diagnostic line DP20 at port ACC2.
k. Disconnect the Accumulator 2 hose at port ACC2 T-piece. Refer to (a) Accumulator to
Main Hydraulic Valve Hoses on page 14-80.
l. Disconnect the Diagnostic line DP21 at port ACC3.
m. Disconnect the Accumulator 3 hose at port ACC3 T-piece. Refer to (a) Accumulator to
Main Hydraulic Valve Hoses on page 14-80.
n. Install caps to all disconnected hose ends.
o. Install plugs to all disconnected valve ports.
15. Disconnect the steering system hoses as follows:
a. Identify and tag all steering system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Disconnect the Steering Valve hose at port LSO. Refer to (g) Hydraulic Control Valve
Load Sensing Hose on page 12-54.
d. Disconnect the Emergency Steering Valve hose at port P2. Refer to (o) Emergency
Steering Valve Pressure Hose on page 12-60.
e. Disconnect the Steering Valve hose at port ORB. Refer to (h) Steering Control Valve
Supply Hose (1) on page 12-55.
f. Disconnect the Diagnostic hose DP18 at Port TPO.
g. Install caps to all disconnected hose ends.
h. Install plugs to all disconnected valve ports.
16. Disconnect the differential lock system hoses as follows:
a. Identify and tag all differential lock system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Disconnect the Axle Difflock hose at port DL T-piece. Refer to (2) Removal and
Disassembly on page 9-5.
d. Disconnect the Dropbox Control Valve hose at port DL T-piece. Refer to (2) Removal
and Disassembly on page 9-5.

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11 Hydraulic System

e. Install caps to all disconnected hose ends.

f. Install plugs to all disconnected valve ports.
17. Disconnect the OCDB system connection Relief Valve connection (48) at port WB.
18. Remove the main hydraulic valve (1) from the valve mounting bracket (2) (refer to Figure
11.5):
a. Install M10 eye bolts (7) on the top of the valve (1).
b. Attach suitable lifting equipment to the valve (1) and take an initial strain.
c. Remove the four mounting bolts (3), spring washers (5) and washers (4) securing
the valve (1) to the bracket (2).
d. Using standard lifting equipment, lift the valve (1) from the bracket (2).

1 6

3, 4, 5 8, 4, 5

7
MOT05275

Figure 11.5 - Main Hydraulic Valve Removal

1. Main Hydraulic Valve 4. Washer 7. Eye Bolt
2. Valve Mounting 5. Washer - Spring 8. Bolt
Bracket
3. Bolt 6. Front Frame (Ref)

19. Move the valve to a clean maintenance area.

Further disassembly should only be done by a vendor approved workshop.
20. If necessary, remove the valve mounting bracket (2) (refer to Figure 11.5):
a. Remove the four mounting bolts (8), spring washers (5) and washers (4) securing the
bracket (2) to the front frame.
b. Lift the bracket (2) from the front frame.

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 Hydraulic System 11

(3) Disassembly
Numbers in parentheses refer to Appendix B Hydraulic System Schematic Diagram on page
B-1, unless otherwise specified.

PROCEDURE
1. Remove bolts and washers (3, 4 and 5, Figure 11.5), securing the valve mounting bracket
(2, Figure 11.5) to the main valve assembly. Remove the valve mounting bracket.
2. Identify and tag all the electrical harness connections, to the main hydraulic valve.
3. Disconnect the electrical harness connectors as follows:
a. Accumulator 1 low pressure connector (WA5.B8) ‘port PS3’.
b. Accumulator 2 low pressure connector (WA9.B13) ‘port PS2’.
c. Steering system low pressure connector (WA10.B14) ‘port PS1’.
d. Cold start solenoid connector (WA2.Q6) ‘port CT14’.
e. Park/emergency brake solenoid connector (WA11.Q17) ‘port CT31’.
f. Park brake sense connector (WA4.B11) ‘port PS4’.
g. Body raise solenoid connector (WA6.Q8) ‘port CT7.
h. Body lower solenoid connector (WA7.Q9) ‘port CT3’.
i. Body float system solenoid connector (WA8.Q10) ‘port CT29’.
j. Fan stop control valve connector (WA3.Q11) ‘port DF1’.
k. Fan stop control valve connector (WA1.Q2) ‘port DF2’.
4. Disconnect the Electrical Pressure Sensors. Refer toFigure 11.6. Remove sensors (1, 2
and 3) and O-Rings (4).
3
PS1
4

4 5
1

PS3

2 4

PS4
4 MOT05280
PS2 1
Figure 11.6 - Hydraulic Valve Sensors
1. Sensor - ACC1 / 3. Sensor - Steering 5. Main Hydraulic Valve
ACC2
2. Sensor - PB 4. O-Ring

5. Install blanking caps to all connections to prevent ingress of dirt.

6. If required identify and tag the elbows, adapters and switches and disconnect as follows:
Body hoist connections. Refer to Figure 13.1.
a. Ensure that the bolts (7), washers (8), O-Ring (5) and split flanges (6) are removed
from ‘Port T2’ (item ‘C’ on body schematic).
b. Ensure that the bolts (11), washers (12), O-Rings (9) and split flanges (10) are removed
from ‘Ports A and B’.
c. Ensure that the manifold plates (13) have been removed from the flange ‘Ports A and
B’. Remove the diagnostic adaptors (14) from the manifold adaptors (13).

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11 Hydraulic System

Cooling System connections.

a. Ensure that the bolts (50), washers (47), O-Ring (53) and split flanges (69) are removed
from ‘Port P1’.
b. Remove adaptors from ‘Ports DF1 and DF2’.
c. Remove tee (60) and adaptor (59), from ‘Port TS’.
d. Remove tee’s (55 and 54), elbow (adaptor) (42) and connector (adaptor) (61), from
‘Port LSP’.
Braking System connections. Refer to 14.1 Description on page 14-4.
a. Remove adaptor (46), from ‘Port B1’.
b. Remove adaptors (75), from ‘Port B2 and T1’.
c. Remove adaptors (47), from ‘Port PB and PBP’.
d. Remove reducer (34), tee (33) and adaptor (48) from ‘Port ACC1’.
e. Remove elbow (76), reducer (34), tee (33) and adaptor (48) from ‘Port ACC2’.
f. Remove reducer (34), tee (33) and adaptor (48) from ‘Port ACC3’.

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 Hydraulic System 11

Steering System connections. Refer to Figure 12.1

a. Remove connector (adaptor) (40), from ‘Port P2’.
b. Remove connector (adaptor) (42), from ‘Port ORB’.
c. Remove connectors (adaptors) (36), from ‘Port LSO and TPO’.
Differential Lock System connection. Refer to Figure 9.5
a. Remove tee (28) and adaptor (29), from ‘Port DL’.
OCDB System connection.
a. Remove adaptor (64), from ‘Port WB’.
Install blanking caps to all connections and ports to prevent ingress of dirt.
7. If required remove all the integral valves and assemblies, clean and examine for wear or
damage. Refer to Figure 11.2 and Figure 11.3.
8. If any integral valve or assembly is badly damaged, inspect the mating bore of the main
hydraulic valve housing. The housing must be replaced if damaged.

(4) Assembly
Numbers in parentheses refer to Appendix B Hydraulic System Schematic Diagram on page
B-1, unless otherwise specified.
If removed, all integral valves must be re-installed into the correct locations on the main
hydraulic valve assembly (refer to Figure 11.2 and Figure 11.3). All integral valves must be
torque tightened to correct value. Refer to (6) Integral Valve Torque Values on page 11-22.
Replace all O-rings and seals before assembly.

PROCEDURE
1. If removed, install the fittings, adaptors etc. to the main valve housing as follows:
Remove blanking caps before assembly.
OCDB System connection.
a. Install adaptor (64), to ‘Port WB’. Torque tighten to 60 Nm (44.3 lbf ft).
Differential Lock System connection. Refer to Figure 9.5
a. Install adaptor (29) and T-piece (28), to ‘Port DL’. Torque tighten both to 35 Nm (25.8
lbf ft).
Steering System connections. Refer to Figure 12.1.
a. Install connectors (adaptors) (36), to ‘Port LSO and TPO’. Torque tighten both to 20
Nm (14.8 lbf ft).
b. Install connector (adaptor) (42), to ‘Port ORB’. Torque tighten both to 160 Nm (118 lbf ft).
c. Install connector (adaptor) (40), to ‘Port P2’. Torque tighten both to 110 Nm (81.1 lbf ft).
Braking System connections. Refer to Figure 14.1.
a. Install adaptor (48), reducer (34), and T-piece (33), to ‘Port ACC3’. Torque tighten
adaptor to 60 Nm (44.3 lbf ft) and reducer and T-piece to 35 Nm (25.8 lbf ft).
b. Install adaptor (48), T-piece (33), reducer (34) and elbow (76), to ‘Port ACC2’. Torque
tighten adaptor to 60 Nm (44.3 lbf ft) and reducer, T-piece and elbow to 35 Nm (25.8
lbf ft).
c. Install adaptor (48), reducer (34), and T-piece (33), to ‘Port ACC1’. Torque tighten
adaptor to 60 Nm (44.3 lbf ft) and reducer and T-piece to 35 Nm (25.8 lbf ft).
d. Install adaptors (47), to ‘Port PB and PBP’. Torque tighten both to 20 Nm (14.8 lbf ft).
e. Install adaptors (75), to ‘Port B2 and T1’. Torque tighten both to 60 Nm (44.3 lbf ft).
f. Install adaptor (46), to ‘Port B1’. Torque tighten to 60 Nm (44.3 lbf ft).

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11 Hydraulic System

Cooling System connections. Refer to 18.1 Description on page 18-2.

a. Install connector (adaptor) (61), elbow (adaptor) (42) and T-piece’s (55 and 54), to
‘Port LSP’. Torque tighten connector to 20 Nm (14.8 lbf ft) and elbow and T-piece’s to
35 Nm (25.8 lbf ft).
b. Install adaptor (59) and T-piece (60), to ‘Port TS’. Torque tighten adaptor to 20 Nm
(14.8 lbf ft) and T-piece to 35 Nm (25.8 lbf ft).
c. Install adaptors, to ‘Ports DF1 and DF2’. Torque tighten both to 60 Nm (44.3 lbf ft).
d. Install split flanges (69) and secure with bolts (50), washers (47), O-Ring (53), to ‘Port
P1’. Torque tighten to 50 Nm (36.9 lbf ft).
Body Hoist connections. Refer to Figure 13.1.
a. Install the diagnostic adaptors (14) to the manifold plates (13). ‘Ports A and B’. Remove
the from the manifold adaptors (13).
b. Install the bolts (11), washers (12), O-Rings (9), split flanges (10), manifold plates (13)
and secure to ‘Ports A and B’. Torque tighten to 50 Nm (36.9 lbf ft).
c. Install the bolts (7), washers (8), O-Ring (5) and split flanges (6) to ‘Port T2’ (item ‘C’ on
body schematic). Torque tighten to 50 Nm (36.9 lbf ft).
2. Identify all the electrical harness connections, to the main hydraulic valve. Connect the
connectors as follows:
Remove blanking caps from all connections.
• Fan stop control valve connector (WA1.Q2) ‘port DF2’.
• Fan stop control valve connector (WA3.Q11) ‘port DF1’.
• Body float system solenoid connector (WA8.Q10) ‘port CT29’.
• Body lower solenoid connector (WA7.Q9) ‘port CT3’.
• Body raise solenoid connector (WA6.Q8) ‘port CT7.
• Park brake sense connector (WA4.B11) ‘port PS4’.
• Park/emergency brake solenoid connector (WA11.Q17) ‘port CT31’.
• Cold start solenoid connector (WA2.Q6) ‘port CT14’.
• Steering system low pressure connector (WA10.B14) ‘port PS1’.
• Accumulator 2 low pressure connector (WA9.B13) ‘port PS2’.
• Accumulator 1 low pressure connector (WA5.B8) ‘port PS3’.
Electrical Pressure Sensors. Refer to Figure 11.6.
a. Install sensors (1, 2 and 3) and O-Rings (4). Torque tighten sensors (2 and 3) to 20
Nm (14.8 lbf ft) and sensors (1) to 34 Nm (25.1 lbf ft).
3. Install bolts and washers (3, 4 and 5, Figure 11.5), and secure the valve mounting bracket
(2, Figure 11.5) to the main valve assembly.

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 Hydraulic System 11

(5) Installation
Numbers in parenthesis refer to Figure 11.1, Figure 11.2 and Figure 11.3; unless otherwise
specified.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. If necessary, Install the valve mounting bracket (2) (refer to Figure 11.5):
a. Position the bracket (2) at its attachment point on the front frame.
b. Install the four mounting bolts (8), spring washers (5) and washers (4) securing the
bracket (2) to the front frame.
5. Install the main hydraulic valve (1) on the valve mounting bracket (2) (refer to Figure 11.5):
a. If necessary, install M10 eye bolts (7) on the top of the valve (1).
b. Attach suitable lifting equipment to the valve (1) and take an initial strain.
c. Using standard lifting equipment, lift the valve (1) onto the bracket (2).
d. Install the four mounting bolts (3), spring washers (5) and washers (4) to secure the
valve (1) to the bracket (2).
6. Connect the OCDB system connection Relief Valve connection at port WB. Torque tighten
to 40 Nm (30 lbf ft).
7. Disconnect the differential lock system hoses as follows:
a. Identify all differential lock system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Remove caps from all disconnected hose ends.
d. Remove plugs from all disconnected valve ports.
e. Connect the Axle Difflock hose at port DL T-piece. Refer to (3) Assembly and
Installation on page 9-7.
f. Connect the Dropbox Control Valve hose at port DL T-piece. Refer to (3) Assembly and
Installation on page 9-7.
g. Torque tighten to 25 Nm (18 lbf ft).
8. Connect the steering system hoses as follows:
a. Identify all steering system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Remove caps from all disconnected hose ends.
d. Remove plugs from all disconnected valve ports.
e. Connect the Steering Valve hose at port LSO. Refer to (g) Hydraulic Control Valve Load
Sensing Hose on page 12-67.
f. Torque tighten to 25 Nm (18 lbf ft).
g. Connect the Emergency Steering Valve hose at port P2. Refer to (o) Emergency
Steering Valve Pressure Hose on page 12-73.
h. Torque tighten to 55 Nm (40 lbf ft).
i. Connect the Steering Valve hose at port ORB. Refer to (h) Steering Control Valve
Supply Hose (1) on page 12-68.

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11 Hydraulic System

j. Torque tighten to 150 Nm (110 lbf ft).

k. Connect the Diagnostic hose DP18 at Port TPO.
l. Torque tighten to 25 Nm (18 lbf ft).
9. Connect the braking system hoses as follows:
a. Identify all braking system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Remove caps from all disconnected hose ends.
d. Remove plugs from all disconnected valve ports.
e. Connect the Treadle Valve hose at port B1. Refer to (b) Main Hydraulic Valve to Treadle
Valve Pedal Assembly Hoses on page 14-25.
f. Torque tighten to 55 Nm (40 lbf ft).
g. Connect the Treadle Valve hose at port B2. Refer to (b) Main Hydraulic Valve to Treadle
Valve Pedal Assembly Hoses on page 14-25.
h. Torque tighten to 55 Nm (40 lbf ft).
i. Connect the Tank Return hose at port T1.
j. Torque tighten to 55 Nm (40 lbf ft).
k. Connect the Interlock Solenoid Valve hose at port PBP. Refer to (a) Main Hydraulic
Valve to Interlock Solenoid Valve Hose on page 14-90.
l. Torque tighten to 25 Nm (18 lbf ft).
m. Connect the Parking Brake hose at port PB. Refer to (a) Parking Brake Tractor Supply
Hose on page 14-106.
n. Torque tighten to 25 Nm (18 lbf ft).
o. Connect the Diagnostic line DP19 at port ACC1.
p. Torque tighten to 25 Nm (18 lbf ft).
q. Connect the Accumulator 1 hose at port ACC1 T-piece. Refer to (a) Accumulator to
Main Hydraulic Valve Hoses on page 14-82.
r. Torque tighten to 40 Nm (30 lbf ft).
s. Connect the Diagnostic line DP20 at port ACC2.
t. Torque tighten to 25 Nm (18 lbf ft).
u. Connect the Accumulator 2 hose at port ACC2 T-piece. Refer to (a) Accumulator to
Main Hydraulic Valve Hoses on page 14-82.
v. Torque tighten to 40 Nm (30 lbf ft).
w. Connect the Diagnostic line DP21 at port ACC3.
x. Torque tighten to 25 Nm (18 lbf ft).
y. Connect the Accumulator 3 hose at port ACC3 T-piece. Refer to (a) Accumulator to
Main Hydraulic Valve Hoses on page 14-82.
z. Torque tighten to 40 Nm (30 lbf ft).
10. Connect the cooling system hoses as follows:
a. Identify all cooling system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Remove caps from all disconnected hose ends.
d. Remove plugs from all disconnected valve ports.
e. Connect the Main Hydraulic Pump hose at port P1.
f. Torque tighten to 50 Nm (37 lbf ft).
g. Connect the Fan cooling system hose at port DF1.
h. Torque tighten to 55 Nm (40 lbf ft).
i. Connect the Fan cooling system hose at port DF2.
j. Torque tighten to 55 Nm (40 lbf ft).
k. Connect the Diagnostic line DP13 at port TS T-piece.
l. Torque tighten to 25 Nm (18 lbf ft).
m. Connect the Transmission pressure hose at port TS T-piece.
n. Torque tighten to 25 Nm (18 lbf ft).
o. Connect the Hydraulic pump hose at port LSP T-piece.
p. Torque tighten to 40 Nm (30 lbf ft).
q. Connect the Diagnostic line DP16 at port LSP T-piece.
r. Torque tighten to 25 Nm (18 lbf ft).

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 Hydraulic System 11

11. Connect the body system hoses as follows:

a. Identify all body system hoses connected to the valve.
b. Position suitable containers under hose ends.
c. Remove caps from all disconnected hose ends.
d. Remove plugs from all disconnected valve ports.
e. Connect the Body Raise hose at port A. Refer to (a) Main Hydraulic Valve Body Raise
Hose on page 13-10.
f. Connect the Body Lower hose at port B. Refer to (b) Main Hydraulic Valve Body Lower
Hose on page 13-11.
g. Connect the Hydraulic Tank Return hose at port T2 (C). Refer to (c) Main Hydraulic
Valve Body Return Hose on page 13-11.
h. Connect the Diagnostic hose connections DP7 at port A.
i. Torque tighten to 25 Nm (18 lbf ft).
j. Connect the Diagnostic hose connections DP8 at port B.
k. Torque tighten to 25 Nm (18 lbf ft).
12. Connect the electrical harness connection:
a. Identify the electrical harness connection, hydraulic valve X18.
b. Remove cap from both connections.
c. Connect connector X18.
13. Lower the operator’s cab. Refer to (5) Lowering the Cab on page 19-14.
14. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
15. Place the battery master switch in the ‘ON’ position.
16. Start the engine. Refer to 5.11 Starting on page 5-27.
17. Bleed the brake system. Refer to (7) Bleeding the Service Brakes on page 14-61.
18. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
19. Check for leaks.
20. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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11 Hydraulic System

(6) Integral Valve Torque Values

Refer to Figure 11.2 and Figure 11.3.
Table 11.2 - Integral Valve Tightening Torques
Valve No. Tighten Torque
Description Qty
(CT) Nm (lbf ft)
1 Main Relief Valve 1 300 (221.3)
2 Ground Pump Relief Valve 1 100 (73.8)
3 Ground Pump Unload Cartridge 1 180 (132.8)
3A Ground Pump Unload Orifice 1 5 (3.7)
4 Ground Pump Check Cartridge 1 180 (132.8)
5 Steering Check Cartridge 1 180 (132.8)
6 Ground Pump Reverse Flow Check 1 180 (132.8)
7 Priority Valve 1 300 (221.3)
8 Pilot / Brake Check Cartridge 1 70 (51.6)
9 Brake Pressure Reducer 1 70 (51.6)
10 Accumulator Check Cartridge 1 70 (51.6)
11 Accumulator Check Cartridge 1 70 (51.6)
12 Unloader Pilot Cartridge 1 45 (33.2)
13 Unload Orifice Plug 1 5 (3.7)
14 Cold Start Solenoid 1 45 (33.2)
Coil Nut 1 3.5 (2.6)
15 Load Sense Orifice Plug 1 5 (3.7)
16 Steering / Unload Shuttle 1 9 (6.6)
17 Load Sense Shuttle 1 9 (6.6)
18 Steering Orifice Plug 1 9 (6.6)
19 Pump LS Orifice Plug 1 9 (6.6)
20 Hoist LS Relief Valve 1 45 (33.2)
21 DC Pilot Control Reducer 1 70 (51.6)
22 Fan Speed Solenoid Cartridge 1 100 (73.8)
Coil Nut 1 3.5 (2.6)
23 Fan Speed Solenoid Cartridge 1 100 (73.8)
Coil Nut 1 3.5 (2.6)
24 Dual Check 1 9 (6.6)
25 Hoist Pilot Shuttle 1 9 (6.6)
26 Hoist / Fan Shuttle 1 9 (6.6)
27 DC Pilot Control Reducer 1 30 (22.1)
Coil Nut 1 3.5 (2.6)
28 DC Pilot Control Reducer 1 30 (22.1)
Coil Nut 1 3.5 (2.6)

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 Hydraulic System 11

Valve No. Tighten Torque

Description Qty
(CT) Nm (lbf ft)
29 Body Float Solenoid Cartridge 1 45 (33.2)
Coil Nut 1 3.5 (2.6)
30 Hoist LS Orifice Plug 1 5 (3.7)
31 Park Break Solenoid Valve 1 15 (11)
Coil Nut 1 3.5 (2.6)
32 Main Brake Pilot Valve 1 30 (22.1)
33 Pilot Valve Orifice Plug 1 5 (3.7)
34 Hoist Shuttle 1 9 (6.6)
35 Accumulator Orifice Plug 1 20 (14.8)
36 Hoist LS Pilot Cartridge 1 30 (22.1)
37 Cavity Plug 1 50 (36.9)
38 Check Cartridge 1 45 (33.2)
39 Fan Orifice Plug 1 5 (3.7)
41 Hoist DC Valve 1
42 Anti-Cavity Check 1 45 (33.2)
43 Hoist Relief Valve 1 45 (33.2)

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11 Hydraulic System

(7) O-Ring Face Seals (ORFS)

Numbers in parentheses refer to Figure 11.7, unless otherwise specified.
Where hydraulic lines are fitted with O-Ring Face Seals (ORFS) connections, the following
procedure should be carried out during Installation.

Figure 11.7 - Assembly of Typical ORFS Connector

1. Hose/Tube 3. Fitting 5. O-Ring
2. Nut 4. O-Ring 6. Sleeve

PROCEDURE
1. Ensure that the O-ring/seal (4) is in place and that the joining surfaces are clean. If
necessary, retain the O-ring/seal (4) in place with a light coating of grease or Vaseline.
2. Initially, the nut (2) should be tightened by hand.
3. Where a hose (1) is fitted, ensure that it is not twisted or kinked when the nut (2) is tightened
so that it is allowed to adopt a natural position.
4. Where a tube (1) is fitted, ensure that the connection is aligned correctly.
5. Tighten the nut (2) a further 1/4 to 1/2 a turn using the correct size spanner (wrench).
6. Check that a satisfactory hose or tube routing has been achieved.

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 Hydraulic System 11

11.3 Hydraulic Tank

(1) Description

6
4
5,7
15
14

19
11
21
20

16,17
18
2
3

16,17
'A'
13
12

22
1

44
25

24
26

11
23

8 9
10
'B'
31

36
AT TRANSMISSION

'A'
DIPSTICK

30
32
33
38

29

35
32
37
34

40

BREATHER
28

LINES
27
42

39
30
32
33

43
41

MOT04532

Figure 11.8 - Exploded View of Hydraulic Tank and Mounting

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11 Hydraulic System

1. Hydraulic Tank 16. Drain Valve - Magnetic 31. Valve - Breather

2. Cover Plate - Filter 17. Seal - Bonded 32. Bushing
3. Gasket 18. Screw - Socket C/S 33. Nipple
4. Filter Assembly 19. Cover Plate Assembly 34. Bracket - Breather
5. Support - Filter 20. Bolt 35. Connector
Assembly
6. Element Assembly 21. Lockwasher 36. Elbow
7. O-Ring Kit 22. Magnetic Filter 37. Hose Assembly
8. Bolt 23. Bolt 38. Bracket - Breather
9. Washer 24. Plate 39. Bolt
10. Cover Plate Assembly 25. Locknut 40. Elbow
11. Gasket 26. Washer - Hardened 41. Bolt
12. Cap Assembly 27. Lockwasher 42. Locknut
13. Gasket 28. Washer 43. Washer
14. Gauge - Oil Level 29. Hose Assembly 44. Magnetic Filter
15. Gauge Fluid Level 30. Breather

Numbers in parentheses refer to Figure 11.8, unless otherwise specified.

The hydraulic tank (1) is divided into 4 main compartments:
• Main Hydraulic Tank compartment
• OCDB Hydraulic Tank compartment
• Hydraulic Oil Return compartment
• Battery Box Compartment
Main Hydraulic Tank
The main hydraulic tank is the common reservoir for the steering, braking, body hoist and
transmission oil cooler fan drive systems.
The main tank, has a capacity of 298 litres and contains a level sensor and temperature sensor
(installed on the pump suction line) (3 and 5Figure 11.9), a level gauge (14), magnetic filter (44)
and a breather line assembly, connected at point ‘B’.
OCDB Hydraulic Tank
The Oil Cooled Disk Brake (OCDB) tank is the reservoir for brake cooling system.
The OCDB tank has a capacity of 115 litres and contains a magnetic filter (22) a level gauge
(15) and a breather line assembly connected at point ‘A’.
Hydraulic Oil Return
The hydraulic oil return compartment contains the main tank return line filter (4) that feeds the
main tank. A restriction indicator (1, Figure 11.9) is linked to the main filter (4) and transmits a
signal to illuminate the filter restriction warning light (4, Figure 15.75) when the filters require
replacing.
Battery Box
For battery box compartment, refer to 15.8 Battery Box Assembly on page 15-55.

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 Hydraulic System 11

2
3

5
6

7 MOT05294

Figure 11.9 - Hydraulic Tank Sensors

1. Indicator - Restriction 4. Main Hydraulic Tank 7. Suction Line - Pump
2. Washer - Copper 5. Sensor - Temperature
3. Sensor - Level 6. Washer - Copper

(2) Operation
Numbers in parentheses refer to Figure 11.8, unless otherwise specified.
Oil is added to the main hydraulic tank (1) through the filter assembly (4), remove cover plate (2).
The hydraulic oil is drawn from the main hydraulic tank (9, Figure 11.10) by the main hydraulic
pump (1, Appendix B Hydraulic System Schematic Diagram on page B-1), main suction line
‘Port S’. The pump then supplies the main hydraulic valve (5, Appendix B Hydraulic System
Schematic Diagram on page B-1) via the check valve (porting block) (2, Appendix B Hydraulic
System Schematic Diagram on page B-1) ‘Port P1’, to supply the various hydraulic systems.
Emergency steering oil is drawn from the hydraulic tank (10, Figure 11.10) by an emergency
pump (3, Appendix B Hydraulic System Schematic Diagram on page B-1) and is supplied to
the main hydraulic valve ‘Port P2’. If a failure occurs in the main hydraulic pump (1, Appendix
B Hydraulic System Schematic Diagram on page B-1), the emergency pump (3, Appendix B
Hydraulic System Schematic Diagram on page B-1) will supply the steering system with oil to
enable the machine to be brought to a safe halt.
Return oil from the hydraulic systems flows through the hydraulic oil cooler (35, Appendix B
Hydraulic System Schematic Diagram on page B-1) and the filter assembly (21, Appendix B
Hydraulic System Schematic Diagram on page B-1) before entering the tank storage area. The
filter assembly (4) has a bypass valve which allows oil to bypass element when it is cold or
when the filter element is plugged. The bypass valve opens at a differential pressure of 2.5
bar (36.3 psi). Replace the elements (6) when the filter restriction warning light (4, Figure
15.75) illuminates.

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11 Hydraulic System

1
2

3
4
5

15
6
14
13

12

8 7
9
11 10
MOT05295

Figure 11.10 - Hydraulic Tank Hose Connections

1. Main Return Line 6. OCDB Return Line 11. Tank Drains
2. Air Breather Ports 7. OCDB Relief Return 12. Brake Return Lines
3. Cooling Fan Return 8. OCDB Suction Line 13. Main Pump Case Drain Lines
Line
4. Brake Interlock Valve 9. Main Pump Suction 14. Emergency Steering Pump
Return Line Case Drain Hose
5. OCDB Relief 10. Emergency Steering 15. Cooling Fan Drain Line
Unloader Pump Suction Hose

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 Hydraulic System 11

(3) Removal
The Hydraulic Tank Assembly has a Battery Box Compartment. For Removal and
Disassembly of the Battery Box Compartment, refer to 15.8 Battery Box Assembly on
page 15-55.
Refer to, Appendix B Hydraulic System Schematic Diagram on page B-1.
Numbers in parentheses refer to Figure 11.8, unless otherwise specified.

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

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine. Turn the steering wheel in both directions several
times to relieve any pressure in the steering circuit. Operate the treadle valve continuously
to discharge accumulators.
2. Block all road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'OFFf' position.
3. Tilt the operator’s cab. Refer to (4) Tilting the Cab on page 19-12
4. Remove the left hand Fender Assembly as required. Refer to (1) Removal on page 16-51.
5. Remove blanking caps from the remote drain lines (11, Figure 11.10) at the bottom of
the hydraulic tanks. Install a length of hose on remote drain fitting, open drain cock and
drain hydraulic oil into a suitable container. Close drain cock, remove hose and reinstall
blanking cap.
6. Tag, identify and disconnect the electrical harness connections that follow:
Refer to, Figure 11.9.
Cap all connections to prevent ingress of dirt.
a. Filter Restriction connection (1) ‘B3.X1’
b. Tank Oil Level connection (3) ‘B28.X1’.
c. Oil Temperature connection (5) ‘B29.X1’.
7. Ensure all hydraulic lines connected to the main hydraulic tank assembly are identified for
ease of installation. Refer to, Figure 11.10. With suitable containers catch any oil leakage
when disconnecting hydraulic lines. Install blanking caps to all open lines and fittings.
Disconnect the hydraulic lines as follows:
Brake System lines, refer to Figure 14.1
a. Remove bolts (55), washers (56), split flanges (53) and O-ring (54), disconnect Main
Return line (9).
b. Treadle Valve Return lines (8 and 12).
c. Interlock Solenoid Valve Return line (27).
Cooling Fan System lines.
a. Remove bolts (52), washers (49), split flanges (38) and O-Ring (46), disconnect Main
Pump Suction line (32).
b. Main Pump Drain lines ‘L2 and L3’ (33 and 72).
c. Cooling Fan return line (2).
d. Cooling Fan Drain line (5).

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11 Hydraulic System

Brake System lines, refer to Figure 14.1

a. Remove bolts (45), washers (46), split flanges (448) and O-Ring (47), disconnect
OCDB Suction line (1).
b. Remove bolts (45), washers (46), split flanges (448) and O-Ring (47), disconnect
OCDB Relief Return line (13).
c. OCDB Return line (41).
d. OCDB Relief Unloader line (49).
Steering System lines, refer to Figure 12.1.
a. Emergency Steering Pump Suction line (27).
b. Emergency Steering Pump Drain line (26).
Main Tank breather line to transmission dipstick point:
a. Breather line (37).
8. Disconnect the cabin tilt manual pump hose connection. Refer to (4) Tilting the Cab on
page 19-12
9. Install suitable lifting equipment and secure the hydraulic tank assembly.
10. Remove the bolts and washers (2 and 3, Figure 11.11) securing the hydraulic tank (1) to
the front frame assembly.
11. Ensure the bolts, washers and nuts securing the LH fender assembly are removed (location
8, Figure 11.11). Refer to (1) Removal on page 16-51.
12. Remove the nuts, washers, bolts and shims (6, 5, 4 and 7, Figure 11.11) securing the
hydraulic tank (1) to the front frame assembly.
13. Record the size of shim (7, Figure 11.11) used, if any.
14. Carefully remove the hydraulic tank (1) assembly from the unit to a clean work area for
inspection.

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 Hydraulic System 11

2
3

8
1

4 5 7 5 6
MOT05296

Figure 11.11 - Hydraulic Tank and Mounting

1. Hydraulic Tank 4. Bolt 7. Shim
Assembly
2. Bolt 5. Washer - Hardened 8. Fender Attachment Point
3. Washer 6. Locknut

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11 Hydraulic System

(4) Disassembly and Inspection

Numbers in parentheses refer to Figure 11.8, unless otherwise specified.

� CAUTION
• Splashing liquid. Wear a suitable face shield when using compressed air to dry hydraulic
tank and components.

PROCEDURE
1. Identify, tag and remove the following sensors:
Hydraulic sensors, refer to Figure 11.9.
a. Restriction Sensor / Indicator (1) ‘B3’.
b. Tank Oil Level Sensor (3) ‘B28.X1’.
c. Oil Temperature Sensor (5) ‘B29.X1’.
2. Identify, tag and remove the OCDB tank breather assembly, as follows:
a. Disconnect and remove breather hose (29).
b. Remove connector / adaptor (35) and bushing /reducer (32) at tank ‘Point A’.
c. Remove breather (30).
d. Remove connector / adaptor (35) bushing /reducer (32) and nipple (33).
e. Remove bolt (39), lockwasher (27) and washer (28) securing bracket (38) to the tank
assembly. Remove bracket (38).
3. Identify, tag and remove the following adaptors / connectors:
a. Breather assembly ‘Point B’, breather valve (31) and elbow (36).
Brake System lines, refer to Figure 14.1
a. Treadle Valve Return line elbows (29).
b. Interlock Solenoid Valve Return line elbow (69).
Cooling Fan System lines.
a. Main Pump Drain lines ‘L2 and L3’ connectors / adaptors (40).
b. Cooling Fan return line elbow (9) and connector / adaptor (81).
c. Cooling Fan Drain line elbow (7).
Brake System lines, refer to Figure 14.1
a. OCDB return line, elbow (40).
b. OCDB relief unloader, elbow (52).
Steering System lines, refer to Figure 12.1.
a. Emergency Steering Pump Suction line connector / adaptor (33).
b. Emergency Steering Pump Drain line connector / adaptor (31).
4. Remove bolts, lockwashers and washers (18, 76 and 77,) securing the OCDB relief
unloader valve (86) to the tank assembly.
5. Remove bolts (23), washers (26) and nuts (25) securing plate (24) to the hydraulic tank
assembly. Remove plate (24) and the cab tilt hand pump assembly attached.
6. Clean the hydraulic tank (1) and its components with a suitable solvent and dry with
compressed air. Replace any damaged components.
7. Inspect the hydraulic tank (1) for weld cracks and security of internal pipes and weld
fitments.
8. Inspect the sensors (‘B3, B28 and B29’). Replace if required.

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 Hydraulic System 11

9. If required, replace the breather assemblies (30).

10. If required, replace the filter element (4). Refer to (2) Replacing Filter Element on page
11-71.
11. Inspect the magnetic filters (44 and 22). Clean / Replace filters if required.
12. Inspect the filter / baffle assembly, part of the cover plate assembly (19). Clean the baffle
assembly.

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11 Hydraulic System

(5) Assembly
Numbers in parentheses refer to Figure 11.8, unless otherwise specified.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Install bolts (23), washers (26) and nuts (25) and secure plate (24) and the cab tilt hand
pump, to the hydraulic tank assembly.
2. Install bolts, lockwashers and washers (18, 76 and 77) and secure the OCDB relief
unloader valve (86) to the tank assembly.
3. Identify and install the following adaptors / connectors:
Steering System lines, refer to Figure 12.1.
a. Emergency Steering Pump Drain line connector / adaptor (31). Torque tighten to 78
Nm (57.5 lbf ft).
b. Emergency Steering Pump Suction line connector / adaptor (33). Torque tighten to 200
Nm (147.5 lbf ft).
OCDB Lines.
a. OCDB relief unloader, elbow (52). Torque tighten to 35 Nm (25.8 lbf ft).
b. OCDB return line, elbow (40). Torque tighten to 180 Nm (132.8 lbf ft).
Cooling Fan System lines.
a. Cooling Fan Drain line elbow (7). Torque tighten to 40 Nm (29.5 lbf ft).
b. Cooling Fan return line elbow (9) and connector / adaptor (81). Torque tighten
connector / adaptor to 180 Nm (132.8 lbf ft) and elbow to 125 Nm (92.2 lbf ft).
c. Main Pump Drain lines ‘L2 and L3’ connectors / adaptors (40). Torque tighten to 78
Nm (57.5 lbf ft).
Brake System lines, refer to Figure 14.1
a. Interlock Solenoid Valve Return line elbow (69). Torque tighten to 40 Nm (29.5 lbf ft).
b. Treadle Valve Return line elbows (29). Torque tighten to 78 Nm (57.5 lbf ft).
a. Breather assembly ‘Point B’, breather valve (31) and elbow (36). Apply PTFE thread
tape to both elbow and breather.
4. Identify and install the OCDB tank breather assembly, as follows:
a. Install bolt (39), lockwasher (27) and washer (28) and secure bracket (38) to the tank
assembly.
b. Install connector / adaptor (35) bushing /reducer (32) and nipple (33). Apply PTFE
thread tape to adaptor, reducer and nipple.
c. Install breather (30).
d. Install connector / adaptor (35) and bushing /reducer (32) at tank ‘Point A’. Apply PTFE
thread tape to adaptor and reducer.
e. Connect breather hose (29). Torque tighten to 70 Nm (51.6 lbf ft).
5. Identify and install the following sensors:
Hydraulic sensors, refer to Figure 11.9.
a. Oil Temperature Sensor (5) ‘B29.X1’. Torque tighten to 30 Nm (22.2 lbf ft).
b. Tank Oil Level Sensor (3) ‘B28.X1’. Torque tighten to 30 Nm (22.2 lbf ft).

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 Hydraulic System 11

c. Restriction Sensor / Indicator (1) ‘B3’.

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11 Hydraulic System

(6) Installation
Numbers in parentheses refer to Figure 11.8, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure lifting equipment is correctly
secured and of adequate capacity to do the job safely.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all hydraulic lines fitted with ORFS connections, as described in (7) O-Ring Face
Seals (ORFS) on page 11-24. Renew all O-rings where used.

PROCEDURE
1. Using a suitable lifting device, secure the hydraulic tank (1) and position on the machine.
2. Install the nuts, washers, bolts and shims (6, 5, 4 and 7, Figure 11.11) and secure the
hydraulic tank (1) to the front frame assembly. Shims to be used as required.
3. Install the bolts, washers and nuts and secure the LH fender assembly to the tank assembly
(1) (location 8, Figure 11.11). Refer to (2) Installation on page 16-57.
4. Install the bolts and washers (2 and 3, Figure 11.11) and secure the hydraulic tank (1) to
the front frame assembly.
5. Connect the cabin tilt manual pump hose connection. Refer to (2) Removal on page 19-8
6. Re-install ORFS. connectors into correct ports. Replace O-rings and seals. Refer to (7)
O-Ring Face Seals (ORFS) on page 11-24. Renew all O-rings where used.
7. Remove all blanking caps, identify and connect the hydraulic lines that follow:
Refer to, Figure 11.10.
Main Tank breather line to transmission dipstick point:
a. Breather line (37). Torque tighten to 50 Nm (36.9 lbf ft).
Steering System lines, refer to Figure 12.1.
a. Emergency Steering Pump Drain line (26). Torque tighten to 55 Nm (40.5 lbf ft).
b. Emergency Steering Pump Suction line (27). Torque tighten to 190 Nm (140.1 lbf ft).
OCDB System lines.
a. OCDB Relief Unloader line (49). Torque tighten to 35 Nm (25.8 lbf ft).
b. OCDB Return line (41). Torque tighten to 125 Nm (92.2 lbf ft).
c. Install bolts (45), washers (46), split flanges (448) and O-Ring (47), and connect OCDB
Relief Return line (13). Torque tighten bolts to 42 Nm (31 lbf ft).
d. Install bolts (45), washers (46), split flanges (448) and O-Ring (47), and connect OCDB
Suction line (1). Torque tighten bolts to 42 Nm (31 lbf ft).
Cooling Fan System lines.
a. Cooling Fan Drain line (5). Torque tighten to 25 Nm (18.4 lbf ft).
b. Cooling Fan return line (2). Torque tighten to 125 Nm (92.2 lbf ft).
c. Main Pump Drain lines ‘L2 and L3’ (33 and 72). Torque tighten to 55 Nm (40.5 lbf ft).

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 Hydraulic System 11

d. Install bolts (52), washers (49), split flanges (38) and O-Ring (46), and connect Main
Pump Suction line (32). Torque tighten bolts to 210 Nm (155 lbf ft).
Brake System lines, refer to Figure 14.1
a. Interlock Solenoid Valve Return line (27). Torque tighten to 25 Nm (18.4 lbf ft).
b. Treadle Valve Return lines (8 and 12). Torque tighten to 55 Nm (40.5 lbf ft).
c. Install bolts (55), washers (56), split flanges (53) and O-Ring (54), and connect Main
Return line (9). Torque tighten bolts to 104 Nm (77 lbf ft).
8. Identify and connect the electrical harness connections that follow:
Refer to, Figure 11.9.
Remove all blanking caps.
a. Oil Temperature connection (5) ‘B29.X1’.
b. Tank Oil Level connection (3) ‘B28.X1’.
c. Filter Restriction connection (1) ‘B3.X1’
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
10. Turn battery master switch to ‘ON’ position, place the steering lock bar in the ‘Stowed’
position and remove any wheel blocks, start engine. Operate the brake, body and steering
systems. Check hydraulic lines and fittings for leaks. Tighten where required.
11. Check hydraulic tank oil level and replenish if required.
12. Bleed the brake system. Refer to (7) Bleeding the Service Brakes on page 14-61.

11.4 Main Hydraulic Pump

(1) Description

7, 6, 5

7, 4

7, 8
1 2

MOT05297

Figure 11.12 - Main Hydraulic Pump Installation

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11 Hydraulic System

1. Main Tandem Pump 4. Bolt 7. Loctite 243

2. Dropbox Pump (8 cc) 5. Bolt 8. Hexagon Socket
3. Mounting Bracket 6. Washer

X1 1 4 P1
2

MOT05299
L2 S X2 L3 3
Figure 11.13 - Main Hydraulic Pump Connections
1. Porting Block S. Port ‘S’ - Suction Line X2. Port ‘X2’ - Load Sense
2. Dropbox Pump (8 cc) L2. Port ‘L2’ - Pump return P1. Port ‘P1’ - Main Hyd. Valve
3. Main Tandem Pump L3. Port ‘L3’ - Pump return
4. Capscrews X1. Port ‘X1’ - Load Sense

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TA400 Tier2
Maintenance Manual
1

20
37 2 SET TO 35 BAR
30
4 12
10 26
41 21
16
23
39
18 29
3 24
15 22
28 19
34 14 23

7 9
27 33
22 19
36 11
17
32 SET TO 32 BAR
33

Revision 1.0
38 4
37
30 2
21
25 41
5 20
NOT USED 38
35
39
25 34
40
13 16 14 15
6

Figure 11.14 - Exploded View of Main Hydraulic Pump

31 49
48
47
8

44 45

43

MOT05298
42

Page 11-39
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Hydraulic System 11
11 Hydraulic System

1. Hydraulic Pump - 18. Bushing - Bearing 35. Pin

Tandem
2. Control Valve 19. Bearing 36. Washer
3. Gasket - Plate 20. Bearing - Tapered 37. Plug
4. Capscrew 21. Shim 38. Plug
5. Cover (Transit Only) 22. Ring - Stop 39. Rotating Group
6. Housing - Front 23. Spring 40. Plate - Control Front
7. Housing - Rear 24. Shaft Seal 41. Elbow
8. Housing - Port Rear 25. O-Ring 42. Piston and Shoe
9. Swash Plate - Front 26. Plate - Control Rear 43. Plate - Retaining (Set)
10. Swash Plate - Rear 27. O-Ring 44. Plate
11. Driveshaft - Front 28. Seal 45. Cylinder Block
12. Driveshaft - Rear 29. Circlip 46. Pressure Pin
13. Hub - Splined 30. Pin - Roll 47. Shim
14. Piston - Control 31. Capscrew 48. Spring
15. Rod - Piston 32. Capscrew 49. Circlip
16. Plug 33. Screw - Flathead
17. Shell - Bearing 34. Plug

15 14 16 2 41 16 14 15

30
23 6 34 34 7

19

22 27
29

12
11

24 5

9,17,33 39 40 20 13 8 20 26 39 10,18,33 19 22

SM3543

Figure 11.15 - Sectional View of Main Hydraulic Pump

2. Control Valve 13. Hub - Splined 26. Control Plate - Rear
5. Cover 14. Control Piston 27. O-Ring

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 Hydraulic System 11

6. Housing - Front 15. Piston Rod 29. Circlip

7. Housing - Rear 16. Plug 30. Dowel
8. Housing - Centre 19. Bearing 34. Plug
9. Swash Plate - Front 20. Bearing 39. Rotating Group
10. Swash Plate - Rear 22. Stop Ring 40. Control Plate - Front
11. Driveshaft - Front 23. Spring 41. Elbow
12. Driveshaft - Rear 24. Seal - Shaft 45. Cylinder Block

Numbers in parentheses refer to Figure 11.8 and Figure 11.15, unless otherwise specified.
The hydraulic pump is mounted on the left-hand side of the transmission power take off (PTO).
It is a 'tandem' axial piston, variable displacement pump with load sense and pressure regulator
to match the flow and pressure to the demand. 'Tandem' in the sense that it contains two
complete pump assemblies to provide the desired output levels.
The pump supplies hydraulic oil for the steering, braking and body hoist systems, as well as
the transmission oil cooler fan drive system.
The components of the pump can be divided into three sub-groupings:
Rotating Group
The rotating group (39) provides the main rotary pumping action. The group consists of the
driveshafts (11 and 12), cylinder block (45), piston and shoe (42), retaining (set) plate (43),
spherical bush (44), cylinder springs (43), pressure pin (46), shim (47) and circlip (49). Refer
to Figure 11.16.

42

C
11, 12

43

D
45

26, 40

SM2845

Figure 11.16 - Rotating Group

11. Driveshaft 42. Piston and Shoe B. Outlet Kidney Slot
12. Driveshaft 43. Plate - Retaining (Set) C. Inlet Port

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11 Hydraulic System

26. Control Plate 45. Cylinder Block D. Inlet Kidney Slot

40. Control Plate A. Outlet Port

Figure 11.17 - Variable Displacement Action

Swash Plate Group
Varies the pump's delivery flow rate. Consists of the respective swash plates (9 and 10),
bearing shells (17 and 18), control pistons (14), control rods (15), and springs (23).
Valve Cover Group
Provides the switching of oil between suction and delivery ports. Consists of front control
plate (40), rear control plate (26), dowels (30), centre housing (8), front housing (6) and rear
housing (7).
Technical Data
Technical Data
Displacement: 60 CC/Rev each unit
Maximum speed at full load: 2 700 rpm
Maximum flow at full load/speed: 314 l/min
Power at maximum flow: 135 kW
Torque at full load, 250 bar: 477 Nm
Weight: 44 Kg approx
Fill: 1 Litre approx

(2) Operation
Numbers in parentheses refer to Figure 11.14, Figure 11.15 and Figure 11.16, unless otherwise
specified. Refer to Figure 11.18.

NOTICE
• The description below applies equally to both hydraulic pumps, as they are connected to
a common drive shaft, except where the condition identifying operation of the load sense
control valve is detailed, and the orientation of the load sense pipe work connections.

When the front pump's driveshaft (11) rotates, the rear pump's driveshaft (12) will also rotate,
being linked to each other via splined hub (13). The cylinder blocks (45) for both front and rear
elements are also spline coupled to the respective shafts (11 and 12), these will also rotate.

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 Hydraulic System 11

If the swash plates (9 [forward] and 10 [rear]) have been tilted, the pistons and shoes (42)
arranged in the cylinder blocks (45) will both rotate with the cylinder blocks in a reciprocate
motion once per revolution.
Each individual piston from either front or rear pump rotating groups, will move away from the
control plate (40 [forward] or 26 [rear]) for half a rotation (suction stroke), and move towards
the control plate (40 or 26) for the second half of rotation (delivery stroke). The larger the tilt
angle of the swash plate (9 or 10), the longer the piston (42) stroke and the higher the pump's
displacement. As the swash plate (9 or 10) tilting angle approaches zero, the piston (42) does
not stroke and therefore delivers minimum displacement. (Refer to Figure 11.17).

Figure 11.18 - Exploded View Control Valve

1. Cap 10. Spacer 19. Capscrew
2. O-Ring 11. Spring 20. Plug
3. Nut 12. Spring 21. Plug
4. Set screw 13. Spring Seat 22. O-Ring
5. Plug 14. Spool 23. Gasket plate
6. Plug 15. Spring 24. Plug
7. O-Ring 16. Spring 25. Plug
8. Spacer 17. Spring Seat 26. Valve Body
9. O-Ring 18. Spool

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11 Hydraulic System

Control Valve
The control valves (2) are a pilot-operated differential pressure type spool regulator for load
sense control. The load sense feedback signal from the main hydraulic valve is fed to the load
sense port via elbow (41) on the pump control valve body (26, Figure 11.18). This feedback
signal acts on the spring chamber end of the spool (14, Figure 11.18).
Unregulated Condition
Refer to Figure 11.19. When the pump pressure is low and the load sense signal is wide open.
The preload cut-off pressure spool springs (15 & 16, Figure 11.18) shifts the cut-off pressure
spool (18, Figure 11.18) to its extreme left position.
When the pressure drop across the main hydraulic valve is low, both sides of the differential
pressure spool (14, Figure 11.18) sense the same pressure and therefore the spool (14, Figure
11.18) remains in the extreme left position. This condition causes the oil at the control piston
(14) and rod (15) to be vented, causing springs (23) to move piston rods and pistons (15 and
14) and thus the swash plate (9 and 10) to maximum pump displacement.

Figure 11.19 - Pump Schematic - Unregulated Figure 11.20 - Pump Schematic - Regulated
Condition Condition

Regulated Condition
Refer to Figure 11.20. Pump pressure builds up and the pressure drop across the main hydraulic
valve increases. The preload cutoff pressure spool springs (15 & 16, Figure 11.18) still retains
the spool (18, Figure 11.18) in its extreme left position. However, since the pressure drop is
increased, the pressure on the left hand side of the differential pressure spool (14, Figure 11.18)
(pump delivery pressure) overcomes the combination of the preload of springs (11 & 12, Figure
11.18) and pressure in the load sense line in the right hand side of the differential pressure spool
(14, Figure 11.18). Therefore the spool (14, Figure 11.18) moves towards the right, blocking
vent line and causing pressure at the large side of piston (14) to increase, overcoming the force
of spring (23). This reduces the swash plate (9 and 10) angle and hence pump displacement.
This movement will continue until the pump flow across the main hydraulic valve reduces the
pressure drop to the value determined by the preload of the differential spool springs (11 and
12, Figure 11.18). As the pressure builds the preload of the differential spool springs (11 and
12, Figure 11.18) ensures that the load sense pressure is 35 bar (508 psi) (rear pump), 32 bar
(464 psi) (front pump) below the pump delivery pressure until the cut-off point is achieved.
The pump also has a pressure limiting function, used for example when steering cylinder
reaches the end of it's stroke. In this condition the delivery pressure will rise, and the load sense
control will try to raise delivery pressure above the now 'dead head' pressure. This causes
differential pressure spool (14, Figure 11.18) to shift to the extreme right, allowing oil pressure
to pass through cutoff pressure spool (18, Figure 11.18) and reach the large side of piston (14),
overcoming spring (23) force and reducing swash plate (9 & 10) angle to zero.

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 Hydraulic System 11

(3) Removal
Numbers in parentheses refer to Figure 11.12, Figure 11.13 and Figure 11.14, unless otherwise
specified.

� CAUTION
• To prevent personal injury and property damage, be sure wheel blocks, blocking materials
and lifting equipment are properly secured and of adequate capacity to perform the task
safely.
• Hydraulic fluid pressure will remain within the system after engine shut down. Operate the
treadle pedal continuously until the pressure has dissipated before carrying out any work on
the braking system or serious injury could result.

PROCEDURE
1. Position the machine in a level work area, apply the parking brake, switch off the engine
and turn the steering wheel in both directions several times to relieve any pressure in
the steering circuit.
2. Operate the treadle valve continuously to relieve pressure in the braking system. Block all
road wheels and place battery master switch in the 'Off' position. Place steering lock bar
in the 'Locked' position.
3. Remove blanking cap from remote drain line at the bottom of the hydraulic tank. Install a
length of hose on remote drain fitting, open the drain cock and drain the hydraulic oil into a
suitable container. Close the drain cock, remove the hose and reinstall the blanking cap.
4. Clean the pump housing and surrounding area with a suitable solvent.
5. Ensure all hydraulic lines connected to the main hydraulic pump assembly are identified for
ease of installation.
6. Disconnect the Cooling Fan System lines as follows:
a. Remove bolts (43), washers (48), split flanges (36) and O-Ring (45), disconnect Main
Tank Suction line (32). ‘Port S’.
b. Main Tank Drain lines (33 and 72). ‘Ports L3 and L3’.
c. Remove bolts (73), washers (66), split flanges (69) and O-Ring (53), disconnect Main
Hydraulic Valve line (70). Porting Block ‘Port P1’.
d. Main Hydraulic Valve Load Sense lines (71). ‘Ports X1 and X2’.
e. Diagnostic lines DP14 and DP15 (58). Porting Block ‘Ports TP1 and TP2’.
7. Disconnect the Dropbox Pump lines, refer to Figure 7.6, as follows:
a. Dropbox filter line (29). ‘Port OUT’.
b. Dropbox suction filter line (30). ‘Port IN’.
8. With suitable containers catch any oil leakage when disconnecting hydraulic lines.
9. Install blanking caps to all open lines and fittings.
10. Support the pump assembly with suitable lifting equipment.
11. Remove bolts and washers (5 and 6, Figure 11.12) securing the mounting bracket (3,
Figure 11.12) to the transmission assembly.
12. Remove bolts and washers (5 and 4, Figure 11.21) securing the main pump assembly to
the PTO stud kit assembly (2, Figure 11.21). Remove the main pump assembly.
13. Remove the O-Ring (3, Figure 11.21) from the pump. Wash the outside of the pump
thoroughly with a suitable solvent and move it to a clean work area for disassembly.
Discard the O-Ring.

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11 Hydraulic System

2
3
4
5

6 MOT05300

Figure 11.21 - PTO / Main Hydraulic Pump Mounting

1. PTO 3. O-Ring 5. Nut
2. Stud Kit Assembly 4. Washer 6. Main Tandem Pump

(4) Disassembly
Numbers in parentheses refer to Figure 11.14, unless otherwise specified.

NOTICE
• Discard and renew all O-rings and seals removed during disassembly.

PROCEDURE
1. Remove bolt and hexagon socket (4 and 8, Figure 11.12) securing the mounting bracket
and the dropbox pump (3 and 2, Figure 11.12) to the main hydraulic pump. Remove the
mounting bracket and the dropbox pump. Refer to (4) Removal on page 7-47.
2. Remove the capscrews (4, Figure 11.13) securing the porting block (1, Figure 11.13) to the
main hydraulic pump assembly.
3. Identify, tag and disconnect the Cooling Fan System line adaptors / elbows etc. that follow:
a. Elbows (41 and 44), ‘Ports L2 and L3’.
b. Elbows (56), ‘Ports X1 and X2’.
c. Adaptors (57), ‘Ports TP1 and TP2’.
4. Install blanking caps to all open lines and fittings.

(a) Rear Pump

Numbers in parentheses refer to Figure 11.14, unless otherwise specified.

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 Hydraulic System 11

NOTICE
• Discard and replace all O-rings and seals removed during disassembly.

PROCEDURE
1. Ensure any residual oil is removed from the pump housings (6, 7 and 8).
2. Secure the pump assembly (1) at the rear housing assembly (7), in a suitable fixture.
Refer to Figure 11.22.
3. Mark the location of the centre housing (8) in relation to the front and rear housings (6 and

7). Refer to Figure 11.22 positions .

4. Remove capscrews (4) securing the control valves (2) to there respective housing units.
Remove the control units. Refer to Figure 11.23.
5. Remove elbows (41) from the control valves (2).

Figure 11.22 - Locating Reference for Housings Figure 11.23 - Control Valve Removal

6. Loosen the eight capscrews (31). Remove the four capscrews (31) securing the rear pump
housing (7) to the centre housing (8). Refer to Figure 11.24.
7. Using suitable lifting equipment. Lift the front housing (6) and centre housing (8) from the
rear housing (7) assembly. Ensure that control plate (26) is secure when lifting the housing
assemblies (6 and 8) clear of the rear pump housing (7). Refer to Figure 11.25.

Figure 11.24 - Removal of Capscrews Figure 11.25 - Removal of Front Pump from Rear
Pump

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11 Hydraulic System

8. Remove the bearing (20) and shim (21). Ensure not to damage the sealing surface. Refer
to Figure 11.26.
9. Orientate the rear housing (7), to allow removal of the rotating group (39). Remove the
rotating group as shown on Figure 11.27.

SM3434 SM3550

Figure 11.26 - Bearing / Shim Removal Figure 11.27 - Rotating Group Removal

10. Remove the plug (16). Pull out the control piston (14) using a suitably sized screwdriver.
Refer to Figure 11.28.
11. Turn the swash plate (10) inside of housing along the z-axis. Remove the piston rod (15)
and swash plate (10) from the housing (7) as shown in Figure 11.29.

15

10

*
SM3551 SM3552

Figure 11.28 - Control Group Removal Figure 11.29 - Swash Plate / Piston Rod Removal

12. Remove the two bearing shells (18) and spring (23) from the housing (7), as shown in
Figure 11.30.
13. Remove the drive shaft (12) with the bearing (19) inner race still fitted to the shaft. Refer to
Figure 11.31.

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 Hydraulic System 11

Figure 11.30 - Bearing Shell Removal Figure 11.31 - Drive Shaft Removal

14. Pull outer race of bearing (19) out of housing (7) using a suitable bearing puller. Refer to
Figure 11.32.
15. Remove the shim (22) as shown in Figure 11.33.

Figure 11.32 - Bearing Race Removal Figure 11.33 - Shim Removal

(b) Front Pump

Numbers in parentheses refer to Figure 11.14, unless otherwise specified.
This task is to be carried out with reference to, (a) Rear Pump on page 11-46.

NOTICE
• Discard and replace all O-rings and seals removed during disassembly.

PROCEDURE
1. Secure the pump assembly (1) at the front housing assembly (6), in a suitable fixture.
2. Remove the four capscrews (31) securing centre housing (8) to the front housing (6).
Refer to Figure 11.34.
3. Using suitable lifting equipment, remove centre housing (8) from the mating face on the
front housing (6). Ensure that control plate (40) is secure when lifting the centre housing (8)
clear of the front pump housing (6). Refer to Figure 11.35.
4. Remove O-Rings (25), control plate (40) and splined hub (13). Refer to Figure 11.34.

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11 Hydraulic System

Figure 11.34 - Housing Removal Figure 11.35 - Housing Removal

5. Pull the bearing (20) from the centre housing (8) using a suitable bearing puller, ensure
not to damage the sealing surfaces. Refer to Figure 11.36.
6. Remove the bearing (20) inner race and shim (21). Take care not to damage the sealing
surfaces. Refer to Figure 11.37.

Figure 11.36 - Bearing Removal Figure 11.37 - Shim and Bearing Removal

7. Orientate the front housing (6) horizontally on a bench to allow for removal of the rotating
group (39). Remove the rotating group (39) as shown in Figure 11.38.
8. Remove the plug (16), control piston (14), and piston rod (15). Refer to Figure 11.39.

Figure 11.38 - Rotating Group Removal Figure 11.39 - Control Piston Removal

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 Hydraulic System 11

9. Remove the drive shaft (11). The bearing (19) inner race should be attached to the
driveshaft at this stage. Remove the circlip (29) and shaft seal (24). Refer to Figure 11.40.
10. Pull the outer race of the tapered bearing (19) out from the housing (6), using suitable
bearing pullers, as shown in Figure 11.41.

Figure 11.40 - Drive Shaft and Bearing Removal Figure 11.41 - Bearing Removal

11. Remove the shim (22). Refer to Figure 11.42.

Figure 11.42 - Shim Removal

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(c) Control Valve

Numbers in parentheses refer to Figure 11.14 and Figure 11.18, unless otherwise specified.

NOTICE
• The control valve (2) is supplied as a complete assembly.

PROCEDURE
1. If the control valve (2) has not already been removed from the front and rear housings (6
and 7), do so at this stage, by removing the four capscrews (19).
2. If it is necessary to disassemble the control valve (2), the following steps should be followed.
3. Remove the two protective caps (1) and O-Rings (2).
4. Remove the nuts (3) and O-Rings (2).
5. Unscrew the plugs (5 and 6). This should allow for careful removal of the following items
contained within the control valve body (26):
a. O-Rings (7 and 9)
b. Shims (8 and 10)
c. Springs (11, 12, 15 and 16)
d. Spring seats (13 and 17)
e. Spools (14 and 18)

(5) Inspection

NOTICE
• Before inspection of parts, clean all parts with a suitable solvent.

(a) Rotating Group

Numbers in parentheses refer to Figure 11.14, unless otherwise specified.

PROCEDURE
1. Inspect the cylinder block (45) for wear, scratches or erosion. If cylinder block (45) condition
is questionable, replace the entire rotating group (39).
2. Check each cylinder block bore for excessive wear. Use piston and shoe assemblies (42)
for this purpose. The pistons should be a very close fit and slide in and out of the cylinder
block bores. No binding can be tolerated. If binding occurs, clean the cylinder block (45)
and the piston and shoe assemblies (42). Lubricate the cylinder block bores with clean
hydraulic oil and slide the pistons in and out again. Even minor contamination of the oil
may cause a piston to seize up in a cylinder block bore.
3. Inspect the retaining plate (43) for heavy wear and for cracks. Replace it if it is defective.

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(b) Pump Housing and Associated Parts

Numbers in parentheses refer to Figure 11.14, unless otherwise specified.

PROCEDURE
1. Inspect both pump housings (6 and 7) for erosion, cracks and burrs. Clean up minor burrs
with an India stone. If erosion or cracks are noted, replace the affected pump housing (6
or 7 respectively).
2. Inspect the inner and outer races of the tapered bearings (19 and 20) for nicks and pitting.
Make sure the inner race turns freely within the outer race. If either of the tapered bearings
require replacement, both the inner and outer races must be replaced. To remove the outer
races from the pump housings (6 and 7), or the centre housing (8), carry this out using
tooling in accordance with the manufacturer's guidelines.
3. Inspect the control plates (26 and 40) for erosion, excessive wear, heavy scratches and
cracks. If any of the above conditions are found, replace the control plate.
4. Inspect the springs (23) and the control piston parts (14 and 15) for burrs, scratches and
cracks. Clean up minor scratches with grade 500 grit paper. Remove burrs with an India
stone. Pistons (14) should move freely over their respective rods (15).

(c) Driveshaft and Associated Parts

Numbers in parentheses refer to Figure 11.14, unless otherwise specified.

PROCEDURE
1. Inspect the driveshafts (11 and 12) for wear, chipped splines and burrs. Remove burrs with
an India stone. Inspect the contact area of the tapered bearings (19 and 20) and of the
shaft seal (24). Replace any driveshaft (11 or 12) if wear or scoring is greater than 0.127
mm (0.005 in) total indicator reading (T.I.R.).
2. Inspect the inner and outer races of the tapered bearings (19 and 20) for roughness, pitting
of rollers and excessive end play. Make sure the inner race turns freely within the outer
race. If a tapered bearing (19 or 20) needs replacement, both the inner and outer races
must be replaced.
3. Inspect the mounting flange of each of the pump housings (6 & 7) for nicks and burrs.
Remove minor nicks and burrs with an India stone. Also check the pump housing (8) for
damaged or stripped threads. If any thread is damaged, replace the pump housing.
4. Check the remaining pump parts for excessive wear, damaged threads, burrs, cracks
and/or erosion. Renew any part that is in a questionable condition.

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(6) Assembly
Numbers in parentheses refer to Figure 11.14, unless otherwise specified.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Identify the Cooling Fan System line adaptors / elbows etc. that follow:
a. Porting block adaptors (57), ‘Ports TP1 and TP2’. Torque tighten to 35 Nm (25.8 lbf ft).
b. Elbows (56), ‘Ports X1 and X2’. Torque tighten to 35 Nm (25.8 lbf ft).
c. Elbows (41 and 44), ‘Ports L2 and L3’. Torque tighten to 110 Nm (81.1 lbf ft).
2. Remove all blanking caps.
3. Connect the Cooling Fan System line adaptors / elbows etc. that follow:
a. Porting block adaptors (57), ‘Ports TP1 and TP2’. Torque tighten to 35 Nm (25.8 lbf ft).
b. Elbows (56), ‘Ports X1 and X2’. Torque tighten to 35 Nm (25.8 lbf ft).
c. Elbows (41 and 44), ‘Ports L2 and L3’. Torque tighten to 110 Nm (81.1 lbf ft).
4. Ensure O-Rings are installed in the porting block (1, Figure 11.13) SAE port, and install
the capscrews (4, Figure 11.13) and secure the porting block to the main hydraulic pump
assembly.
5. Install the mounting bracket and the dropbox pump, using bolt and hexagon socket (4 and
8, Figure 11.12) and secure the mounting bracket and the dropbox pump (3 and 2, Figure
11.12) to the main hydraulic pump. Refer to (8) Installation on page 7-50.

(a) Front and Rear Pumps

NOTICE
• Ensure that all damaged parts are repaired or renewed before assembly.
• Before assembly wash each part with clean oil and dry them with compressed air. Assemble
the pump in a clean work area to prevent contamination.
• When assembling, apply clean oil on the sliding surfaces and bearings.
• When assembling parts that easily detach, for example O-Rings, apply clean grease to
prevent them from being misplaced.
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.
• Where stated, the following assembly steps apply to both front and rear pump units!
• Take care not to damage the shaft seal (24) during steps 1 - 3.

Numbers in parentheses refer to Figure 11.14, unless otherwise specified.

PROCEDURE
1. For both the front and rear housings (6 and 7), press in the stop ring (22) and the outer race
of bearing (19) using a suitable tool. Refer to Figure 11.43.

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2. For both the front and rear housings (6 and 7), locate the plug (34) into housing. Secure the
plug (34) to a torque value of 127 Nm (93.7 Ibf ft). Refer to Figure 11.43.
3. For both the front and rear housings (6 and 7), assemble the respective driveshafts (11
and 12) in their correct positions. Ensure that the bearing outer race is seated fully on the
driveshaft. Refer to Figure 11.44.

SM3418

Figure 11.43 - Pump Assembly Figure 11.44 - Pump Assembly; Drive Shaft

4. Ensure that the splined hub (13) is located inside bore of the centre housing (8).
5. Press in the outer races of bearings (20) into the centre housing (8). Refer to Figure 11.45.
6. Assemble the front and rear pump to the centre housing. Ensure that the points marked
during disassembly match up. Refer to Figure 11.22.
7. Tighten the eight screws (31), to a value of 165 Nm (122 lbf ft).
8. For both the front and rear housings (6 and 7), measure the dimension between the end
face 'A' of the housing and the front face 'B' of the centre housing (8). Refer to Figure 11.46.

(21) (21)

'A' 'B' 'A' 'B'

'C' 'C'

SM3585

Figure 11.45 - Centre Housing / Bearing Race Figure 11.46 - Bearing Preload
Dimension: 'A' to 'B' = 'C'
Dimension ‘C’ = 0 - 0.05 mm (0 - 0.002 in)

9. If dimension 'C' is outside the specified tolerance, install the shim (21) to obtain the desired
value.
10. Temporarily install the O-Ring (27), cover (5) and secure with screws (32) and washers (36)
to the rear housing assembly (7). Refer to Figure 11.50.

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11. Assemble the shaft seal (24) using a suitable driver to tap the seal into place. Ensure that
the sealing ring is greased and that the surface of the seal is not damaged. Secure the
circlip (29) in place using suitable pliers. Refer to Figure 11.48.

Figure 11.47 - Rear Housing Assembly Figure 11.48 - Front Housing Assembly

12. Fit the bearing shells (17 and 18) and spring (23) into both front and rear housings (6 and
7). Ensure that ample grease is used. Refer to Figure 11.49.
13. Assemble the swash plate (9 and 10) and piston rod (15) into the correct bore of both the
front and the rear housing (6 and 7). Refer to Figure 11.49.
14. Assemble the control piston (14) and plug (16) into both the front and the rear housing (6
and 7). Refer to Figure 11.50. Use Loctite 242™ on the threads of the plug (16) prior to
securing it. Secure the plugs (16) to a torque value of 190 Nm (140 Ibf-ft).

Figure 11.49 - Assembly of Bearing Shells and Figure 11.50 - Rear Housing Assembly
Spring

15. Assemble the pressure pins (46) using a suitable assembly aid. Use a suitable combination
of bolt, nut and washer type to allow the spring and pins to be enclosed and compressed,
in tightening of the bolt/nut combination. Tighten the assembly aids sufficiently enough to
allow the circlip to be locked in place. On removal of assembly aids, the spring face will be
held against full extension by the inner face of the circlip, similarly the pins will be held on
the inner shoulder of the piston housing, thus retaining the assembly. Refer to Figure 11.51.

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 Hydraulic System 11

45
47
46
48

2
3
49
44

SM3425

Figure 11.51 - Rear Housing Assembly

1. Bolt - Assembly Aid 45. Plate 47. Shim
2. Washer - Assembly 45. Cylinder Block 48. Spring
Aid
3. Nut - Assembly Aid 46. Pressure Pin 49. Circlip

16. Oil the pistons and shoes (42). Assemble pistons (42) with the retaining plates (43).
17. Fit the rotary groups to both the front and rear pump housings (6 and 7 respectively). It may
be necessary to use a suitably sized O-Ring to aid the assembly. Refer to Figure 11.52.
18. Assemble the bearings (20) and adjustment shims (21) to the front and rear drive shafts (11
and 12 respectively). Refer to Figure 11.53.

Figure 11.52 - Insert Rotating Group Figure 11.53 - Drive Shaft Assembly

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19. Insert the splined hub (13) into the bore of the centre housing (8). Assemble the control
plates (40 and 26), dowels (30) and O-Rings (25) to the housing (8). Ensure that the
O-Rings are greased prior to being inserted in the grooves. Refer to Figure 11.54.
Maintain the correct location using the dowels (30).
Ensure that marked positions on all housing components are matched correctly as they
were created at the disassembly stage. Refer to Figure 11.22.
20. Assemble the centre housing (8) to the front pump housing (6), securely using the four
screws (31). Torque screws (31) to 165 Nm (122 Ibf ft). Refer to Figure 11.55.

SM3588

Figure 11.54 - Centre Housing Assembly Figure 11.55 - Securing Centre and Front Pump
Housings

21. Use suitable lifting equipment, lift the sub-assembled front pump and centre housing
elements. Orientate these to facilitate assembly into the rear housing unit. Refer to Figure
11.56.
22. Ensure the correct position of the control plate (40), and ensure that the O-Ring (25) is
fitted in the groove.
23. Secure the front assembly to the rear/centre pump assembly with the four screws (31).
Torque the screws (31) to a value of 165 Nm (122 Ibf ft). Refer to Figure 11.57.

Figure 11.56 - Assembly to Rear Pump Figure 11.57 - Securing Pump Assembly

24. Install the control valves (2) to both pumps, using the screws (4), with new gasket plate (3).
Torque tighten screw to 12-15.5 Nm (9-11.5 Ibf ft).

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 Hydraulic System 11

(b) Control Valve

Numbers in parentheses refer to Figure 11.18, unless otherwise specified.
If the control valve has been disassembled, the following task is to be completed.

PROCEDURE
1. Install the following components to the control valve body:
a. Spools (14 and 18)
b. Spring seats (13 and 17)
c. Springs (11, 12, 15 and 16)
d. Shims (8 and 10)
e. O-Rings (7 and 9)
2. Install plugs (5 and 6).
3. Install O-Rings (2) and nuts (3).
4. Install O-Rings (2) and protective caps (1).
5. Install the control valves (26) to both pumps, using the screws (19), with new gasket plate
(23). Torque tighten screw to 12-15.5 Nm (9-11.5 Ibf ft).

(7) Installation
Numbers in parentheses refer to (3) Removal on page 11-45, unless otherwise specified.

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

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all hydraulic lines fitted with ORFS connections as described in (7) O-Ring Face
Seals (ORFS) on page 11-24. Renew all O-rings where used.
• It is very important that the pump casing is completely filled with hydraulic oil. This will
ensure proper lubrication of the internal parts of pump when it is initially operated. Fill the
pump casing through the drain port. Filling only the suction line is totally insufficient.

PROCEDURE
1. Support the pump assembly with suitable lifting equipment.
2. Ensure dropbox pump and mounting bracket are installed. Refer to Figure 11.12 and (8)
Installation on page 7-50.
3. Apply White soft paraffin BP lubricant to the mating surfaces of the pump assembly (6).
4. Install a new O-Rring (3) to the pump.
5. Apply Loctite 243 to the PTO studs (2).

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6. Push the pump inward to engage with the coupling in the transmission power take off.
Secure the pump assembly to the transmission with the four nuts (5) and washers (4).
Torque tighten nuts to 90 Nm (66.4 lbf ft).
7. Apply Loctite 243 to bolts (5, Figure 11.12).
8. Install bolts and washers (5 and 6, Figure 11.12) and secure bracket assembly (3, Figure
11.12) to the transmission assembly. Torque tighten to 100 Nm (73.8 lbf ft).
9. Remove all blanking caps.
10. Identify the hydraulic lines.
11. Connect the Dropbox Pump lines (refer to Figure 7.6) that follow:
a. Dropbox suction filter line (30). ‘Port IN’. Torque tighten to 150 Nm (110 lbf ft).
b. Dropbox filter line (29). ‘Port OUT’. Torque tighten to 55 Nm (40.5 lbf ft).
12. Connect the Cooling Fan System lines that follow:
a. Diagnostic lines DP14 and DP15 (58). Porting Block ‘Ports TP1 and TP2’. Torque
tighten to 24 Nm (17.7 lbf ft).
b. Main Hydraulic Valve Load Sense lines (71). ‘Ports X1 and X2’. Torque tighten to
35 Nm (25.8 lbf ft).
c. Install bolts (73), washers (66), split flanges (69) and O-Ring (53), and connect Main
Hydraulic Valve line (70). Porting Block ‘Port P1’. Torque tighten bolts to 92 Nm (67.9
lbf ft).
d. Install bolts (43), washers (48), split flanges (36) and O-Ring (45), and connect Main
Tank Suction line (32). ‘Port S’. Torque tighten bolts to 92 Nm (67.9 lbf ft).
e. Before connecting case drain lines, fill the pump casing through drain port with clean
hydraulic oil as used in the hydraulic tank. Refer to (1) Recommended Lubricants
on page 4-16.
f. Main Tank Drain lines (33 and 72). ‘Ports L3 and L3’. Torque tighten to 55 Nm (40.5
lbf ft).
13. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.

(8) Filling and Bleeding

� WARNING
• It is vital that the procedure detailed below is followed following replacement of the Main
Hydraulic Pump, a Steering Cylinder, a Body Cylinder or any other significant hydraulic
component. Failure to remove air from the system will lead to premature pump failure.

NOTICE
• When filling the hydraulic system be prepared for the tank level to fall as the individual
system components draw hydraulic fluid. The tractor requires approximately 50 L and the
trailer a further 60 L approximately.

PROCEDURE
1. If the hydraulic system is being re-commissioned following component failure, flush and
clean the entire system of contaminants.
2. Fill both sections of the Main Hydraulic Pump and its ports with clean hydraulic oil. Refer to
(1) Recommended Lubricants on page 4-16, for oil specifications.

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 Hydraulic System 11

3. Apply petroleum jelly to the O-Rings of the suction pipe flanges, then attach them and
tighten the bolts sequentially.
4. Fit bleed elbows and tees to the top and bottom hydraulic connections at both body
cylinders.
5. Fill the hydraulic tank using a pump connected through the filter assembly.
6. Disconnect the pump case drain lines at the return ports (13, Figure 11.10) on the hydraulic
tank and install protective caps to the tank fittings. The exposed hose ends are to be left
open to allow oil flow from the pump drains to be observed.
7. Operate the engine for a few seconds at a time, at idle speed, to purge air from the pump
outlet to the brake accumulators. Air is removed by bleeding it off at the diagnostic points
at the left-hand fender. Bleed Accumulator 3 (Primary Accumulator, 21, (10) Pressure
Checks on page 11-62) first, followed by Accumulator 1 (Front Brake Accumulator, 19, (10)
Pressure Checks on page 11-62) and then Accumulator 2 (Rear Brake Accumulator, 20,
(10) Pressure Checks on page 11-62). Once air has been bled from all three accumulators,
the engine can be continuously run for the remainder of the bleeding activities.
8. Connect the pump case drain (13, Figure 11.10). Refer to (7) Installation on page 11-59.
9. Slowly steer the truck from lock to lock, in short bursts, to remove air and fill the steering
cylinders with hydraulic fluid. Operating the steering in short bursts minimizes the return
flow of fluid to the hydraulic tank.
10. Undo and remove the two bolts with nuts and washers (30, 28 and 29 Figure 21.1 that
secure the striker plate (32, Figure 21.1 for the ‘body down’ proximity switch to the
underside of the body, remove striker plate.
11. Open the bleed screws on the top of both body hoist cylinders (Step 4.).
12. Operate the body control lever forward (down) in short bursts, until the top of the cylinders
have been bled of entrained air.
13. Release the body control lever. Close the bleed screws at the top of both body hoist
cylinders.
14. Open the bleed screws at the bottom of both body hoist cylinders (Step 4.).
15. Operate the body control lever rearward (raise) in short bursts, until the bottom of the
cylinders have been bled of entrained air.
16. Release the body control lever. Close the bleed screws at the bottom of both body hoist
cylinders.
17. Repeat, Step 11.
18. Run the engine at idle speed, raise and lower the body several times to check its operation.
19. Ensure the body in its fully lowered position, stop the engine and refit the ‘body down’
proximity switch to the underside of the body, securing it using the bolts with washers and
nuts removed in (Step 10.. Torque tighten to 42 Nm (31 lbf ft).
20. If required remove the bleed elbows and tees installed to the top and bottom hydraulic
connections at both body cylinders.
21. Recheck the hydraulic fluid level in the tank and top it up if necessary.
22. Check that all truck functions operate correctly.

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11 Hydraulic System

(9) Starting

PROCEDURE
1. Ensure the pump case drain lines (13, Figure 11.10) are connected and free from
obstructions. Any restriction in the pump case drain flow back to tank can cause high case
drain pressure which can lead to an early pump failure.
2. Ensure that all hydraulic controls are set to a neutral position, the steering lock bar is in
the 'Locked' position and the battery master switch is placed in the 'On' position. Start
the engine and allow the pump to run unloaded for a period to ensure that all residual
air within the system is released.
3. Check for external leakage, abnormal noise and vibrations.
4. Remove the wheel blocks and place the steering lock bar in the 'Stowed' position. Start the
engine and check hydraulic systems for proper operation.

(10) Pressure Checks

� WARNING
• Machine has to fully articulate to check pump pressures, therefore steering lock bar cannot
be 'Locked'. To prevent personal injury and property damage, exercise extreme caution
while working around articulation and oscillation pivot area.

To check pump delivery pressure (cut-off pressure) the steering should be operated full lock
against the stops. The pump is checked against the steering system as this is the highest
pressure requirement in the hydraulic circuit.
(a) Delivery Pressure (cut-off pressure)
Install a pressure gauge capable of at least 240 bar (3 480 psi) on the main pump front section
diagnostic checkpoint (TP1), DP 14 (14, Figure 11.58). Operate the steering against the stops,
the pressure should be 240 bar (3 480 psi).
Install a pressure gauge capable of at least 240 bar (3 480 psi) on the main pump rear section
diagnostic checkpoint (TP2), DP 15 (15, Figure 11.58). Operate the steering against the stops,
the pressure should be 240 bar (3 480 psi).
(b) Differential Pressure ΔP (load sense pressure)
There are two control units fitted one to each pump. Each control unit must have their
differential pressure set. Install a pressure gauge capable of measuring 240 bar (3 480 psi) on
the load sense diagnostic checkpoint DP 16 (16, Figure 11.58).
Measure both DP 14 and DP 16.
With the steering in the neutral position, the pressure at the main pump front section DP 14
gauge should be 32 bar (464 psi) greater than the pressure at the front pump load sense
DP 16 gauge.
Measure both DP 15 and DP 16.
With the steering in the neutral position, the pressure at the main pump rear section DP
15 gauge should be 35 bar (507 psi) greater than the pressure at the rear pump load sense
DP 16 gauge.

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 Hydraulic System 11

MOT05033

Figure 11.58 - Diagnostic Pressure Check Points, Left-hand Fender

1. Dropbox Difflock - 9. Pilot Raise - 18. Steering -
TP1 TPA TPO
2. Dropbox Lubrication - 10. Pilot Lower - 19. Accumulator No.1
TP3 TPB
3. Dropbox High Ratio - 11. Transmission - 20. Accumulator No.2
GS1 TS
4. Dropbox Low Ratio - 13. Parking Brake 21. Accumulator No.3
GS2
5. Cross-Axle Difflock 14. Hydraulic Pump-Front - 22. Brakes-Front
TP1
7. Body Hoist Raise - 15. Hydraulic Pump-Rear - 23. Brakes-Rear
A TP2
8. Body Hoist Lower - 16. Load Sense Pump -
B LSP

If these pressures are not observed, then the pump may require to be reset, refer to (11)
Troubleshooting on page 11-64.

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11 Hydraulic System

(11) Troubleshooting
Table 11.3 - Main Hydraulic Pump Troubleshooting
Symptom Probable Cause
Rotation Speed too high, air intake, cavitation
Irregular Noise
or mechanical damage
Power comparison of engine pump (do outputs
match each other), pump fails to swivel out,
No or insufficient flow
inner leakage, dirt specific wear (stroke limitation
on a too small swivel angle)
Power comparison of engine pump (do outputs
match each other), pump fails to swivel out,
No or insufficient pressure
inner leakage, dirt specific wear (stroke limitation
on a too small swivel angle)
Air suction, inner leakage, dirt specific fluctuation
Pressure / flow
wear, power unit damage, controller unstable.

If steering cannot be operated or is excessively heavy, the pump delivery pressure is likely to be
low and the pump setting should be checked.
If the difference between delivery pressure and load sense pressure (ΔP) is equal to the desired
values proceed to (b) Delivery Pressure Setting on page 11-66.
However, if ΔP is not equal to desired value carry out complete (12) Pump Settings on page
11-65.

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 Hydraulic System 11

(12) Pump Settings

� CAUTION
• It is very important that the pump casing is completely filled with hydraulic oil before the
pump is operated. Fill the pump casing through the drain port. Filling only the suction
line is totally insufficient.

(a) Differential Pressure Setting

Numbers in parentheses refer to Figure 11.18 and Figure 11.58, unless otherwise specified.

NOTICE
• Pressure should always be adjusted on the increase. Hence if the ΔP pressure is too high,
the set screw should be turned counter-clockwise first to bring the pressure below the
desired level, then increased to attain the desired value.

PROCEDURE
1. Install a pressure gauge capable of at least 240 bar (3 500 lb/in²) into main pump front
diagnostic checkpoint pressure point (14, Figure 11.58) on the left hand fender to measure
pump delivery pressure (cut-off pressure) (Gauge A).
2. Install a pressure gauge capable of at least 240 bar (3 480 lb/in²) into the pump load sense
diagnostic checkpoint on the left hand fender (16, Figure 11.58) to measure the load sense
pressure setting (Gauge B).
3. Ensure that all hydraulic controls are set to a neutral position, the steering lock bar is in the
'Locked' position and place the battery master switch in the 'ON' position. Start the engine
and allow to run at low idle. This allows the pump to run unloaded for a period to ensure
that all residual air within the system is released. Check for external leaks.
Pressure values are for one full Clockwise (CW) or Counter-clockwise (CCW) rotation of
the set screw.

Figure 11.59 - Pressure Adjustments at Control Valve

Differential Pressure (LS pressure)
Delivery Pressure (Cut-off pressure)
4. Check readings on both pressure gauges. Pump delivery pressure (Gauge A) should
always be greater than load sense pressure (Gauge B). This differential pressure (ΔP)

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11 Hydraulic System

should be equal to 35 bar (507 lb/in²). If the ΔP pressure differs from the desired value,
then adjustment may be necessary.
• If the pump delivery pressure (Gauge A) is less than the desired value disconnect either the
left-hand combination cooler or the right-hand cooler fan disconnect solenoids, causing the
solenoid valve to default to an open position, allowing hydraulic oil to the fan motor. This
will place a demand on the pump causing the pump delivery pressure to increase.
• Pressure should always be adjusted on the increase. Hence if the ΔP pressure is too high,
the set screw should be turned counter-clockwise first to bring the pressure below the
desired level, then increased to attain the desired value.
5. At the differential pressure (load sense) valve (1, Figure 11.59) unlock the cap (1, Figure
11.18) to allow the nut (3, Figure 11.18) to be unlocked. Turn the set screw (1, Figure 11.59)
clockwise (looking straight at set screw) to increase the ΔP pressure, or counter-clockwise
to decrease the ΔP pressure.
6. Recheck the readings on both pressure gauges. Pump delivery pressure (Gauge A) should
be at correct value.
7. Once the correct ΔP pressure is achieved, tighten the nut (3, Figure 11.18) at the differential
pressure (load sense) port on the control valve. The protective cap should be replaced and
tightened to 21 Nm (15.5 Ibf / ft).
8. The differential pressure is now set. Repeat procedure with gauge A connected to main
pump rear section diagnostic checkpoint (15, Figure 11.58). Both differential pressure
settings of both sections of the main hydraulic pump are now set.
9. Switch off the engine and relieve the system pressures as described in 'Removal'.
10. Remove the pressure gauges from the diagnostic check points.

(b) Delivery Pressure Setting

Numbers in parentheses refer to Figure 11.18, Figure 11.58 and Figure 11.59, unless otherwise
specified.

� WARNING
• The machine has to fully articulate to set pump, therefore steering lock bar cannot be
'Locked'. To prevent personal injury and property damage, exercise extreme caution while
working around articulation and oscillation pivot area.

NOTICE
• Steering has to be operated over the relief (against stops), as this is the maximum pressure
the pump must deliver. Setting pump against any other operation would result in the pump
being set at a lower maximum delivery pressure.
• Pressure should always be adjusted on the increase. Hence if the cut-off pressure is too
high, the set screw (2, Figure 11.59) should be turned counterclockwise to decrease the
cut-off pressure below 240 bar (3 480 lb/in²), then turn set screw (2, Figure 11.59) clockwise
to attain 240 bar (3 480 lb/in²).
• A change in pump tone should be heard when cut-off pressure is reached, as the pump
de-strokes to standby condition.

There should be no requirement to adjust the set screw (2, Figure 11.59) at the delivery
pressure (cut-off pressure) port, as this is factory set. The cut-off pressure sets the pump

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 Hydraulic System 11

delivery pressure. If the set screw (2, Figure 11.18) or nut (3, Figure 11.18) has been moved, it
will be necessary to reset the pump delivery pressure by following the procedure given below:

PROCEDURE
1. Install a pressure gauge capable of at least 240 bar (3 480 lb/in²) into main pump front
section diagnostic checkpoint on the left hand fender (14, Figure 11.58) to measure the
pump delivery pressure (cut-off pressure).
2. Start the engine and run it at full throttle. Steer full lock against the stops. Observe the
pressure on the gauge. This cut-off pressure should be 240 bar (3 480 lb/in²). If the pressure
reading differs or the steering is excessively heavy, then carry out steps which follow.
3. At the delivery pressure (cut-off pressure) port, unlock the nut (3, Figure 11.18) and turn the
set screw (2, Figure 11.59) clockwise to increase the cut-off pressure, or counter-clockwise
to decrease the cut-off pressure (adjustment is approximately 50 bar [725 lb/in²] per turn).
4. Once the correct cut-off pressure has been attained, revert the steering to the neutral
position, then steer full lock against the stops. Observe the gauge to confirm that the cut-off
pressure is set to 240 bar (3 480 lbf/in²).
5. If no change in pump tone is heard, the cut-off pressure is too high. Return to step 3 of the
procedure. If problem persists, refer to Figure 12.1.
6. Once the correct pressure is achieved, tighten the nut (3, Figure 11.18) at the cut-off
pressure port on the control valve. The protective cap should be replaced and tightened to
21 Nm (15.5 Ibf ft).
7. The differential pressure (load sense) and cut-off pressure are now set. Repeat the
procedure with the pressure gauge connected to main pump rear section diagnostic
checkpoint (15, Figure 11.58). Both sections of the main pump are now set.
Switch off the engine and relieve system the pressures as described in 'Removal'.
8. Remove the pressure gauge from the diagnostic checkpoint.

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11 Hydraulic System

(13) Adjustable O-Ring Seal Hydraulic Pipe Fittings

It is vital that any hydraulic pipe fitting which has the facilitate be adjusted is correctly fitted, in
order to ensure that the male threaded stub of the fitting does not extend too deeply into the
tapped hole of the housing where it is installed. Correct installation will avoid the possibility of
the fitting impinging on internal components. The fitting procedure is itemized below.

PROCEDURE
1. Unscrew the lock-nut of the hydraulic fitting until is fully backed off against the shoulder on
the pipe, as shown on Figure 11.60.

Figure 11.60 - Hydraulic Fitting with Lock-nut Backed Off

2. Install the fitting in the housing, hand tight, as shown on Figure 11.61.

Figure 11.61 - Hydraulic Fitting Secured Hand Tight

3. Unscrew the fitting one full turn, while aligning the elbow to the desired attitude to the
appropriate angle required by the connecting pipework, as shown on Figure 11.62.

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 Hydraulic System 11

Figure 11.62 - Hydraulic Fitting Backed Off for Alignment

4. Tighten the lock-nut to the appropriate torque, as itemized below. Figure 11.63 shows a
cross-section of the fitting in its fully tightened position. Figure 11.64 illustrates the complete
hydraulic fitting in its installed condition.

Figure 11.63 - Hydraulic Fitting Tightened to Correct Torque

Figure 11.64 - Hydraulic Fitting, Installed Condition

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11 Hydraulic System

(14) Recommended Periodic Oil Change Periods and Oil Specifications

All pump parts are lubricated by the hydraulic oil therefore the oil must be kept clean to
minimize pump wear. Whenever there is a hydraulic system failure, the oil should be drained,
the entire system flushed, oil filter replaced and clean hydraulic oil added to eliminate all metal
particles or foreign matter.
(15) Wear Limits
Before reassembling the pump after disassembly, the Pump Wear Limits table should be
consulted to establish which components should be replaced.
11.5 Maintenance
(1) Checking Oil Level

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

NOTICE
• Tighten all fasteners, without special torques specified, to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

Numbers in parentheses refer to Figure 11.8, unless otherwise specified.

PROCEDURE
1. Operate the body hoist and the steering systems several times to bring the oil to correct
operating temperature.
2. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine. Turn the steering wheel in both directions several
times to relieve any pressure in the steering circuit. Operate the treadle valve continuously
to discharge accumulators.
3. Block all road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'OFF' position.
4. Check the oil level and add if low. Oil should at least reach the minimum level in the sight
gauge (14). If oil is required, remove the cover plate (2) and fill the hydraulic tank (1) with
hydraulic oil specified in (1) Recommended Lubricants on page 4-16. Install the cover plate
(2) on the hydraulic tank (1) and tighten.

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 Hydraulic System 11

(2) Replacing Filter Element

Numbers in parentheses refer to Figure 11.8, unless otherwise specified.

� CAUTION
• Splashing liquid. Wear a suitable face shield when using compressed air to dry hydraulic
tank and components.

NOTICE
• Tighten all fasteners, without special torques specified, to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine. Turn the steering wheel in both directions several
times to relieve any pressure in the steering circuit. Operate the treadle valve continuously
to discharge accumulators.
2. Block all road wheels, place the steering lock bar in the 'Locked' position and the battery
master switch in the 'OFF' position.
3. Open the drain valve (44) and drain the hydraulic oil into a suitable container. Seal the
drain valve (44).
4. Remove the socket screws (18) securing the cover plate (2) to the top of the hydraulic
tank (1). Discard the gasket (3).
5. Remove the filter assembly (4) from the hydraulic tank (1).
6. Remove and discard the element (6) from the filter assembly (4). Discard the O-ring (7).
7. Clean the inside of the hydraulic tank (1) with a suitable solvent and dry with compressed air.
8. Install a new element (6) in the filter assembly (4).
9. Fill the hydraulic tank (1) with hydraulic oil specified in (1) Recommended Lubricants on
page 4-16.
10. Install the filter assembly (4) in the hydraulic tank (1), complete with a new O-ring (7).
11. Place a new gasket (3) and cover plate (2) on the hydraulic tank (1). Secure with socket
screws (18).
12. Place the battery master switch in the 'ON' position and the steering lock bar in the 'Stowed'
position, remove all wheel blocks, start the engine and operate the steering, braking and
body hoist systems to circulate the oil.
13. Switch off the engine, check for leaks and check the oil level as described in (1) Checking
Oil Level on page 11-70.
14. Bleed the brake system. Refer to (7) Bleeding the Service Brakes on page 14-61.

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11 Hydraulic System

(3) Transmission Cooler Fan Drive Troubleshooting

Symptom Possible Cause Remedy
Fan will not rotate once MCU no receiving appropriate Replace transmission cooler
transmission oil temperature signal from transmission fan drive temperature switch.
is >90 °C (195 °F). cooler fan drive temperature Refer to (1) Description on
switch, when transmission oil page 11-3.
is >90 oC (195 oF).
Fan drive solenoid, located (a) Check signal from MCU
on right hand fender remains - Pin C1:24. Should be low
closed. signal.
(b) Check electrical
connections.
(c) Replace fan drive solenoid.
Check for output fault at MCU Ref. Output from Pin C1:19.
Ref. Section Hydraulic
System ECU MCU
Fan control logic valve (18) Replace fan control logic
sticking in the open position. valve (18).
Contamination in load sense Disconnect fan at main
orifices (44 & 45) and/or hydraulic valve assembly
shuttle valves (22 & 25). and plug port DF. Raise and
lower the body several times
to flush out system. If this is
unsuccessful, replace main
hydraulic valve assembly.
Fan will not modulate its Residual current at hydraulic Check current at valve (17).
speed over the desired proportional valve (17).
temperature range.
No voltage at hydraulic (a) Check electric connections
proportional valve (17). at valve (17).
(b) Check analog signal from
Trans. Cooler Fan Drive
Temperature Switch.
(c) Check output signal from
MCU Pin C1:19.
Fan Proportional Solenoid Replace Valve (17).
Valve (17) Faulty.
Contamination or Air in Load Disconnect the fan and plug
Sense Drillings or Shuttle port DF. Raise and lower the
Valves (22 & 25) body several times to flush
out the system. If this does
not work change the whole
manifold block.
Fan Pressure Modulating Replace valve (18).
Valve (18) Faulty
Contamination in Orifices (44 Clean Orifices (44 & 45).
& 45)

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 Hydraulic System 11

Symptom Possible Cause Remedy

Fan Proportional Solenoid Replace Valve (17).
Fan Speed too low. (17) Faulty.
Faulty Fan Motor. Replace Fan Motor. Ref.
Section Transmission Oil
Cooler
Fan unstable over the speed Orifices(44 or 45) Blocked. Clean Orifices
range when another function
Fan Proportional Pressure Replace Valve (17)
is selected.
Solenoid (17) Faulty.
Fan Pressure Modulating Replace Valve (18)
Logic Valve (18) Faulty.
Check Main Pump setting.
Ref. Section Main Hydraulic
Pump

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11 Hydraulic System

Intentionally Left Blank

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 Steering System 12

Table of Content
12 Steering System........................................................................................12-1
12.1 Description ................................................................................................... 12-3
12.2 Steering Column .......................................................................................... 12-6
(1) Description............................................................................................... 12-6
(2) Removal .................................................................................................. 12-7
(3) Installation ............................................................................................... 12-8
12.3 Steering Control Valve................................................................................ 12-10
(1) Description............................................................................................. 12-10
(2) Operation............................................................................................... 12-12
(3) Removal ................................................................................................ 12-13
(4) Disassembly .......................................................................................... 12-14
(5) Inspection .............................................................................................. 12-15
(6) Assembly ............................................................................................... 12-15
(7) Installation ............................................................................................. 12-17
(8) Troubleshooting ..................................................................................... 12-19
12.4 Steering Cylinders...................................................................................... 12-20
(1) Description............................................................................................. 12-20
(2) Removal ................................................................................................ 12-22
(3) Disassembly .......................................................................................... 12-23
(4) Inspection .............................................................................................. 12-24
(5) Assembly ............................................................................................... 12-24
(6) Installation ............................................................................................. 12-25
(7) Maintenance .......................................................................................... 12-27
(8) Special Tools ......................................................................................... 12-27
12.5 Steering Lock ............................................................................................. 12-29
(1) Fit the Steering Lock.............................................................................. 12-29
(2) Stow the Steering Lock.......................................................................... 12-29
12.6 Emergency Steering Pump ........................................................................ 12-31
(1) Description............................................................................................. 12-31
(2) Operation............................................................................................... 12-32
(3) Removal ................................................................................................ 12-34
(4) Overhaul ................................................................................................ 12-35
(5) Disassembly .......................................................................................... 12-35
(a) Rotating Group.................................................................................. 12-37
(6) Inspection .............................................................................................. 12-38
(a) Rotating Group.................................................................................. 12-38
(b) Pump Housing and Associated Parts ............................................... 12-38
(c) Bearing Shells................................................................................... 12-38
(d) Driveshaft and Associated Parts....................................................... 12-39
(7) Assembly ............................................................................................... 12-39
(a) Rotating Group.................................................................................. 12-41
(8) Installation ............................................................................................. 12-42
12.7 Emergency Steering Valve Block ............................................................... 12-44
(1) Description............................................................................................. 12-44
(2) Removal ................................................................................................ 12-46
(3) Installation ............................................................................................. 12-47
12.8 System Hoses ............................................................................................ 12-49
(1) Removal ................................................................................................ 12-49

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12 Steering System

(a) LH Turn Supply Hose........................................................................ 12-49

(b) LH Turn LH Cylinder Supply Hose .................................................... 12-50
(c) LH Turn RH Cylinder Supply Hose ................................................... 12-51
(d) RH Turn Supply Hose ....................................................................... 12-51
(e) RH Turn LH Cylinder Supply Hose ................................................... 12-52
(f) RH Turn RH Cylinder Supply Hose................................................... 12-53
(g) Hydraulic Control Valve Load Sensing Hose .................................... 12-54
(h) Steering Control Valve Supply Hose (1) ........................................... 12-55
(i) Steering Control Valve Supply Hose (2) ........................................... 12-55
(j) Steering Control Valve Return Hose (1)............................................ 12-56
(k) Steering Control Valve Return Hose (2)............................................ 12-57
(l) Emergency Steering Valve Supply Hose .......................................... 12-58
(m) Emergency Steering Pump Case Drain Hose................................... 12-58
(n) Emergency Steering Pump Load Sensing Hose............................... 12-59
(o) Emergency Steering Valve Pressure Hose....................................... 12-60
(p) Emergency Steering Valve Return Hose .......................................... 12-60
(2) Installation ............................................................................................. 12-62
(a) LH Turn Supply Hose........................................................................ 12-62
(b) LH Turn LH Cylinder Supply Hose .................................................... 12-63
(c) LH Turn RH Cylinder Supply Hose ................................................... 12-64
(d) RH Turn Supply Hose ....................................................................... 12-64
(e) RH Turn LH Cylinder Supply Hose ................................................... 12-65
(f) RH Turn RH Cylinder Supply Hose................................................... 12-66
(g) Hydraulic Control Valve Load Sensing Hose .................................... 12-67
(h) Steering Control Valve Supply Hose (1) ........................................... 12-68
(i) Steering Control Valve Supply Hose (2) ........................................... 12-68
(j) Steering Control Valve Return Hose (1)............................................ 12-69
(k) Steering Control Valve Return Hose (2)............................................ 12-70
(l) Emergency Steering Valve Supply Hose .......................................... 12-71
(m) Emergency Steering Pump Case Drain Hose................................... 12-71
(n) Emergency Steering Pump Load Sensing Hose............................... 12-72
(o) Emergency Steering Valve Pressure Hose....................................... 12-73
(p) Emergency Steering Valve Return Hose .......................................... 12-73

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 12
12.1

TA400 Tier2
54,65,66,67,68,69

Maintenance Manual
5 60 63 47
61 18 18 29
62
Description

17,49,51 14 38
R.H. STEERING CYL.
38
12 2
EMERGENCY 35
32 STEERING
37
7 27
PUMP S
Steering System

14 LS
3
D
STEERING VALVE
46 25
51 13 39 EMERGENCY
11 53 52 STEERING 36
LS VALVE
49 50
L R DIFFLOCK 30
VALVE
T P
21
11 20,24 23
1 34 34 26
48

Revision 1.0
8 58
58
55
22
9 34 59
TANK
RETURN
32 TUBE
31
HYDRAULIC TANK 57
/ BATTERY BOX 33 40 28
L.H. STEERING CYL.
P2

Figure 12.1 - Steering System Schematic

62 HYDRAULIC
56
60 18 CONTROL
61 VALVE ORB
63 47
6 36 LSO
23 15 TPO
42
64,65 10 36
66,67,68,69 43,44,45
TO DIAGNOSTIC
4 24 PLATE POS. 9

MOT05180

Page 12-3
15-Sep-2017
Steering System 12
12 Steering System

1. Hose 24. Clamp 47. Grease Fitting

2. Hose 25. Bracket 48. Clamp
3. Hose 26. Emergency Steering Pump 49. Bolt
Case Drain Hose
4. Hose 27. Emergency Steering Pump 50. Bolt
Suction Hose
5. Hose 28. Hose Assembly 51. Washer
6. Hose 29. Load Sense Feedback Hose 52. Washer
7. Hose 30. Hose 53. Lockwasher
8. Hose 31. Connector 54. Clamp
9. Hose 32. Plug 55. Pipe
10. Diagnostic Hose 33. Adaptor 56. Hose
11. Adaptor 34. Clamp 57. Hose
12. Elbow 35. Elbow 58. O-Ring
13. Bulkhead Union 36. Elbow 59. Clamp
14. Tee Piece 37. Elbow 60. Nipple
15. Adaptor 38. Adaptor 61. Elbow
16. Not Used 39. Elbow 62. Hose Assembly
17. Clamp 40. Adaptor 63. Elbow
18. Adaptor 41. Not Used 64. Clamp
19. Not Used 42. Connector 65. Clamp
20. Bracket 43. Diagnostic Nipple 66. Bolt
21. Clamp 44. Bulkhead Adaptor 67. Nut
22. Clamp 45. Dustcap 68. Washer
23. Clamp 46. Bracket 69. Lockwasher

The Steering System Consists of:

• Steering Column. Refer to (1) Description on page 12-6.
• Steering Control Valve (SCV). Refer to (1) Description on page 12-10.
The SCV, which is mounted on the underside of the cab floor, is connected to the steering
column and controls hydraulic oil flow to the steering cylinders.
The SCV is of a closed centre design, there is no flow of oil through the valve until the
steering column is operated.
• Steering Cylinders. Refer to (1) Description on page 12-20.
There are two single stage, double acting cushioned steering cylinders on the machine.
The cylinder base end is connected to the front frame, and the piston rod end is connected
to the articulation and oscillation pivot. Single stage double acting means that the piston rod
can have oil applied to either side, extending or retracting the piston rod.
Cylinder mounting is by pins, spacers, seals and, spherical bearings secured with circlips.
Spherical bearings permit a limited amount of cylinder misalignment when travelling over
rough terrain.
• Steering Lock.
The lock can be fitted to lock together the tractor and trailer.

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 Steering System 12

• Emergency Steering Pump (ESP). Refer to (1) Description on page 12-31.

The ESP ground driven pump, mounted on the transmission, provides flow to the steering
system in the event that the main hydraulic pump can no longer function effectively. Refer
to (1) Description on page 11-37.
• Emergency Steering Valve Block (ESVB). Refer to (1) Description on page 12-44.
• System Hoses

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12 Steering System

12.2 Steering Column

(1) Description

26

28

20 3
19

5
21 23

22
26 23
23
13 24 23 5
14
8
11
9 27
17
12
15
16
24
7 23
10 18 1
4
25
2

MOT05352

Figure 12.2 - Steering Column and Valve

1. Steering Column 11. Rubber Mounting 21. Bellows
Assembly
2. Adjustment Lever 12. Lockwasher 22. Stalk Bracket
3. Locknut 13. Bolt 23. Dome Head Bolt
4. Tension Spring 14. Washer 24. Washer
5. Cover 15. Washer 25. Steering Valve
6. Steering Wheel 16. Locknut 26. Bolt
7. Washer 17. Bolt 27. Indicator Stalk
8. Seal 18. Nut 28. Cover
9. Plate 19. Sliding Joint Assembly
10. Stub Shaft 20. Sliding Joint

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 Steering System 12

(2) Removal
Numbers in parentheses refer to Figure 12.2, unless otherwise specified.

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the steering system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Fit the Steering lock. Refer to (1) Fit the Steering Lock on page 12-29.
3. Stop the engine. Refer to 5.12 Stopping on page 5-28.
4. Place the battery master switch in the ‘OFF’ position.
5. Ensure the pressure in the steering hydraulic system has been dissipated.
6. Remove the steering wheel (6):
a. Remove the centre cap (28) from the centre of the steering wheel (6).
b. Remove the locknut (3).
c. Remove the steering wheel (6) from the steering column assembly (1).
7. Remove the indicator stalk (27):
a. Identify and tag electrical connector S5.
b. Disconnect electrical connector S5.
c. Remove dome headed bolts (23) and washers (24).
d. Remove front cover (5).
e. Support the indicator stalk (27).
f. Remove dome headed bolts (23) and washers (24).
g. Remove rear cover (5).
h. Separate the indicator stalk (27) from stalk bracket (22).
i. Remove dome headed bolts (23).
j. Separate the stalk bracket (22) from the steering column assembly (1).
8. Remove the sliding joint assembly (19):
a. Slide the bellows (21) up the sliding joint (20).
b. Loosen the bolt (26) securing the lower universal joint of the sliding joint (20).
c. Support the sliding joint (20).
d. Loosen the bolt (26) securing the upper universal joint of the sliding joint (20).
e. Remove the sliding joint (20) from the stub shaft (10) of the steering valve (25) and the
lower serrated shaft of the steering column assembly (1).
f. Remove the seal (8) from the stub shaft (10) of the steering valve (25).
9. Remove the steering column assembly (1):
a. Remove the steering wheel (6). Refer to Step 6..
b. Remove the indicator stalk (27). Refer to Step 7..
c. Remove the sliding joint assembly (19). Refer to Step 8..
d. Support the steering column assembly (1).
e. Remove the nuts (18) and washers (7).
f. Separate the steering column assembly (1) from the support brackets.

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12 Steering System

(3) Installation
Numbers in parentheses refer to Figure 12.2, unless otherwise specified.

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the steering system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to the standard torques listed in Standard Bolt and Nut Torque
Specifications section. Refer to 22.3 Standard Bolt and Nut Torque Specifications on page
22-5.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Install the steering column assembly (1):
a. Align the steering column assembly (1) with the support brackets.
b. Support the steering column assembly (1).
c. Install the washers (7) and nuts (18).
d. Install the sliding joint assembly (19). Refer to Step 4..
e. Install the indicator stalk (27). Refer to Step 5..
f. Install the steering wheel (6). Refer to Step 6..
4. Install the sliding joint assembly (19):
a. Install the seal (8) to the stub shaft (10) of the steering valve (25).
b. Slide the bellows (21) onto the sliding joint (20).
c. Install the sliding joint (20) to the stub shaft (10) of the steering valve (25) and the lower
serrated shaft of the steering column assembly (1).
d. Support the sliding joint (20).
e. Tighten the bolts (26) securing the lower and upper universal joints of the sliding joint
(20).
f. Slide the bellows (21) down the sliding joint (20) to cover the lower universal joint
of the sliding joint (20).
5. Install the indicator stalk (27):
a. Align the stalk bracket (22) with the steering column assembly (1).
b. Install dome headed bolts (23).
c. Align the indicator stalk (27) with stalk bracket (22).
d. Connect electrical connector S5.
e. Support the indicator stalk (27).
f. Fit rear cover (5) to stalk bracket (22) and steering column assembly (1).
g. Install dome headed bolts (23) and washers (24).
h. Fit front cover (5) to stalk bracket (22) and steering column assembly (1).
i. Install dome headed bolts (23) and washers (24).

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 Steering System 12

6. Install the steering wheel (6):

a. Install the steering wheel (6) onto the steering column assembly (1).
b. Install the locknut (3).
c. Tongue tighten the locknut (3) to 80 Nm (lbf ft).
d. Install the centre cap (28) to the centre of the steering wheel (6).
7. Remove the Steering lock. Refer to (2) Stow the Steering Lock on page 12-29.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.

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12 Steering System

12.3 Steering Control Valve

(1) Description

8 6 4 2
1

13 14 15 28
29

27

26

9
10 3 3 5 3

26

17 16 18
20 21 22
12

24 25 19 23

MOT05337

Figure 12.3 - Exploded View of Steering Valve

14 and 15
16 23 11 9 10 8 7 6 4

24

1
25

2
21

20 22

17 23 18 13 12 3

MOT05333

Figure 12.4 - Sectional View of Steering Valve

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 Steering System 12

1. Capscrews 11. Centering Pin 21. Seal

2. End Cap 12. Check Balls 22. O-Ring
3. O-Rings 13. Centering Spring 23. O-Ring
4. Gerotor Housing 14. Balls 24. Retaining Ring
5. Gerotor Gear 15. Key 25. Dust Seal
6. Wear Plate 16. Needle Bearing 26. Plug and O-Rings
7. Driveshaft 17. Bearing Race 27. Power Limiter Valves
8. Valve Housing 18. Bearing Race 28. Plugs
9. Control Sleeve 19. Front Retainer 29. O-Rings
10. Control Spool 20. Backup Ring

Numbers in parentheses refer to Figure 12.3 and Figure 12.4 unless otherwise specified.
The steering valve, is mounted on the underside of the cab floor and connected to the steering
column, and controls hydraulic flow in the steering system. The steering valve is of a closed
centre design, which means that the valve does not have any flow through it when it is in
the neutral or no steering position.
The steering valve has integral cylinder relief valves which relieve shock loads on the steering
cylinders by transferring excessive pressure applied to the oil by the road shock, to the opposite
end of the cylinders. This shock, if left unchecked, might damage steering linkage components.
The main components of the steering valve are valve housing (8), gerotor housing (4), gerotor
gear (5), driveshaft (7), sleeve (9) and spool (10).
There are five ports on valve housing (8) as follows:
Table 12.1 - Steering Valve Ports
Port Description
P Supply from hydraulic control valve
T Return to hydraulic tank
R Cylinder supply for right hand turn
L Cylinder supply for left hand turn
LS Load sensing to hydraulic control valve

Turning action of the steering wheel is transmitted through the steering column to sleeve (9)
and driveshaft (7), which is fastened to the sleeve with centring pin (11). Rotation of driveshaft
(7) causes gerotor gear (5) to rotate in gerotor housing (4). When gerotor gear (5) rotates, oil in
gerotor housing (4) pockets is forced out and flows through spool (10) and sleeve (9) to the
steering cylinder port. Refer to Figure 12.5.

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12 Steering System

Figure 12.5 - Gerotor Gear Set Figure 12.6 - Porting of Spool and Sleeve
1. Supply 4. LH turn supply
2. Load sensing 5. Return to tank
3. RH turn supply

Spool (10) contains porting matched to sleeve (9) and rotates within sleeve (9) to provide
directional control of the oil. Refer to Figure 12.6.
(2) Operation
Numbers in parentheses refer to Figure 12.3 and Figure 12.4, unless otherwise specified.
When the operator turns the steering wheel a certain number of degrees for either a left or right
hand turn, the movement is transmitted through the steering column to spool (10). After a
minimum rotation of 2.5 degrees, the ports in spool (10) start to align with ports in sleeve (9).
When the steering wheel is rotated to a maximum of 10 degrees the ports are fully aligned
allowing full oil flow. After 10 degrees of travel in either direction the spool (10) and sleeve (9)
rotate as an assembly through centring pin (11).
Oil from the hydraulic control valve flows into valve housing (8) at port P and is channelled
through sleeve (9) and spool (10) to gerotor housing (4). Porting in gerotor housing (4) permits
oil to flow into pockets formed by gerotor housing (4) and gerotor gear (5). As spool (10)
rotates, driveshaft (7) also rotates which, in turn, rotates gerotor gear (5) to which it is splined.
When gerotor gear (5) rotates it progressively forces oil out of the pockets of gerotor housing
(4). Refer to Figure 12.3.
The oil is channelled through sleeve (9) and spool (10) and exits valve housing (8) through port
R for a right hand turn, or port L for a left hand turn. Oil then travels through steering hoses
to the steering cylinders.
As the steering cylinder pistons move, oil forced out of the steering cylinders returns to valve
housing (8). The return oil passes through sleeve (9) and spool (10) and exits through port
T to main hydraulic tank.
When the steering effort is released, centring spring (13) which was put under tension by the
rotation of spool (10), forces sleeve (9) to rotate back to its original position. This puts the
ports out of alignment and stops pump oil flow to the steering cylinders. The machine stops
turning further but will hold the present turning radius until spool (10) is rotated past the 2.5
degree minimum.

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 Steering System 12

(3) Removal
Numbers in parentheses refer to Figure 12.2, unless otherwise specified.

� DANGER
Never place yourself under an unsupported body due to the potential for crush.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the steering system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Remove the sliding joint assembly (19). Refer to (2) Removal on page 12-7.
7. Remove the mat from the floor of the cab to gain access to the bolts (13).
8. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
9. Disconnect the hoses:
a. Identify and tag all hoses connected to the steering valve (25).
b. Position suitable containers under hose ends.
c. Disconnect hydraulic control valve (HCV) supply hose (1, Refer to Figure 12.1) to
the HCV at Port S.
d. Disconnect tank return hose (8, Refer to Figure 12.1) to the hydraulic tank at Port T.
e. Disconnect HCV load sensing hose (9, Refer to Figure 12.1) to HCV at Port LS.
f. Disconnect LH turn supply hose (2, Refer to Figure 12.1) to steering cylinders at Port L.
g. Disconnect RH turn supply hose (3, Refer to Figure 12.1) to steering cylinders at Port R.
h. If necessary, remove the adaptors (11) from the steering valve (25).
i. Install caps to all disconnected hose ends.
j. Install plugs to all disconnected steering valve (25) ports.

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12 Steering System

10. Remove the steering valve (25) and plate (9) assembly:
a. Note the installed position of plate (9).
b. Support the steering valve (25) and plate (9) assembly.
c. Remove the locknuts (16), washers (15 and 14) and bolts (13).
d. Separate the steering valve (25) and plate (9) assembly from the cab underside.
11. If necessary, separate the plate (9) and stub shaft (10) from steering valve (25):
a. Remove the bolts (17) and lockwashers (12).
b. Note the installed position of plate (9) to steering valve (25).
c. Separate the plate (9) from steering valve (25).
d. Separate the stub shaft (10) from steering valve (25).
12. If necessary, remove and discard the rubber mountings (11) from the plate (9).
13. Move the steering valve (25) to a clean maintenance area.
Further disassembly should only be done by a vendor approved workshop.

(4) Disassembly
Numbers in parentheses refer to Figure 12.3 and Figure 12.4, unless otherwise specified.

NOTICE
• Disassembly should only be done by a competent trained engineer.
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.

PROCEDURE
1. Prepare a clean and dry working area.
2. Disassemble the gerotor end:
a. Place the steering valve vertically in a vice with the end cap (2) up.
b. Remove cap screws (1).
c. Separate the end cap (2) from gerotor housing (4).
d. Remove and discard O-ring (3).
e. Remove the gerotor gear (5) from the end of driveshaft (7).
f. Separate the gerotor housing (4) from wear plate (5).
g. Remove and discard O-ring (3).
h. Separate the wear plate (6) from housing (8).
i. Remove and discard O-ring (3).
3. Remove the front retainer (19):
a. Remove the steering valve from the vice and place on a bench on a cloth to prevent
damaging the surface finish.
b. Using circlip pliers, remove the retaining ring (24).
c. Push on the drive (7) to push the front retainer (19) out of housing (8).
4. Disassemble the front retainer (19):
a. Remove dust seal (25).
b. Remove O-ring (23).
c. Remove back-up ring (20), seal (21) and O-ring (22).
5. Pull on the drive (7) to pull the control sleeve (9) and spool (10) out of housing (8).

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 Steering System 12

6. Disassemble the control sleeve (9) and spool (10):

a. Remove the key (15).
b. Remove the balls (14) and centering spring (13).
c. Remove the centering pin (11).
d. Separate the control sleeve (9), control spool (10) and drive (7).
e. Remove the balls (12).
7. Remove needle thrust bearing (16) and bearing races (17 and 18).

(5) Inspection

NOTICE
• Replace all O-rings and seals with new at assembly. Lubricate O-rings and seals with a
petroleum jelly.

PROCEDURE
1. Clean all metal parts with a suitable solvent and blow dry with compressed air. Do not wipe
dry 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.
3. Do not use course grit or try to file any metal parts.

(6) Assembly
Numbers in parentheses refer to Figure 12.3 and Figure 12.4, unless otherwise specified.

NOTICE
• Disassembly should only be done by a competent and trained engineer.
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.

PROCEDURE
1. Prepare a clean and dry working area.
2. Install needle thrust bearing (16) and bearing races (17 and 18).
3. Assemble the front retainer (19):
a. Install back-up ring (20), seal (21) and O-ring (22).
b. Install O-ring (23).
c. Install dust seal (25).
4. Install the front retainer (19):
a. Remove the steering valve from the vice and place on a bench on a cloth to prevent
damaging the surface finish.
b. Push the front retainer (19) into the housing (8).
c. Using circlip pliers, install the retaining ring (24).

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12 Steering System

7 10

7 9 10

11

9 11

12
MOT05331 MOT05332

Figure 12.7 - Assembling Control Figure 12.8 - Installing Driveshaft

Sleeve and Spool with Centering Pin
7. Driveshaft 10. Control Spool 7. Driveshaft 10. Control Spool
9. Control Sleeve 11. Centering Pin 9. Control Sleeve 11. Centering Pin
12. Check Balls

5. Assemble the control sleeve (9) and spool (10). Refer to Figure 12.7 and Figure 12.8:
a. Install the balls (12) into the control spool (10).
b. Align the centering pin (11) holes in the control sleeve (9), control spool (10) and
driveshaft (7).
c. Install the centering pin (11).
d. Mark the two driveshaft (7) tooth slots that are parallel with the centering pin (11).
e. Install the balls (14) and centering spring (13).
f. Install the key (15).
6. Push on the driveshaft (7) to fit the control sleeve (9) and spool (10) into housing (8).
7. Turn the driveshaft (7), to align the marks made on the driveshaft (7) tooth slots parallel
with the port face.
8. Assemble the gerotor end:
a. Place the steering valve vertically in a vice with the end cap (2) up.
b. Install new O-ring (3) to housing (8).
c. Align the wear plate (6) with housing (8).
d. Install new O-ring (3) to wear plate (6).
e. Orientate the gerotor housing (4).
f. Align the gerotor housing (4) to wear plate (6).
g. Install new O-ring (3) to gerotor housing (4).
h. Install the gerotor gear (5).
i. Align the end cap (2) to gerotor housing (4).
j. Install capscrews (1).
k. Pre-tighten capscrews (1) to 20–27 Nm (15–20 lbf.ft) in the sequence shown in Figure
12.9.
l. Torque tighten capscrews (1) to 100 Nm (75 lbf.ft) in the sequence shown in Figure 12.9.

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 Steering System 12

Figure 12.9 - Capscrew Tightening Sequence

(7) Installation
Numbers in parentheses refer to Figure 12.2, unless otherwise specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the steering system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all fasteners to standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.
• Ensure the cab electrical harness from the body control lever is at the front when lever is
installed.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.

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12 Steering System

3. If removed, install new rubber mountings (11) to the plate (9).

4. If removed, install stub shaft (10) and plate (9) to steering valve (25):
a. Fit the stub shaft (10) to steering valve (25).
b. Align plate (9) with steering valve (25) as noted during removal.
c. Install the bolts (17) and lockwashers (12).
d. Torque tighten bolts (17).
5. If removed, install adaptors (11) to the steering valve (25).
6. Install the steering valve (25) and plate (9) assembly:
a. Align the steering valve (25) and plate (9) assembly with the attachment points on the
cab underside as noted during removal.
b. Support the steering valve (25) and plate (9) assembly.
c. Install the bolts (13), washers (14 and 15) and locknuts (16).
d. Torque tighten locknuts (16).
7. Connect the hoses:
a. Remove plugs from all disconnected steering valve (25) ports.
b. Remove caps from all disconnected hose ends.
c. Connect hydraulic control valve (HCV) supply hose (1, Refer to Figure 12.1) to the
HCV at Port S.
d. Connect tank return hose (8, Refer to Figure 12.1) to the hydraulic tank at Port T.
e. Connect HCV load sensing hose (9, Refer to Figure 12.1) to HCV at Port LS.
f. Connect LH turn supply hose (2, Refer to Figure 12.1) to steering cylinders at Port L.
g. Connect RH turn supply hose (3, Refer to Figure 12.1) to steering cylinders at Port R.
8. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
9. Install the mat to the floor of the cab.
10. Install the sliding joint assembly (19). Refer to (3) Installation on page 12-8.
11. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
12. Place the battery master switch in the ‘ON’ position.
13. Start the engine. Refer to 5.11 Starting on page 5-27.
14. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times to purge air out of the system.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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 Steering System 12

(8) Troubleshooting
Numbers in parentheses refer to Figure 12.3 and Figure 12.4, unless otherwise specified.
Table 12.2 - Steering Valve Troubleshooting
Condition Possible Cause Remedy
Steering wheel does not Binding in steering linkage to Align as required
centre steering valve
Worn gerotor housing (4) Replace parts
and/or gear (5)
Broken centring spring (13) Replace parts
Burrs on control sleeve (9) or Disassemble and repair or
spool (10) replace parts
Apparent inability to steer Dirt in system Drain and flush system. Refill
when wheel is turned slowly with clean oil
Slow/Hard steering Excessive wear to control Replace parts
sleeve (9) or spool (10)
Excessive wear to gerotor Replace part
housing (4)
Opposite steering Hoses installed incorrectly Reconnect correctly
Steering wheel rocking back Wrong orientation between Realign as per instructions
and forth gerotor gear (5) and driveshaft
(7)
Steering wheel continues to Binding in steering linkage to Align as required
turn steering valve
Burrs on control sleeve (9) or Disassemble and repair or
spool (10) replace
Dirt in system Drain and flush system. Refill
with clean oil
Broken centring spring (13) Replace parts
No steering action Control sleeve (9) and spool Disassemble and repair or
(10) locked together replace

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12 Steering System

12.4 Steering Cylinders

(1) Description

10 9

1
2
3

5
25

18
21 19

16
17

STEERING LOCK
19

14

7
12
8

11
23

13
22 23 22

15
24
25

1
2
3

5
9 10

MOT04686_p

Figure 12.10 - Sectional View of Steering Cylinder and Mounting

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 Steering System 12

1. Bolt 10. Spherical Bearing 19. Wear Ring

2. Lockwasher 11. Shell 20. Rod Seal
3. Hardened Washer 12. Rod 21. Nylon Ring
4. Pin 13. Piston 22. Wear Ring
5. Spacer 14. Retainer 23. Seal
6. Steering Lock 15. Cushion Sleeve 24. Set Screw
7. Steering Lock Pin 16. O-ring 25. Grease Nipple
8. Steering Cylinder 17. O-ring
9. Circlip 18. Rod Wiper

There are two single stage, double acting steering cylinders, on the machine. Each cylinder
base end is connected to the tractor chassis and each piston rod eye end is connected to the
body chassis. Single stage, double acting means that the piston rod can have oil applied to
either end, extending or retracting the piston rod.
Cylinder mounting is by means of pins.
When the operator turns the steering wheel for a steering operation, movement of the piston
rod generates force required to pivot the tractor. In the neutral position, with the steering valve
centralized, oil movement between the steering cylinders and the steering valve is stopped.
Trapped oil in the system locks both steering cylinders and the angle of steering set by the
operator is maintained.

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12 Steering System

(2) Removal
Numbers in parentheses refer to Figure 12.10, unless otherwise specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the steering system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• The procedure to remove the LH and RH cylinder is identical. The procedure for the LH
cylinder is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Gain access to the work area:
a. Remove the LH front tire and rim assembly. Refer to (3) Removing Tire and Rim
Assembly from Machine on page 9-125.
b. Remove the LH top rear mudflap (18, Refer to Figure 16.11). Refer to (1) Removal
on page 16-43.
c. Remove the LH wheel arch mudflap (17, Refer to Figure 16.11). Refer to (1) Removal
on page 16-43.
7. Position suitable containers under hose ends.
8. Remove the LH turn supply hose (5, Refer to Figure 12.1). Refer to (1) Removal on page
12-49.
9. Remove the RH turn supply hose (7, Refer to Figure 12.1). Refer to (1) Removal on page
12-49.
10. Attach suitable lifting equipment to the cylinder (8) and take an initial strain.

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 Steering System 12

11. At the pivot assembly attachment point:

a. Remove the bolt (1), lockwasher (2) and hardened washer (3).
b. Remove the pin (4) and spacers (5).
12. Separate the cylinder (8) from the pivot assembly attachment point.
13. At the front chassis attachment point:
a. Remove the bolt (1), lockwasher (2) and hardened washer (3).
b. Remove the pin (4) and spacers (5).
14. Separate the cylinder (8) from the front chassis attachment point.
15. Using standard lifting equipment, lift the cylinder (8) from its attachment brackets on the
front chassis and pivot assembly.
16. Move the cylinder (8) to a clean maintenance area.

(3) Disassembly
Numbers in parentheses refer to Figure 12.10, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• The procedure to disassemble the LH and RH cylinders is identical. The procedure for
the LH cylinder is detailed below.

PROCEDURE
1. Prepare a clean and dry working area.
2. Remove spherical bearings (10) from base and rod ends of steering cylinder (8):
a. Remove circlip (9).
b. Press out spherical bearing (10).
c. Repeat steps a. and b. for the second spherical bearing (10).
3. Remove the rod (12) from shell (11):
a. Remove lock ring from retainer (14).
b. Using the end cap torque tool (refer to Figure 12.11), unscrew retainer (14) until thread
is disengaged from shell (11).
c. Support rod (12).
d. Withdraw rod (12) from shell (11). Ensure centre lines of rod (12) and shell (11) remain
aligned during removal of rod (12).
e. Place rod (12) on supports which will not damage the piston rod diameter.
4. Disassemble the piston (13):
a. Remove and discard wear rings (22) from piston (13).
b. Remove and discard seal (23) from piston (13).
c. Remove set screw (24) from wear ring (22) groove in piston (13).
d. Provide an anti-torsion device through rod (12) eye.
e. Using the piston torque tool (refer to Figure 12.12), unscrew piston (13) from rod (12).
f. Remove cushion sleeve (15) from piston (13).
5. Remove retainer (14) from rod (12).

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12 Steering System

6. Disassemble the retainer (14):

a. Remove and discard O-ring (16).
b. Remove and discard O-ring (17).
c. Remove and discard wear rings (19).
d. Remove and discard nylon ring (21) and rod seal (20).
e. Remove and discard rod wiper (18).

(4) Inspection
Numbers in parentheses refer to Figure 12.10, unless otherwise specified.

PROCEDURE
1. Clean all parts of the steering cylinder (8) with a suitable solvent and dry with clean, lint-free
cloths. Clean all grooves carefully to remove any foreign material.
2. Check shell (11) and outer diameter of piston (13) for scratches, cracks or other defects.
Remove ridges, nicks and scratches with a fine stone and reclean.
3. Inspect rod (12) for distortion, cracks or other defects. Replace rod (12) if defective area
is irreparable.
4. Check spherical bearings (10) for wear and replace if necessary.

(5) Assembly
Numbers in parentheses refer to Figure 12.10, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• The procedure to assemble the LH and RH cylinders is identical. The procedure for the LH
cylinder is detailed below.

PROCEDURE
1. Prepare a clean and dry working area.
2. Assemble the retainer (14):
a. Install new rod wiper (18).
b. Install new nylon ring (21) and rod seal (20).
c. Install new wear rings (19).
d. Install new O-ring (17).
e. Install new O-ring (16).
3. Install retainer (14) onto rod (12), taking care not to damage rod wiper (18) on the thread.

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 Steering System 12

4. Assemble the piston (13):

a. Provide an anti-torsion device through rod (12) eye.
b. Apply Loctite 243 to first two threads of piston (14).
c. Using the piston torque tool (refer to Figure 12.12), screw piston (13) to rod (12).
d. Torque tighten piston (13) to 742 - 810 Nm (547 - 597 lbf ft).
e. Install set screw (24) to wear ring (22) groove in piston (13).
f. Torque tighten set screw (24) to 14 - 20 Nm (10 - 15 lbf ft).
g. Ensure the extreme of set screw (24) is below the level of wear ring (22) groove.
h. Install new wear rings (22) onto piston (13).
i. Install new piston seal (23) onto piston (13).
j. Install cushion sleeve (15) to piston (13).
5. Install the rod (12) into shell (11):
a. Grease outside diameter of piston (13) and O-rings (16 and 17) in retainer (14) to
aid installation.
b. Slide rod (12) 75% of the way into shell (11). Take care not to damage seal (23) on
shell (11) threads. Ensure centre lines of rod (12) and shell (11) remain aligned during
installation of rod (12).
c. Support rod (12).
d. Install retainer (14) to shell (11) hand tight.
e. Push rod (12) to the fully retracted position
f. Using the end cap torque tool (refer to Figure 12.11), torque tighten retainer (14) to
540 - 607 Nm (398 - 448 lbf ft).
6. Install spherical bearings (10) to base and rod ends of cylinder (8):
a. Install spherical bearing (10).
b. Install circlip (9) to secure spherical bearing (10).
c. Repeat steps a. and b. for the second spherical bearing (10).
7. Install plugs to all ports to prevent ingress of dirt.

(6) Installation
Numbers in parentheses refer to Figure 12.10, unless otherwise specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

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

NOTICE
• Tighten all the fasteners to the standard torques listed in Standard Bolt and Nut Torque
Specifications section. Refer to 22.3 Standard Bolt and Nut Torque Specifications on page
22-5.
• The procedure to install the LH and RH cylinders is identical. The procedure for the LH
cylinder is detailed below.

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12 Steering System

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Attach suitable lifting equipment to the cylinder (8).
5. Using lifting equipment, align the cylinder (8) with its attachment bracket on the front chassis.
6. At the front chassis attachment point:
a. Install the spacers (5) and pin (4).
b. Install the bolt (1), lockwasher (2) and hardened washer (3).
7. Using lifting equipment, align the cylinder (8) with its attachment bracket on the pivot
assembly.
8. At the pivot assembly attachment point:
a. Install the spacers (5) and pin (4).
b. Install the bolt (1), lockwasher (2) and hardened washer (3).
9. Torque tighten the bolts (1).
10. Using the grease nipples (26), lubricate the pins (4) with specified lubricant. Refer to (1)
Recommended Lubricants on page 4-16. Lubricate slowly until excess lubricant is observed.
11. Install the LH turn supply hose (5, Refer to Figure 12.1). Refer to (2) Installation on page
12-62.
12. Install the RH turn supply hose (7, Refer to Figure 12.1). Refer to (2) Installation on page
12-62.
13. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
14. Place the battery master switch in the ‘ON’ position.
15. Start the engine. Refer to 5.11 Starting on page 5-27.
16. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times to purge air out of the system.
17. Check for leaks.
18. Check hydraulic tank oil level and replenish if required.

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 Steering System 12

(7) Maintenance
Numbers in parentheses refer to Figure 12.10, unless otherwise specifed.
Every 250 hours: Lubricate pins (4) as described in (1) Recommended Lubricants on page
4-16. Inspect cylinders for leaks, if leaks are found, replace seals with seals contained in the
Service Repair Kit, as specified in the parts book.
(8) Special Tools
Numbers in parentheses refer to Figure 12.10, unless otherwise specified.
Two special tools are required to disassemble and assemble the Steering Cylinder. For the
special tool to:
• disassemble/assemble retainer (15), refer to Figure 12.11.
• disassemble/assemble piston (14), refer to Figure 12.12.
These two special tools can be fabricated as shown in Figure 12.11 and Figure 12.12. Refer to
22.2 Service Tools on page 22-4, for part numbers of general service tools required. These
tools are available from your dealer.

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12 Steering System

Figure 12.11 - End Cap Torque Tool

Figure 12.12 - Piston Torque Tool

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 Steering System 12

12.5 Steering Lock

(1) Fit the Steering Lock
Numbers in parentheses refer to Figure 12.10, unless otherwise specified.

� CAUTION
• When working in the area between the tractor and trailer be aware of the risk of injury
whilst the tractor is being steered.

NOTICE
• The hooked end of the steering lock is installed to the attachment point on the front chassis
frame.

PROCEDURE
1. Remove the steering lock (6) from its stowed position:
a. Remove the steering lock pins (7).
b. Lift the steering lock (6) from its stowed position.
2. Install the steering lock (6) to the attachment point on the rear chassis frame:
a. Align the non hooked end of the steering lock (6) with the attachment point on the
rear chassis frame.
b. Install the associated steering lock pin (7).
3. Steer the tractor into a suitable position.
4. Install the steering lock (6) to the attachment point on the front chassis frame:
a. Install the steering lock pin (7) to the attachment point on the front chassis frame.
b. Swing the steering lock (6) down until the hook is sitting on the steering lock pin (7),
installed in step a.
c. Steer the tractor until the hook of the steering lock (6) has engaged with the steering
lock pin (7), installed in step a.
d. Remove the steering lock pin (7), installed in step a.
e. Swing the steering lock (6) down to engage with the attachment point on the front
chassis frame.
f. Re-install the steering lock pin (7) to lock the tractor and the trailer together.

(2) Stow the Steering Lock

Numbers in parentheses refer to Figure 12.10, unless otherwise specified.

� CAUTION
• When working in the area between the tractor and trailer be aware of the risk of injury
whilst the tractor is being steered.

PROCEDURE
1. Remove the steering lock (6) from its fitted position:
a. Remove the steering lock pins (7).

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12 Steering System

b. Lift the steering lock (6) from its fitted position.

2. Install the steering lock (6) to its stowed position:
a. Align the steering lock (6) with its stowed position attachment points.
b. Install the steering lock pins (7).

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 Steering System 12

12.6 Emergency Steering Pump

(1) Description
Numbers in parentheses refer to Figure 12.13, unless otherwise specified.

37

36

38 39

40

MOT05103

Figure 12.13 - Exploded View of Emergency Steering Pump

1. Emergency Steering 15. Swash Plate 29. Capscrew
Pump
2. Control Valve 16. Driveshaft 30. Plug
3. Gasket Plate 17. Plug 31. Pin
4. Screw 18. Spring 32. Roll Pin
5. Adaptor 19. Shim 33. Plug
6. O-ring 20. Stop Ring 34. Plug
7. Adaptor 21. Bearing 35. Gasket
8. O-ring 22. Bearing - Tapered 36. Emergency Steering Valve
Block
9. Rotating Group 23. Bearing Shells 37. Capscrew
10. Control Plate 24. Seal - Shaft 38. Washer
11. Control Piston 25. O-Ring 39. Nut
12. Piston Rod 26. O-Ring 40. Stud
13. Pump Housing 27. Seal
14. End Cover 28. Circlip

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12 Steering System

� CAUTION
• Never drive a pump in the wrong direction of rotation as pump seizure will result.

The emergency steering pump (1) is mounted on the dropbox. Refer to 7.1 Dropbox and
Mounting on page 7-3.
The emergency steering pump is an axial piston, variable displacement (adjustable) pump,
capable of high pressure operation. It provides flow to steering circuit in the event that the
main pump can no longer function. Pump control valve (2) regulates system pressure at 240
bar (3 480 psi).
The emergency steering pump is assembled for right hand (clockwise) rotation, as viewed
from driveshaft (16) end.
The major pump components include: driveshaft (16), pump housing (13), swash plate (15),
rotating group (9), control piston (11), bias spring (18), end cover (14) and pump control
valve (2).
The variable displacement unit incorporates a mechanism that governs the angle of swash plate
(15) which, in turn controls the stroke length of each piston as rotating group (9) and driveshaft
(16) rotate. End cover (14) includes the inlet and outlet ports. Bearing (21) in pump housing
(13) and tapered bearing (22) in end cover (14) support driveshaft (16).
(2) Operation
Numbers in parentheses refer to Figure 12.14, unless otherwise specified.

Figure 12.14 - Pump Rotation and Oil Flow

1. Piston Assembly 4. Retaining Plate 6. Intake Kidney Slot
2. Swash Plate 5. Cylinder Housing 7. Outlet Kidney Slot
3. Driveshaft

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 Steering System 12

Rotation of driveshaft (3) causes the cylinder housing (5), retaining plate (4) and piston
assembly (1) to rotate. The piston assembly (1) shoes are held against the swash plate (2)
by the retaining plate (4). The angle of the swash plate (2) imparts a reciprocating motion to
each piston assembly (1) piston within the cylinder housing (5). Inlet and outlet ports connect to
a kidney slotted valve plate. As the pistons move out of the cylinder housing (5), a vacuum
is created and fluid is forced into the void by atmospheric pressure. The fluid moves with the
cylinder housing (5), past the intake kidney slot (6), to the outlet kidney slot (7). The motion of
the pistons reverse and fluid is pushed out of the cylinder housing (5) into the outlet port.
Internal pump leakage oil is returned to tank through a line at the case drain port on the steering
pump. Refer to Figure 12.15.

Figure 12.15 - Hydraulic Schematic of Steering Pump Operation

Variable Displacement

Figure 12.16 - Variable Displacement Action

Variable displacement is effected by altering the angularity between the shoe plate and
driveshaft axes, as shown by views ‘A’, ‘B’ and ‘C’ in Figure 12.16.
During pump operation, load or system pressure is continually fed to the bias piston and the
control piston spool chamber.

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The operation of the control piston is such that when the system pressure (pump outlet) reaches
the spring setting, the valve spool moves to meter fluid to the pump control piston. As the force
produced by the control piston overcomes the force of the bias piston, the shoe plate angle
moves toward the minimum displacement position.(View ‘C’ in Figure 12.16).
The amount of angular movement of the swash plate (i.e. displacement change) is determined
by system flow demand and the resulting system pressure. Equilibrium is achieved when the
new displacement matches the system requirement.
(3) Removal
Numbers in parentheses refer to Figure 12.13, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the steering system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Gain access to the work area.
6. Drain the oil from the emergency steering pump (1) and emergency steering valve block
(36):
a. Position a suitable container under the emergency steering pump (1) drain plug.
b. Remove drain plug from underside of emergency steering pump (1).
c. Allow oil to drain.
d. Install drain plug to underside of emergency steering pump (1).
7. Remove the emergency steering valve block (36). Refer to (2) Removal on page 12-46.
8. Disconnect hoses from emergency steering pump (1):
a. Identify and tag all hoses connected to the emergency steering pump (1).
b. Disconnect load sense feedback hose (29, Refer to Figure 12.1) to emergency steering
valve block.
c. If necessary, remove adaptor (38, Refer to Figure 12.1).
d. Disconnect emergency steering pump case drain hose (26, Refer to Figure 12.1) to
hydraulic tank.
e. If necessary, remove elbow (39, Refer to Figure 12.1).
f. Install caps to all disconnected hose ends.

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 Steering System 12

g. Install plugs to all disconnected emergency steering valve block (1, Refer to Figure
12.21) ports.
9. Remove the emergency steering pump (1):
a. Using a suitable lifting device, support the emergency steering pump (1).
b. Remove the nuts (39) and washers (38).
c. Pull emergency steering pump (1) rearward to disengage pump driveshaft from dropbox
drive coupling.
d. Separate emergency steering pump (1) from dropbox.
e. Using standard lifting equipment, lift the emergency steering pump (1) away from the
dropbox.
f. Remove and discard gasket (35).
g. Install plugs to all disconnected emergency steering pump (1) ports.
h. If necessary, remove studs (40).
10. Wash the outside of emergency steering pump (1) thoroughly with a suitable solvent.
11. Move the emergency steering pump (1) to a clean maintenance area.

(4) Overhaul
In most cases, the pump will not require a complete overhaul as described within this section
of the manual. Repair of this unit is intricate and should not be attempted without proper
knowledge and tools.
(5) Disassembly
Numbers in parentheses refer to Figure 12.13, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• The pump control valve (2) can only be replaced as an assembly. Therefore, no further
disassembly is required.

PROCEDURE
1. Prepare a clean and dry working area.
2. Remove pump control valve (2):
a. Remove four screws (4) securing pump control valve (2) to housing (13).
b. Separate control valve (2) from housing (13).
c. Remove and discard gasket plate (3).
3. Remove end cover (14):
a. Secure emergency steering pump (1) in a suitable jig or fixture; orientated with end
cover (14) and capscrews (29) facing upwards for disassembly.
b. Match mark end cover (14) and pump housing (13) to aid at assembly stage.
c. Remove capscrews (29) from end cover (14).
d. Using suitable lifting equipment, separate end cover (14) from pump housing (13).
e. Remove control plate (10) and tapered bearing (22) outer race.
f. Remove roll pin (32) from end cover (14).
g. Remove and discard O-ring (25).
h. Using a suitable bearing puller, pull tapered bearing (22) outer race from control plate
(10).

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12 Steering System

4. Remove tapered bearing (22) inner race and shim (19) from end of driveshaft (16). Take
care not to damage sealing surfaces.
5. Using suitable lifting equipment, lay emergency steering pump (1) horizontal.
6. Remove rotating group (9) from the pump housing (13). If the rotating group (9) requires
disassembling further, refer to (a) Rotating Group on page 12-37.
7. Remove control piston (11):
a. Remove plug (17) from pump housing (13).
b. Remove and discard O-ring (26).
c. Prise control piston (11) out of pump housing (13) using the flat surface of a suitable
screwdriver. Refer to Figure 12.17.
d. Remove piston rod (12).

Figure 12.17 - Control Piston Removal Figure 12.18 - Swash Plate Removal

8. Remove swash plate (15) using a suitable tool. Slight rotation of swash plate (15) through
the z-axis may be required to aid in removal from inner bore of the pump housing (13).
Refer to Figure 12.18.
9. Remove spring (18) from pump housing (13).
10. Remove bearing shells (23) from pump housing (13).
11. Remove driveshaft (16). The bearing (21) inner race will be mated to the driveshaft at
this stage.
12. Remove bearing (21) outer race:
a. Using suitable lifting equipment, secure pump housing (13) on the bench or fixture, in
correct orientation for removal of the bearing (21) outer race.
b. Using suitable bearing pullers, remove bearing (21) outer race from the bore of the
pump housing (13).
13. Remove stop ring (20) from the pump housing (13).
14. Remove circlip (28) and shaft seal (24) from the opposite end of the pump housing.
15. Remove plug (33) from the pump housing (13).

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 Steering System 12

(a) Rotating Group

4
8
6 7
1 2 5
3

5 7

6
MOT05104

Figure 12.19 - Rotating Group Detail

1. Piston Assembly 4. Cylinder Housing 7. Spring
2. Retaining Plate 5. Pins 8. Circlip
3. Tapered End Cap 6. Back-up Plate

Numbers in parentheses refer to Figure 12.19, unless otherwise specified.

� WARNING
• The spring (7) located within the cylinder housing (4) is under high tension and can cause
bodily harm. Ensure circlip (8) is removed using the manufacturers guidelines.

PROCEDURE
1. Remove piston assembly (1) from cylinder housing (4) bores.
2. Remove retaining plate (2).
3. Remove tapered end cap (3).
4. Remove circlip (8).
5. Remove spring (7) and back-up plate (6).
6. Remove pins (5).

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(6) Inspection

NOTICE
• Before inspection of parts, clean all parts with a suitable solvent.

(a) Rotating Group

Numbers in parentheses refer to Figure 12.19, unless otherwise specified.

PROCEDURE
1. Inspect cylinder housing (4) for wear, scratches and/or erosion. If cylinder housing (4)
condition is questionable, replace the entire rotating group.
2. Check each cylinder housing (4) bore for excessive wear. Use piston assembly (1) and
retaining plate (2) for this purpose. The piston assembly (1) should be a very close fit and
slide in and out of the cylinder housing (4) bores. No binding can be tolerated. If binding
occurs, clean cylinder housing (4), piston assembly (1) and retaining plate (2). Lubricate
cylinder housing (4) bores with clean hydraulic oil and try again. Even minor contamination
of the oil may cause a piston assembly (1) to seize up in a cylinder housing (4) bore.
3. Inspect retaining plate (2) for heavy wear and/or cracks. Replace if defective.

(b) Pump Housing and Associated Parts

Numbers in parentheses refer to Figure 12.13, unless otherwise specified.

PROCEDURE
1. Inspect pump housing (13) for erosion, cracks and burrs. Clean up minor burrs with an India
stone. If erosion or cracks are noted, replace pump housing (13).
2. Inspect inner and outer races of tapered bearings (21 and 22) for nicks and pitting. Make
sure the inner race turns freely within the outer race. If either of the tapered bearings
need replaced, both the inner and outer races must be replaced. To remove the outer
races from pump housing (13) or end cover (14) do so using tooling in accordance with
manufacturers guidelines.
3. Inspect control plate (10) for erosion, excessive wear, heavy scratches and cracks. If any of
the above conditions are found, replace the control plate.

(c) Bearing Shells

Numbers in parentheses refer to Figure 12.13, unless otherwise specified.

PROCEDURE
1. Inspect bearing shells (23) face for wear, roughness or scoring. Check the hubs and
bearing surfaces for wear and cracks. Replace if defective.
2. Inspect bearing shells (23) for heavy wear and/or cracks. Replace if defective.

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 Steering System 12

(d) Driveshaft and Associated Parts

Numbers in parentheses refer to Figure 12.13, unless otherwise specified.

PROCEDURE
1. Inspect driveshaft (16) for wear, chipped splines and burrs. Remove burrs with an India
stone. Inspect contact area of tapered bearings (21 and 22) and shaft seal (24). Replace
driveshaft (16) if wear or scoring is greater than 0.127 mm (0.005 in) total indicator reading
(TIR).
2. Check remaining pump parts for excessive wear, damaged threads, burrs, cracks and/or
erosion. Replace any part that is in a questionable condition.

(7) Assembly
Numbers in parentheses refer to Figure 12.13, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• If required, obtain a new shaft seal kit and a new bearing kit.
• Apply a light film of clean hydraulic oil to all new seals to make assembly easier and provide
initial lubrication of moving parts.
• Orientate driveshaft (16) so that the splined end of shaft will be protruding through the end
face of the pump housing (13) when the shaft is in the assembly position.

PROCEDURE
1. Prepare a clean and dry working area.
2. Install sealing ring (20) and bearing (21) outer race into pump housing (13):
a. Using suitable lifting equipment, secure pump housing (13) on the bench or fixture, in
correct orientation for installation of the sealing ring (20) and bearing (21) outer race.
b. Grease the sealing ring (20).
c. Install stop ring (20) into open end of pump housing (13). Tap lightly to ensure that stop
ring (20) sits on shoulder face.
d. Install bearing (21) outer race in correct orientation inside pump housing and tap home
until fully seated on shoulder.
3. Temporarily install driveshaft (16):
a. Instal bearing (21) inner race onto driveshaft (16). Make sure inner race is fully home
on the driveshaft (16) shoulder.
b. Install shim (19) and tapered bearing (22) inner race onto the end of driveshaft (16) that
extends out of the open end of the pump housing (13). Make sure shim (19) and inner
race seat correctly onto the driveshaft (16).
c. Install driveshaft (16), taping lightly on the end face of the shaft until the bearing (21)
is in position.

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4. Temporarily install end cover (14):

a. Using suitable lifting equipment, place end cover (14), on a bench or suitable jig fixture.
b. Using a suitable driver and plastic mallet, install the tapered bearing (22) outer race
onto end cover (14).
c. Insert new O-ring (25) into mating groove on end cover (14).
d. Using suitable lifting equipment, align end cover (14) with pump housing (13) using
match marks made during disassembly..
e. Install capscrews (29) to end cover (14).
f. Torque tighten capscrews (29) to 130 Nm (96 lbf ft).
5. Measure the distance between the parallel faces of the pump housing (13) and the end
cover (14). Refer to Figure 12.20. Distance should be 0 - 0.05 mm. If necessary adjust the
thickness of the shim (19) to achieve the correct measurement.

14

13
MOT03983

Figure 12.20 - Measurement Detail

13. Pump Housing 14. End Cover

6. Once the correct measurement has been obtained, remove end cover (14), tapered bearing
(22) inner race and shim (19).
7. Install shaft seal (24) into pump housing (13):
a. Using suitable lifting equipment, rotate main pump housing (13).
b. Using a suitable driver, tap shaft seal (24) down to meet the stop ring (20). Correct
orientation of shaft seal (24) is important.
c. Using suitable circlip pliers, fit circlip (28) into groove of pump housing (13).
d. Visually check to ensure circlip (28) is correctly located in the groove.
8. Using suitable lifting equipment, rotate pump housing (13) assembly in the fixture.
9. Grease the bearing shells (23).
10. Insert bearing shells (23) and spring (18) to pump housing (13), in the correct orientation.
11. Assemble swash plate (15) and piston rod (12) into the pump housing (13) using suitable
tool.
12. Check correct position of piston rod (12) and spring (18).
13. Install rotating group (9) into the pump housing (13). If the rotating group (9) requires
assembling, refer to (a) Rotating Group on page 12-41.
14. Using suitable lifting equipment, lay emergency steering pump (1) horizontal on the bench.
15. Install tapered bearing (22) inner race and shim (19) onto end of driveshaft (16). Take care
not to damage sealing surfaces.

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 Steering System 12

16. Install end cover (14):

a. Install control plate (10) and lock with roll pin (32).
b. Using suitable lifting equipment, align end cover (14) with pump housing (13) using
match marks made during disassembly..
c. Install capscrews (29) to end cover (14).
d. Torque tighten capscrews (29) to 130 Nm (96 lbf ft).
17. Install control piston (11):
a. Install control piston (11) into pump housing (13).
b. Install new O-ring (26).
c. Apply Loctite 242 to threads of plug (17).
d. Install plug (17) to pump housing (13).
e. Torque tighten the plug (17) to 190-210 Nm (140-155 Ibf ft).
18. Install pump control valve (2):
a. Install new gasket plate (3).
b. Align control valve (2) with housing (13).
c. Install four screws (4) to secure pump control valve (2) to housing (13).
d. Torque tighten screws (4) to 15.5 Nm (11.5 Ibf ft).
19. Install plug (33) into the pump housing (13).

(a) Rotating Group

Numbers in parentheses refer to Figure 12.19, unless otherwise specified.

PROCEDURE
1. Install pins (5) into the bore of the cylinder housing (4). Ensure orientation is correct.
2. Install back-up plate (6) and spring (7).
3. Using a suitable combination of bolt, nut and washer compress the spring (7) sufficiently
enough for the circlip (8) to be installed.
4. Install circlip (8).
5. Remove the bolt, nut and washer used to compress the spring (7).
6. Lubricate cylinder housing (4) and retaining plate (2) with oil.
7. Install tapered end cap (3).
8. Install retaining plate (2).
9. Install piston assembly (1) into cylinder housing (4) bores.

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12 Steering System

(8) Installation
Numbers in parentheses refer to Figure 12.13, unless otherwise specified.

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

� 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.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.
• Tighten all hydraulic lines fitted with ORFS connections. Renew all 'O' rings where used.
• It is very important that the pump cavity is completely filled with hydraulic oil. This will
ensure proper lubrication of the internal parts of the pump when it is initially operated.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install the emergency steering pump (1):
a. If removed, install studs (40).
b. Apply Loctite 648 to the mounting studs (40).
c. Coat steering pump shaft spline (16) with molybdenum disulphide grease and the
mating surface of the pump with white soft paraffin grease.
d. Install new gasket (35).
e. Remove plugs from all disconnected emergency steering pump (1) ports.
f. Using standard lifting equipment, lift the emergency steering pump (1) local to the
dropbox.
g. Align emergency steering pump (1) with dropbox drive coupling.
h. Push emergency steering pump (1) forward to engage pump driveshaft with dropbox
drive coupling.
i. Using a suitable lifting device, support the emergency steering pump (1).
j. Install the nuts (39) and washers (38).
k. Torque tighten nuts (39) to 87 Nm (64.2 lbf ft).
5. Connect hoses to emergency steering pump (1):
a. Remove caps from all disconnected hose ends.

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 Steering System 12

b. Remove plugs from all disconnected emergency steering valve block (1, Refer to
Figure 12.21) ports.
c. If removed, install adaptor (38, Refer to Figure 12.1).
d. Connect load sense feedback hose (29, Refer to Figure 12.1) to emergency steering
valve block.
e. If removed, install elbow (39, Figure 12.1).
f. Connect emergency steering pump case drain hose (26, Figure 12.1) to hydraulic tank.
6. Install the emergency steering valve block (36). Refer to (3) Installation on page 12-47.
7. Fill the emergency steering pump (1) and emergency steering valve block (36) with clean oil
as specified in (1) Recommended Lubricants on page 4-16.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
11. Check for leaks.
12. Check hydraulic tank oil level and replenish if required.

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12.7 Emergency Steering Valve Block

(1) Description
Numbers in parentheses refer to Figure 12.21, unless otherwise specified.

11

10

2
2
CT

9
4
8

7
5

6 MOT05106

Figure 12.21 - Emergency Steering Valve Block

1. Emergency Steering Valve 5. Port ‘P’ 9. Relief Valve
Block
2. Port ‘LS’ 6. O-ring 10. Capscrew
3. Port ‘S’ (Not Shown) 7. Port ‘D’ 11. O-ring
4. Seal Kit 8. Seal Kit

The emergency steering valve block is mounted on the emergency steering pump (refer to (1)
Description on page 12-31; to maintain the emergency steering pump pressure output whatever
the direction of the machine.
Emergency steering valve block internal valves include:
• Check valves CT1, CT2, CT3 and CT4
• Sequencing valve CT5
• Flow control valve CT6
The hydraulic flow through check valves CT2 and CT3 is for one direction and CT1 and CT4
for the opposite direction.
Sequencing valve CT5 and flow control valve CT6 control the rate and pressure of the hydraulic
flow.

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 Steering System 12

Emergency steering valve block ports include:

• D connected by hose (30, refer to Figure 12.1) to difflock valve T-piece.
• LS connected by hose (29, refer to Figure 12.1) to emergency steering pump port X, to
provide load sense feedback.
• P connected by hose (28, refer to Figure 12.1) to hydraulic control valve port P2.
• S connected by hose (27, refer to Figure 12.1) to hydraulic tank connection.

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(2) Removal
Numbers in parentheses refer to Figure 12.21, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the steering system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Gain access to the work area.
6. Drain oil from the emergency steering pump. Refer to (3) Removal on page 12-34.
7. Disconnect hoses from emergency steering valve block (1):
a. Identify and tag all hoses connected to the emergency steering valve block (1).
b. Disconnect hose (30, refer to Figure 12.1) to difflock valve T-piece at Port D.
c. If necessary, remove elbow (36, refer to Figure 12.1).
d. Disconnect load sense feedback hose (29, refer to Figure 12.1) to emergency steering
pump control valve at Port LS.
e. If necessary, remove adaptor (38, refer to Figure 12.1).
f. Disconnect hose (28, refer to Figure 12.1) to hydraulic control valve port P2 at Port P.
g. If necessary, remove elbow (37, refer to Figure 12.1).
h. Disconnect emergency steering pump suction hose (27, refer to Figure 12.1) to
hydraulic tank connection at Port S.
i. If necessary, remove elbow (35, refer to Figure 12.1).
j. Install caps to all disconnected hose ends.
k. Install plugs to all disconnected emergency steering valve block (1) ports.
8. Remove the emergency steering valve block (1):
a. Support the emergency steering valve block (1).
b. Remove the capcrews (10) securing the emergency steering valve block (1) to the
emergency steering pump.
c. Separate the emergency steering valve block (1) from the emergency steering pump.
d. Remove and discard O-rings (6).
e. Install plugs to all disconnected emergency steering valve block (1) and emergency
steering pump ports.
9. Move the block (1) to a clean maintenance area.

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(3) Installation
Numbers in parentheses refer to Figure 12.21, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install the emergency steering valve block (1):
a. Remove plugs from all disconnected emergency steering valve block (1) and
emergency steering pump ports.
b. Fit new O-rings (6).
c. Lift the emergency steering valve block (1) into position.
d. Align the emergency steering valve block (1) with the emergency steering pump.
e. Support the emergency steering valve block (1).
f. Install the capcrews (10) to secure the emergency steering valve block (1) to the
emergency steering pump.
g. Torque tighten the capcrews (10).
5. Connect hoses to emergency steering valve block (1):
a. Remove caps from all disconnected hose ends.
b. Remove plugs from all disconnected emergency steering valve block (1) ports.
c. If removed, install elbow (36, refer to Figure 12.1) to Port D.
d. Connect hose (30, refer to Figure 12.1) to difflock valve T-piece at Port D.
e. If removed, install adaptor (38, refer to Figure 12.1) at Port LS.
f. Connect load sense feedback hose (29, refer to Figure 12.1) to emergency steering
pump control valve at Port LS.
g. If removed, install elbow (37, refer to Figure 12.1) at Port P.
h. Connect hose (28, refer to Figure 12.1) to hydraulic control valve port P2 at Port P.
i. If removed, install elbow (35, refer to Figure 12.1) at Port S.
j. Connect emergency steering pump suction hose (27, refer to Figure 12.1) to hydraulic
tank connection at Port S.
6. Fill the emergency steering pump and emergency steering valve block (1) with clean oil as
specified in (1) Recommended Lubricants on page 4-16.
7. Place the battery master switch in the ‘ON’ position.

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8. Start the engine. Refer to 5.11 Starting on page 5-27.

9. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
10. Check for leaks.
11. Check hydraulic tank oil level and replenish if required.

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 Steering System 12

12.8 System Hoses

(1) Removal
Numbers in parentheses refer to Figure 12.1, unless otherwise specified.

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

� CAUTION
• Hydraulic fluid pressure will remain within the steering system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

(a) LH Turn Supply Hose

NOTICE
• The Left Hand (LH) turn supply hose (2) routes from port L of steering control valve to
the T-piece (14) installed to bracket (25).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (2).
9. Note the installed route of hose (2).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (2):
a. Disconnect hose (2) from T-piece (14).
b. Drain any trapped oil.
c. Disconnect hose (2) from adaptor (11) at port L of steering control valve.
d. Drain any trapped oil.
e. Install caps to both ends of hose (2) to prevent ingress of dirt.
f. Install cap to adaptor (11) at port L.
g. Install cap to T-piece (14).
12. Separate the hose (2) from clamp (17).
13. Lift the hose (2) from its installed position.
14. Move the hose (2) to a clean maintenance area.

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(b) LH Turn LH Cylinder Supply Hose

NOTICE
• The LH turn LH cylinder supply hose (4) routes from the T-piece (14) installed to bracket
(25) to the LH steering cylinder.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
a. Remove the LH front tire and rim assembly. Refer to (3) Removing Tire and Rim
Assembly from Machine on page 9-125.
b. Remove the LH top rear mudflap (18, Refer to Figure 16.11). Refer to (1) Removal
on page 16-43.
c. Remove the LH wheel arch mudflap (17, Refer to Figure 16.11). Refer to (1) Removal
on page 16-43.
8. Identify and tag hose (4).
9. Note the installed route of hose (4).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (4):
a. Disconnect hose (4) from bulkhead union (13).
b. Drain any trapped oil.
c. Disconnect hose (4) from LH steering cylinder adaptor (15).
d. Drain any trapped oil.
e. Install caps to both ends of hose (4) to prevent ingress of dirt.
f. Install cap to bulkhead union (13).
g. Install cap to LH steering cylinder adaptor (15).
12. Separate the hose (4) from clamps (23 and 24).
13. Lift the hose (4) from its installed position.
14. Move the hose (4) to a clean maintenance area.

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(c) LH Turn RH Cylinder Supply Hose

NOTICE
• The LH turn RH cylinder supply hose (4) routes from the T-piece (14) installed to bracket
(25) to the RH steering cylinder.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
a. Remove the RH front tire and rim assembly. Refer to (3) Removing Tire and Rim
Assembly from Machine on page 9-125.
b. Remove the RH top rear mudflap (64, Refer to Figure 16.12). Refer to (1) Removal
on page 16-43.
c. Remove the RH wheel arch mudflap (75, Refer to Figure 16.12). Refer to (1) Removal
on page 16-43.
8. Identify and tag hose (5).
9. Note the installed route of hose (5).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (5):
a. Disconnect hose (5) from T-piece (14).
b. Drain any trapped oil.
c. Disconnect hose (5) from RH steering cylinder adaptor (18).
d. Drain any trapped oil.
e. Install caps to both ends of hose (5) to prevent ingress of dirt.
f. Install cap to T-piece (14).
g. Install cap to RH steering cylinder adaptor (18).
12. Lift the hose (5) from its installed position.
13. Move the hose (5) to a clean maintenance area.

(d) RH Turn Supply Hose

NOTICE
• The Right Hand (RH) turn supply hose (3) routes from port R of steering control valve to
the T-piece (14) installed to bracket (25).

PROCEDURE

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1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (3).
9. Note the installed route of hose (3).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (3):
a. Disconnect hose (3) from T-piece (14).
b. Drain any trapped oil.
c. Disconnect hose (3) from adaptor (11) at port R of steering control valve.
d. Drain any trapped oil.
e. Install caps to both ends of hose (3) to prevent ingress of dirt.
f. Install cap to adaptor (11) at port R.
g. Install cap to T-piece (14).
12. Separate the hose (3) from clamp (17).
13. Lift the hose (3) from its installed position.
14. Move the hose (3) to a clean maintenance area.

(e) RH Turn LH Cylinder Supply Hose

NOTICE
• The RH turn LH cylinder supply hose (6) routes from the T-piece (14) installed to bracket
(25) to the LH steering cylinder.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
a. Remove the LH front tire and rim assembly. Refer to (3) Removing Tire and Rim
Assembly from Machine on page 9-125.
b. Remove the LH top rear mudflap (18, Refer to Figure 16.11). Refer to (1) Removal
on page 16-43.

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c. Remove the LH wheel arch mudflap (17, Refer to Figure 16.11). Refer to (1) Removal
on page 16-43.
8. Identify and tag hose (6).
9. Note the installed route of hose (6).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (6):
a. Disconnect hose (6) from bulkhead union (13).
b. Drain any trapped oil.
c. Disconnect hose (6) from LH steering cylinder adaptor (18).
d. Drain any trapped oil.
e. Install caps to both ends of hose (6) to prevent ingress of dirt.
f. Install cap to bulkhead union (13).
g. Install cap to LH steering cylinder adaptor (18).
12. Separate the hose (6) from clamps (23).
13. Lift the hose (6) from its installed position.
14. Move the hose (6) to a clean maintenance area.

(f) RH Turn RH Cylinder Supply Hose

NOTICE
• The RH turn RH cylinder supply hose (7) routes from the T-piece (14) installed to bracket
(25) to the RH steering cylinder.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
a. Remove the RH front tire and rim assembly. Refer to (3) Removing Tire and Rim
Assembly from Machine on page 9-125.
b. Remove the RH top rear mudflap (64, Refer to Figure 16.12). Refer to (1) Removal
on page 16-43.
c. Remove the RH wheel arch mudflap (75, Refer to Figure 16.12). Refer to (1) Removal
on page 16-43.
8. Identify and tag hose (7).
9. Note the installed route of hose (7).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (7):
a. Disconnect hose (7) from T-piece (14).
b. Drain any trapped oil.

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12 Steering System

c. Disconnect hose (7) from RH steering cylinder adaptor (18).

d. Drain any trapped oil.
e. Install caps to both ends of hose (7) to prevent ingress of dirt.
f. Install cap to T-piece (14).
g. Install cap to RH steering cylinder adaptor (18).
12. Separate the hose (7) from clamp (54).
13. Lift the hose (7) from its installed position.
14. Move the hose (7) to a clean maintenance area.

(g) Hydraulic Control Valve Load Sensing Hose

NOTICE
• The Hydraulic Control Valve (HCV) sensing hose (9) routes from port LS of steering control
valve to port LSO of HCV.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (9).
9. Note the installed route of hose (9).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (9):
a. Disconnect hose (9) from elbow (36) at port LSO of hydraulic control valve.
b. Drain any trapped oil.
c. Disconnect hose (9) from elbow (12) at port LS of steering control valve.
d. Drain any trapped oil.
e. Install caps to both ends of hose (9) to prevent ingress of dirt.
f. Install cap to elbow (36) at port LSO.
g. Install cap to elbow (12) at port LS.
12. Lift the hose (9) from its installed position.
13. Move the hose (9) to a clean maintenance area.

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 Steering System 12

(h) Steering Control Valve Supply Hose (1)

NOTICE
• The Steering Control Valve (SCV) supply hose (56) routes from port ORB of Hydraulic
Control Valve (HCV) to pipe assembly (55).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (56).
9. Note the installed route of hose (56).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (56):
a. Disconnect hose (56) from connector (42) at port ORB of hydraulic control valve.
b. Drain any trapped oil.
c. Disconnect hose (56) from pipe assembly (55).
d. Drain any trapped oil.
e. Remove and discard O-ring (58).
f. Install caps to both ends of hose (56) to prevent ingress of dirt.
g. Install cap to connector (42) at port ORB.
h. Install cap to pipe assembly (55) end.
12. Separate the hose (56) from clamp (59).
13. Lift the hose (56) from its installed position.
14. Move the hose (56) to a clean maintenance area.

(i) Steering Control Valve Supply Hose (2)

NOTICE
• The Steering Control Valve (SCV) supply hose (1) routes from pipe assembly (55) to port
P of SCV.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.

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12 Steering System

4. Ensure the pressure in the steering system has been dissipated.

5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (1).
9. Note the installed route of hose (1).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (1):
a. Disconnect hose (1) from adaptor (11) at port P of steering control valve.
b. Drain any trapped oil.
c. Disconnect hose (1) from pipe assembly (55).
d. Drain any trapped oil.
e. Remove and discard O-ring (58).
f. Install caps to both ends of hose (1) to prevent ingress of dirt.
g. Install cap to adaptor (11) at port P.
h. Install cap to pipe assembly (55) end.
12. Separate the hose (1) from clamp (24).
13. Lift the hose (1) from its installed position.
14. Move the hose (1) to a clean maintenance area.

(j) Steering Control Valve Return Hose (1)

NOTICE
• The Steering Control Valve (SCV) return hose (8) routes from port T of SCV to pipe
assembly (55).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (8).
9. Note the installed route of hose (8).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (8):
a. Disconnect hose (8) from adaptor (11) at port T of steering control valve.
b. Drain any trapped oil.
c. Disconnect hose (8) from pipe assembly (55).
d. Drain any trapped oil.

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e. Remove and discard O-ring (58).

f. Install caps to both ends of hose (8) to prevent ingress of dirt.
g. Install cap to adaptor (11) at port T.
h. Install cap to pipe assembly (55) end.
12. Separate the hose (8) from clamp (48).
13. Lift the hose (8) from its installed position.
14. Move the hose (8) to a clean maintenance area.

(k) Steering Control Valve Return Hose (2)

NOTICE
• The Steering Control Valve (SCV) return hose (57) routes from pipe assembly (55) to
tank return tube.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (57).
9. Note the installed route of hose (57).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (57):
a. Disconnect hose (57) from pipe assembly (55).
b. Drain any trapped oil.
c. Disconnect hose (57) from tank return tube.
d. Drain any trapped oil.
e. Remove and discard O-ring (58).
f. Install caps to both ends of hose (57) to prevent ingress of dirt.
g. Install cap to pipe assembly (55) end.
h. Install cap to tank return tube end.
12. Separate the hose (57) from clamps (59 and 22).
13. Lift the hose (57) from its installed position.
14. Move the hose (57) to a clean maintenance area.

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(l) Emergency Steering Valve Supply Hose

NOTICE
• The Emergency Steering Valve (ESV) supply hose (27) routes from the hydraulic tank to
port S of the ESV.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (27).
9. Note the installed route of hose (27).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (27):
a. Disconnect hose (27) from elbow (35) at port S of ESV.
b. Drain any trapped oil.
c. Disconnect hose (27) from hydraulic tank.
d. Drain any trapped oil.
e. Install caps to both ends of hose (27) to prevent ingress of dirt.
f. Install cap to elbow (35) at port S.
g. Install cap to hydraulic tank port.
12. Separate the hose (27) from clamps (34).
13. Lift the hose (27) from its installed position.
14. Move the hose (27) to a clean maintenance area.

(m) Emergency Steering Pump Case Drain Hose

NOTICE
• The Emergency Steering Pump (ESP) case drain hose (26) routes from the ESP to the
hydraulic tank.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.

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5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.

6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (26).
9. Note the installed route of hose (26).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (26):
a. Disconnect hose (26) from ESP.
b. Drain any trapped oil.
c. Disconnect hose (26) from hydraulic tank.
d. Drain any trapped oil.
e. Install caps to both ends of hose (26) to prevent ingress of dirt.
f. Install cap to ESP port.
g. Install cap to hydraulic tank port.
12. Lift the hose (26) from its installed position.
13. Move the hose (26) to a clean maintenance area.

(n) Emergency Steering Pump Load Sensing Hose

NOTICE
• The Emergency Steering Pump (ESP) load sensing hose (29) routes from the ESP to port
LS of the Emergency Steering Valve (ESV).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Gain access to the work area.
7. Identify and tag hose (29).
8. Note the installed route of hose (29).
9. Position suitable containers under both hose ends.
10. Disconnect the hose (29):
a. Disconnect hose (29) from ESP.
b. Drain any trapped oil.
c. Disconnect hose (29) from port LS of the ESV.
d. Drain any trapped oil.
e. Install caps to both ends of hose (29) to prevent ingress of dirt.
f. Install cap to ESP port.
g. Install cap to port LS of the ESV.
11. Lift the hose (29) from its installed position.

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12. Move the hose (29) to a clean maintenance area.

(o) Emergency Steering Valve Pressure Hose

NOTICE
• The Emergency Steering Valve (ESV) pressure hose (28) routes from port P2 of the
Hydraulic Control Valve (HCV) to port P of the ESV.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Gain access to the work area.
7. Identify and tag hose (28).
8. Note the installed route of hose (28).
9. Position suitable containers under both hose ends.
10. Disconnect the hose (28):
a. Disconnect hose (28) from elbow (37) at port P of ESV.
b. Drain any trapped oil.
c. Disconnect hose (28) from adaptor (40) at port P2 of HCV.
d. Drain any trapped oil.
e. Install caps to both ends of hose (28) to prevent ingress of dirt.
f. Install cap to elbow (37) at port S.
g. Install cap to adaptor (40) at port P2.
11. Lift the hose (28) from its installed position.
12. Move the hose (28) to a clean maintenance area.

(p) Emergency Steering Valve Return Hose

NOTICE
• The Emergency Steering Valve (ESV) return hose (30) routes from port D of the ESV to
port T of the difflock valve.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the steering system has been dissipated.

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5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.

6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (30).
9. Note the installed route of hose (30).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (30):
a. Disconnect hose (30) from elbow (36) at port D of the ESV.
b. Drain any trapped oil.
c. Disconnect hose (30) from T-piece at port T of the dropbox valve.
d. Drain any trapped oil.
e. Install caps to both ends of hose (30) to prevent ingress of dirt.
f. Install cap to elbow (36) at port D.
g. Install cap to T-piece at port T.
12. Lift the hose (30) from its installed position.
13. Move the hose (30) to a clean maintenance area.

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(2) Installation
Numbers in parentheses refer to Figure 12.1, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all ORFS connections to (7) O-Ring Face Seals (ORFS) on page 11-24.

(a) LH Turn Supply Hose

NOTICE
• The Left Hand (LH) turn supply hose (2) routes from port L of steering control valve to
the T-piece (14) installed to bracket (25).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (2):
a. Remove caps from both ends of hose (2).
b. Remove cap from adaptor (11) at port L.
c. Remove cap from T-piece (14).
d. Install hose (2) to route noted during removal.
e. Connect hose (2) to T-piece (14).
f. Connect hose (2) to adaptor (11) at port L of steering control valve.
6. Install the hose (2) to clamp (17).
7. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.

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9. Place the battery master switch in the ‘ON’ position.

10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required.

(b) LH Turn LH Cylinder Supply Hose

NOTICE
• The LH turn LH cylinder supply hose (4) routes from the T-piece (14) installed to bracket
(25) to the LH steering cylinder.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (4):
a. Remove caps from both ends of hose (4).
b. Remove cap from bulkhead union (13).
c. Remove cap from LH steering cylinder adaptor (15).
d. Install hose (4) to route noted during removal.
e. Connect hose (4) to bulkhead union (13).
f. Connect hose (4) to LH steering cylinder adaptor (15).
6. Install the hose (4) to clamps (23 and 24).
7. Install the LH wheel arch mudflap (17, Refer to Figure 16.11). Refer to (2) Installation
on page 16-47.
8. Install the LH top rear mudflap (18, Refer to Figure 16.11). Refer to (2) Installation on
page 16-47.
9. Install the LH front tire and rim assembly. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
10. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
11. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
12. Place the battery master switch in the ‘ON’ position.
13. Start the engine. Refer to 5.11 Starting on page 5-27.
14. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required.

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(c) LH Turn RH Cylinder Supply Hose

NOTICE
• The LH turn RH cylinder supply hose (4) routes from the T-piece (14) installed to bracket
(25) to the RH steering cylinder.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (5):
a. Remove caps from both ends of hose (5).
b. Remove cap from T-piece (14).
c. Remove cap from RH steering cylinder adaptor (18).
d. Install hose (5) to route noted during removal.
e. Connect hose (5) to T-piece (14).
f. Connect hose (5) to RH steering cylinder adaptor (18).
6. Install the RH wheel arch mudflap (75, Refer to Figure 16.12). Refer to (2) Installation
on page 16-47.
7. Install the RH top rear mudflap (64, Refer to Figure 16.12). Refer to (2) Installation on
page 16-47.
8. Install the RH front tire and rim assembly. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
9. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
14. Check for leaks.
15. Check hydraulic tank oil level and replenish if required.

(d) RH Turn Supply Hose

NOTICE
• The Right Hand (RH) turn supply hose (3) routes from port R of steering control valve to
the T-piece (14) installed to bracket (25).

PROCEDURE

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1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (3):
a. Remove caps from both ends of hose (3).
b. Remove cap from adaptor (11) at port R.
c. Remove cap from T-piece (14).
d. Install hose (3) to route noted during removal.
e. Connect hose (3) to T-piece (14).
f. Connect hose (3) to adaptor (11) at port R of steering control valve.
6. Install the hose (3) to clamp (17).
7. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
9. Place the battery master switch in the ‘ON’ position.
10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required.

(e) RH Turn LH Cylinder Supply Hose

NOTICE
• The RH turn LH cylinder supply hose (6) routes from the T-piece (14) installed to bracket
(25) to the LH steering cylinder.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (6):
a. Remove caps from both ends of hose (6).
b. Remove cap from bulkhead union (13).
c. Remove cap from LH steering cylinder adaptor (18).
d. Install hose (6) to route noted during removal.
e. Connect hose (6) to bulkhead union (13).
f. Connect hose (6) to LH steering cylinder adaptor (18).
6. Install the hose (6) to clamps (23).

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7. Install the LH wheel arch mudflap (17, Refer to Figure 16.11). Refer to (2) Installation
on page 16-47.
8. Install the LH top rear mudflap (18, Refer to Figure 16.11). Refer to (2) Installation on
page 16-47.
9. Install the LH front tire and rim assembly. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
10. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
11. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
12. Place the battery master switch in the ‘ON’ position.
13. Start the engine. Refer to 5.11 Starting on page 5-27.
14. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required.

(f) RH Turn RH Cylinder Supply Hose

NOTICE
• The RH turn RH cylinder supply hose (7) routes from the T-piece (14) installed to bracket
(25) to the RH steering cylinder.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (7):
a. Remove caps from both ends of hose (7).
b. Remove cap from T-piece (14).
c. Remove cap from RH steering cylinder adaptor (18).
d. Install hose (7) to route noted during removal.
e. Connect hose (7) to T-piece (14).
f. Connect hose (7) to RH steering cylinder adaptor (18).
6. Install the hose (7) to clamp (54).
7. Install the RH wheel arch mudflap (75, Refer to Figure 16.12). Refer to (2) Installation
on page 16-47.
8. Install the RH top rear mudflap (64, Refer to Figure 16.12). Refer to (2) Installation on
page 16-47.
9. Install the RH front tire and rim assembly. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
10. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.

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11. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
12. Place the battery master switch in the ‘ON’ position.
13. Start the engine. Refer to 5.11 Starting on page 5-27.
14. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required.

(g) Hydraulic Control Valve Load Sensing Hose

NOTICE
• The Hydraulic Control Valve (HCV) sensing hose (9) routes from port LS of steering control
valve to port LSO of HCV.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (9):
a. Remove caps from both ends of hose (9).
b. Remove cap from elbow (36) at port LSO.
c. Remove cap from elbow (12) at port LS.
d. Install hose (9) to route noted during removal.
e. Connect hose (9) to elbow (36) at port LSO of hydraulic control valve.
f. Connect hose (9) to elbow (12) at port LS of steering control valve.
6. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
7. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
11. Check for leaks.
12. Check hydraulic tank oil level and replenish if required.

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(h) Steering Control Valve Supply Hose (1)

NOTICE
• The Steering Control Valve (SCV) supply hose (56) routes from port ORB of Hydraulic
Control Valve (HCV) to pipe assembly (55).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (56):
a. Remove caps from both ends of hose (56).
b. Remove cap from connector (42) at port ORB.
c. Remove cap from pipe assembly (55) end.
d. Install hose (56) to route noted during removal.
e. Connect hose (56) to connector (42) at port ORB of hydraulic control valve.
f. Install new O-ring (58).
g. Connect hose (56) to pipe assembly (55).
6. Install the hose (56) to clamp (59).
7. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
9. Place the battery master switch in the ‘ON’ position.
10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required.

(i) Steering Control Valve Supply Hose (2)

NOTICE
• The Steering Control Valve (SCV) supply hose (1) routes from pipe assembly (55) to port
P of SCV.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.

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4. Gain access to the work area.

5. Connect the hose (1):
a. Remove caps from both ends of hose (1).
b. Remove cap from adaptor (11) at port P.
c. Remove cap from pipe assembly (55) end.
d. Install hose (1) to route noted during removal.
e. Connect hose (1) to adaptor (11) at port P of steering control valve.
f. Install new O-ring (58).
g. Connect hose (1) to pipe assembly (55).
6. Install the hose (1) to clamp (24).
7. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
9. Place the battery master switch in the ‘ON’ position.
10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required.

(j) Steering Control Valve Return Hose (1)

NOTICE
• The Steering Control Valve (SCV) return hose (8) routes from port T of SCV to pipe
assembly (55).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (8):
a. Remove caps from both ends of hose (8).
b. Remove cap from adaptor (11) at port T.
c. Remove cap from pipe assembly (55) end.
d. Install hose (8) to route noted during removal.
e. Connect hose (8) to adaptor (11) at port T of steering control valve.
f. Install new O-ring (58).
g. Connect hose (8) to pipe assembly (55).
6. Install the hose (8) to clamp (48).
7. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.

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9. Place the battery master switch in the ‘ON’ position.

10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required.

(k) Steering Control Valve Return Hose (2)

NOTICE
• The Steering Control Valve (SCV) return hose (57) routes from pipe assembly (55) to
tank return tube.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (57):
a. Remove caps from both ends of hose (57).
b. Remove cap from pipe assembly (55) end.
c. Remove cap from tank return tube end.
d. Install new O-ring (58).
e. Install hose (57) to route noted during removal.
f. Connect hose (57) to pipe assembly (55).
g. Connect hose (57) to tank return tube.
6. Install the hose (57) to clamps (59 and 22).
7. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
9. Place the battery master switch in the ‘ON’ position.
10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required.

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(l) Emergency Steering Valve Supply Hose

NOTICE
• The Emergency Steering Valve (ESV) supply hose (27) routes from the hydraulic tank to
port S of the ESV.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Connect the hose (27):
a. Remove caps from both ends of hose (27).
b. Remove cap from elbow (35) at port S.
c. Remove cap from hydraulic tank port.
d. Install hose (27) to route noted during removal.
e. Connect hose (27) to elbow (35) at port S of ESV.
f. Connect hose (27) to hydraulic tank.
6. Install the hose (27) to clamps (34).
7. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
9. Place the battery master switch in the ‘ON’ position.
10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required.

(m) Emergency Steering Pump Case Drain Hose

NOTICE
• The Emergency Steering Pump (ESP) case drain hose (26) routes from the ESP to the
hydraulic tank.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.

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5. Connect the hose (26):

a. Remove caps from both ends of hose (26).
b. Remove cap from ESP port.
c. Remove cap from hydraulic tank port.
d. Install hose (26) to route noted during removal.
e. Connect hose (26) to ESP.
f. Connect hose (26) to hydraulic tank.
6. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
7. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
11. Check for leaks.
12. Check hydraulic tank oil level and replenish if required.

(n) Emergency Steering Pump Load Sensing Hose

NOTICE
• The Emergency Steering Pump (ESP) load sensing hose (29) routes from the ESP to port
LS of the Emergency Steering Valve (ESV).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Ensure the pressure in the steering system has been dissipated.
4. Gain access to the work area.
5. Connect the hose (29):
a. Remove caps from both ends of hose (29).
b. Remove cap from ESP port.
c. Remove cap from port LS of the ESV.
d. Install hose (29) to route noted during removal.
e. Connect hose (29) to ESP.
f. Connect hose (29) to port LS of the ESV.
6. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
7. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
11. Check for leaks.

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12. Check hydraulic tank oil level and replenish if required.

(o) Emergency Steering Valve Pressure Hose

NOTICE
• The Emergency Steering Valve (ESV) pressure hose (28) routes from port P2 of the
Hydraulic Control Valve (HCV) to port P of the ESV.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Connect the hose (28):
a. Remove caps from both ends of hose (28).
b. Remove cap from elbow (37) at port S.
c. Remove cap from adaptor (40) at port P2.
d. Install hose (28) to route noted during removal.
e. Connect hose (28) to elbow (37) at port P of ESV.
f. Connect hose (28) to adaptor (40) at port P2 of HCV.
5. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
6. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
7. Place the battery master switch in the ‘ON’ position.
8. Start the engine. Refer to 5.11 Starting on page 5-27.
9. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
10. Check for leaks.
11. Check hydraulic tank oil level and replenish if required.

(p) Emergency Steering Valve Return Hose

NOTICE
• The Emergency Steering Valve (ESV) return hose (30) routes from port D of the ESV to
port T of the difflock valve.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.

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12 Steering System

5. Connect the hose (30):

a. Remove caps from both ends of hose (30).
b. Remove cap from elbow (36) at port D.
c. Remove cap from T-piece at port T.
d. Install hose (30) to route noted during removal.
e. Connect hose (30) to elbow (36) at port D of the ESV.
f. Connect hose (30) to T-piece at port T of the dropbox valve.
6. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
7. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct steering operation by driving the machine and turning the steering wheel
from lock to lock several times.
11. Check for leaks.
12. Check hydraulic tank oil level and replenish if required.

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 Body System 13

Table of Content
13 Body System .............................................................................................13-1
13.1 Description ................................................................................................... 13-2
13.2 Hydraulic Hoses and Tubes ......................................................................... 13-5
(1) Removal .................................................................................................. 13-5
(a) Main Hydraulic Valve Body Raise Hose.............................................. 13-5
(b) Main Hydraulic Valve Body Lower Hose ............................................. 13-6
(c) Main Hydraulic Valve Body Return Hose ............................................ 13-6
(d) Body Raise Tube ................................................................................ 13-7
(e) Body Lower Tube ................................................................................ 13-7
(f) Body Raise Hose ................................................................................ 13-8
(g) Body Lower Hose................................................................................ 13-8
(h) Cylinder Lower Tube ........................................................................... 13-9
(2) Installation ............................................................................................... 13-9
(a) Main Hydraulic Valve Body Raise Hose............................................ 13-10
(b) Main Hydraulic Valve Body Lower Hose ........................................... 13-11
(c) Main Hydraulic Valve Body Return Hose .......................................... 13-11
(d) Body Raise Tube .............................................................................. 13-12
(e) Body Lower Tube .............................................................................. 13-12
(f) Body Raise Hose .............................................................................. 13-13
(g) Body Lower Hose.............................................................................. 13-14
(h) Cylinder Lower Tube ......................................................................... 13-14
13.3 Body Control Lever .................................................................................... 13-15
(1) Description............................................................................................. 13-15
(2) Removal ................................................................................................ 13-17
(3) Installation ............................................................................................. 13-18
13.4 Hoist Cylinders ........................................................................................... 13-19
(1) Description............................................................................................. 13-19
(2) Removal ................................................................................................ 13-21
(3) Disassembly .......................................................................................... 13-22
(4) Inspection .............................................................................................. 13-23
(5) Assembly ............................................................................................... 13-23
(6) Installation ............................................................................................. 13-24
(7) Maintenance .......................................................................................... 13-25
(8) Special Tools ......................................................................................... 13-25

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 13
13.1

Page 13-2
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22
27
13 Body System

23
24
18
Description

7 8
Body System

19,20
25,26
28
4 3 6 5 21
TANK RETURN TUBE
SEC 250-0020 1

C 17

Revision 1.0
TO DIAGNOSTIC
PLATE 11
A B
12

10 A = BODY RAISE
A B = BODY LOWER
9 C = TANK RETURN A
14
B

Figure 13.1 - Tractor Body System

15 B TRAILER
13 PIPES

14
16 MAIN HYD. VALVE
SEC. 215-0050

MOT03732_p

TA400 Tier2
Maintenance Manual
TA400 Tier2
FROM MAIN

Maintenance Manual
HYDRAULIC VALVE

B A

48,49
35
47
38
42 35 36
48
49 39
46
40
45 49
46 44 31
35
49
32 30
41 37 33

Revision 1.0
38 34
35 35
43 29
35 39
40
37
31

Figure 13.2 - Trailer Body System

32 30
33
34
35
29
A = BODY RAISE
B = BODY LOWER
C = TANK RETURN

MOT04349_p

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Body System 13
13 Body System

1. Hose 18. Bracket 35. O Ring

2. Hose 19. Split Bush 36. Bracket
3. Hose 20. Clamp 37. Hose
4. O Ring 21. Tube Clamp 38. Clamp
5. O Ring 22. Eye Bolt 39. Bolt
6. Split Flange 23. Spring 40. Washer
7. Bolt 24. Chain 41. Tube
8. Lockwasher 25. Stacking Nut Socket 42. Tube
Head
9. O Ring 26. Bolt 43. Bracket
10. Split Flange 27. Carbine Hook 44. Bracket
11. Bolt 28. Washer 45. Clamp
12. Spring Washer 29. Connector 46. Nut
13. Manifold Plate 30. Tube 47. Bracket
14. Male to Male Adapter 31. Elbow 48. Bolt
15. Hose 32. Tube Clamp 49. Washer
16. Hose 33. Top Plate
17. Bracket 34. Bolt

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 Body System 13

13.2 Hydraulic Hoses and Tubes

(1) Removal
Numbers in parentheses refer to Figure 13.1 and Figure 13.2, unless otherwise specified.

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

� CAUTION
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

(a) Main Hydraulic Valve Body Raise Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body system has been dissipated.
5. Gain access to the work area.
6. Identify and tag raise hose (1).
7. Position suitable containers under both ends of hose (1).
8. Disconnect the hose (1):
a. Remove bolts (11) and spring washers (12)
b. Remove split flange (10).
c. Disconnect hose (1) from manifold plate (13).
d. Drain any trapped oil.
e. Remove and discard O-ring (9).
f. Disconnect hose (1) from tube (42).
g. Remove and discard O-ring (35).
h. Install caps to both ends of hose (1) to prevent ingress of dirt.
i. Install cap to end of tube (42).
j. Install cap to manifold plate (13).
9. Separate the hose (1) from double tube clamp (21):
a. Remove the set bolt from the double tube clamp (21).
b. Separate the hose (1) from double tube clamp (21):
10. Separate the hose (1) from clamp (20):
a. Remove the bolts (26) and washers (28) from the clamp (20).
b. Separate the hose (1) from clamp (20).
c. Separate the split bush (19) from the hose (1).
11. Move the hose (1) to a clean maintenance area.

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13 Body System

(b) Main Hydraulic Valve Body Lower Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body system has been dissipated.
5. Gain access to the work area.
6. Identify and tag lower hose (2).
7. Position suitable containers under both ends of the hose (2).
8. Disconnect the hose (2):
a. Remove bolts (11) and spring washers (12)
b. Remove split flange (10).
c. Disconnect hose (2) from manifold plate (13).
d. Drain any trapped oil.
e. Remove and discard O-ring (9).
f. Disconnect hose (2) from tube (41).
g. Remove and discard O-ring (35).
h. Install caps to both ends of hose (2) to prevent ingress of dirt.
i. Install cap to end of tube (41).
j. Install cap to manifold plate (13).
9. Separate the hose (2) from double tube clamp (21):
a. Remove the set bolt from the double tube clamp (21).
b. Separate the hose (2) from double tube clamp (21):
10. Separate the hose (2) from clamp (20):
a. Remove the bolts (26) and washers (28) from clamp (20).
b. Separate the hose (2) from clamp (20).
c. Separate the split bush (19) from hose (2).
11. Move the hose (2) to a clean maintenance area.

(c) Main Hydraulic Valve Body Return Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body system has been dissipated.
5. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
6. Gain access to the work area.
7. Identify and tag return hose (3).
8. Position suitable containers under both ends of the hose (3).

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9. Disconnect the hose (3):

a. Remove bolts (7) and lock washers (8).
b. Remove split flange (6).
c. Disconnect hose (3) from main hydraulic valve.
d. Drain any trapped oil.
e. Remove and discard O-ring (5).
f. Disconnect hose (3) from tank return tube.
g. Remove and discard O-ring (4).
h. Install caps to both ends of hose (3) to prevent ingress of dirt.
i. Install a cap to port in main hydraulic valve.
j. Install a cap to tank return tube.
10. Move the hose (3) to a clean maintenance area.

(d) Body Raise Tube

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body system has been dissipated.
5. Gain access to the work area.
6. Identify and tag raise tube (42).
7. Position suitable containers under the base end of the cylinder and end of tube (42).
8. Remove main hydraulic valve body raise hose (1). Refer to (a) Main Hydraulic Valve Body
Raise Hose on page 13-5.
9. Remove body raise hoses (37). Refer to (f) Body Raise Hose on page 13-8.
10. Disconnect the tube (42):
a. Remove the cover.
b. Release the clamp (45).
c. Release the clamps (38) attaching tube (42) to the brackets (36 & 43).
d. Drain any trapped oil.
e. Install caps to ends of tube (42) to prevent ingress of dirt.
f. Install cap to end of main hydraulic valve body raise hose (1).
g. Install caps to end of body raise hoses (37).
h. If necessary, remove clamp (45) from bracket (47).
11. Move the tube (42) to a clean maintenance area.

(e) Body Lower Tube

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body system has been dissipated.

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13 Body System

5. Gain access to the work area.

6. Identify and tag raise tube (41).
7. Position suitable containers under the base end of the cylinder and end of tube (41).
8. Remove main hydraulic valve body lower hose (2). Refer to (b) Main Hydraulic Valve
Body Lower Hose on page 13-6.
9. Remove body lower hoses (37). Refer to (g) Body Lower Hose on page 13-8.
10. Disconnect the tube (41):
a. Remove the cover.
b. Release clamp (45).
c. Release clamps (38) attaching tube (41) to the brackets (36 & 43).
d. Drain any trapped oil.
e. Install caps to ends of tube (41) to prevent ingress of dirt.
f. Install cap to end of main hydraulic valve body lower hose (2).
g. Install caps to end of body lower hoses (37).
h. If necessary, remove clamp (45) from bracket (44).
11. Move the tube (41) to a clean maintenance area.

(f) Body Raise Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body system has been dissipated.
5. Gain access to the work area.
6. Identify and tag raise hose (37).
7. Position suitable containers under the base end of the cylinder and end of tube (42).
8. Disconnect the hose (37):
a. Disconnect hose (37) from connector (29).
b. Drain any trapped oil.
c. Disconnect hose (37) from tube (42).
d. Remove and discard O-rings (35).
e. If necessary, remove connector (29) from base end of cylinder.
f. Install caps to both ends of hose (37) to prevent ingress of dirt.
g. Install cap to end of tube (42).
h. Install cap to connector (29) or port in base end of cylinder.
9. Move the hose (37) to a clean maintenance area.

(g) Body Lower Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.

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 Body System 13

3. Place the battery master switch in the ‘OFF’ position.

4. Ensure the pressure in the body system has been dissipated.
5. Gain access to the work area.
6. Identify and tag lower hose (37).
7. Position suitable containers under the base end of the cylinder and end of tube (41).
8. Disconnect the hose (37):
a. Disconnect hose (37) from tube (30).
b. Drain any trapped oil.
c. Disconnect hose (37) from tube (41).
d. Remove and discard O-rings (35).
e. Install caps to both ends of hose (37) to prevent ingress of dirt.
f. Install caps to end of tubes (30 & 41).
9. Move the hose (37) to a clean maintenance area.

(h) Cylinder Lower Tube

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body system has been dissipated.
5. Gain access to the work area.
6. Identify and tag lower tube (30).
7. Position suitable containers under the base and rod ends of the cylinder.
8. Remove lower hose (37). Refer to (g) Body Lower Hose on page 13-8.
9. Disconnect the tube (30):
a. Remove Bolts (34), top plate (33) and tube clamp (32).
b. Separate tube (30) from elbow (31).
c. Drain any trapped oil.
d. Remove elbow (31) from rod end of cylinder.
e. Install caps to both ends of tube (30) to prevent ingress of dirt.
f. Install a cap to port in rod end of cylinder.
10. Move the tube (30) to a clean maintenance area.

(2) Installation
Numbers in parentheses refer to Figure 13.1 and Figure 13.2, unless otherwise specified.

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

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13 Body System

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all ORFS connections to (7) O-Ring Face Seals (ORFS) on page 11-24.

(a) Main Hydraulic Valve Body Raise Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Connect the hose (1):
a. Remove caps from both ends of hose (1).
b. Remove cap from end of tube (42).
c. Remove cap from manifold plate (13).
d. Install new O-ring (9).
e. Connect hose (1) to manifold plate (13).
f. Install split flange (10).
g. Install spring washers (12) and bolts (11).
h. Torque tighten the bolts (11) to 50 Nm (31 lbf ft).
i. Install new O-ring (35).
j. Connect hose (2) to tube (41).
5. Fit the hose (1) to double tube clamp (21):
a. Fit the hose (1) to double tube clamp (21):
b. Install the set bolt to the double tube clamp (21).
6. Fit the hose (1) to clamp (20):
a. Fit the split bush (19) onto hose (1).
b. Fit the hose (1) to clamp (20).
c. Install washers (28) and bolts (26) to clamp (20).
7. Place the battery master switch in the ‘ON’ position.
8. Start the engine. Refer to 5.11 Starting on page 5-27.
9. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
10. Check for leaks.
11. Check hydraulic tank oil level and replenish if required.

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 Body System 13

(b) Main Hydraulic Valve Body Lower Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Connect the hose (2):
a. Remove caps from both ends of hose (2).
b. Remove cap from end of tube (41).
c. Remove cap from manifold plate (13).
d. Install new O-ring (9).
e. Connect hose (2) to manifold plate (13).
f. Install split flange (10).
g. Install spring washers (12) and bolts (11).
h. Torque tighten the bolts (11) to 50 Nm (31 lbf ft).
i. Install new O-ring (35).
j. Connect hose (2) to tube (41).
5. Fit the hose (2) to double tube clamp (21):
a. Fit the hose (2) to double tube clamp (21):
b. Install the set bolt to the double tube clamp (21).
6. Fit the hose (2) to clamp (20):
a. Fit the split bush (19) onto hose (2).
b. Fit the hose (2) to clamp (20).
c. Install washers (28) and bolts (26) to clamp (20).
7. Place the battery master switch in the ‘ON’ position.
8. Start the engine. Refer to 5.11 Starting on page 5-27.
9. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
10. Check for leaks.
11. Check hydraulic tank oil level and replenish if required.

(c) Main Hydraulic Valve Body Return Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Connect the hose (3):
a. Remove caps from both ends of hose (3).
b. Remove cap from port in main hydraulic valve.
c. Remove cap from tank return tube.
d. Install new O-ring (5).
e. Connect hose (3) to main hydraulic valve.
f. Install split flange (6).
g. Install lock washers (8) and bolts (7).

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13 Body System

h. Torque tighten the bolts (7) to 50 Nm (31 lbf ft).

i. Install new O-ring (4).
j. Connect hose (3) to tank return tube.
5. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
6. Place the battery master switch in the ‘ON’ position.
7. Start the engine. Refer to 5.11 Starting on page 5-27.
8. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
9. Check for leaks.
10. Check hydraulic tank oil level and replenish if required.

(d) Body Raise Tube

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Position suitable containers under the base end of the cylinder and end of tube (42).
5. Connect the tube (42):
a. If removed, install clamp (45) to bracket (47).
b. Remove caps from ends of tube (42) to prevent ingress of dirt.
c. Remove cap from end of main hydraulic valve body raise hose (1).
d. Remove caps from end of body raise hoses (37).
e. Fit the tube (42) to the clamps (45 & 38).
f. Install clamp (45).
g. Install clamps (38).
h. Install the cover.
6. Install main hydraulic valve body raise hose (1). Refer to (a) Main Hydraulic Valve Body
Raise Hose on page 13-10.
7. Install body raise hoses (37). Refer to (f) Body Raise Hose on page 13-13.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
11. Check for leaks.
12. Check hydraulic tank oil level and replenish if required.

(e) Body Lower Tube

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.

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 Body System 13

3. Gain access to the work area.

4. Position suitable containers under the base end of the cylinder and end of tube (41).
5. Connect the tube (41):
a. If removed, install clamp (45) to bracket (44).
b. Remove caps from ends of tube (41).
c. Remove cap from end of main hydraulic valve body lower hose (2).
d. Remove caps from end of body lower hoses (37).
e. Fit the tube (41) to the clamps (45 & 38).
f. Install clamp (45).
g. Install clamps (38).
h. Install the cover.
6. Install main hydraulic valve body lower hose (2). Refer to (b) Main Hydraulic Valve Body
Lower Hose on page 13-11.
7. Install body lower hoses (37). Refer to (g) Body Lower Hose on page 13-14.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
11. Check for leaks.
12. Check hydraulic tank oil level and replenish if required.

(f) Body Raise Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Position suitable containers under the base end of the cylinder and end of tube (42).
5. Connect the hose (37):
a. Remove caps from both ends of hose (37).
b. Remove cap from end of tube (42).
c. Remove cap from connector (29) or port in base end of cylinder.
d. If removed, install connector (29) to base end of cylinder.
e. Install new O-rings (35).
f. Connect hose (37) to connector (29).
g. Connect hose (37) to tube (42).
6. Place the battery master switch in the ‘ON’ position.
7. Start the engine. Refer to 5.11 Starting on page 5-27.
8. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
9. Check for leaks.
10. Check hydraulic tank oil level and replenish if required.

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13 Body System

(g) Body Lower Hose

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Position suitable containers under the base end of the cylinder and end of tube (41).
5. Connect the hose (37):
a. Remove caps from both ends of hose (37).
b. Remove caps from end of tubes (30 & 41).
c. Install new O-rings (35).
d. Connect hose (37) to tube (30).
e. Connect hose (37) to tube (41).
6. Place the battery master switch in the ‘ON’ position.
7. Start the engine. Refer to 5.11 Starting on page 5-27.
8. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
9. Check for leaks.
10. Check hydraulic tank oil level and replenish if required.

(h) Cylinder Lower Tube

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Position suitable containers under the base and rod ends of the cylinder.
5. Connect the tube (30):
a. Remove caps from both ends of tube (30).
b. Remove cap from port in rod end of cylinder.
c. Install elbow (31) to rod end of cylinder.
d. Join tube (30) to elbow (31).
e. Install tube clamp (32), top plate (33) and bolts (34).
6. Install lower hose (37). Refer to (g) Body Lower Hose on page 13-14.
7. Place the battery master switch in the ‘ON’ position.
8. Start the engine. Refer to 5.11 Starting on page 5-27.
9. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
10. Check for leaks.
11. Check hydraulic tank oil level and replenish if required.

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 Body System 13

13.3 Body Control Lever

(1) Description

3 3

MOT05309_p
Figure 13.3 - Body Control Lever
1. Body Control Lever 2. Bolts 3. Electrical Connectors

NOTICE
• The body must remain lowered with the body control lever in the Neutral position until it
is necessary to operate the body. Failure to comply to this could result in overheating the
hydraulic oil and failure of the hydraulic system components.

The body control lever is mounted on the right hand side dash panel, next to the transmission
shift controller.

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13 Body System

When the body control lever is operated, a voltage is sent to the MCU, which converts voltage
to current. This current controls the body raise and lower proportional pressure control valves,
producing a pilot pressure to shift the control spool in the main hydraulic valve. This allows
the flow of oil to reach the body cylinders, to either raise or lower the body. Refer to 13.1
Description on page 13-2.
The three operating positions of the lever from front to rear are:
• Lower Push the lever forward to this position to lower (power-down) the body. Keep the
lever pushed forward until the body has fully lowered then release the lever and the lever
will return to the Neutral position. If the body is above the proximity switch, releasing the
lever will stop lowering and the lever will return to the Neutral position. When the body
reaches the proximity switch, the lever springs back the Neutral position and power down
is ramped back to allow the body to float down onto the chassis.
• Neutral The middle default position of the lever. The lever will return to this position when
released during raising or lowering and will remain in this position when released. The
body should be fully lowered and in the Neutral position while the machine is in motion.
If the body is above the proximity switch, the body will stop raising or lowering and hold
the body at any desired height. If the body is below the proximity switch, the body will
float down onto the chassis.
• Raise Pull the lever back to this position to raise the body. Keep the lever pulled back until
the body has fully raised to 65° then release the lever and the lever will return to the Neutral
position. If the body is above the proximity switch, releasing the lever will stop raising and
the lever will return to the Neutral position.

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 Body System 13

(2) Removal
Numbers in parentheses refer to Figure 13.3, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body hydraulic system has been dissipated.
5. Gain access to the underside of the right hand console.
6. Identify and tag the electrical connectors S24.X1 & S24.X2 (3).
7. Disconnect the electrical connectors S24.X1 & S24.X2 (3).
8. Support body control lever (1).
9. Remove bolts (2) securing body control lever to the right hand console.
10. Remove body control lever (1) from mounting location.
11. Move the body control lever (1) to a clean maintenance area.

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13 Body System

(3) Installation
Numbers in parentheses refer to Figure 13.3, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all fasteners to standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.
• Ensure the cab electrical harness from the body control lever is at the front when lever is
installed.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the underside of the right hand console.
4. Position body control lever (1) at mounting location.
5. Support body control lever (1).
6. Install bolts (2) to secure body control lever to the right hand console.
7. Torque tighten bolts (2).
8. Locate electrical harness connectors S24.X1 & S24.X2 (3).
9. Connect and secure the electrical connectors S24.X1 & S24.X2 (3) to body control lever (1).
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Check for correct operation of the body control lever by raising and lowering the body
several times. Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page
21-9.

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 13.4

TA400 Tier2
(1)

Maintenance Manual
24
7
INSTALLATION OF
GREASE LINE
Description

11 8
Hoist Cylinders

9
10

15 25
20 14

24

Revision 1.0
17 16 16 17

26 27 28 29 30 22 31 23 12 13 32 21 32 33 34 33 18 19

BODY MOUNTING FRAME MOUNTING

5 3
6

Figure 13.4 - Sectional View of Hoist Cylinder and Mounting

GROOVE 2
THIS SIDE 1
3
2 6
ORIENTATION OF
1 CUSHION SLEEVE 4

P11860_p

Page 13-19
15-Sep-2017
Body System 13
13 Body System

1. Bolt 13. Rod 25. Lock Ring

2. Lockwasher 14. Piston 26. Rod Wiper
3. Washer 15. Retainer 27. Nylon Ring
4. Chassis Pin 16. Spherical Bearing 28. Rod Seal
5. Body Pin 17. Circlip 29. Backup Ring
6. Spacer 18. Cushion Sleeve 30. O-ring
7. 45° Elbow 19. Circlip 31. O-ring
8. Hose 20. Grub Screw 32. O-ring
9. Coupling 21. Cushion Spear 33. Wear Ring
10. Grease Nipple 22. Cushion Sleeve 34. Piston Seal
11. Hoist Cylinder 23. Circlip
12. Shell 24. Grease Nipple

There are two single stage, double acting body hoist cylinders, cushioned at both ends of the
stroke, on the machine. Each cylinder base end is connected to the trailer chassis and each
piston rod eye end is connected to the body. Single stage, double acting means that the piston
rod can have oil applied to either end, extending or retracting the piston rod.
The cushioning effect when the cylinder is being extended is obtained by a tapered spear on the
piston rod passing through a cushioned sleeve. This gradually slows the piston which in turn
helps to control destructive shock effects when the piston reaches the full extent of its travel.
The cushioning effect when the cylinder is being retracted is obtained by a tapered spear at
the base end of the cylinder body entering a cavity in the piston rod through a cushioning
ring. This gradually slows the piston which in turn helps to control destructive shock effects
when the piston bottoms.
Cylinder mounting is by means of pins.

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 Body System 13

(2) Removal
Numbers in parentheses refer to Figure 13.4, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• The procedure to remove the LH and RH cylinders is identical. The procedure for the LH
cylinder is detailed.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the body system has been dissipated.
5. Gain access to the work area. Remove the hose (8) from the body end of the cylinder
(11) at the 45° elbow (7).
6. Position suitable containers under the ends of the body lower and raise hoses.
7. Remove the body lower and raise hoses. Refer to (f) Body Raise Hose on page 13-8
and (g) Body Lower Hose on page 13-8.
8. Attach suitable lifting equipment to the cylinder (11) and take an initial strain.
9. At the body attachment point:
a. Remove the bolt (1), lockwasher (2) and washer (3).
b. Remove the upper pin (5) and spacers (6).
10. At the chassis attachment point:
a. Remove the bolt (1), lockwasher (2) and washer (3).
b. Remove the upper pin (4) and spacers (6).
11. Separate the cylinder (11) from the body and chassis attachment points.
12. Using standard lifting equipment, lift the cylinder (11) from its attachment brackets on the
trailer chassis and body.
13. Move the cylinder (11) to a clean maintenance area.
14. If necessary, remove the cylinder tube. Refer to (h) Cylinder Lower Tube on page 13-9.

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13 Body System

(3) Disassembly
Numbers in parentheses refer to Figure 13.4, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• The procedure to disassemble the LH and RH cylinders is identical. The procedure for
the LH cylinder is detailed below.

PROCEDURE
1. Prepare a clean and dry working area.
2. If necessary, remove the cylinder tube. Refer to (h) Cylinder Lower Tube on page 13-9.
3. Remove spherical bearings (16) from base and rod ends of cylinder (11):
a. Remove circlip (17).
b. Press out spherical bearing (16).
c. Repeat steps a. and b. for the second spherical bearing (16).
4. Remove the rod assembly (13) from shell assembly (12):
a. Remove lock ring (25) from retainer (15).
b. Using the end cap torque tool (refer to (8) Special Tools on page 13-25), unscrew
retainer (15) until thread is disengaged from shell assembly (12).
c. Support rod assembly (13).
d. Withdraw rod assembly (13) from shell assembly (12). Ensure centre lines of rod
assembly (13) from shell assembly (12) remain aligned during removal of rod assembly
(13).
e. Place rod assembly (13) on supports which will not damage the piston rod diameter.
5. Disassemble the piston (14):
a. Remove and discard wear rings (33) from piston (14).
b. Remove and discard piston seal (34) from piston (14).
c. Remove grub screw (20) from wear ring (33) groove in piston (14).
d. Provide an anti-torsion device through rod assembly (13) eye.
e. Using the piston torque tool (refer to (8) Special Tools on page 13-25), unscrew piston
(14) from rod assembly (13).
f. Remove circlip (19).
g. Remove cushion sleeve (18) from piston (14).
6. Remove cushion spear (21) from rod assembly (13):
a. Remove cushion spear (21) from rod assembly (13).
b. Remove and discard O-rings (32).
7. Remove retainer (15) from rod assembly (13).
8. Disassemble the retainer (15):
a. Remove circlip (23).
b. Remove cushion sleeve (22).
c. Remove and discard O-ring (31).
d. Remove and discard O-ring (30) and back up ring (29).
e. Remove and discard nylon ring (27) and rod seal (28).
f. Remove and discard rod wiper (26).

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 Body System 13

(4) Inspection
Numbers in parentheses refer to Figure 13.4, unless otherwise specified.

PROCEDURE
1. Clean all parts of the hoist cylinder (11) with a suitable solvent and dry with clean, lint-free
cloths. Clean all grooves carefully to remove any foreign material.
2. Check shell (12) and outer diameter of piston (14) for scratches, cracks or other defects.
Remove ridges, nicks and scratches with a fine stone and reclean.
3. Inspect rod (13) for distortion, cracks or other defects. Replace rod (13) if defective area
is irreparable.
4. Check spherical bearings (16) for wear and replace if necessary.

(5) Assembly
Numbers in parentheses refer to Figure 13.4, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• The procedure to assemble the LH and RH cylinders is identical. The procedure for the LH
cylinder is detailed below.

PROCEDURE
1. Prepare a clean and dry working area.
2. Assemble the retainer (15):
a. Install new O-ring (31).
b. Install new O-ring (30) and back up ring (29).
c. Install new nylon ring (27) and rod seal (28).
d. Install new rod wiper (26).
e. Install cushion sleeve (22). Refer to Figure 13.4 for correct orientation of cushion
sleeve (20).
f. Install circlip (23) to secure cushion sleeve (22).
3. Install retainer (15) onto rod assembly (13), taking care not to damage rod wiper (26)
on the thread.
4. Install cushion spear (21) onto rod assembly (13):
a. Install new O-rings (32).
b. Install cushion spear (21) onto rod assembly (13).
5. Assemble the piston (14):
a. Provide an anti-torsion device through rod assembly (13) eye.
b. Apply Loctite 243 to first two threads of piston (14).
c. Using the piston torque tool (refer to (8) Special Tools on page 13-25), screw piston
(14) to rod assembly (13).
d. Torque tighten piston (14) to 1 200 - 1 500 Nm (885 - 1106 lbf ft).
e. Install grub screw (20) to wear ring (33) groove in piston (14).
f. Torque tighten grub screw (20) to 48 Nm (35 lbf ft).

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TA400 Tier2 Page 13-23
13 Body System

g. Ensure the extreme of grub screw (20) is below the level of wear ring (33) groove.
h. Install new wear rings (33) onto piston (14).
i. Install new piston seal (34) onto piston (14).
j. Install cushion sleeve (18) to piston (14).
k. Install circlip (19) to secure cushion sleeve (18).
6. Install the rod assembly (13) into shell assembly (12):
a. Grease outside diameter of piston (14) and O-rings (30 & 31) in retainer (15) to aid
installation.
b. Slide rod assembly (13) 75% of the way into shell assembly (12). Take care not to
damage piston seal (34) on shell assembly (12) threads. Ensure centre lines of rod
assembly (13) from shell assembly (12) remain aligned during installation of rod
assembly (13).
c. Support rod assembly (13).
d. Install retainer (15) to shell assembly (12) hand tighten.
e. Push rod assembly (13) to the fully retracted position
f. Using the end cap torque tool (refer to (8) Special Tools on page 13-25), torque tighten
retainer (15) to 200 - 270 Nm (147.5 - 199 lbf ft).
g. If necessary, re-drill retainer (15) for lock ring (25) tang, 3.175 x 13 mm (0.125 x 0.51
in) deep.
h. Install lock ring (25) to retainer (15).
7. Install spherical bearings (16) to base and rod ends of cylinder (11):
a. Install spherical bearing (16).
b. Install circlip (17) to secure spherical bearing (16).
c. Repeat steps a. and b. for the second spherical bearing (16).
8. If necessary, install the cylinder tube. Refer to (h) Cylinder Lower Tube on page 13-14.
9. Install plugs to all ports to prevent ingress of dirt.

(6) Installation
Numbers in parentheses refer to Figure 13.4, unless otherwise specified.

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

NOTICE
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• The procedure to install the LH and RH cylinders is identical. The procedure for the LH
cylinder is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If removed, install the cylinder tube. Refer to (h) Cylinder Lower Tube on page 13-14.
4. Gain access to the work area.

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 Body System 13

5. Attach suitable lifting equipment to the cylinder (11).

6. Using lifting equipment, align the cylinder (11) with its attachment brackets on the trailer
chassis and body.
7. At the body attachment point:
a. Install the spacers (6) and upper pin (5).
b. Install the washer (3), lockwasher (2) and bolt (1).
8. At the chassis attachment point:
a. Install the spacers (6) and lower pin (4).
b. Install the washer (3), lockwasher (2) and bolt (1).
9. Torque tighten the bolts (1) to 66 Nm (49 lbf ft).
10. Install the hose (8) to the body end of the cylinder (11) at the 45 elbow (7).
11. Install the body lower and raise hoses. Refer to (f) Body Raise Hose on page 13-13 and (g)
Body Lower Hose on page 13-14.
12. Using the grease nipples (10 & 24), lubricate the upper and lower pins (5 & 4) with specified
lubricant. Refer to (1) Recommended Lubricants on page 4-16. Lubricate slowly until
excess lubricant is observed.
13. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank.
14. Place the battery master switch in the ‘ON’ position.
15. Start the engine. Refer to 5.11 Starting on page 5-27.
16. Check for correct operation of the body by raising and lowering the body several times.
Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page 21-9.
17. Check for leaks.
18. Check hydraulic tank oil level and replenish if required.

(7) Maintenance
Numbers in parentheses refer to Figure 13.4, unless otherwise specified.
Every 250 hours: Lubricate chassis and body pins (4 and 5) as described in (1) Recommended
Lubricants on page 4-16. Inspect cylinders for leaks, if leaks are found, replace seals with seals
contained in the Service Repair Kit, as specified in the parts book.
(8) Special Tools
Numbers in parentheses refer to Figure 13.4, unless otherwise specified.
Two special tools are required to disassemble and assemble the Host Cylinder. Refer to (3)
Disassembly on page 13-22and (5) Assembly on page 13-23.For the special tool to
• Disassemble/Assemble retainer (15), refer to Figure 13.5.
• Disassemble/Assemble piston (14), refer to Figure 13.6.
These two special tools can be fabricated as shown in Figure 13.5 and Figure 13.6. Refer to
22.2 Service Tools on page 22-4, for part numbers of general service tools required. These
tools are available from your dealer.

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13 Body System

Figure 13.5 - End Cap Torque Tool

Figure 13.6 - Piston Rod Torque Tool

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 Braking System 14

Table of Content
14 Braking System.........................................................................................14-1
14.1 Description ................................................................................................... 14-4
14.2 Treadle Valve Pedal Assembly..................................................................... 14-8
(1) Description............................................................................................... 14-8
(a) Treadle Valve ...................................................................................... 14-9
(b) Service Brake Pedal Assembly......................................................... 14-11
(2) Operation............................................................................................... 14-12
(a) Normal Service Brake Application .................................................... 14-12
(b) Normal Service Brake Release......................................................... 14-12
(c) Emergency Stop Brake Application .................................................. 14-12
(d) Emergency Stop Brake Release....................................................... 14-13
(e) Advanced Engine Braking................................................................. 14-13
(3) Removal ................................................................................................ 14-14
(a) Treadle Valve .................................................................................... 14-14
(b) Service Brake Pedal Assembly......................................................... 14-15
(4) Disassembly .......................................................................................... 14-16
(a) Treadle Valve .................................................................................... 14-16
(b) Pedal Assembly ................................................................................ 14-17
(5) Assembly ............................................................................................... 14-18
(a) Pedal Assembly ................................................................................ 14-18
(b) Treadle Valve .................................................................................... 14-19
(6) Installation ............................................................................................. 14-20
(a) Pedal Assembly ................................................................................ 14-20
(b) Treadle Valve .................................................................................... 14-21
(7) Hose Removal ....................................................................................... 14-22
(a) Treadle Valve Pedal Assembly to Hydraulic Tank Hoses.................. 14-22
(b) Main Hydraulic Valve to Treadle Valve Pedal Assembly
Hoses................................................................................................ 14-23
(8) Hose Installation .................................................................................... 14-24
(a) Treadle Valve Pedal Assembly to Hydraulic Tank Hoses.................. 14-24
(b) Main Hydraulic Valve to Treadle Valve Pedal Assembly
Hoses................................................................................................ 14-25
14.3 Service Brakes ........................................................................................... 14-27
(1) Description and Operation..................................................................... 14-27
(2) Removal and Disassembly .................................................................... 14-29
(3) Assembly and Installation...................................................................... 14-34
(4) Special Tools ......................................................................................... 14-41
(5) Hose Removal ....................................................................................... 14-42
(a) Service Brakes Tractor Supply Hose ................................................ 14-42
(b) Service Brakes Front Axle Hoses ..................................................... 14-43
(c) Remote Bleed Hoses ........................................................................ 14-44
(d) Service Brakes Tractor Supply Hose ................................................ 14-44
(e) Service Brakes Tractor Interface Hose ............................................. 14-45
(f) Service Brakes Trailer Supply Tube.................................................. 14-46
(g) Service Brakes Centre Axle Hoses................................................... 14-47
(h) Centre Axle Manifold Block to Centre Axle Service Brake
Hoses................................................................................................ 14-47
(i) Service Brakes Trailer Supply Hose to Rear Axle Manifold
Block ................................................................................................. 14-48

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14 Braking System

(j)
Service Brakes Rear Axle Hoses...................................................... 14-49
(6) Hose Installation .................................................................................... 14-51
(a) Service Brakes Tractor Supply Hose ................................................ 14-51
(b) Service Brakes Front Axle Hoses ..................................................... 14-52
(c) Remote Bleed Hoses ........................................................................ 14-53
(d) Service Brakes Tractor Supply Hose ................................................ 14-54
(e) Service Brakes Tractor Interface Hose ............................................. 14-55
(f) Service Brakes Trailer Supply Tube.................................................. 14-56
(g) Service Brakes Centre Axle Hoses................................................... 14-57
(h) Centre Axle Manifold Block to Centre Axle Service Brake
Hoses................................................................................................ 14-58
(i) Service Brakes Trailer Supply Hose to Rear Axle Manifold
Block ................................................................................................. 14-59
(j) Service Brakes Rear Axle Hoses...................................................... 14-60
(7) Bleeding the Service Brakes ................................................................. 14-61
14.4 Accumulators ............................................................................................. 14-62
(1) Description............................................................................................. 14-62
(2) Removal ................................................................................................ 14-65
(3) Disassembly .......................................................................................... 14-67
(4) Inspection .............................................................................................. 14-68
(5) Assembly ............................................................................................... 14-69
(6) Installation ............................................................................................. 14-70
(7) Discharging............................................................................................ 14-72
(8) Charging ................................................................................................ 14-73
(9) Maintenance .......................................................................................... 14-76
(a) Testing Nitrogen Pressure................................................................. 14-76
(b) Testing Charge Valve for Leakage .................................................... 14-77
(10) Special Tools ......................................................................................... 14-79
(11) Hose Removal ....................................................................................... 14-80
(a) Accumulator to Main Hydraulic Valve Hoses .................................... 14-80
(12) Hose Installation .................................................................................... 14-82
(a) Accumulator to Main Hydraulic Valve Hoses .................................... 14-82
14.5 Interlock Solenoid Valve ............................................................................. 14-84
(1) Removal ................................................................................................ 14-84
(2) Installation ............................................................................................. 14-85
(3) Hose Removal ....................................................................................... 14-87
(a) Main Hydraulic Valve to Interlock Solenoid Valve Hose.................... 14-87
(b) Interlock Solenoid Valve to Treadle Valve Pedal Assembly
Hose.................................................................................................. 14-88
(c) Interlock Solenoid Valve to Hydraulic Tank Hose.............................. 14-89
(4) Hose Installation .................................................................................... 14-90
(a) Main Hydraulic Valve to Interlock Solenoid Valve Hose.................... 14-90
(b) Interlock Solenoid Valve to Treadle Valve Pedal Assembly
Hose.................................................................................................. 14-91
(c) Interlock Solenoid Valve to Hydraulic Tank Hose.............................. 14-92
14.6 Parking Brake............................................................................................. 14-93
(1) Description............................................................................................. 14-93
(2) Removal ................................................................................................ 14-95
(3) Disassembly .......................................................................................... 14-96
(4) Inspection .............................................................................................. 14-97

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 Braking System 14

(5) Assembly ............................................................................................... 14-98

(6) Installation ........................................................................................... 14-100
(7) Hose Removal ..................................................................................... 14-102
(a) Parking Brake Tractor Supply Hose................................................ 14-102
(b) Parking Brake Tractor Interface Hose............................................. 14-103
(c) Parking Brake Trailer Supply Tube ................................................. 14-103
(d) Parking Brake Trailer Supply Hose ................................................. 14-104
(8) Hose Installation .................................................................................. 14-106
(a) Parking Brake Tractor Supply Hose................................................ 14-106
(b) Parking Brake Tractor Interface Hose............................................. 14-107
(c) Parking Brake Trailer Supply Tube ................................................. 14-108
(d) Parking Brake Trailer Supply Hose ................................................. 14-108
(9) Bleeding the Parking Brake ................................................................. 14-110

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TA400 Tier2 Page 14-3
 14
14.1

Page 14-4
15-Sep-2017
4 5 6
17 50 49 48 48 49 50
1
14 60
14 Braking System

3 59
61,60
Description

49 48 48 48 48 58
PRESS 47 48 75
SWITCH 41 48
59
49, 48
Braking System

47 50
29 48
42 48
49, 74 81,82
47 47 50 83,84
27 2 85,86
13
47 49,50 31
30 8
12
17 47 76
47 77
47 78

Revision 1.0
28 49 46
50 32 80
44 49 47
48
36 79
48 43 14
48 37
45 7
52 47
15
54 15 D
C1 C2
57 53 38

Figure 14.1 - Tractor Brake System Schematic

DP 19 20 21 23 22 13 68,
69, 47
47 47 47
62 64 40 70
65 67 68, 67
69,
70 39 66 55
55
63 47 16 16 47
66

MOT05138

TA400 Tier2
Maintenance Manual
TA400 Tier2
Maintenance Manual
20
93
88 94 88
95

35
47 47
89
50
22
100,101 25
90 98
102
11 92
91 99 23 92
97 49 51
C1
107 C2
51 51
96 B3
B3
10
103,104 C2
9
C1

Revision 1.0
51
18 92 92
52
52
105,106 33 96
52
21 24

47 47
19,56

Figure 14.2 - Trailer Brake System Schematic

8 87 87

108 34,56
109
110
111

MOT05152

Page 14-5
15-Sep-2017
Braking System 14
14 Braking System

1. Treadle Valve Pedal 41. Diagnostic Hose (Tractor 81. Pipe Clamp
Assembly Service Brakes)
2. Main Hydraulic Valve 42. Diagnostic Hose (Trailer 82. Split Bush
Service Brakes)
3. Interlock Solenoid Valve 43. Diagnostic Hose 83. Stacking Nut
(Accumulator 1)
4. Accumulator 1 44. Diagnostic Hose 84. Lockwasher
(Accumulator 2)
5. Accumulator 2 45. Diagnostic Hose 85. Bolt
(Accumulator 3)
6. Accumulator 3 46. Diagnostic Hose (Parking 86. Split Bush
Brake)
7. Front Axle Manifold Block 47. Adaptors 87. LHS Brake Guards
8. Tractor Interface Plate 48. Elbows 88. RHS Brake Guards
9. Centre Axle Manifold 49. T-pieces 89. Pipe Clamp
Block
10. Rear Axle Manifold Block 50. Reducers 90. Pipe Clamp
11. Parking Brake 51. Connectors 91. Split Bush
12. Hose 52. Bulkhead Adaptors 92. Pipe Clamp
13. Hose 53. Dustcaps 93. Pipe Clamp
14. Hose 54. Diagnostic Plate 94. Stacking Bolt
15. Hoses (Front Axle) 55. Diagnostic Nipple 95. Locking Plate
16. Bleed Hoses (Front Axle) 56. O-rings 96. Strap
17. Hose 57. Plug 97. Sleeve
18. Hose 58. Bracket 98. Bracket
19. Tube (Trailer Service 59. Bolts 99. Spring
Brakes)
20. Hose 60. Washers 100. Bolt
21. Hose (Centre Axle) 61. Nuts 101. Washer
22. Hose (Centre Axle) 62. Split Flanges 102. Carbine Hook
23. Hose 63. O-ring 103. Clamp
24. Hose (Rear Axle) 64. Bolts 104. Split Bush
25. Hose (Parking Brake) 65. Lockwashers 105. Bolt
26. Hose 66. Clamps 106. Washer
27. Hose 67. Brackets 107. Chain
28. Hose 68. Bolts 108. Clamp
29. Hose (Accumulator 1) 69. Lockwashers 109. Split Bush
30. Hose (Accumulator 2) 70. Washers 110. Nut
31. Hose (Accumulator 3) 71. Bracket 111. Bolt
32. Hose (Parking Brake) 72. Bracket
33. Hose (Parking Brake) 73. Bracket
34. Tube (Parking Brake) 74. Bracket
35. Hose (Parking Brake) 75. Strap

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 Braking System 14

36. Hose 76. Pipe Clamp

37. Hose 77. Pipe Clamp
38. Tube 78. Pipe Clamp
39. Hose 79. Pipe Clamp
40. Hose 80. Locking Plate

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.
The braking system is of closed centre design wherein constant pressure is stored in
accumulators and is regulated as required to retard or stop the machine.
The braking system consists of:
• Treadle Valve Pedal Assembly (1). Refer to (1) Description on page 14-8.
The treadle valve pedal assembly is installed to the front bulkhead of the operator’s cab
to control the level of hydraulic fluid pressure applied to front and rear service brakes
and the maximum pressure available to these circuits. It is operated by a foot pedal in
the operator's cab.
• Service Brakes. Refer to (1) Description and Operation on page 14-27.
The service brakes are of the enclosed, forced oil cooled immersed, multi-disc type and are
installed to the front, centre and rear axles to provide normal braking.
• Accumulators (4,5,6). Refer to (1) Description on page 14-62.
There are three accumulators mounted on the exhaust cradle assembly on the rear left
hand side of the tractor for:
a the front axle service brakes
b the centre and rear axle service brakes
c the parking brake and body pilot pressure system
All three accumulators are of the piston type and are charged with nitrogen to 103 bar (1
494 psi), at 20 °C (68 °F).
The cylinder pressure will increase or decrease proportionally with temperature changes.
An accumulator pressure reading can vary about 4.3 bar (62 psi) with 22 °C (72 °F)
temperature change. Such temperature changes could easily occur between noon and
midnight of the same day. Refer to (5) Accumulator Safety on page 2-22 for nitrogen
pressures at ambient temperatures of other than 20 °C (68 °F).
• Interlock Solenoid Valve (3). Refer to (1) Removal on page 14-84.
• Parking Brake. Refer to (1) Description on page 14-93.
The parking brake assembly (11) is mounted to brackets behind the pivot assembly
installation and between the trailer chassis frame rails and the brake disk is installed
between the yoke of the pivot assembly and the centre axle driveshaft. The parking brake
assembly is of 'Inverted Design', which means that it requires brake system pressure to
hold it off.
• System Hoses.
System hoses connect between the hydraulic tank, main hydraulic valve, treadle valve
pedal assembly, accumulators, manifold blocks and service brakes.

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TA400 Tier2 Page 14-7
14 Braking System

14.2 Treadle Valve Pedal Assembly

(1) Description
Numbers in parentheses refer to Figure 14.3, unless otherwise specified.
The treadle valve pedal assembly (1) consists of the service brake pedal assembly and treadle
valve (2).

2 1

7
16
17
18
=
14
15 13

9
12

8
6
4
11
10
5 11
10
3

MOT05346

Figure 14.3 - Treadle Valve Pedal Assembly

1. Treadle Valve and 7. Cable tie 13. Gasket
Service Brake Pedal
Assembly
2. Treadle Valve 8. Screws 14. Screws
3. Pedal Assembly 9. Washers 15. Washers
4. Microswitch 10. Screws 16. Mounting Plate
5. Cap Screws 11. Lockwashers 17. Gasket
6. Nut 12. Bracket 18. Beading

The tandem circuit modulating treadle valve (2) is a closed centre controller which controls the
level of hydraulic oil pressure applied to the front and rear service brakes and the maximum
pressure available to these circuits. It is operated by the brake pedal in the operator's cab,
and with the engine running, is automatically applied by the park brake solenoid valve within
the main hydraulic valve.
In the normal position, the brake pedal is in the up position. In this condition, the regulated
pressure outlet ports of the treadle valve (A1 and A2) Figure 14.1 are directly linked to the
hydraulic tank ports (T1 and T2). While the pedal is in this position the brakes are released.

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 Braking System 14

When the engine exhaust brake request switch has been selected, and the transmission is in
'lockup' the first 5° (±1°) movement of the brake pedal engages the engine brake Figure 15.96.
Further movement of the brake pedal applies the service brakes in addition to the engine
brake. The engine brake will disengage when the brake pedal is released, or when any of the
operating conditions become out of range.
A microswitch (4), mounted on the brake assembly (3), sends a signal (via the MCU) to activate
the rear brake lights and (when selected) the engine exhaust brake system when the brake
pedal is depressed.
(a) Treadle Valve

27
20
26
25 17 10
24 1
22
9
21 23
16
8
15
6
14 7
19 13
6
18
12
5

11 4

MOT05347

Figure 14.4 - Treadle Valve

1. Treadle Valve 10. Piston 19. O-ring
2. Boot 11. Spring 20. O-ring
3. Push Rod 12. Spring 21. Housing
4. Spring 13. Shim(s) 22. Cap Screws
5. Cup 14. Retainer 23. Washers
6. Cap Screws 15. Cup 24. Spool
7. Pilot Housing 16. O-ring 25. Spring
8. Cup 17. Housing 26. O-ring
9. Piston 18. Spool 27. End Plug

Numbers in parentheses refer to Figure 14.4, unless otherwise specified.

The main components of the treadle valve are the housings (7, 17 and 21), spools (18 and 24),
push rod (3) and pistons (9 and 10).

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14 Braking System

Figure 14.5 - Treadle Valve Ports

P1. Pressure from main A1. Pressure to rear (trailer) T1. Tank return, rear brakes
hydraulic valve, port B2 brakes
P2. Pressure from main A2. Pressure to front T2. Tank return, front brakes
hydraulic valve, port B1 (tractor) brakes
PP. Pressure from main
hydraulic valve port
PBP (via interlock
solenoid valve port 1)

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 Braking System 14

(b) Service Brake Pedal Assembly

18 16 10
17
3 19, 20 13
1

11

14

12
11
17
5
3
15 9
14 8
3
7
6

4
3

MOT05351

Figure 14.6 - Service Brake Pedal Assembly

1. Pedal Assembly 8. Spring 15. Pin
2. Brake Pedal 9. Cup 16. Cam
3. E-rings 10. Clevis 17. E-rings
4. Pin 11. E-rings 18. Pin
5. Pin 12. Pin 19. Cap Screw
6. Push Rod 13. Base 20. Nut
7. Boot 14. E-rings

Numbers in parentheses refer to Figure 14.6, unless otherwise specified.

The main components of the service brake pedal assembly are brake pedal (2), push rod (6),
clevis (10), base (13) and cam (16).

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14 Braking System

(2) Operation
Numbers in parentheses refer to Figure 14.4, unless otherwise specified.
(a) Normal Service Brake Application
Refer to Figure 14.7. When the operator depresses the brake pedal, the push rod (3) is moved
up and pushes on pistons (9 and 10) which in turn push spools (18 and 24) up. As spools (18
and 24) move up, the metering notches move out of the tank cavity and close outlet ports 'A1'
and 'A2' off to tank ports 'T1' and 'T2'. Spools (18 and 24) continue to move upwards until the
metering notches become exposed to the inlet pressure ports. This movement opens inlet ports
'P1’ and 'P2' to outlet ports 'A1' and 'A2' respectively. As hydraulic pressure builds in the brake
system, oil flows through the small orifice in spools (18 and 24) and into the cavities above the
spools. As pressure rises in the brake system it also rises in the cavities above the spools
forcing spools (18 and 24) downwards closing outlet ports 'A1' and 'A2'. Spools (18 and 24) are
now balanced between the brake pressure and the pressure of springs (11 and 12) generated
by the operator's force on the brake pedal. Spools (18 and 24) have closed off the inlet ports,
outlet ports and the tank ports and will remain in this position as long as the brake pedal is not
moved. If the operator further depresses the brake pedal, spools (18 and 24) will move up and
build more pressure in the brake until it balances the brake pedal force.
(b) Normal Service Brake Release
Refer to Figure 14.8. When the operator releases the brake pedal, spools (18 and 24) will
become unbalanced and move downwards, opening outlet ports 'A1' and 'A2' to tank. At this
point, oil in the 'A1' and 'A2' lines is released to the hydraulic tank through tank ports 'T1' and
'T2', releasing the brakes.

Figure 14.7 - Normal Service Brake Figure 14.8 - Normal Service Brake Release
Application

(c) Emergency Stop Brake Application

Refer to Figure 14.9. Pushing in the park/emergency control results in the de-energization of
the park brake solenoid valve within the main hydraulic valve. This allows full pressure to enter
the 'PP' port in the treadle valve simulating a full and immediate depression of the brake pedal,
thus pushing the spools (18 and 24) upwards and thereby applying maximum braking action.

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 Braking System 14

Figure 14.9 - Park/Emergency Brake Figure 14.10 - Park/Emergency Brake

Application Release

(d) Emergency Stop Brake Release

Refer to Figure 14.10. Pulling out the park/emergency control with park brake OFF Relay
energised (i.e transmission in gear) will energize the park brake solenoid valve within the main
hydraulic valve, allowing the pressure in the 'PP' line to fall via the return to tank port opened
within the park brake solenoid valve. Outlet ports 'A1' and 'A2' are opened to tank ports 'T1’ and
'T2' allowing oil in the 'A1' and 'A2' lines to return to tank, releasing the brakes.
(e) Advanced Engine Braking
The brake pedal microswitch sends a signal (via the MCU) to activate the engine exhaust brake
system (if selected) and the rear brake lamps.
The first 5° (±1° ) movement of the brake pedal engages the Engine Brake (when selected),
providing the transmission is in 'lockup'. Further movement of the brake pedal applies the
service brakes in addition to the engine brake. The engine brake will disengage when the brake
pedal is released, or when any of the operating conditions become out of range.

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14 Braking System

(3) Removal

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

(a) Treadle Valve

Numbers in parentheses refer to Figure 14.3, unless otherwise specified.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Tilt the hood. Refer to (5) Raising the Hood on page 16-38.
4. Place the battery master switch in the ‘OFF’ position.
5. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
6. Ensure the pressure in the braking system has been dissipated.
7. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
8. Disconnect the hoses:
a. Identify and tag all hoses connected to the valve (2).
b. Position suitable containers under hose ends.
c. Disconnect diagnostic hose (42, Refer to Figure 14.1) at Port A1.
d. Disconnect hose (17, Refer to Figure 14.1) at Port A1.
e. Disconnect diagnostic hose (36, Refer to Figure 14.1) at Port A2.
f. Disconnect hose (14, Refer to Figure 14.1) at Port A2.
g. Disconnect hose (12, Refer to Figure 14.1) at Port P1.
h. Disconnect hose (13, Refer to Figure 14.1) at Port P2.
i. Disconnect hose (36, Refer to Figure 14.1) at Port T1.
j. Disconnect hose (37, Refer to Figure 14.1) at Port T2.
k. Disconnect hose (27, Refer to Figure 14.1) at Port PP.
l. If necessary, remove the reducers (50), tees (49), elbows (48) and adaptors (47, Refer
to Figure 14.1) from the treadle valve (2).
m. Install caps to all disconnected hose ends.
n. Install plugs to all disconnected treadle valve (2) ports.
9. Remove the treadle valve (2):
a. Note the installed position of valve (2).
b. Support the valve (2).
c. Remove the cap screws (5) and nuts (6).
d. Separate the valve (2) from pedal assembly (3).

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 Braking System 14

10. Move the treadle valve (2) to a clean maintenance area.

Further disassembly should only be done by a vendor approved workshop.

(b) Service Brake Pedal Assembly

Numbers in parentheses refer to Figure 14.3, unless otherwise specified.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Remove the treadle valve (2). Refer to (a) Treadle Valve on page 14-14.
8. Remove the brake pedal activated/deactivated switch (4):
a. Identify and tag connector S27.
b. Remove and discard cable tie (7).
c. Disconnect connector S27.
d. Remove the screws (8) and washers (9).
e. Separate the brake pedal activated/deactivated microswitch (4) from the bracket (12).
9. Remove the pedal assembly (3):
a. Remove screws (10) and lockwashers (11).
b. Separate the pedal assembly (3) and bracket (12) from the operator’s compartment
front bulkhead.
c. Remove and discard gasket (13).
10. Move the pedal assembly (3) to a clean maintenance area.
Further disassembly should only be done by a vendor approved workshop.
11. If necessary, remove mounting plate (16) and gasket (17):
a. Remove screws (14) and lockwashers (15).
b. Separate the mounting plate (16) from the operator’s compartment front bulkhead.
c. Remove and discard gasket (17).

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14 Braking System

(4) Disassembly

NOTICE
• Disassembly should only be done by a competent trained engineer.
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.

(a) Treadle Valve

Numbers in parentheses refer to Figure 14.4, unless otherwise specified.

NOTICE
Spools (18 and 24) and housings (17 and 21) are matched sets. Do not mix sets.

PROCEDURE
1. Prepare a clean and dry working area.
2. Remove boot (2) from push rod (3).
3. Remove push rod (3) and spring (4) from pilot housing (7).
4. Separate pilot housing (7) and housing (17):
a. Remove cap screws (6).
b. Separate pilot housing (7) from housing (17).
c. Remove and discard O-ring (16) from housing (17).
5. Using a wooden dowel, remove piston (9) through the bottom end of pilot housing (7).
Be careful not to damage housing (7) bore.
6. Remove cups (8 and 15) from pilot housing (7). Be careful not to damage O-ring or back-up
ring grooves. Note direction cups (8 and 15) were installed in housing (7) bore.
7. Remove piston (10), springs (11 and 12), shim(s) (13) and retainer (14) from housing (17).
8. Note number of shim(s) (13).
9. Remove cup (15) from housing (17). Be careful not to damage housing (17) bore.
10. Remove end-plug (27) and spring (25) from housing (21).
11. Remove and discard O-ring (26) from end-plug (27).
12. Separate housings (17 and 21):
a. Remove cap screws (22) and washers (23).
b. Separate housings (17 and 21).
c. Remove and discard O-rings (20 and 19) from housings (17 and 21) respectively.
13. Separate spools from housings:
a. Remove spool (24) from housing (21). Be careful not to damage housing (21) bore.
b. Note direction spool (24) was installed in housing (21).
c. Keep spool (24) and housing (21) together.
d. Remove spool (18) through the bottom end of housing (17). Be careful not to damage
housing (17) bore.
e. Note direction spool (18) was installed in housing (17).
f. Keep spool (18) and housing (17) together.

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 Braking System 14

(b) Pedal Assembly

Numbers in parentheses refer to Figure 14.6, unless otherwise specified.

PROCEDURE
1. Prepare a clean and dry working area.
2. Disconnect brake pedal (2) from clevis (10):
a. Remove E-rings (3) from pins (4 and 5).
b. Remove pins (4 and 5).
c. Disconnect push rod (6) from pedal (2) and clevis (10).
d. Remove boot (7), spring (8) and cup (9) from push rod (6).
e. Remove and discard boot (7).
3. Remove clevis (10) from base (13):
a. Remove E-rings (11) from pin (12).
b. Remove pin (12).
c. Separate clevis (10) from base (13).
4. Remove pedal (2) from base (13):
a. Remove E-rings (14) from pin (15).
b. Remove pin (15).
c. Separate pedal (2) from base (13).
5. If necessary, remove cam (16) from clevis (10):
a. Remove E-rings (17) from pin (18).
b. Remove pin (18).
c. Separate cam (16) from clevis (10).
6. If necessary, remove cap screw (19) and nut (20).

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14 Braking System

(5) Assembly

NOTICE
• Assembly should only be done by a competent trained engineer.
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.

(a) Pedal Assembly

Numbers in parentheses refer to Figure 14.6, unless otherwise specified.

NOTICE
If cap screw (19) and nut (20) were removed, adjust once the Treadle Valve and Pedal
Assembly is installed.

PROCEDURE
1. Prepare a clean and dry working area.
2. If necessary, install cap screw (19) and nut (20).
3. If necessary, install cam (16) to clevis (10):
a. Align cam (16) with clevis (10).
b. Install pin (18).
c. Install E-rings (17) to pin (18).
4. Connect pedal (2) to base (13):
a. Align pedal (2) with base (13).
b. Install pin (15).
c. Install E-rings (14) to pin (15).
5. Connect clevis (10) to base (13):
a. Align clevis (10) with base (13).
b. Install pin (12).
c. Install E-rings (11) to pin (12).
6. Connect pedal (2) to clevis (10):
a. Install a new boot (7), spring (8) and cup (9) to push rod (6).
b. Connect push rod (6) to pedal (2) and clevis (10).
c. Install pins (4 and 5).
d. Install E-rings (3) to pins (4 and 5).

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 Braking System 14

(b) Treadle Valve

Numbers in parentheses refer to Figure 14.4, unless otherwise specified.

NOTICE
Spools (18 and 24) and housings (17 and 21) are matched sets. Do not mix sets.

PROCEDURE
1. Prepare a clean and dry working area.
2. Install spools to housings:
a. Apply clean hydraulic oil as described in (1) Recommended Lubricants on page 4-16
to spool (24).
b. Install spool (24) to housing (21) in the same direction as noted during disassembly. Be
careful not to damage housing (21) bore.
c. Apply clean hydraulic oil as described in (1) Recommended Lubricants on page 4-16
to spool (18).
d. Install spool (18) through the bottom end of housing (17) in the same direction as noted
during disassembly. Be careful not to damage housing (17) bore.
3. Join housings (17 and 21):
a. Apply clean hydraulic oil as described in (1) Recommended Lubricants on page 4-16 to
new O-rings (19 and 20).
b. Install O-rings (19 and 20) to housings (21 and 17) respectively.
c. Align housings (17 and 21).
d. Apply Loctite 242 to threads of cap screws (22).
e. Install cap screws (22) and washers (23).
f. Torque tighten cap screws (22) to 29.8-33.9 Nm (22-25 lbf.ft).
4. Install end-plug (27):
a. Apply clean hydraulic oil as described in (1) Recommended Lubricants on page 4-16
to new O-ring (26). Install O-ring (26) to end-plug (27).
b. Install end-plug (27) and spring (25) to housing (21). Torque tighten end-plug (27)
to 47.5-54.2 Nm (35-40 lbf.ft).
5. Install cup (15) to housing (17). Be careful not to damage housing (17) bore.
6. Assemble springs (11 and 12), shim(s) (13) and retainer (14) in piston (10). Install the
number of shims noted during disassembly.
7. Install piston (10) to housing (7) bore.
8. Install cups (20 and 23) to pilot housing (21) in the same directions as noted during
disassembly.
9. Install piston (19) through the bottom end of pilot housing (21).
10. Join pilot housing (7) to housing (17):
a. Apply clean hydraulic oil as described in (1) Recommended Lubricants on page 4-16
to new O-ring (16).
b. Install O-ring (16) to housing (17).
c. Align pilot housing (7) with housing (17).
d. Install cap screws (6). Torque tighten cap screws to 29.8-33.9 Nm (22-25 lbf.ft).
11. Install spring (4) and push rod (3) to pilot housing (7).
12. Install boot (2) to push rod (3) and over pilot housing (7).

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14 Braking System

(6) Installation

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all fasteners to standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

(a) Pedal Assembly

Numbers in parentheses refer to Figure 14.3, unless otherwise specified.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If removed, install mounting plate (16) and gasket (17):
a. Install a new gasket (17).
b. Align the mounting plate (16) with the operator’s compartment front bulkhead.
c. Install screws (14) and lockwashers (15).
4. Install the pedal assembly (3):
a. Install a new gasket (13).
b. Align the pedal assembly (3) and bracket (12) with the operator’s compartment front
bulkhead.
c. Install screws (10) and lockwashers (11).
5. Install the brake pedal activated/deactivated switch (4):
a. Align the brake pedal activated/deactivated switch (4) with its attachment point on the
bracket (12).
b. Install crews (8) and washers (9).
c. Connect connector S27.
d. Install a new cable tie (7).
6. Install the treadle valve (2). Refer to (b) Treadle Valve on page 14-21.
7. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
8. Place the battery master switch in the ‘ON’ position.

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 Braking System 14

9. Start the engine. Refer to 5.11 Starting on page 5-27.

10. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
11. Check for leaks.
12. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.
13. Adjust the cap screw (19, Figure 14.6) and nut (20, Figure 14.6) if removed / altered
during disassembly:
a. Adjust cap screw (18) to allow the treadle valve spool to fully release.
b. Torque tighten nut (17) to 24.4 -29.8 Nm (18-22lbf.ft).

(b) Treadle Valve

Numbers in parentheses refer to Figure 14.3, unless otherwise specified.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Tilt the hood. Refer to (5) Raising the Hood on page 16-38.
3. Place the battery master switch in the ‘OFF’ position.
4. Install the treadle valve (2):
a. Align the valve (2) with the pedal assembly (3).
b. Support the valve (2) and install cap screws (5) and washers (6).
c. Torque tighten the cap screws (5) to 24.4-29.8 Nm (18-22 lbf.ft)
5. Connect the hoses:
a. Position suitable containers under hose ends and Remove caps from all disconnected
hose ends.
b. Remove plugs from all disconnected treadle valve (2) ports.
c. If removed, install the reducers (50), tees (49), elbows (48) and adaptors (47, Refer
to Figure 14.1) to the treadle valve (2).
d. Connect diagnostic hose (42, Refer to Figure 14.1) at Port A1.
e. Connect hose (17, Refer to Figure 14.1) at Port A1.
f. Connect diagnostic hose (41, Refer to Figure 14.1) at Port A2.
g. Connect hose (14, Refer to Figure 14.1) at Port A2.
h. Connect hose (12, Refer to Figure 14.1) at Port P1.
i. Connect hose (13, Refer to Figure 14.1) at Port P2.
j. Connect hose (36, Refer to Figure 14.1) at Port T1.
k. Connect hose (37, Refer to Figure 14.1) at Port T2.
l. Connect hose (27, Refer to Figure 14.1) at Port PP.
6. Lower the hood. Refer to (6) Lowering the Hood on page 16-39.
7. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
8. Place the battery master switch in the ‘ON’.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Bleed the brake system. Refer to (7) Bleeding the Service Brakes on page 14-61.
11. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.

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14 Braking System

12. Check for leaks.

13. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(7) Hose Removal

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service brake pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.

(a) Treadle Valve Pedal Assembly to Hydraulic Tank Hoses

NOTICE
• Hose (36) routes from port T1 of the treadle valve (1) to the hydraulic tank and hose (37)
routes from port T2 of the treadle valve (1) to the hydraulic tank.
• The procedure to remove both hoses is similar. The procedure for hose (36) is detailed
below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (36).
9. Note the installed route of hose (36).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (36) at the treadle valve (1):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Disconnect hose (36) from elbow (48).
c. Drain any trapped oil.
d. Remove elbow (48) from port T1.
e. Install cap to end of hose (36).

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 Braking System 14

f. Install cap to port T1.

g. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
12. Disconnect the hose (36) at the hydraulic tank:
a. Disconnect hose (36) from elbow (48).
b. Drain any trapped oil.
c. Remove elbow (48) from port.
d. Install cap to end of hose (36).
e. Install cap to port.
13. As necessary, remove any straps, clamps, etc securing hose (36).
14. Lift the hose (36) from its installed position.
15. Move the hose (36) to a clean maintenance area.

(b) Main Hydraulic Valve to Treadle Valve Pedal Assembly Hoses

NOTICE
• Hose (13) routes from port B1 of the main hydraulic valve (2) to port P2 of the treadle
valve (1) and hose (12) routes from port B2 of the main hydraulic valve (2) to port P1
of the treadle valve (1).
• The procedure to remove both hoses is similar. The procedure for hose (13) is detailed
below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (13).
9. Note the installed route of hose (13).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (13) at the treadle valve (1):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Disconnect hose (13) from elbow (48).
c. Drain any trapped oil.
d. Remove elbow (48) from port P2.
e. Install cap to end of hose (13).
f. Install cap to port P2.
g. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
12. Disconnect the hose (13) at the main hydraulic valve (2):
a. Disconnect hose (13) from adaptor (47).
b. Drain any trapped oil.

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14 Braking System

c. Remove adaptor (47) from port B1.

d. Install cap to end of hose (13).
e. Install cap to port B1.
13. As necessary, remove any straps, clamps, etc securing hose (13).
14. Lift the hose (13) from its installed position.
15. Move the hose (13) to a clean maintenance area.

(8) Hose Installation

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all ORFS connections to (7) O-Ring Face Seals (ORFS) on page 11-24.

(a) Treadle Valve Pedal Assembly to Hydraulic Tank Hoses

NOTICE
• Hose (36) routes from port T1 of the treadle valve (1) to the hydraulic tank and hose (37)
routes from port T2 of the treadle valve (1) to the hydraulic tank.
• The procedure to install both hoses is similar. The procedure for hose (36) is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Install hose (36) to route noted during removal.
6. Position suitable containers under both hose ends.

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 Braking System 14

7. Connect the hose (36) at the treadle valve (1):

a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Remove cap from port T1.
c. Install elbow (48) to port T1.
d. Remove cap from end of hose (36).
e. Connect hose (36) to elbow (48).
f. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
8. If necessary,
9. Connect the hose (36) at the hydraulic tank:
a. Remove cap from port.
b. Install elbow (48) to port.
c. Remove cap from end of hose (36).
d. Connect hose (36) to elbow (48).
10. As necessary, install any straps, clamps, etc securing hose (36).
11. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
12. Place the battery master switch in the ‘ON’ position.
13. Start the engine. Refer to 5.11 Starting on page 5-27.
14. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
15. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
16. Check for leaks.
17. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(b) Main Hydraulic Valve to Treadle Valve Pedal Assembly Hoses

NOTICE
• Hose (13) routes from port B1 of the main hydraulic valve (2) to port P2 of the treadle
valve (1) and hose (12) routes from port B2 of the main hydraulic valve (2) to port P1
of the treadle valve (1).
• The procedure to install both hoses is similar. The procedure for hose (13) is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Install hose (13) to route noted during removal.
6. Position suitable containers under both hose ends.
7. Connect the hose (13) at the treadle valve (1):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.

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14 Braking System

b. Remove cap from port P2.

c. Install elbow (48) to port P2.
d. Remove cap from end of hose (13).
e. Connect hose (13) to elbow (48).
f. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
8. Connect the hose (13) at the main hydraulic valve (2):
a. Remove cap from port B1.
b. Install adaptor (47) to port B1.
c. Remove cap from end of hose (13).
d. Connect hose (13) to adaptor (47).
9. As necessary, install any straps, clamps, etc securing hose (13).
10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
14. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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 Braking System 14

14.3 Service Brakes

(1) Description and Operation

34
35

MOT5401

Figure 14.11 - Oil Cooled Disc Brake Assembly and Installation

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14 Braking System

1. Brake Housing 13. Screws 25. Stop Ring

2. O-rings 14. Brake Piston 26. Screws
3. Sealing Holder 15. U-ring 27. O-ring
4. O-ring 16. Support ring 28. O-ring
5. Seal slide ring 17. U-ring 29. Plug
6. Screw neck 18. Support ring 30. O-ring
7. O-ring 19. Guide Ring 31. Hub Carrier
8. Vent Valve 20. Friction Disks 32. Bolts
9. Plug 21. Reaction Disks 33. Washers
10. O-ring 22. Clutch Disk 34. Pins
11. Anchor Plate 23. Guide Ring 35. Pins
12. O-ring 24. Cup Springs

The service brakes are of the enclosed, forced oil cooled multiple disc type. The service brakes
are actuated by hydraulic oil as specified in (1) Recommended Lubricants on page 4-16.
Multiple discs within the brake assemblies are cooled by brake cooling oil from the cooling
system. Refer to 18.2 Brake Cooling on page 18-4.
The OCDB assembly is bolted to the stub axle and houses a sandwich of friction discs splined
to a hub rotor. There are five friction discs (20) in each brake assembly.
When the treadle valve is actuated, hydraulic oil enters the brake assembly and forces the brake
piston (14) against the rotating friction discs (20) which react with stationary reaction discs (21).
The reaction discs (21) are retained by scalloped tangs at the outside diameter, which in turn
transfers the reaction torque to the rigid outside housing (1), slowing or stopping wheel rotation.
In an emergency situation, application of the park/ emergency valve will actuate the service
brakes and the parking brake to bring the machine to a halt. In this condition, a restriction in
the 'Px' line from the brake manifold valve will slow oil flow from the parking brake allowing the
service brakes to actuate momentarily ahead of the parking brake.
When the treadle valve or park/emergency brake is released, hydraulic pressure against piston
(14) is relieved and cup springs (24) force the piston (14) to return to its original position, thus,
relieving the pressure against the brake disc pack.

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 Braking System 14

(2) Removal and Disassembly

Numbers in parentheses refer to Figure 14.11, unless otherwise specified.

� 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.

� CAUTION
• Hydraulic fluid pressure will remain within the braking system after engine shut down.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the braking system or serious injury could result.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• The procedure to remove and disassemble the front, centre and rear axle OCDB is similar.
The procedure for the front axle LHS OCDB is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
5. Ensure the pressure in the braking system has been dissipated.
6. Gain access to the work area.
7. Drain the Differential Drive Head.
8. Drain the OCDB.
9. Disconnect or remove hose (15). Refer to (b) Service Brakes Front Axle Hoses on page
14-43.
10. Remove hose (16). Refer to (c) Remote Bleed Hoses on page 14-44.
11. Disconnect or remove cooling system hoses (6 and 7, Refer to Figure 18.3). Refer to
18.1 Description on page 18-2.
12. Remove the axle group (hub). Refer to (2) Removal and Disassembly on page 9-110.
13. Separate the sealing holder (3) from the brake housing (1) (refer to Figure 14.12):
a. Remove two hex headed screws (13).
b. Install adjusting screws 15501167 (ST1) to the two free threads to aid with removal.
c. Remove the remaining screws (13).
d. Using suitable lifting equipment, separate and lift the sealing holder (3) from the brake
housing (1).

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14 Braking System

ST1

13

MOT05385

Figure 14.12 - Sealing Holder Separation from Figure 14.13 - Sealing Holder Disassembly
Brake Housing
1. Brake Housing 3. Sealing Holder 3. Sealing Holder 4. O-ring
13. Screws ST1 Adjusting Screws 5. Seal Slide Ring ST2 Resetting
Device

14. Disassemble the sealing holder (3) (Refer to Figure 14.13):

a. Using resetting device 15270132 (ST2), leaver the slide ring seal (5) out of the holder
(3).
b. Remove and discard the O-ring (4) from the holder (3).
15. Remove the disc set, consisting of the friction discs (20), reaction discs (21) and clutch disc
(22) from the brake housing (1). Refer to Figure 14.14.

11
ST1 ST1
ST3

20,21,22 1
MOT05386 MOT05387

Figure 14.14 - Disc Set Removal Figure 14.15 - Brake Housing Seperation
1. Brake Housing 20. Friction Discs 1. Brake Housing 11. Anchor Plate
21. Reaction Discs 22. Clutch Disc ST1 Adjusting ST3 Eyebolts
Screws
ST1 Adjusting
Screws

16. Remove the brake housing (1) from the anchor plate (11) (refer to Figure 14.15):
a. Install eyebolts 15270115 (ST3) to the brake housing (1).
b. Using suitable lifting equipment and the eyebolts (ST3) and lifting tackle 15501170
(ST4) , remove the brake housing (1) from the anchor plate (11).
c. Remove the eyebolts (ST3) from the brake housing (1).

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 Braking System 14

d. Remove the adjusting screws (ST1) from the anchor plate (11).
e. Remove and discard O-ring (12).
17. Remove the stop ring (25) from the brake piston (14) (refer to Figure 14.16 and Figure
14.17):
a. Remove the screws (26).
b. Using resetting device (ST2), press out the stop ring (25) from the brake piston (14).

MOT05405 MOT05406
Figure 14.16 - Stop Ring Removal Figure 14.17 - Stop Ring Removal
14. Brake Piston 25. Stop Ring 14. Brake Piston 25. Stop Ring
26. Screws

18. Using compressed air, separate the piston (14) from the brake housing (1). Refer to
Figure 14.18.
19. Remove the cup spring assembly (24).
20. Disassemble the brake housing (1) (refer to Figure 14.19):
a. Remove the guide ring (19).
b. Remove the U-ring (17) and support ring (18).
c. Remove the U-ring (15) and support ring (16).
d. Remove the guide ring (23).
e. Remove and discard the O-rings (2).
f. Remove the plug (9).
g. Remove and discard O-ring (10).

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14 Braking System

14

19
18
1 17
15
16
23
9 1

MOT05383 SM-3975

Figure 14.18 - Brake Piston Separation Figure 14.19 - Brake Housing

1. Brake Housing 14. Brake Piston 1. Brake Housing 9. Plug
15. U-ring 16. Support Ring
17. U-ring 18. Support Ring
19. Guide Ring 23. Guide Ring

21. Remove the hub carrier (31) from the anchor plate (11) (refer to Figure 14.20, Figure 14.21
and Figure 14.22):
a. Remove two bolts (32) and washers (33).
b. Install adjusting screws (ST1) to the two free threads to aid with removal.
c. Remove bolts (32) and washers (33).
d. Install eyebolts (ST3) to the hub carrier (31).
e. Using suitable lifting equipment and the eyebolts (ST3) and lifting tackle (ST4), remove
the hub carrier (31) from anchor plate (11).
f. Remove eyebolts (ST3) from the hub carrier (31).
g. Remove and discard O-ring (27) from anchor plate (11).
h. Remove and discard O-ring (28) from hub carrier (31).

ST1 ST1

ST3

11
31
27
33
32
31

MOT05407
Figure 14.20 - Hub Carrier Removal Figure 14.21 - Hub Carrier Separation
11. Anchor Plate 31. Hub Carrier 27. O-ring 31. Hub Carrier
32. Bolts 33. Washers ST1 Adjusting ST3 Eyebolts
Screws
ST1 Adjusting
Screws

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 Braking System 14

22. Separate anchor plate (11) from axle housing (refer to Figure 14.23):
a. Install eyebolts (ST3) to the anchor plate (11).
b. Using suitable lifting equipment and the eyebolts (ST3) and lifting tackle (ST4), lift the
anchor plate (11) off adjusting screws (ST1) and away from the axle housing.
c. Remove the adjusting screws (ST1) from the axle housing.
d. Remove the vent valve (8) and screw neck (6).
e. Remove and discard the O-ring (7).
f. Remove the pins (34 and 35) from the axle housing.

ST3
ST1
28

31

11

MOT05389

Figure 14.22 - Remove O-ring from Hub CarrierFigure 14.23 - Separate Anchor Plate from Axle
Housing
28. O-ring 31. Hub Carrier 11. Anchor Plate ST1 Adjusting
Screws
ST3 Eyebolts

23. Move the OCDB component parts to a clean maintenance area.

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14 Braking System

(3) Assembly and Installation

Numbers in parentheses refer to Figure 14.11, unless otherwise specified.

� 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.

� CAUTION
• Hydraulic fluid pressure will remain within the braking system after engine shut down.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the braking system or serious injury could result.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• Tighten all the fasteners to the standard torques listed in Standard Bolt and Nut Torque
Specifications section. Refer to 22.3 Standard Bolt and Nut Torque Specifications on page
22-5.
• The procedure to assemble and install the front, centre and rear axle OCDB is similar. The
procedure for the front axle LHS OCDB is detailed below.

PROCEDURE
1. Place the battery master switch in the ‘OFF’ position.
2. Prepare a clean and dry working area.
3. Gain access to the work area.
4. Install the anchor plate (11) flush to the axle housing (refer to Figure 14.24):
a. Apply Loctite 574 to the mounting face of the axle housing.
b. Install the adjusting screws 15501167 (ST1) to the axle housing.
c. Install the eyebolts 15270115 (ST3) to the anchor plate (11).
d. Using suitable lifting equipment and the eyebolts (ST3) and lifting tackle (ST4), lift the
anchor plate (11) onto adjusting screws (ST1) and flush to the axle housing.

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 Braking System 14

ST3
ST1
28

31

11

MOT05389

Figure 14.24 - Install Anchor Plate to Axle Housing Figure 14.25 - Install O-ring on Hub Carrier
11. Anchor Plate ST1 Adjusting Screws 28. O-ring 31. Hub Carrier
ST3 Eyebolts

5. Install the hub carrier (31) to the anchor plate (11) (refer to Figure 14.25, Figure 14.26,
Figure 14.27, Figure 14.28 and Figure 14.29):
a. Apply grease to new O-rings (27 and 28).
b. Install the O-ring (28) to hub carrier (31).
c. Apply Loctite 574 to the mounting face of the anchor plate (11).
d. Install the O-ring (27) to anchor plate (11).
e. Install the eyebolts (ST3) to the hub carrier (31).
f. Using suitable lifting equipment and the eyebolts (ST3) and lifting tackle (ST4), lift the
hub carrier (31) onto adjusting screws (ST1) and flush to the anchor plate (11).
g. Remove the eyebolts (ST3) from the hub carrier (31).
h. Apply grease to pins (34 and 35) and install with slots in direction of force.
i. Remove the adjusting screws (ST1).
j. Apply adhesive 15500690 to bolts (32).
k. Install the washers (33) and bolts (32). Torque tighten bolts (32) to 460 Nm (339 Ibf ft).

ST1 ST1

ST3

11
31
27
33
32
31

MOT05407

Figure 14.26 - Hub Carrier Installation Figure 14.27 - Hub Carrier Installation to Anchor
Plate
27. O-ring 31. Hub Carrier 11. Anchor Plate 31. Hub Carrier
ST1 Adjusting ST3 Eyebolts 32. Bolts 33. Washers
Screws
ST1 Adjusting
Screws

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14 Braking System

31
32
34 34 32
35 34,35
35
34,35

31
A

Figure 14.28 - Pin Installation Figure 14.29 - Anchor Plate and Hub Carrier
Installation
31. Hub Carrier 32. Bolts 11. Anchor Plate 31. Hub Carrier
34. Pins 35. Pins 32. Bolts 34. Pins
A Direction of 35. Pins
Force

6. Install the axle group (hub). Refer to (4) Assembly and Installation on page 9-114.
7. Adjust the wheel bearing rolling moment. Refer to 9.5 Axle Group/Hub on page 9-109.
8. Remove the axle group (hub). Refer to (2) Removal and Disassembly on page 9-110.
9. Assemble the brake housing (1) (refer to Figure 14.30):
a. Using spirit, clean the annular grooves of the brake housing.
b. Install guide ring (23), with the gap at the top.
c. Install U-ring (15) and support ring (16).
d. Install U-ring (17) and support ring (18).
e. Install guide ring (19), with the gap at the top.
f. Apply Loctite 415 to the ends of the guide rings (23 and 19).

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 Braking System 14

14

19
18
17 1

15
16
23
9 1

SM-3975 MOT05383

Figure 14.30 - Brake Housing Figure 14.31 - Brake Piston Installation

1. Brake Housing 9. Plug 1. Brake Housing 14. Brake Piston
15. U-ring 16. Support Ring
17. U-ring 18. Support Ring
19. Guide Ring 23. Guide Ring

10. Install the cup spring assembly (24).

11. Install the piston (14) into the brake housing (1) (refer to Figure 14.31 and Figure 14.32):
a. Apply oil to the U-rings (15 and 17), support rings (16 and 18) and guide rings (19
and 23).
b. Align the piston (14) with the brake housing (1).
c. Install the sliding pads 15501171 (ST5), two armed puller 15501172 (ST6) and support
shim 15501173 (ST7).
d. Using sliding pads (ST5), two armed puller (ST6) and support shim (ST7); press the
piston (14) into the brake housing (1) until contact is obtained.
e. Remove the sliding pads (ST5), two armed puller (ST6) and support shim (ST7).

Figure 14.32 - Brake Piston Installation Tools

12. Install the stop ring (25) into the brake piston (14) (refer to Figure 14.33 and Figure 14.34):
a. Using resetting device (ST2), press the stop ring (25) into the brake piston (14).
b. Install the screws (26). Torque tighten to 34 Nm (25 lbf.ft)
c.

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14 Braking System

MOT05406 MOT05405
Figure 14.33 - Stop Ring Installation Figure 14.34 - Stop Ring Installation
14. Brake Piston 25. Stop Ring 14. Brake Piston 25. Stop Ring
26. Screws

13. Install the brake housing (1) to the anchor plate (11) (refer to Figure 14.35):
a. Apply grease to new O-rings (2, 10 and 12).
b. Install the O-rings (2) to the brake housing (1).
c. Install the O-ring (10) to the brake housing (1).
d. Install the plug (9) to the brake housing (1).
e. Torque tighten the plug (9) to 60 Nm ( lbf.ft).
f. Install the O-ring (12) to the brake housing (1).
g. Install eyebolts 15270115 (ST3) to the brake housing (1).
h. Using suitable lifting equipment and the eyebolts (ST3) and lifting tackle 15501170
(ST4) , install the brake housing (1) flush to the anchor plate (11).
i. Remove the eyebolts (ST3) from the brake housing (1).
j. Temporarily install three hex headed screws (13) finger tight to hold the brake housing
(1) to the anchor plate (11).
14. Install the disc set, consisting of the friction discs (20), reaction discs (21) and clutch disc
(22) to the brake housing (1) (refer to Figure 14.36):
a. Mount the Spline Mandrel 15501176 (ST8) to the hub carrier (31).
b. Install the clutch disc (22) over the spline mandrel (ST8).
c. Starting with a reaction disc (21), install alternatively a reaction disc (21) and friction
disc (20) five times over the spline mandrel (ST8).

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 Braking System 14

ST1
11
ST1 ST8

ST3
20,21,22

11
1
14
1 3
13
MOT05387 SM - 3977
Figure 14.35 - Brake Housing Installation Figure 14.36 - Disc Set Installation
1. Brake Housing 11. Anchor Plate 1. Brake Housing 20. Friction Discs
ST1 Adjusting ST3 Eyebolts 21. Reaction 22. Clutch Disc
Screws Discs
ST1 Adjusting ST8 Spline
Screws Mandrel

15. Check the disc clearance (refer to Figure 14.37):

a. Using a depth vernier gauge, measure and record dimension X between the mounting
face of the brake housing (1) and the outermost reaction disc (21).
b. Using a depth vernier gauge, measure and record dimension Y between the mounting
face of the sealing holder (3) and the inner face of the sealing holder (3).
c. Subtract dimension Y from dimension X to determine the clearance.
» The clearance for new discs is 1.6+/–0.3 mm and worn discs is 4.1 mm.
d. If the clearance is acceptable proceed to Step 16.. If the clearance is unacceptable
replace the outermost reaction disc (21) and repeat Step 15 .

Figure 14.37 - Disc Clearance Figure 14.38 - Sealing Holder Assembly

1. Brake Housing 3. Sealing Holder 3. Sealing Holder 4. O-ring
11. Anchor Plate 14. Brake Piston 5. Seal Slide Ring ST2 Resetting
Device
20. Friction Discs 21. Reaction Discs
22. Clutch Disc

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14 Braking System

16. Assemble the sealing holder (3) (refer to Figure 14.38):

a. Grease new O-ring (4).
b. Install the O-ring (4) to the holder (3).
c. Grease new slide ring seal (5).
d. Using resetting device 15270132 (ST2), install the slide ring seal (5) into the holder (3).
17. Install the sealing holder (3) to the brake housing (1) (refer to Figure 14.39 and Figure
14.40):
a. Remove the temporarily installed hex headed screws (13).
b. Apply Loctite 574 to the mounting face of the brake housing (1).
c. Using suitable lifting equipment, align the sealing holder (3) with the brake housing (1).
d. Install the hex headed screws (13).
e. Remove the adjusting screws (ST1) from the anchor plate (11).
f. Install the two remaining hex headed screws (13).
g. Torque tighten the screws (13) to 390 Nm (288 lbf.ft).
h. Remove the Spline Mandrel (ST8) from the hub carrier (31).

ST1

13
ST8

11
1 11
3
ST8 1
13 3

Figure 14.39 - Sealing Holder Installation to Brake Figure 14.40 - OCDB Installed
Housing
1. Brake Housing 3. Sealing Holder 1. Brake 3. Sealing Holder
Housing
11. Anchor Plate 13. Screws 11. Anchor Plate 13. Screws
ST1 Adjusting ST8 Spline Mandrel ST8 Spline
Screws Mandrel

18. Install the axle group (hub). Refer to (4) Assembly and Installation on page 9-114.
19. Connect or Install cooling system hoses (6 and 7, Refer to Figure 18.3).
20. Connect or Install hose (15). Refer to (b) Service Brakes Front Axle Hoses on page 14-52.
21. Install hose (16). Refer to (c) Remote Bleed Hoses on page 14-53.
22. Fill the Differential Drive Head.
23. Fill the OCDB.
24. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
25. Place the battery master switch in the ‘ON’ position.
26. Start the engine. Refer to 5.11 Starting on page 5-27.
27. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.

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 Braking System 14

28. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
29. Check for leaks.
30. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(4) Special Tools

The following special tools are used to remove, disassemble, assemble and install the OCDB.
ST Terex Trucks Part Number Description
ST1 15501167 Adjusting Screws
ST2 15270132 Resetting Device
ST3 15270115 Eyebolts
ST4 Lifting Tackle
ST5 15501171 Sliding Pads
ST6 15501172 Two Armed Puller
ST7 15501173 Support Shims
ST8 15501176 Spline Mandrel

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14 Braking System

(5) Hose Removal

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service brake pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.

(a) Service Brakes Tractor Supply Hose

NOTICE
• Hose (14) routes from port A2 of the treadle valve (1) to the front axle manifold block (7).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (14).
9. Note the installed route of hose (14).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (14) at the valve (1):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Disconnect hose (14) from T-piece (49).
c. Drain any trapped oil.
d. Install cap to end of hose (14).
e. Install cap to T-piece (49).
f. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
12. Disconnect the hose (14) at the front axle manifold block (7):
a. Disconnect hose (14) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from port.
d. Install cap to end of hose (14).
e. Install cap to port.

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 Braking System 14

13. As necessary, remove any straps, clamps, etc securing hose (14).
14. Lift the hose (14) from its installed position.
15. Move the hose (14) to a clean maintenance area.

(b) Service Brakes Front Axle Hoses

NOTICE
• Hoses (15) route from the front axle manifold block (7) to the front axle service brakes.
• The procedure to remove the two hoses is similar.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Gain access to the work area.
7. Identify and tag hose (15).
8. Note the installed route of hose (15).
9. Position suitable containers under both hose ends.
10. Disconnect the hose (15) at the service brake:
a. Disconnect hose (15) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from service brake.
d. Install cap to end of hose (15).
e. Install cap to service brake port.
11. Disconnect the hose (15) at the front axle manifold block (7):
a. Disconnect hose (15) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from port.
d. Install cap to end of hose (15).
e. Install cap to port.
12. As necessary, remove any straps, clamps, etc securing hose (15).
13. Lift the hose (15) from its installed position.
14. Move the hose (15) to a clean maintenance area.

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(c) Remote Bleed Hoses

NOTICE
• Hoses (16) are installed to the front service brakes.
• The procedure to remove the two hoses is similar.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Gain access to the work area.
7. Identify and tag hose (16).
8. Note the installed route of hose (16).
9. Position suitable containers under both hose ends.
10. Disconnect the hose (16) at the service brake:
a. Disconnect hose (16) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from service brake.
d. Install cap to end of hose (16).
e. Install cap to service brake port.
11. Lift the hose (16) from its installed position.
12. Move the hose (16) to a clean maintenance area.

(d) Service Brakes Tractor Supply Hose

NOTICE
• Hose (17) routes from port A1 of the treadle valve (1) to the tractor interface (8).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.

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 Braking System 14

8. Identify and tag hose (17).

9. Note the installed route of hose (17).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (17) at the treadle valve (1):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Disconnect hose (17) from T-piece (49).
c. Drain any trapped oil.
d. Install cap to end of hose (17).
e. Install cap to T-piece (49).
f. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
12. Disconnect the hose (17) at the tractor interface (8):
a. Disconnect hose (17) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from tractor interface (8).
d. Install cap to end of hose (17).
e. Install cap to tractor interface (8) port.
13. As necessary, remove any straps, clamps, etc securing hose (17).
14. Lift the hose (17) from its installed position.
15. Move the hose (17) to a clean maintenance area.

(e) Service Brakes Tractor Interface Hose

NOTICE
• Hose (18) routes from the tractor interface (8) to the trailer interface tube (19).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Gain access to the work area.
7. Identify and tag hose (18).
8. Position suitable containers under both hose ends.
9. Disconnect the hose (18) at the tractor interface (8):
a. Disconnect hose (18).
b. Drain any trapped oil.
c. Install cap to end of hose (18).
d. Install cap to tractor interface (8).
10. Disconnect the hose (18) at tube (19):
a. Disconnect hose (18).
b. Drain any trapped oil.
c. Install cap to end of hose (18).

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14 Braking System

d. Install cap to tube (19) end.

11. Remove the straps (96).
12. Loosen the clamp (103) and split bush (104) by loosening the bolt (105) and washer (106).
13. Pull the hose (18) from the sleeve (97).
14. Move the hose (18) to a clean maintenance area.

(f) Service Brakes Trailer Supply Tube

NOTICE
• Tube (19) routes from the tractor interface hose (18) to the hose (20).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.
3. Stop the engine. Refer to 5.12 Stopping on page 5-28.
4. Place the battery master switch in the ‘OFF’ position.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Remove the cover.
9. Identify and tag tube (19).
10. Position suitable containers under both tube ends.
11. Disconnect hose (18) from tube (19):
a. Disconnect hose (18).
b. Drain any trapped oil.
c. Install cap to end of hose (18).
d. Install cap to end of tube (19).
12. Disconnect hose (20) from tube (19):
a. Disconnect hose (20).
b. Drain any trapped oil.
c. Install cap to end of hose (20).
d. Install cap to end of tube (19).
13. Loosen the clamps (108) and split bush (109) by loosening the bolts (111) and nuts (110).
14. Lift the tube (19) from its installed position.
15. Move the tube (19) to a clean maintenance area.

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 Braking System 14

(g) Service Brakes Centre Axle Hoses

NOTICE
• Hose (20) routes from the trailer interface tube (19) to the center axle manifold block (9).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.
3. Stop the engine. Refer to 5.12 Stopping on page 5-28.
4. Place the battery master switch in the ‘OFF’ position.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Identify and tag hose (20).
9. Note the installed route of hose (20).
10. Position suitable containers under both hose ends.
11. Disconnect hose (20) from tube (19):
a. Disconnect hose (20).
b. Drain any trapped oil.
c. Install cap to end of hose (20).
d. Install cap to end of tube (19).
12. Disconnect the hose (20) at the center axle manifold block (9):
a. Disconnect hose (20) from T-piece (49).
b. Drain any trapped oil.
c. Install cap to end of hose (20).
d. Install cap to T-piece (49).
13. As necessary, remove any straps, clamps, etc securing hose (20).
14. Lift the hose (20) from its installed position.
15. Move the hose (20) to a clean maintenance area.

(h) Centre Axle Manifold Block to Centre Axle Service Brake Hoses

NOTICE
• Hose (21) route from the centre axle manifold block (9) to the LH centre axle service
brake and hose (22) route from the centre axle manifold block (9) to the RH centre axle
service brake
• The procedure to remove the two hoses is similar. The procedure for hose (21) is detailed
below.

PROCEDURE

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14 Braking System

1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.
3. Stop the engine. Refer to 5.12 Stopping on page 5-28.
4. Place the battery master switch in the ‘OFF’ position.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Identify and tag hose (21).
9. Note the installed route of hose (21).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (21) at the service brake:
a. Disconnect hose (21) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from service brake.
d. Install cap to end of hose (21).
e. Install cap to service brake port.
12. Disconnect the hose (21) at the centre axle manifold block (9):
a. Disconnect hose (21) from connector (51).
b. Drain any trapped oil.
c. Remove connector (51) from port.
d. Install cap to end of hose (21).
e. Install cap to port.
13. As necessary, remove any straps, clamps, etc securing hose (21).
14. Lift the hose (21) from its installed position behind the LHS brake guard (87).
15. Move the hose (21) to a clean maintenance area.

(i) Service Brakes Trailer Supply Hose to Rear Axle Manifold Block

NOTICE
• Hose (23) routes from the center axle manifold block (9) to the rear axle manifold block (10).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.
3. Stop the engine. Refer to 5.12 Stopping on page 5-28.
4. Place the battery master switch in the ‘OFF’ position.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Identify and tag hose (23).

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 Braking System 14

9. Note the installed route of hose (23).

10. Position suitable containers under both hose ends.
11. Disconnect the hose (23) at the center axle manifold block (9):
a. Disconnect hose (23) from T-piece (49).
b. Drain any trapped oil.
c. Install cap to end of hose (23).
d. Install cap to T-piece (49).
12. Disconnect the hose (23) at the rear axle manifold block (10):
a. Disconnect hose (23) from connector (51).
b. Drain any trapped oil.
c. Install cap to end of hose (23).
d. Install cap to connector (51).
13. As necessary, remove any straps, clamps, etc securing hose (23).
14. Lift the hose (23) from its installed position.
15. Move the hose (23) to a clean maintenance area.

(j) Service Brakes Rear Axle Hoses

NOTICE
• Hose (24) route from the rear axle manifold block (10) to the LH rear axle service brake and
hose (25) route from the rear axle manifold block (10) to the RH rear axle service brake.
• The procedure to remove the two hoses is similar. The procedure for hose (24) is detailed
below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.
3. Stop the engine. Refer to 5.12 Stopping on page 5-28.
4. Place the battery master switch in the ‘OFF’ position.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Identify and tag hose (24).
9. Note the installed route of hose (24).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (24) at the service brake:
a. Disconnect hose (24) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from service brake.
d. Install cap to end of hose (24).
e. Install cap to service brake port.
12. Disconnect the hose (24) at the rear axle manifold block (10):

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14 Braking System

a. Disconnect hose (24) from connector (51).

b. Drain any trapped oil.
c. Remove connector (51) from port.
d. Install cap to end of hose (24).
e. Install cap to port.
13. As necessary, remove any straps, clamps, etc securing hose (24).
14. Lift the hose (24) from its installed position behind the LHS brake guard (87).
15. Move the hose (24) to a clean maintenance area.

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 Braking System 14

(6) Hose Installation

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all ORFS connections to (7) O-Ring Face Seals (ORFS) on page 11-24.

(a) Service Brakes Tractor Supply Hose

NOTICE
• Hose (14) routes from port A2 of the treadle valve (1) to the front axle manifold block (7).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Install hose (14) to route noted during removal.
6. Position suitable containers under both hose ends.
7. Connect the hose (14) at the valve (1):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Remove cap from T-piece (49).
c. Remove cap from end of hose (14).
d. Connect hose (14) to T-piece (49).
e. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
8. Connect the hose (14) at the front axle manifold block (7):
a. Remove cap from port.
b. Install adaptor (47) to port.
c. Remove cap from end of hose (14).

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14 Braking System

d. Connect hose (14) to adaptor (47).

9. As necessary, install any straps, clamps, etc securing hose (14).
10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
14. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(b) Service Brakes Front Axle Hoses

NOTICE
• Hoses (15) route from the front axle manifold block (7) to the front axle service brakes.
• The procedure to install the two hoses is similar.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (15) to route noted during removal.
5. Position suitable containers under both hose ends.
6. Connect the hose (15) at the service brake:
a. Remove cap from service brake port.
b. Install adaptor (47) to service brake.
c. Remove cap from end of hose (15).
d. Connect hose (15) to adaptor (47).
7. Connect the hose (15) at the front axle manifold block (7):
a. Remove cap from port.
b. Install adaptor (47) to port.
c. Remove cap from end of hose (15).
d. Connect hose (15) to adaptor (47).
8. As necessary, install any straps, clamps, etc securing hose (15).
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.

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 Braking System 14

12. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
13. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
14. Check for leaks.
15. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(c) Remote Bleed Hoses

NOTICE
• Hoses (16) are installed to the front service brakes.
• The procedure to install the two hoses is similar.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (16) to route noted during removal.
5. Position suitable containers under both hose ends.
6. Connect the hose (16) at the service brake:
a. Remove cap from service brake port.
b. Install adaptor (47) to service brake.
c. Remove cap from end of hose (16).
d. Connect hose (16) to adaptor (47).
7. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
11. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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14 Braking System

(d) Service Brakes Tractor Supply Hose

NOTICE
• Hose (17) routes from port A1 of the treadle valve (1) to the tractor interface (8).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Install hose (17) to route noted during removal.
6. Position suitable containers under both hose ends.
7. Connect the hose (17) at the treadle valve (1):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Remove cap from T-piece (49).
c. Remove cap from end of hose (17).
d. Connect hose (17) to T-piece (49).
e. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
8. Connect the hose (17) at the tractor interface (8):
a. Remove cap from tractor interface (8) port.
b. Install adaptor (47) to tractor interface (8).
c. Remove cap from end of hose (17).
d. Connect hose (17) to adaptor (47).
9. As necessary, install any straps, clamps, etc securing hose (17).
10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
14. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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 Braking System 14

(e) Service Brakes Tractor Interface Hose

NOTICE
• Hose (18) routes from the tractor interface (8) to the trailer interface tube (19).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (18) to route noted during removal.
5. Push the hose (18) through the sleeve (97).
6. Position suitable containers under both hose ends.
7. Connect the hose (18) at the tractor interface (8):
a. Remove cap from tractor interface (8).
b. Remove cap from end of hose (18).
c. Connect hose (18) to tractor interface (8).
8. Connect the hose (18) at tube (19):
a. Remove cap from tube (19) end.
b. Remove cap from end of hose (18).
c. Connect hose (18) to tube (19).
9. Tighten the clamp (103) and split bush (104) by tightening the bolt (105) and washer (106).
10. Install the straps (96).
11. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
12. Place the battery master switch in the ‘ON’ position.
13. Start the engine. Refer to 5.11 Starting on page 5-27.
14. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
15. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
16. Check for leaks.
17. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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14 Braking System

(f) Service Brakes Trailer Supply Tube

NOTICE
• Tube (19) routes from the tractor interface cantilever hose (18) to the tube (20).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (18) to route noted during removal.
5. Position suitable containers under both tube ends.
6. Connect hose (18) to tube (19):
a. Remove cap from end of tube (19).
b. Remove cap from end of hose (18).
c. Connect hose (18).
7. Connect hose (20) to tube (19):
a. Remove cap from end of tube (19).
b. Remove cap from end of hose (20).
c. Connect hose (20).
8. Tighten the clamps (108) and split bush (109) by tightening the bolts (111) and nuts (110).
9. Install the cover. Refer to.
10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
14. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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 Braking System 14

(g) Service Brakes Centre Axle Hoses

NOTICE
• Hose (20) routes from the trailer interface tube (19) to the center axle manifold block (9).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (20) to route noted during removal.
5. Position suitable containers under both hose ends.
6. Connect hose (20) to tube (19):
a. Remove cap from end of hose (20).
b. Remove cap from end of tube (19).
c. Connect hose (20).
7. Connect the hose (20) at the center axle manifold block (9):
a. Remove cap from T-piece (49).
b. Remove cap from end of hose (20).
c. Connect hose (20) to T-piece (49).
8. As necessary, install any straps, clamps, etc securing hose (20).
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
13. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
14. Check for leaks.
15. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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14 Braking System

(h) Centre Axle Manifold Block to Centre Axle Service Brake Hoses

NOTICE
• Hose (21) route from the centre axle manifold block (9) to the LH centre axle service
brake and hose (22) route from the centre axle manifold block (9) to the RH centre axle
service brake
• The procedure to install the two hoses is similar. The procedure for hose (21) is detailed
below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (21) to route noted during removal.
5. Position suitable containers under both hose ends.
6. Connect the hose (21) at the service brake:
a. Remove cap from service brake port.
b. Install adaptor (47) to service brake.
c. Remove cap from end of hose (21).
d. Connect hose (21) to adaptor (47).
7. Connect the hose (21) at the centre axle manifold block (9):
a. Remove cap from port.
b. Install connector (51) to port.
c. Remove cap from end of hose (21).
d. Connect hose (21) to connector (51).
8. As necessary, install any straps, clamps, etc securing hose (21).
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
13. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
14. Check for leaks.
15. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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 Braking System 14

(i) Service Brakes Trailer Supply Hose to Rear Axle Manifold Block

NOTICE
• Hose (23) routes from the center axle manifold block (9) to the rear axle manifold block (10).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (23) to route noted during removal.
5. Position suitable containers under both hose ends.
6. Connect the hose (23) at the center axle manifold block (9):
a. Remove cap from T-piece (49).
b. Remove cap from end of hose (23).
c. Connect hose (23) to T-piece (49).
7. Connect the hose (23) at the rear axle manifold block (10):
a. Remove cap from connector (51).
b. Remove cap from end of hose (23).
c. Connect hose (23) to connector (51).
8. As necessary, install any straps, clamps, etc securing hose (23).
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
13. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
14. Check for leaks.
15. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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14 Braking System

(j) Service Brakes Rear Axle Hoses

NOTICE
• Hose (24) route from the rear axle manifold block (10) to the LH rear axle service brake and
hose (25) route from the rear axle manifold block (10) to the RH rear axle service brake.
• The procedure to install the two hoses is similar. The procedure for hose (24) is detailed
below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (24) to route noted during removal.
5. Position suitable containers under both hose ends.
6. Connect the hose (24) at the service brake:
a. Remove cap from service brake port.
b. Install adaptor (47) to service brake port.
c. Remove cap from end of hose (24).
d. Connect hose (24) to adaptor (47).
7. Connect the hose (24) at the rear axle manifold block (10):
a. Remove cap from port.
b. Install connector (51) to port.
c. Remove cap from end of hose (24).
d. Connect hose (24) to connector (51).
8. As necessary, install any straps, clamps, etc securing hose (24).
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
13. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
14. Check for leaks.
15. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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 Braking System 14

(7) Bleeding the Service Brakes

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.

PROCEDURE
1. Prepare a clean and dry working area.
2. Place the battery master switch in the ‘ON’ position.
3. Start the engine. Refer to 5.11 Starting on page 5-27.
4. Bleed the rear left hand (LH) service brake:
a. Locate a bucket of clean oil under the service brake.
b. Fit a clear hose to the breather and submerge the other end of the hose in a bucket of
clean oil.
c. While the operator is operating the foot pedal, undo the breather using a suitable ring
spanner or a special socket.
d. Allow oil to flow through the hose and into the bucket until it runs clear but NOT aerated.
e. Close the breather.
f. Stop operating the foot pedal.
g. Repeat steps c. to f. a further eight times until NO air is visible when the breather is
opened.
h. Remove the hose from the breather.
i. Torque tighten the breather to 18 Nm (32 lbf ft).
5. Repeat Step 4. to bleed the rear right hand (RH) service brake.
6. Repeat Step 4. to bleed the centre LH service brake.
7. Repeat Step 4. to bleed the centre RH service brake.
8. Repeat Step 4. to bleed the front LH service brake.
9. Repeat Step 4. to bleed the front RH service brake.
10. Bleed the parking brake. Refer to (9) Bleeding the Parking Brake on page 14-110.
11. Stop the engine. Refer to 5.12 Stopping on page 5-28.
12. Place the battery master switch in the ‘OFF’ position.

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14 Braking System

14.4 Accumulators
(1) Description

19

20 21 22 23 24

1
2
3

14
13
7
17
9
18 8

5
6 9
15
8

16

12
11

6
5 12
11
5
6

10

6
4
5

MOT05412

Figure 14.41 - Accumulator Installation

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 Braking System 14

1. Top Cover 9. Washers 17. D-Clamp

2. Bolts 10. Bottom Mounting Frame 18. Accumulator
3. Washers 11. Cap Nuts 19. Charging Valves
4. Side Cover 12. Washers 20. Cap
5. Bolts 13. D-Clamp 21. Valve Core
6. Washers 14. Accumulator 22. Locknut
7. Top Mounting Frame 15. D-Clamp 23. O-ring
8. Cap Nuts 16. Accumulator 24. Valve Body

14 8
9
10
15
12
13
12

11

7
6
4

3 5
2

MOT05413

Figure 14.42 - Exploded View of Typical Accumulator Assembly

1. Accumulator Assembly 6. O-ring 11. Piston
2. Charging Valve 7. Back-up Washer 12. O-ring
3. O-ring 8. End Cap 13. Back-up Washer
4. Gas Cap 9. O-ring 14. Screws
5. Cylinder 10. Back-up Washer 15. Bracket

Numbers in parentheses refer to Figure 14.42, unless otherwise specified.

There are three accumulators mounted on the exhaust cradle located at the rear of the cab;
one for the front brake system and one for the rear. The front and rear brake accumulators are
supplemented by a third (primary) accumulator. Refer to Figure 14.41.
The primary accumulator supports the service brake system and the body pilot pressure
system. All three accumulators are of the piston type. Each accumulator consists of a charging
valve assembly (2), end cap (8), cylinder (5) and piston (11).
Charging valve (19) is equipped with a locking feature. Loosening locknut (22, Figure 14.41)
will open the valve so that the charge can be checked or the accumulator charged.

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14 Braking System

The piston (11) acts as a separator dividing the cylinder (5) into two sections. The top section
nearest the charging valve (2) contains the nitrogen charge. Hydraulic oil from the main
hydraulic pump flows through check valves in the main hydraulic valve and into the bottom
section of the accumulators.
Accumulator pressure is monitored by pressure switches located in the main hydraulic valve,
which send a signal to illuminate warning lights in the dash panel when the pressure drops
below 122 bar (1 769 psi). The warning lights will remain illuminated until the pressure rises
above 135 bar (1 958 psi).

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 Braking System 14

(2) Removal
Numbers in parentheses refer to Figure 14.41, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.
• Accumulators are charged with Nitrogen. To prevent personal injury and property damage
do not attempt to remove or disassemble until all Nitrogen pressure is completely relieved.

NOTICE
• The procedure to remove all three accumulators is similar. The procedure for Accumulator
number 1 is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Remove the top cover (1):
a. Remove the bolts (2) and washers (3).
b. Separate the top cover (1) from the top mounting frame (7).
9. Depressurize the accumulator. Refer to (7) Discharging on page 14-72.
10. Remove the side cover (4):
a. Support the side cover (4).
b. Remove the bolts (5) and washers (6).
c. Separate the side cover (4) from the top mounting frame (7) and bottom mounting
frame (10).
11. Disconnect the hose (refer to Figure 14.1):
a. Identify and tag the hose (29) connected to accumulator (4).
b. Position a suitable container under hose end.

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14 Braking System

c. Disconnect hose (29).

d. Remove the reducer (50), tee (49) and elbow (48).
e. Install a cap to the disconnected hose end.
12. Attach suitable lifting equipment to the accumulator (16) and take an initial strain.
13. Remove the accumulator (16):
a. Support the accumulator (16).
b. Remove the nuts (8) and washers (9) securing the accumulator (16) to the top mounting
frame (7).
c. Remove the D-clamp (13).
d. Remove the cap nuts (11) and washers (12).
e. Using standard lifting equipment, lift the accumulator (16) from the bottom mounting
frame (10).
f. Install a plug to disconnected accumulator (16) port.
14. Move the accumulator (16) to a clean maintenance area.
Further disassembly should only be done by a vendor approved workshop.

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 Braking System 14

(3) Disassembly
Numbers in parentheses refer to Figure 14.42, unless otherwise specified.

� CAUTION
• Accumulators are charged with Nitrogen. To prevent personal injury and property damage
do not attempt to remove or disassemble until all Nitrogen pressure is completely relieved.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• The procedure to disassemble all three accumulators is similar. The procedure for
Accumulator number 1 is detailed below.

PROCEDURE
1. Prepare a clean and dry working area.
2. Position the accumulator horizontally either on a work bench secured with a strap wrench
or place in a vice.
3. Check that the Nitrogen pressure is completely discharged.
4. Remove the bracket (15):
a. Remove the screws (14).
b. Separate the bracket (15) from the end cap (8).
5. Remove the charge valve (3):
a. Remove the charging valve (3).
b. Remove and discard O-ring (4).
6. Remove the gas cap (5):
a. Fit screws into threaded holes of gas cap (5).
b. Place a long bar between the screws.
c. Using the bar, remove the gas cap (5) from the tube (6).
d. Remove and discard O-ring (7) and back-up washer (8) taking care not to damage
the gas cap (5) groves.
7. Remove the hydraulic cap (9):
a. Fit screws into threaded holes of hydraulic cap (9).
b. Place a long bar between the screws.
c. Using the bar, remove the hydraulic cap (9) from the tube (6).
d. Remove and discard O-ring (10) and back-up washer (11) taking care not to damage
the hydraulic cap (9) groves.
8. Remove the piston (12):
a. Using a soft-faced bar from the hydraulic cap (9) end of the tube (6), push on the
piston (12) until out of the tube (6).
b. Remove and discard O-ring (13) and back-up washers (14) taking care not to damage
the piston (12) groves.

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14 Braking System

(4) Inspection
Numbers in parentheses refer to Figure 14.42, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.

PROCEDURE
1. Prepare a clean and dry working area.
2. Wash all metal components with a suitable solvent and thoroughly air dry.
3. Inspect the piston (12) for cracks or burrs. Replace the piston (12) if it is excessively scored
or worn.
4. Use an inspection lamp to check the bore of the tube (6) 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. Renew the complete
accumulator assembly if the inside of the bore (6) is excessively scored or worn.
5. Inspect the threads in the gas and hydraulic caps (5 and 9) and the threads in the tube (6)
for damage. Renew all parts worn or damaged beyond repair.

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 Braking System 14

(5) Assembly
Numbers in parentheses refer to Figure 14.42, unless otherwise specified.

� CAUTION
• Accumulators are charged with Nitrogen. To prevent personal injury and property damage
do not attempt to remove or disassemble until all Nitrogen pressure is completely relieved.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• The procedure to assemble all three accumulators is similar. The procedure for Accumulator
number 1 is detailed below.

PROCEDURE
1. Prepare a clean and dry working area.
2. Position the accumulator horizontally either on a work bench secured with a strap wrench
or place in a vice.
3. Install the piston (12):
a. Install new O-rings (13) and back-up washer (14) taking care not to damage the piston
(12) groves.
b. Using a soft-faced bar from the hydraulic cap (9) end of the tube (6), push the piston
(12) into the tube (6).
4. Install the hydraulic cap (9):
a. Install new O-ring (10) and back-up washer (11) taking care not to damage the
hydraulic cap (9) groves.
b. Fit screws into threaded holes of hydraulic cap (9).
c. Place a long bar between the screws.
d. Using the bar, install the hydraulic cap (9) to the tube (6).
5. Install the gas cap (5):
a. Install new O-ring (7) and back-up washer (8) taking care not to damage the gas cap
(5) groves.
b. Fit screws into threaded holes of gas cap (5).
c. Place a long bar between the screws.
d. Using the bar, install the gas cap (5) to the tube (6).
6. Install the charge valve (3):
a. Install a new O-ring (4).
b. Install the charge valve (3).
7. Install the bracket (15):
a. Align the bracket (15) with the end cap (8).
b. Install the screws (14).

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14 Braking System

(6) Installation
Numbers in parentheses refer to Figure 14.41, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to the standard torques listed in Standard Bolt and Nut Torque
Specifications section. Refer to 22.3 Standard Bolt and Nut Torque Specifications on page
22-5.
• The procedure to install all three accumulators is identical. The procedure for Accumulator
number 1 is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Attach suitable lifting equipment to the accumulator (16).
5. Install the accumulator (16):
a. Remove plug from accumulator (16) port.
b. Using standard lifting equipment, lift the accumulator (16) onto the bottom mounting
frame (10).
c. Support the accumulator (16).
d. Install the cap nuts (11) and washers (12).
e. Install the D-clamp (15).
f. Install the nuts (8) and washers (9) securing the accumulator (16) to the top mounting
frame (7).
6. Connect the hose (refer to Figure 14.1):
a. Position a suitable container under hose end.
b. Install the reducer (50), tee (49) and elbow (48).
c. Remove cap from disconnected hose end.
d. Connect hose (29).
7. Install the side cover (4):
a. Align the side cover (4) with the top (7) and bottom (10) mounting frames.

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 Braking System 14

b. Support the side cover (4)

c. Install the bolts (5) and washers (6).
8. Charge the accumulator. Refer to (8) Charging on page 14-73.
9. Install the top cover (1):
a. Align the plate (1) with the top mounting frame (7).
b. Install the bolts (2) and washers (3).
10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Bleed the brake system. Refer to (7) Bleeding the Service Brakes on page 14-61.
14. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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14 Braking System

(7) Discharging
Numbers in parentheses refer to Figure 14.41, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service break pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.
• Accumulators are charged with Nitrogen. To prevent personal injury and property damage
do not attempt to remove or disassemble until all Nitrogen pressure is completely relieved.

NOTICE
• The procedure to discharge all three accumulators is identical. The procedure for
Accumulator number 1 is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
5. Ensure the pressure in the braking system has been dissipated.
6. Gain access to the work area.
7. Gain access to the charging valve (19):
a. Locate the top cover (1).
b. Remove the bolts (2) and washers (3).
c. Separate the top cover (1) from the top mounting frame (7).
d. Locate the charging valve (19).
8. Discharge the Nitrogen:
a. Make sure that the charging valve (19) is closed internally by turning the locknut (22)
clockwise.
b. Remove the cap (20) and the core (21) from the charging valve (19).
c. Slowly turn the locknut (22) anticlockwise to open the charging valve (19).
d. Allow the Nitrogen to discharge.
9. Check that the Nitrogen has discharged. Refer to (a) Testing Nitrogen Pressure on page
14-76.

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 Braking System 14

(8) Charging
Numbers in parentheses refer to Figure 14.41, unless otherwise specified.

� WARNING
• To prevent personal injury and property damage, be sure the wheel chocks and lifting
equipment are properly secured and of adequate capacity to do the job safely.
• A high pressure nitrogen pressure regulator must be used with the charging assembly kit.
Failure to use pressure regulator could cause property damage, personal injury or death.

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service brake pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.
• Accumulators are charged with Nitrogen. To prevent personal injury and property damage
do not attempt to remove or disassemble until all Nitrogen pressure is completely relieved.
• Do not use oxygen or any gas other than nitrogen to charge an accumulator. Oxygen under
pressure coming into contact with oil or grease will cause a violent explosion. Always double
check to make sure you are using nitrogen to prevent personal injury and property damage.

NOTICE
• The procedure to charge all three accumulators is identical. The procedure for Accumulator
number 1 is detailed below.
• Either oil or water pumped nitrogen can be used to charge the accumulator. Both types
are readily available from a local compressed gas dealer.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
5. Ensure the pressure in the braking system has been dissipated.
6. Gain access to the work area.
7. Gain access to the charging valve (19):
a. Locate the top cover (1).
b. Remove the bolts (2) and washers (3).
c. Separate the top cover (1) from the top mounting frame (7).
d. Locate the charging valve (19).
8. Prepare the charging valve (19):
a. Remove the cap (20) from the charging valve (19).

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14 Braking System

b. Loosen the locknut (22) by turning it anticlockwise one to two turns.

9. Connect the charging line (1, refer to (10) Special Tools on page 14-79) to the charging
valve (19):
a. Connect the charging line (1, refer to (10) Special Tools on page 14-79) to the charging
valve (19).
b. Rotate the 'T' handle of the valve chuck (2, refer to (10) Special Tools on page 14-79)
anticlockwise until it stops.
c. Screw the swivel nut down on the charging valve (19)
10. Turn the 'T' handle of the valve chuck (2, refer to (10) Special Tools on page 14-79)
clockwise until the valve core (21) is depressed.
11. Check the bleeder valve (10, refer to (10) Special Tools on page 14-79) is tight and does
not leak.
12. , Check that the cylinder valve (4, refer to (10) Special Tools on page 14-79) and tank valve
(6, refer to (10) Special Tools on page 14-79) are closed.
13. Using the gland nut (8, refer to (10) Special Tools on page 14-79) connect the charging
assembly kit to the Nitrogen bottle/tank/supply. If necessary, use the cylinder adapter
(9, refer to (10) Special Tools on page 14-79) to connect the charging assembly kit to
the Nitrogen bottle/tank/supply.
14. , Open the tank valve (6, refer to (10) Special Tools on page 14-79) slowly.
» The pressure gauge (5, refer to (10) Special Tools on page 14-79) will register the
Nitrogen bottle/tank/supply pressure.
15. Slowly open the cylinder valve (4, refer to (10) Special Tools on page 14-79) and charge
the accumulator to 103 bar (1 494 psi) at 20 °C (68 °F) ambient temperature, closing the
valve occasionally. The pressure gauge (5, refer to (10) Special Tools on page 14-79)
will register the charge pressure.
» The charge pressure should be 103 bar (1 494 psi) at 20 °C (68 °F) ambient temperature.
Refer to(5) Accumulator Safety on page 2-22 for the nitrogen pressures at ambient
temperatures of other than 20 °C (68 °F).
16. Check the Nitrogen charge pressure:
a. Close the tank valve (6, refer to (10) Special Tools on page 14-79).
b. Open the bleeder valve (10, refer to (10) Special Tools on page 14-79) momentarily to
relieve the pressure between the Nitrogen bottle/tank/supply and pressure gauge (5,
refer to (10) Special Tools on page 14-79).
» This will allow the pressure gauge (5, refer to (10) Special Tools on page 14-79)
needle to settle and provide an accurate charge pressure.
17. Repeat steps 14 thru 16 until the correct pressure for the ambient temperature has been
reached.
18. Close the cylinder valve (4, refer to (10) Special Tools on page 14-79).
19. Close the tank valve (6, refer to (10) Special Tools on page 14-79).
20. Dissipate the pressure gauge (5, refer to (10) Special Tools on page 14-79) pressure:
a. Open the bleeder valve (10, refer to (10) Special Tools on page 14-79).
b. Allow the Nitrogen to discharge.
c. Close the bleeder valve (10, refer to (10) Special Tools on page 14-79) after the
pressure is relieved.
21. Disconnect the charging assembly kit from the Nitrogen bottle/tank/supply.
22. Disconnect the charging line (1, refer to (10) Special Tools on page 14-79) from the
charging valve (5):

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 Braking System 14

a. Turn the 'T' handle of the valve chuck (2, refer to (10) Special Tools on page 14-79)
anticlockwise to release the valve core (7).
b. Screw the swivel nut of the valve chuck (2, refer (10) Special Tools on page 14-79)
off the charging valve (5)
c. Rotate the 'T' handle of the valve chuck (2, refer to (10) Special Tools on page 14-79)
clockwise until it stops to disconnect the charging line (1, refer to (10) Special Tools on
page 14-79) from the charging valve (5).
23. Prepare the charging valve (19):
a. Tighten the locknut (22) on the charging valve (19) to 11 Nm (100 lbf in).
b. Check the charging valve (19). Refer to (b) Testing Charge Valve for Leakage on
page 14-77.
c. Install the cap (20) on the charging valve (19) and tighten it finger tight.
24. Install the top cover (1):
a. Align the plate (1) with the top mounting frame (7).
b. Install the bolts (2) and washers (3).

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14 Braking System

(9) Maintenance
Inspect each accumulator for leaks. If leaks are found, disassemble and replace all O-rings and
seals. Inspect all hydraulic hoses for wear and leaks. Renew/tighten hoses as required.
(a) Testing Nitrogen Pressure
Numbers in parentheses refer to Figure 14.41, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service break pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.
• Accumulators are charged with Nitrogen. To prevent personal injury and property damage
do not attempt to remove or disassemble until all Nitrogen pressure is completely relieved.

NOTICE
• The procedure to test the Nitrogen charge pressure is similar for all accumulators. The
procedure for Accumulator number 1 is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
5. Ensure the pressure in the braking system has been dissipated.
6. Gain access to the work area.
7. Gain access to the charging valve (19):
a. Locate the top cover (1).
b. Remove the bolts (2) and washers (3).
c. Separate the top cover (1) from the top mounting frame (7).
d. Locate the charging valve (19).
8. Prepare the charging valve (19):
a. Remove the cap (20) from the charging valve (19).
b. Loosen the locknut (22) by turning it anticlockwise one to two turns.
9. Connect the charging line (1, refer to (10) Special Tools on page 14-79) to the charging
valve (5):

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 Braking System 14

a. Connect the charging line (1, refer to (10) Special Tools on page 14-79) to the charging
valve (5).
b. Rotate the 'T' handle of the valve chuck (2, refer to (10) Special Tools on page 14-79)
anticlockwise until it stops.
c. Screw the swivel nut down on the charging valve (5)
10. Turn the 'T' handle of the valve chuck (2, refer to (10) Special Tools on page 14-79)
clockwise until the valve core (7) is depressed.
11. Check the bleeder valve (10, refer to (10) Special Tools on page 14-79) is tight and does
not leak.
12. , Check that the cylinder valve (4, refer to (10) Special Tools on page 14-79) and tank valve
(6, refer to (10) Special Tools on page 14-79) are closed.
13. To read the accumulator Nitrogen charge pressure, slowly open the cylinder valve (4, refer
to (10) Special Tools on page 14-79). The pressure gauge (5, refer to (10) Special Tools on
page 14-79) will register the charge pressure.
» The charge pressure should be 103 bar (1 494 psi) at 20 °C (68 °F) ambient temperature.
Refer to(5) Accumulator Safety on page 2-22 for the nitrogen pressures at ambient
temperatures of other than 20 °C (68 °F).
14. Close the cylinder valve (4, refer to (10) Special Tools on page 14-79).
15. Dissipate the pressure gauge (5, refer to (10) Special Tools on page 14-79) pressure:
a. Open the bleeder valve (10, refer to (10) Special Tools on page 14-79).
b. Allow the Nitrogen to discharge.
c. Close the bleeder valve (10, refer to (10) Special Tools on page 14-79) after the
pressure is relieved.
16. If the Nitrogen charge pressure is correct, disconnect the charging line (1, refer to (10)
Special Tools on page 14-79) from the charging valve (5):
a. Turn the 'T' handle of the valve chuck (2, refer to (10) Special Tools on page 14-79)
anticlockwise to release the valve core (7).
b. Screw the swivel nut of the valve chuck (2, refer (10) Special Tools on page 14-79)
off the charging valve (5)
c. Rotate the 'T' handle of the valve chuck (2, refer to (10) Special Tools on page 14-79)
clockwise until it stops to disconnect the charging line (1, refer to (10) Special Tools on
page 14-79) from the charging valve (5).
17. If the Nitrogen charge pressure is incorrect:
a. Leave the charging line (1, refer to (10) Special Tools on page 14-79) and valve chuck
(2, refer to (10) Special Tools on page 14-79) attached to the charging valve (5).
b. Charge the accumulator. Refer to (8) Charging on page 14-73.
18. Prepare the charging valve (19):
a. Tighten the locknut (22) on the charging valve (19) to 11 Nm (100 lbf in).
b. Check the charging valve (19). Refer to (b) Testing Charge Valve for Leakage on
page 14-77.
c. Install the cap (20) on the charging valve (19) and tighten it finger tight.
19. Install the top cover (1):
a. Align the plate (1) with the top mounting frame (7).
b. Install the bolts (2) and washers (3).

(b) Testing Charge Valve for Leakage

Numbers in parentheses refer to Figure 14.41, unless otherwise specified.

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14 Braking System

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service brake pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.
• Accumulators are charged with Nitrogen. To prevent personal injury and property damage
do not attempt to remove or disassemble until all Nitrogen pressure is completely relieved.

NOTICE
• The procedure to test the charging valves (5) is similar for all three accumulators. The
procedure for Accumulator number 1 is detailed below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
5. Ensure the pressure in the braking system has been dissipated.
6. Gain access to the work area.
7. Gain access to the charging valve (19):
a. Locate the top cover (1).
b. Remove the bolts (2) and washers (3).
c. Separate the top cover (1) from the top mounting frame (7).
d. Locate the charging valve (19).
8. Remove the cap (20) from the charging valve (19).
9. Loosen the locknut (22).
10. Coat the open end of the charging valve (19) with soapy water. Bubbles indicate a leaky
valve core (21).
11. Attempt to reset the valve core (21) by depressing and releasing it quickly once or twice.
12. Recheck for leakage.
If leakage continues, discharge the accumulator. Refer to (7) Discharging on page 14-72.
13. Replace the valve core (21).
14. Tighten the locknut (22) to 11 Nm (100 lbf in).
15. Replace the cap (20) finger tight.

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 Braking System 14

(10) Special Tools

A special tool, the charging kit assembly is used to:
• Charge the accumulator.
• Check the accumulator charge (nitrogen) pressure.

Figure 14.43 - Charging Kit Assembly

1. Line 5. Pressure Gauge 9. Cylinder Adaptor
2. Valve Chuck 6. Tank Valve 10. Bleeder Valve
3. Valve Extension 7. Gland Fitting
4. Cylinder Valve 8. Gland Nut

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14 Braking System

(11) Hose Removal

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service brake pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.

(a) Accumulator to Main Hydraulic Valve Hoses

NOTICE
• Hose (29) routes from accumulator 1 (4) to port ACC1 of the main hydraulic valve (2), hose
(30) routes from accumulator 2 (5) to port ACC2 of the main hydraulic valve (2) and hose
(31) routes from accumulator 3 (6) to port ACC3 of the main hydraulic valve (2).
• The procedure to remove the three hoses is similar. The procedure for hose (29) is detailed
below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Depressurize the accumulator. Refer to (7) Discharging on page 14-72.
7. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
8. Gain access to the work area.
9. Identify and tag hose (29).
10. Note the installed route of hose (29).
11. Position suitable containers under both hose ends.
12. Disconnect the hose (29) at the accumulator (4):
a. Disconnect hose (29) from reducer (50).
b. Drain any trapped oil.
c. Remove reducer (50), T-piece (49) and elbow (48).
d. Install cap to end of hose (29).
e. Install cap to accumulator port.
13. Disconnect the hose (29) at the main hydraulic valve (2):
a. Disconnect hose (29) from reducer (50).

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 Braking System 14

b. Drain any trapped oil.

c. Remove reducer (50), T-piece (49) and adaptor (47) from port ACC1.
d. Install cap to end of hose (29).
e. Install cap to port ACC1.
14. As necessary, remove any straps, clamps, etc securing hose (29).
15. Lift the hose (29) from its installed position.
16. Move the hose (29) to a clean maintenance area.

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14 Braking System

(12) Hose Installation

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all ORFS connections to (7) O-Ring Face Seals (ORFS) on page 11-24.

(a) Accumulator to Main Hydraulic Valve Hoses

NOTICE
• Hose (29) routes from accumulator 1 (4) to port ACC1 of the main hydraulic valve (2), hose
(30) routes from accumulator 2 (5) to port ACC2 of the main hydraulic valve (2) and hose
(31) routes from accumulator 3 (6) to port ACC3 of the main hydraulic valve (2).
• The procedure to install the three hoses is similar. The procedure for hose (29) is detailed
below.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Install hose (29) to route noted during removal.
6. Position suitable containers under both hose ends.
7. Connect the hose (29) at the accumulator (4):
a. Remove cap from accumulator port.
b. Install reducer (50), T-piece (49) and elbow (48).
c. Remove cap from end of hose (29).
d. Connect hose (29) to reducer (50).
8. Connect the hose (29) at the main hydraulic valve (2):

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 Braking System 14

a. Remove cap from port ACC1.

b. Install reducer (50), T-piece (49) and adaptor (47) to port ACC1.
c. Remove cap from end of hose (29).
d. Connect hose (29) to reducer (50).
9. As necessary, install any straps, clamps, etc securing hose (29).
10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
14. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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14 Braking System

14.5 Interlock Solenoid Valve

(1) Removal
Numbers in parentheses refer to Figure 14.1, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service break pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Tilt the hood. Refer to (5) Raising the Hood on page 16-38.
4. Place the battery master switch in the ‘OFF’ position.
5. Operate the service brake pedal continuously to relieve pressure in the hydraulic system.
6. Ensure the pressure in the braking system has been dissipated.
7. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
8. Disconnect the electrical connector:
a. Identify and tag connector.
b. Disconnect connector.
9. Disconnect the hoses:
a. Identify and tag all hoses connected to the valve (3).
b. Position suitable containers under hose ends.
c. Disconnect hose (27) at Port 1.
d. Disconnect hose (26) at Port 2.
e. Disconnect hose (28) at Port 3.
f. If necessary, remove the elbows (48) and adaptor (47) from the valve (3).
g. Install caps to all disconnected hose ends.
h. Install plugs to all disconnected valve (3) ports.
10. Remove the valve (3):
a. Note the installed position of valve (3).
b. Support the valve (3).
c. Remove the bolts (59), washers (60) and nuts (61).
d. Separate the valve (3) from bracket (58).
11. Move the valve (3) to a clean maintenance area.

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 Braking System 14

(2) Installation
Numbers in parentheses refer to Figure 14.1, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all fasteners to standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the hood. Refer to (5) Raising the Hood on page 16-38.
3. Place the battery master switch in the ‘OFF’ position.
4. Install the valve (3):
a. Align the valve (3) with the bracket (58).
b. Support the valve (3).
c. Install the bolts (59), washers (60) and nuts (61).
5. Connect the hoses:
a. Position suitable containers under hose ends.
b. Remove caps from all disconnected hose ends.
c. Remove plugs from all disconnected valve (3) ports.
d. If removed, install the elbows (48) and adaptor (47) to the valve (3).
e. Connect hose (27) at Port 1.
f. Connect hose (26) at Port 2.
g. Connect hose (28) at Port 3.
6. Connect electrical connector.
7. Place the battery master switch in the ‘ON’ position.
8. Lower the hood. Refer to (6) Lowering the Hood on page 16-39.
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
10. Start the engine. Refer to 5.11 Starting on page 5-27.

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14 Braking System

11. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
12. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
13. Check for leaks.
14. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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 Braking System 14

(3) Hose Removal

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service brake pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.

(a) Main Hydraulic Valve to Interlock Solenoid Valve Hose

NOTICE
• Hose (26) routes from port PBP of the main hydraulic valve (2) to port 2 of the interlock
solenoid valve (3).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (26).
9. Note the installed route of hose (26).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (26) at the valve (3):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Disconnect hose (26) from elbow (48).
c. Drain any trapped oil.
d. Remove elbow (48) from port 2.
e. Install cap to end of hose (26).
f. Install cap to port 2.
g. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
12. Disconnect the hose (26) at the main hydraulic valve (2):
a. Disconnect hose (26) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from port PBP.
d. Install cap to end of hose (26).

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14 Braking System

e. Install cap to port PBP.

13. As necessary, remove any straps, clamps, etc securing hose (26).
14. Lift the hose (26) from its installed position.
15. Move the hose (26) to a clean maintenance area.

(b) Interlock Solenoid Valve to Treadle Valve Pedal Assembly Hose

NOTICE
• Hose (27) routes from port 1 of the interlock solenoid valve (3) to port PP of the treadle
valve pedal assembly (1).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Gain access to the work area.
7. Identify and tag hose (27).
8. Note the installed route of hose (27).
9. Position suitable containers under both hose ends.
10. Disconnect the hose (27) at the valve (3):
a. Disconnect hose (27) from elbow (48).
b. Drain any trapped oil.
c. Remove elbow (48) from port 1.
d. Install cap to end of hose (27).
e. Install cap to port 1.
11. Disconnect the hose (27) at valve (1):
a. Disconnect hose (27) from elbow (48).
b. Drain any trapped oil.
c. Remove elbow (48) from port PP.
d. Install cap to end of hose (27).
e. Install cap to port PP.
12. As necessary, remove any straps, clamps, etc securing hose (27).
13. Lift the hose (27) from its installed position.
14. Move the hose (27) to a clean maintenance area.

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 Braking System 14

(c) Interlock Solenoid Valve to Hydraulic Tank Hose

NOTICE
• Hose (28) routes from port 3 of the interlock solenoid valve (3) to the hydraulic tank hose.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (28).
9. Note the installed route of hose (28).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (28) at the valve (3):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Disconnect hose (28) from adaptor (47).
c. Drain any trapped oil.
d. Remove adaptor (47) from port 3.
e. Install cap to end of hose (28).
f. Install cap to port 3.
g. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
12. Disconnect the hose (28) at the hydraulic tank:
a. Disconnect hose (28) from elbow (48).
b. Drain any trapped oil.
c. Remove elbow (48) from port.
d. Install cap to end of hose (28).
e. Install cap to port.
13. As necessary, remove any straps, clamps, etc securing hose (26).
14. Lift the hose (28) from its installed position.
15. Move the hose (28) to a clean maintenance area.

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14 Braking System

(4) Hose Installation

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all ORFS connections to (7) O-Ring Face Seals (ORFS) on page 11-24.

(a) Main Hydraulic Valve to Interlock Solenoid Valve Hose

NOTICE
• Hose (26) routes from port PBP of the main hydraulic valve (2) to port 2 of the interlock
solenoid valve (3).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Install hose (26) to route noted during removal. Position suitable containers under both
hose ends.
5. Connect the hose (26) at the valve (3):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Remove cap from port 2.
c. Install elbow (48) to port 2.
d. Remove cap from end of hose (26).
e. Connect hose (26) to elbow (48).
f. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
6. Connect the hose (26) at the main hydraulic valve (2):
a. Remove cap from port PBP.
b. Install adaptor (47) to port PBP.
c. Remove cap from end of hose (26).

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 Braking System 14

d. Connect hose (26) to adaptor (47).

7. As necessary, install any straps, clamps, etc securing hose (26).
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
9. Place the battery master switch in the ‘ON’ position.
10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
12. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
13. Check for leaks.
14. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(b) Interlock Solenoid Valve to Treadle Valve Pedal Assembly Hose

NOTICE
• Hose (27) routes from port 1 of the interlock solenoid valve (3) to port PP of the treadle
valve pedal assembly (1).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Install hose (27) to route noted during removal. Position suitable containers under both
hose ends.
4. Connect the hose (27) at the valve (3):
a. Remove cap from port 1.
b. Install elbow (48) to port 1.
c. Remove cap from end of hose (27).
d. Connect hose (27) to elbow (48).
5. Connect the hose (27) at valve (1):
a. Remove cap from port PP.
b. Install elbow (48) to port PP.
c. Remove cap from end of hose (27).
d. Connect hose (27) to elbow (48).
6. As necessary, install any straps, clamps, etc securing hose (27).
7. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.

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14 Braking System

11. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
12. Check for leaks.
13. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(c) Interlock Solenoid Valve to Hydraulic Tank Hose

NOTICE
• Hose (28) routes from port 3 of the interlock solenoid valve (3) to the hydraulic tank hose.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Install hose (28) to route noted during removal. Position suitable containers under both
hose ends.
5. Connect the hose (28) at the valve (3):
a. Lower the cab. Refer to (5) Lowering the Cab on page 19-14.
b. Remove cap from port 3.
c. Install adaptor (47) to port 3.
d. Remove cap from end of hose (28).
e. Connect hose (28) to adaptor (47).
f. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
6. Connect the hose (28) at the hydraulic tank:
a. Remove cap from port.
b. Install elbow (48) to port.
c. Remove cap from end of hose (28).
d. Connect hose (28) to elbow (48).
7. As necessary, install any straps, clamps, etc securing hose (26).
8. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
9. Place the battery master switch in the ‘ON’ position.
10. Start the engine. Refer to 5.11 Starting on page 5-27.
11. Bleed the service brakes. Refer to (7) Bleeding the Service Brakes on page 14-61.
12. Check for correct braking operation by driving the machine and applying the brakes several
times to purge air out of the system.
13. Check for leaks.
14. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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 Braking System 14

14.6 Parking Brake

(1) Description
The parking brake consists of the parking brake assembly (11) and brake disc (1).

11
RH FRAME RAIL

12

13
7
14
5 9

RH FRAME RAIL
BRACKET
7
9
9
6
10

4 3
3 2 8
1 9
LH FRAME RAIL
10
BRACKET

MOT05368

Figure 14.44 - Parking Brake Installation

1. Brake Disk 6. Torque Plate 11. Parking Brake Assembly
2. Bolt 7. Bolt 12. Accumulator
3. Washer 8. Clamp Plate 13. Reducer
4. Nut 9. Washer 14. Hose
5. Torque Plate 10. Locknut

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14 Braking System

11
27
20 19 6 5
7
8
25
17
16

18
2
9
14
13 1
3
12
26
21
24

28
23

4
22
10
24 15

MOT05369

Figure 14.45 - Parking Brake Assembly

1. Split Pin 11. Shaft 21. Journal Bearing
2. Chassis Pin 12. Spring Washer 22. Seal
3. Yoke 13. Washer 23. Brake Pads
4. Slack Adjuster 14. Packing 24. Grub Screws
5. Actuator 15. Piston 25. Bracket
6. Nuts 16. Bolts 26. Nut
7. Lock Washers 17. Washers 27. Shaft
8. Washers 18. Caliper 28. Adjustment Screw
9. Cap 19. Gasket
10. Circlip 20. Thrust Bearing

Numbers in parentheses refer to Figure 14.45, unless otherwise specified.

The main components of the parking brake are the slack adjuster (4), actuator (5), cap (9), shaft
(11), piston (15), caliper (18) and brake pads (23).
Operation of the parking brake is by the spring applied/hydraulically released actuator (5). The
actuator (5) is connected through a slack adjuster (4) to the power screw shaft (11) that is
screwed into the piston (15) in the calliper (15) head assembly. The calliper (18) head assembly
slides on torque plates bolted to brackets which are part of the trailer frame.
The parking brake is controlled by a push control on the right hand dash panel which when
selected activates the park brake solenoid valve on the main hydraulic valve, controlling oil
pressure from the brake system to the actuator (5). Selection of the push control releases oil
from the actuator (5) allowing internal springs in the actuator (5) to apply the parking brake.
De-selection of the push control and selecting the transmission gear, directs oil pressure from
the system to the actuator (5), compressing internal springs, to release the parking brake.

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 Braking System 14

In an emergency situation, application of the park/ emergency valve will actuate the service
brakes and the parking brake to bring the machine to a halt. In this condition, a restriction in
the 'PB' line will slow oil flow from the parking brake allowing the service brakes to actuate
momentarily ahead of the parking brake.
(2) Removal

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

Numbers in parentheses refer to Figure 14.44, unless otherwise specified.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the Body. Refer to (6) Raise the Body on page 21-8.
3. Install the steering lock. Refer to (1) Fit the Steering Lock on page 12-29.
4. Stop the engine. Refer to 5.12 Stopping on page 5-28.
5. Place the battery master switch in the ‘OFF’ position.
6. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
7. Ensure the pressure in the braking system has been dissipated.
8. Gain access to the work area.
9. Disconnect the hose:
a. Identify and tag hose (14) connected to the actuator (12).
b. Position suitable containers under the hose end.
c. Disconnect hose (14).
d. If necessary, remove reducer (13).
e. Install a caps to the disconnected hose (14) end.
f. Install a plug to the disconnected actuator (12) port.
10. Attach suitable lifting equipment to the parking brake assembly (11) and take an initial strain.
11. Remove the parking brake assembly (11):
a. Connect a portable hydraulic pump to the disconnected actuator (12) port.
b. Remove the nuts (10), washers (9) and bolts (7).
c. Separate the clamp plate (8) from the LH frame rail bracket.
d. Using the portable hydraulic pump, open the pads of the parking brake assembly (11)
e. Lift the parking brake assembly (11) with torque plates (5 and 6) vertically off the LH
and RH frame rail brackets until clear of the brake disc (1).
f. Separate the parking brake assembly (11) from the torque plates (5 and 6).
g. Disconnect the portable hydraulic pump from the actuator (12) port.

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14 Braking System

h. Install a plug to the disconnected actuator (12) port.

12. Move the parking brake assembly (11) to a clean maintenance area.
Further disassembly should only be done by a vendor approved workshop.
13. Remove the pivot point to centre axle driveline:
a. Locate the 8.5C pivot point to centre axle driveline (1, Refer to 8.2 Rear Drivelines
on page 8-10).
b. Remove the driveline. Refer to (2) Removal on page 8-11.
14. Remove the brake disc (1) from the yoke:
a. Support the brake disc (1).
b. Remove the nuts (4), washers (3) and bolts (2).
c. Separate the brake disc (1) from the yoke.
15. Move the brake disc (1) to a clean maintenance area.

(3) Disassembly
Numbers in parentheses refer to Figure 14.45, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.

PROCEDURE
1. Prepare a clean and dry working area.
2. Disconnect the slack adjuster (4) from actuator (5):
a. Remove the split pin (1).
b. Remove the chassis pin (2).
c. Separate the slack adjuster (4) from the yoke (3).
3. Remove the actuator (5):
a. Remove the nut (6), lock washer (7) and washer (8).
b. Separate the actuator (5) from the cap (9) bracket (25).
c. If necessary, remove the yoke (3) from the shaft (27) of the actuator (5).
4. Remove the slack adjuster (4):
a. Remove the circlip (10).
b. Pull the slack adjuster (4) off the shaft (11).
Further disassembly of the slack adjuster (4) should only be done by a vendor approved
workshop.
c. Remove and discard spring washer (12), washer (13) and packing (14).
5. Remove the cap (9), shaft (11) and piston (15) as a unit:
a. Remove the bolts (16) and washers (17).
b. Pull as a unit, the cap (9), shaft (11) and piston (15) from the caliper (18).
c. Remove and discard gasket (19).
d. Slide the shaft (11) and piston (15) from cap (9).
e. Screw piston (15) from end of shaft (11).
f. Remove and discard thrust bearing (20) from shaft (11).
g. If necessary, remove journal bearing (21) from cap (9).

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6. Remove and discard seal (22) from bore of caliper (18).

7. Remove the brake pads (23) from the caliper (18).

(4) Inspection
Numbers in parentheses refer to Figure 14.45, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.

PROCEDURE
1. Prepare a clean and dry working area.
2. Examine all parts carefully. Parts showing signs of excessive wear, damage or corrosion
should be replaced.
3. Clean all parts with denatured alcohol and either wipe dry with a clean lint free cloth
or blow dry with air.
4. Inspect the calliper (18) bore for scoring, pitting or corrosion. According to the severity
of wear or damage, light scores and stains may be removed. For more severe damage
renew as necessary.
5. Similarly, inspect items whose surfaces may be considered 'critical', for example the piston
(15) outer diameter and mating elements. Any such components whose damage will affect
operational performance or integrity of the system should be replaced where applicable.
6. Check journal bearing (21) for wear. Inside diameter (ID) of bearing (21) may not exceed
1.510 inches (38.35 mm). If ID exceeds 1.510 inches (38.35 mm) replace bearing (21).
7. Check to make sure that the slack adjuster (4) is still functioning properly.
8. Inspect the actuator (5) for damage or cracks. Renew the entire actuator (5), if the outer
housing, pull rod or hydraulic fitting are damaged, or if there is any leakage from the unit.

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14 Braking System

(5) Assembly
Numbers in parentheses refer to Figure 14.45, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• Tighten all fasteners to standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Prepare a clean and dry working area.
2. Install a new seal (22) to bore of caliper (18).
3. Install the brake pads (23) to the caliper (18).
4. Install the cap (9), shaft (11) and piston (15) as a unit:
a. If necessary, install journal bearing (21) to cap (9).
b. Apply grease as described in (1) Recommended Lubricants on page 4-16 to flat face of
new thrust bearing (20).
c. Install thrust bearing (20) over splined end of shaft (11) with greased face of thrust
bearing (20) against thrust collar of shaft (11).
d. Check thrust bearing (20) is installed correctly on shaft (11).
e. Apply grease as described in (1) Recommended Lubricants on page 4-16 to screw
threads at end of shaft (11).
f. Screw piston (15) to end of shaft (11).
g. Apply grease as described in (1) Recommended Lubricants on page 4-16 to outside
of piston (15).
h. Slide the shaft (11) and piston (15) into cap (9).
i. Install a new gasket (19).
j. Push as a unit, the cap (9), shaft (11) and piston (15) into the bore of caliper (18), taking
care not to dislodge the seal (22) installed to the bore of caliper (18).
k. Install the bolts (16) and washers (17).
l. Torque tighten the bolts (16) to 176.26–203.37 Nm (130–150 ft-lbs).
5. Install the actuator (5):
a. Check that the shaft (27) of the actuator (5) is in its fully released position.
b. If removed, install the yoke (3) with nut (26) to the shaft (27) of the actuator (5).
c. Align the actuator (5) with the cap (9) bracket (25).
d. Install new nuts (6), lock washers (7) and washers (8).
e. Torque tighten the nuts (6).
6. Install the slack adjuster (4):
a. Install a new packing (14), washer (13) and spring washer (12).
b. Apply grease as described in (1) Recommended Lubricants on page 4-16 to the spline
of slack adjuster (4).
c. Align the slack adjuster (4) with the shaft (11) so that the yoke (3) is aligned with the
hole in the arm of the slack adjuster (4).
d. Push the slack adjuster (4) onto the shaft (11) with the adjustment screw facing the
actuator (5).
e. Install the circlip (10).
7. Connect the slack adjuster (4) to the actuator (5):

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 Braking System 14

a. Align the yoke (3) with the hole in the arm of the slack adjuster (4). If necessary, adjust
the length of the yoke (3). Tighten nut (26).
b. Install the chassis pin (2).
c. Install the split pin (1).

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14 Braking System

(6) Installation
Numbers in parentheses refer to Figure 14.44, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to the standard torques listed in Standard Bolt and Nut Torque
Specifications section. Refer to 22.3 Standard Bolt and Nut Torque Specifications on page
22-5.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install the brake disk (1) to the yoke:
a. Align the brake disk (1) with the yoke.
b. Support the brake disk (1).
c. Install the bolts (2), washers (3) and nuts (4).
d. Torque tighten the bolts (2) to 70 Nm (52 lb.ft).
5. Install the pivot point to centre axle driveline. Refer to (6) Installation on page 8-14.
6. Attach suitable lifting equipment to the parking brake assembly (11).
7. Install the parking brake assembly (11):
a. Position the torque plate (5) on the RH frame rail bracket with the chamfer up.
b. Install the bolts (7), washers (9) and nuts (10).
c. Torque tighten the bolts (7) to 680 Nm (490 lb.ft).
d. Connect a portable hydraulic pump to the actuator (12) port.
e. Using the portable hydraulic pump, open the pads of the parking brake assembly (11)
f. Lower the parking brake assembly (11) vertically down over the brake disk (1) and
position the cutout in the RH side of the assembly with the torque plate (5).
g. Position the torque plate (6) on the LH frame rail bracket and into the cutout in the RH
side of the parking brake assembly (11).
h. Install the bolts (7) and washers (9).
i. Position the clamp plate (8) to the underside of the LH frame rail bracket.
j. Install the washers (9) and nuts (10).

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 Braking System 14

k. Finger tighten the bolts (7) and nuts (10).

l. Slide the parking brake assembly (11) against the torque plate (5).
m. Slide the torque plate (6) to achieve a gap of 0.635 mm (0.025 inches) between plate
(6) and the cutout in the RH side of the parking brake assembly (11).
n. Using feeler gauges, check the gap is 0.635 mm (0.025 inches).
o. Torque tighten the bolts (7) to 680 Nm (490 lb.ft).
p. Using the portable hydraulic pump, close the pads of the parking brake assembly (11)
q. Turn the adjustment screw (28, refer to Figure 14.45) clockwise until there is 0.75
mm gap both sides of the brake disk (1).
r. Using feeler gauges, check that there is a gap of 0.75 mm both sides of the brake
disk (1).
s. Disconnect the portable hydraulic pump from the actuator (12) port.
8. Connect the hose:
a. Remove cap from disconnected hose (14) end.
b. Remove plug from disconnected actuator (12) port.
c. Position suitable containers under the hose end.
d. If removed, install reducer (13).
e. Connect hose (14).
9. Place the battery master switch in the ‘ON’ position.
10. Remove the steering lock. Refer to (2) Stow the Steering Lock on page 12-29.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Bleed the parking brake. Refer to (9) Bleeding the Parking Brake on page 14-110.
13. Operate the parking brake several times.
14. Using feeler gauges, check that there is a gap between 0.35 – 0.5 mm both sides of the
brake disk (1).
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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14 Braking System

(7) Hose Removal

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• Hydraulic fluid pressure will remain within the braking system after engine shutdown.
Operate the service brake pedal continuously until the pressure has dissipated before
carrying out any work on the hydraulic system or serious injury could result.

(a) Parking Brake Tractor Supply Hose

NOTICE
• Hose (32) routes from port PB of the main hydraulic valve (2) to the tractor interface (8).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
7. Gain access to the work area.
8. Identify and tag hose (32).
9. Note the installed route of hose (32).
10. Position suitable containers under both hose ends.
11. Disconnect the hose (32) at the main hydraulic valve (2):
a. Disconnect hose (32) from adaptor (47).
b. Drain any trapped oil.
c. Remove adaptor (47) from port PB.
d. Install cap to end of hose (32).
e. Install cap to port PB.
12. Disconnect the hose (32) at the tractor interface (8):
a. Disconnect hose (32) from T-piece (49).
b. Drain any trapped oil.
c. Install cap to end of hose (32).
d. Install cap to T-piece (49).
13. As necessary, remove any straps, clamps, etc securing hose (32).
14. Lift the hose (32) from its installed position.

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 Braking System 14

15. Move the hose (32) to a clean maintenance area.

(b) Parking Brake Tractor Interface Hose

NOTICE
• Hose (33) routes from the tractor interface (8) to the trailer interface tube (34).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Stop the engine. Refer to 5.12 Stopping on page 5-28.
3. Place the battery master switch in the ‘OFF’ position.
4. Ensure the pressure in the braking system has been dissipated.
5. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
6. Gain access to the work area.
7. Identify and tag hose (33).
8. Position suitable containers under both hose ends.
9. Disconnect the hose (33) at the tractor interface (8):
a. Disconnect hose (33).
b. Drain any trapped oil.
c. Install cap to end of hose (33).
d. Install cap to tractor interface (8).
10. Disconnect the hose (33) at tube (34):
a. Disconnect hose (33).
b. Drain any trapped oil.
c. Install cap to end of hose (33).
d. Install cap to tube (34) end.
11. Remove the straps (96).
12. Loosen the clamp (103) and split bush (104) by loosening the bolt (105) and washer (106).
13. Pull the hose (33) from the sleeve (97).
14. Move the hose (33) to a clean maintenance area.

(c) Parking Brake Trailer Supply Tube

NOTICE
• Tube (34) routes from the tractor interface hose (33) to the hose (35).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.

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14 Braking System

3. Stop the engine. Refer to 5.12 Stopping on page 5-28.

4. Place the battery master switch in the ‘OFF’ position.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Remove the cover.
9. Identify and tag tube (34).
10. Position suitable containers under both tube ends.
11. Disconnect hose (33) from tube (34):
a. Disconnect hose (33).
b. Drain any trapped oil.
c. Install cap to end of hose (33).
d. Install cap to end of tube (34).
12. Disconnect hose (35) from tube (34):
a. Disconnect hose (35).
b. Drain any trapped oil.
c. Install cap to end of hose (35).
d. Install cap to end of tube (34).
13. Loosen the clamps (108) and split bush (109) by loosening the bolts (111) and nuts (110).
14. Lift the tube (34) from its installed position.
15. Move the tube (34) to a clean maintenance area.

(d) Parking Brake Trailer Supply Hose

NOTICE
• Hose (35) routes from the trailer interface tube (34) to the parking brake accumulator.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.
3. Stop the engine. Refer to 5.12 Stopping on page 5-28.
4. Place the battery master switch in the ‘OFF’ position.
5. Ensure the pressure in the braking system has been dissipated.
6. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
7. Gain access to the work area.
8. Identify and tag hose (35).
9. Note the installed route of hose (35).
10. Position suitable containers under both hose ends.
11. Disconnect hose (35) from tube (34):
a. Disconnect hose (35).

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 Braking System 14

b. Drain any trapped oil.

c. Install cap to end of hose (35).
d. Install cap to end of tube (34).
12. Disconnect the hose (35) at the parking brake actuator:
a. Disconnect hose (32) from reducer (50).
b. Drain any trapped oil.
c. Install cap to end of hose (32).
d. Install cap to reducer (50).
13. As necessary, remove any straps, clamps, etc securing hose (35).
14. Lift the hose (35) from its installed position.
15. Move the hose (35) to a clean maintenance area.

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14 Braking System

(8) Hose Installation

Numbers in parentheses refer to Figure 14.1 and Figure 14.2, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• Tighten all ORFS connections to (7) O-Ring Face Seals (ORFS) on page 11-24.

(a) Parking Brake Tractor Supply Hose

NOTICE
• Hose (32) routes from port PB of the main hydraulic valve (2) to the tractor interface (8).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. If necessary, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. Gain access to the work area.
5. Install hose (32) to route noted during removal.
6. Position suitable containers under both hose ends.
7. Connect the hose (32) at the main hydraulic valve (2):
a. Remove cap from port PB.
b. Install adaptor (47) to port PB.
c. Remove cap from end of hose (32).
d. Connect hose (32) to adaptor (47).
8. Connect the hose (32) at the tractor interface (8):
a. Remove cap from T-piece (49).
b. Remove cap from end of hose (32).
c. Connect hose (32) to T-piece (49).
9. As necessary, install any straps, clamps, etc securing hose (32).

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 Braking System 14

10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Bleed the parking brake. Refer to (9) Bleeding the Parking Brake on page 14-110.
14. Operate the parking brake several times.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(b) Parking Brake Tractor Interface Hose

NOTICE
• Hose (33) routes from the tractor interface (8) to the trailer interface tube (34).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (33) to route noted during removal.
5. Push the hose (33) through the sleeve (97).
6. Position suitable containers under both hose ends.
7. Connect the hose (33) at the tractor interface (8):
a. Remove cap from tractor interface (8).
b. Remove cap from end of hose (33).
c. Connect hose (33).
8. Connect the hose (33) at tube (34):
a. Remove cap from tube (34) end.
b. Remove cap from end of hose (33).
c. Connect hose (33).
9. Tighten the clamp (103) and split bush (104) by tightening the bolt (105) and washer (106).
10. Install the straps (96).
11. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
12. Place the battery master switch in the ‘ON’ position.
13. Start the engine. Refer to 5.11 Starting on page 5-27.
14. Bleed the parking brake. Refer to (9) Bleeding the Parking Brake on page 14-110.
15. Operate the parking brake several times.
16. Check for leaks.

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14 Braking System

17. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(c) Parking Brake Trailer Supply Tube

NOTICE
• Tube (34) routes from the tractor interface cantilever hose (33) to the tube (35).

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install tube (34) to route noted during removal.
5. Tighten the clamps (108) and split bush (109) by tightening the bolts (111) and nuts (110).
6. Position suitable containers under both tube ends.
7. Connect hose (33) to tube (34):
a. Remove cap from end of tube (34).
b. Remove cap from end of hose (33).
c. Connect hose (33).
8. Connect hose (35) to tube (34):
a. Remove cap from end of tube (34).
b. Remove cap from end of hose (35).
c. Connect hose (35).
9. Install the cover.
10. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
11. Place the battery master switch in the ‘ON’ position.
12. Start the engine. Refer to 5.11 Starting on page 5-27.
13. Bleed the parking brake. Refer to (9) Bleeding the Parking Brake on page 14-110.
14. Operate the parking brake several times.
15. Check for leaks.
16. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

(d) Parking Brake Trailer Supply Hose

NOTICE
• Hose (35) routes from the trailer interface tube (34) to the parking brake accumulator.

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 Braking System 14

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Install hose (35) to route noted during removal.
5. Position suitable containers under both hose ends.
6. Connect hose (35) to tube (34):
a. Remove cap from end of hose (35).
b. Remove cap from end of tube (34).
c. Connect hose (35).
7. Connect the hose (35) at the parking brake actuator (11):
a. Remove cap from reducer (50).
b. Remove cap from end of hose (32).
c. Connect hose (32) to reducer (50).
8. As necessary, install any straps, clamps, etc securing hose (35).
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Bleed the parking brake. Refer to (9) Bleeding the Parking Brake on page 14-110.
13. Operate the parking brake several times.
14. Check for leaks.
15. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.

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14 Braking System

(9) Bleeding the Parking Brake

Numbers in parentheses refer to Figure 14.44, unless otherwise specified.

NOTICE
• Cleanliness is essential when working on a hydraulic system or component. Always work in
a clean area, as contamination can cause serious damage to a hydraulic system.
• Tighten all fasteners to standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Prepare a clean and dry working area.
2. Place the battery master switch in the ‘ON’ position.
3. Start the engine. Refer to 5.11 Starting on page 5-27.
4. Locate a bucket underneath the parking brake assembly (11).
5. Operate the parking brake several times.
6. Loosen the hose (14) on the accumulator (12). Allow oil to escape from the parking brake
hose until it runs clear but not aerated.
7. Refit the hose (14) to the accumulator (12).
8. Repeat steps 6 and 7 several times.
9. Check that the hose (14) is correctly tightened to the accumulator (12) on completion.
10. Stop the engine. Refer to 5.12 Stopping on page 5-28.
11. Place the battery master switch in the ‘OFF’ position.

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 Electrical System 15

Table of Content
15 Electrical System ......................................................................................15-1
15.1 Circuit Diagrams and Component Designations .......................................... 15-3
15.2 Main Controller Unit (MCU) .......................................................................... 15-9
(1) Description............................................................................................... 15-9
(2) Operating States.................................................................................... 15-10
(3) Error Codes ........................................................................................... 15-11
(4) Removal ................................................................................................ 15-15
(5) Installation ............................................................................................. 15-16
(6) Programming ......................................................................................... 15-17
(7) Diagnostics ............................................................................................ 15-20
(8) Special Tools ......................................................................................... 15-35
15.3 Transmission Controller Unit (TCU) ........................................................... 15-36
(1) Description............................................................................................. 15-37
(2) Removal ................................................................................................ 15-37
(3) Installation ............................................................................................. 15-38
(4) Diagnostics ............................................................................................ 15-38
15.4 Dashboard Display..................................................................................... 15-39
(1) Removal ................................................................................................ 15-39
(2) Installation ............................................................................................. 15-40
(3) Programming ......................................................................................... 15-41
(4) Diagnostics ............................................................................................ 15-43
15.5 S6 Engine Management System................................................................ 15-44
(1) Diagnostics ............................................................................................ 15-44
(2) Scania Diagnos & Programmer SDP 3.................................................. 15-44
15.6 Printed Circuit Board (PCB) ....................................................................... 15-48
(1) Removal ................................................................................................ 15-49
(a) Disassembly...................................................................................... 15-50
(b) Assembly .......................................................................................... 15-50
(2) Installation ............................................................................................. 15-51
15.7 DC/DC Convertor ....................................................................................... 15-52
(1) Description............................................................................................. 15-52
(2) Removal ................................................................................................ 15-53
(3) Installation ............................................................................................. 15-54
15.8 Battery Box Assembly ................................................................................ 15-55
(1) Description............................................................................................. 15-56
(2) Removal ................................................................................................ 15-57
(3) Disassembly .......................................................................................... 15-58
(4) Assembly ............................................................................................... 15-58
(5) Installation ............................................................................................. 15-58
(6) Battery ................................................................................................... 15-59
(a) Removal............................................................................................ 15-59
(b) Installation......................................................................................... 15-60
(c) Maintenance ..................................................................................... 15-61
(7) Fuse Box ............................................................................................... 15-62
(a) Description ........................................................................................ 15-62
(b) Removal............................................................................................ 15-62
(c) Installation......................................................................................... 15-64
15.9 Control and Display Elements .................................................................... 15-65

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15 Electrical System

(1) Controls and Instruments ...................................................................... 15-65

(2) Displays ................................................................................................. 15-66
(a) Functional Description ...................................................................... 15-66
(b) Menus ............................................................................................... 15-70
(3) Switches ................................................................................................ 15-75
(4) Controls ................................................................................................. 15-79
15.10Switches and Sensors................................................................................ 15-81
(1) Description............................................................................................. 15-82

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 Electrical System 15

15 Electrical System
15.1 Circuit Diagrams and Component Designations
(1) Schematic Diagrams
For electrical wiring schematic diagrams refer to Appendix A Electrical Schematic Diagrams on
page A-1.
(2) Printed Circuit Board

80A 80A F5
S1 F4 X6 F3 X7 X2

15396784
7.5A F6
10A F64
K09 F45
20A 3A
F27
F80 2A F7
5A VF7-11H11-505
F46 15A F28
F65

80A
F81 TYCO RELAY 15A F8
15A 24V 40A F47 20A 5A F29
F66
F82 5A F9
3A F48 2A 3A F30
F67
F83 7.5A F10
F49 5A 15A F31
F68
F84 15A F11
15A F50 7.5 F32
F85
F69 F2 7.5A F12
F51 1A F33
F70
F86 20A 15A F13
F52 1A 5A F34
F71
F87 10A F14
10A F53 15A 1A F35
F72
F88 5A F15
F54 7.5A 5A F36
F73
K10

F89 033209204 20A F16

15A BOSCH RELAY F55 5A 5A F37
F74
F90 24V 10/20A
10A F75 F56 1A 2A F38 K5 K3
F91 0 332 207 402 0 332 207 402
10A F57 2A 15A F39
F76 BOSCH RELAY BOSCH RELAY
F92 24V 10/20A 24V 10/20A
3A 15A
10A F77 F58 F40 X3
K11

VF7-11H11-505
10A F78 TYCO RELAY F59
10A 2A
F41 K4
K14 15A F79
24V 40A
F60 7.5A F42 033209204

15A 15A BOSCH RELAY

F61 F43
24V 10/20A

F62 15A F44

V23134-10056-X408
K15 TYCO RELAY 7.5A
0 332 207 402
24V 40A
F63 X31 5A F93
BOSCH RELAY
24V 10/20A
F94
K13 K12 VF7-11H11-505
K16 X50A X50B TYCO RELAY 20A F17
K6

ST
0 332 207 402 X60B ST X60A 24V 40A
X51A X51B 2A F18
BOSCH RELAY ST
X61B ST X61A
24V 10/20A 15A F19
X52A ST X52B
X62B ST X62A F1 25A F20
X53A ST X53B
ICS:101239

X63B ST X63A 20A F21

80A

VF7-11H11-505
X54A X54B
K17 ST
K7

X64B ST X64A TYCO RELAY 3A F22

0 332 207 402 X55A X55B 24V 40A
ST
BOSCH RELAY X65B ST X65A 15A F23
24V 10/20A X56A ST X56B
X66B X66A 7.5A F24
ST
X57A ST X57B 2A
X67B ST X67A F25
X58A ST X68B 0 332 207 402 15A F26
X68B ST X68A
K8

X59A ST X59B BOSCH RELAY X1

24V 10/20A

MOT04715
Figure 15.1 - Fuse/ Relay PCB

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15 Electrical System

(3) Structure and Location

ENGINE CONTROLLER UNIT (ECU) TRANSMISSION CONTROLLER UNIT (TCU)

TERMINATION
RESISTOR (R1)
A1 K19 ON CAB HARNESS
BELOW DIAGNOSTIC
CAN CAN CONNECTORS CAN2
CAN J-190

TERMINATION RESISTOR
INTERNAL TO
ENGINE ECU CAN2 TERMINATION
RESISTOR (R4)
ON PCB

TERMINATION
MAIN CONTROLLER CAN 2 CAN 4 GIGA DASHBOARD OMNI.A SWITCH RESISTOR
UNIT (MCU) INTERNAL TO
IFM CR0232 36 INPUTS 4 OUTPUTS DIAGNOSTIC
BOX
48 OUTPUTS
32 INPUTS

GIGA
K18 K20 S5 PROGRAMMING
INTERFACE
TERMINATION CAN 1 CAN 1 CAN 2 CAN
RESISTOR
CAN 3 MCU
INTERNAL TO
PROGRAMMING TERMINATION
GIGA PANEL
INTERFACE RESISTOR (R3)
ON PCB

CAN 29BIT ID CAN 3 ACCESS

MOT05278

Figure 15.2 - Electrical System Structure

MOT05279

Figure 15.3 - Electrical Component Locations

1. MCU 2. TCU 3. PCB

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 Electrical System 15

(4) Component Designations

Table 15.1 - Component Designations
Code Description
B Brake and make switches (mechanical operated)
C Connections
D Diodes, resistors and potentiometers
E Electronic control units
F Fuses
G Ground connections
H Heated devices
K Diagnostic connections
L Lamps
M Electric motors
N Audio
O Instruments
P Power supply
R Relays
S Switches (Possible to push by hand or foot)
T Sensors and Monitors
U Antennas
V Solenoid valves
W Warning lamps

(5) Fuses, Switches and Relays

Table 15.2 - Fuses, Switch and Relays
Component Type Function/Description
F1 80A Master Fuse Terminal 30
F2 80A Master Fuse Terminal 30
F3 80A Master Fuse Terminal 15
F4 80A Master Fuse Terminal 15
F5 20A O/P Not Used, I/P-F2
F6 7.5A 30 Terminal Supply, TCU VPE 1&2, I/P-F2
F7 2A Key Switch S25 (Emergency Mode)
F8 15A Terminal 30, I/P-F2
F9 5A Interior Lamp
F10 7.5A Hazard Switch
F11 15A T1 24/12V DC-DC Convertor
F12 7.5A Telematics Connector
F13 15A Work Socket 24V

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15 Electrical System

Component Type Function/Description

F14 10A Driver Seat Air Compressor
F15 5A O/P Not Used, I/P-F2
F16 20A Brake Oil Cooler Fan
F17 20A Scania 30 EMS
F18 2A Spare
F19 15A VBBO
F20 25A Terminal 30, I/P-F1
F21 20A 30 EMS
F22 3A VBBS
F23 15A VBBR
F24 7.5A Terminal 30, I/P-F1
F25 2A Main Controller Programming
F26 20A Terminal 30, I/P-F1
F27 3A Hydraulic Filter Restriction Sensor B3
F28 15A VBB4
F29 5A Sensor Supply
F30 3A Rocker Switch
F31 15A Terminal 15, I/P-F3
F32 20A O/P Not Used, I/P-F3
F33 15A O/P Not Used, I/P-F3
F34 5A Sensor Hydraulic Block
F35 1A VBB MCU Pin 51 EX
F36 5A Terminal 15, I/P-F3
F37 5A Camera System
F38 2A Sensors Trailer
F39 15A Reserve Terminal 15, I/P-F3
F40 15A VBB3
F41 2A S4X.1 Start/ Stop Button
F42 5A O/P Not Used, I/P-F3
F43 15A Front Work Light
F44 15A Rear Work Light
F45 20A Fuel Heater K9
F46 10A O/P Not Used, I/P-K9
F47 20A Fuel Heater K9 ON
F48 2A O/P Not Used, I/P-F3
F49 5A Omnia Switch
F50 7.5A XK .2 Dashboard
F51 1A O/P Not Used, I/P-F3

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 Electrical System 15

Component Type Function/Description

F52 1A 12V Terminal 15
F53 5A Wiper Motors
F54 7.5A O/P Not Used, I/P-F3
F55 5A O/P Not Used, I/P-F3
F56 1A Road Speed Sensor
F57 2A O/P Not Used, I/P-F3
F58 3A Sensor Dropbox
F59 10A O/P Not Used, I/P-K10
F60 7.5A Terminal 15
F61 15A Key Switch, I/P-K11
F62 15A O/P Not Used, I/P-F3
F63 7.5A Horns, I/P-K8
F64 10A O/P Not Used, I/P-F4
F65 5A Relay K17 Brake Pedal Activated
F66 15A VBB1
F67 3A Fuel Level
F68 30A O/P Not Used, I/P-F4
F69 15A S16.X.3 Heated Mirrors
F70 15A O/P Not Used, I/P-F4
F71 10A O/P Not Used, I/P-F4
F72 10A O/P Not Used, I/P-F4
F73 15A O/P Not Used, I/P-F4
F74 15A E13.X1.1, AIRCON
F75 10A Reserve T15 X 6.56
F76 10A A1.C4002.1, SCR
F77 10A X45, Telematics
F78 10A A1.C4001.3, 15 EMS
F79 15A K18.X2.1, VBB2
F80 15A O/P Not Used, I/P-F4
F81 15A O/P Not Used, I/P-F4
F82 15A O/P Not Used, I/P-F4
F83 15A O/P Not Used, I/P-F4
F84 2A O/P Not Used, I/P-F4
F85 2A O/P Not Used, I/P-F4
F86 20A M7 Brake Oil Cooler PWM Fan
F87 20A O/P Not Used, I/P-F4
F88 1A O/P Not Used, I/P-F4
F89 15A O/P Not Used, I/P-F4

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15 Electrical System

Component Type Function/Description

F90 2A O/P Not Used, I/P-F4
F91 15A O/P Not Used, I/P-F4
F92 2A O/P Not Used, I/P-K14
F93 5A O/P Not Used, I/P-X3
F94 5A O/P Not Used, I/P-X3
S1 2 Pole, Toggle Lamp Switch, Battery Master
K3 Micro Relay 12V Terminal 15
K4 Mini Relay Park Brake Solenoid Gnd
K5 Mini Relay Front Wiper Speed 2
K6 Power Relay Front Work Lights
K7 Power Relay Rear Work Lights
K8 Micro Relay Horns
K9 Power Relay Fuel Heater
K10 Mini Relay Spare
K11 Power Relay Emergency Operation
K12 Power Relay Not Placed
K13 Power Relay Brake Oil Cooler Fan
K14 Micro Relay Not Placed
K15 Micro Relay Front Wiper
K16 Micro Relay Rear Wipers
K17 Micro Relay S25 Brake Pedal Activated

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 Electrical System 15

15.2 Main Controller Unit (MCU)

(1) Description

� WARNING
• Turn off battery master switch to isolate the batteries before disconnecting any electrical
components. Before any welding is carried out on a machine, disconnect the following in
this order: Battery earth cable, battery supply cable, alternator earth cables, alternator
supply cables and electrical connections at the engine ECU, transmission TCU, body
control lever, MCU and cab bulkhead to avoid damage to electrical components.

� CAUTION
• The indicator light adjacent to the battery master switch remains ON for 60 seconds after
the battery master switch has been placed in the OFF position. When the light is ON
electrical power remains connected to the machine.

The Main Controller Unit (MCU) (Figure 15.4 and ) is a stand alone interface unit, that controls
and monitors the functions of the machine. The CR0232 MCU (K18) communicates using a
Control Area Network (CAN) databus network. The MCU is also connected with a variety of
input and output devices. It utilizes analog/digital inputs, proportional current outputs and
digital outputs.
The MCU is connected via databus CAN2 (Powertrain databus) to the Engine Controller Unit
(ECU) (A1) and the Transmission Controller Unit (TCU) (K21). Databus CAN3 (HMI databus),
connects the MCU to the GIGA dashboard panel (K20) and the control stock - OMNI switch
(S5). Databus CAN 4 the system diagnostic bus is utilized to interrogate the machine functions
using the CoDeSys software. Refer to Figure 15.2.
The MCU continuously monitors the system and warns the operator when a fault develops, and
also helps diagnose the nature of the fault. The MCU is located inside the cab, on the right
hand side below the console. (Refer to Figure 15.5).

STATUS LED

MOT04713

Figure 15.4 - Main Controller Unit

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15 Electrical System

(2) Operating States

After power on the MCU can be in one of five possible operating states:
Reset
This state is passed through after every power on reset:
• The operating system is initialised.
• Various checks are carried out.
• This temporary state is replaced by the Run or Stop state.
The LED lights orange for a short time.
Run State
This state is reached in the following cases:
• From the reset state (autostart).
• From the stop state by the Run command (only for the operating mode).
Stop State
This state is reached in the following cases:
• From the reset state if no program is loaded
• From the Run state if:
• the stop command is sent via the interface.
• AND in operating mode.
Fatal Error
The MCU goes to this state if a non tolerable error was found. This state can only be left
by a reset.
The LED lights red.
No Operating System
No operating system was loaded, the controller is in the boot loading state. Before loading the
application software the operating system must be downloaded.
The LED flashes green (quickly).
Status LED
The operating states are indicated by the integrated status LED. Refer to (1) Description on
page 15-9 and Table 15.3.
Table 15.3 - Status LED
Flashing
LED colour frequency Description
Off Permanently Out No Operating Voltage
Green 5 Hz No Operating System Loaded
Green 2 Hz RUN State
Green Permanently On STOP State
Red 2 Hz RUN State With Error
Red Permanently On Fatal Error
Yellow/Orange Briefly On Initialisation or Reset Checks

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 Electrical System 15

(3) Error Codes

Table 15.4 - MCU Error Codes
Error Description of Error Check
Code
01 GIGA- DASH NOT LIVE
02 ECU NOT LIVE
03 TCU NOT LIVE
04 OMNIA - LEVER NOT LIVE
05 ---------------
06 ---------------
07 ---------------
08 ---------------
09 ---------------
10 ---------------
11 MCU OUT_00 X1:18 SHORT K2_MainRelayTerminal15_ON
12 MCU OUT_00 X1:18 BREAK K2_MainRelayTerminal15_ON
13 MCU OUT_01 X1:17 SHORT E5_ParkingLights_ON
14 MCU OUT_01 X1:17 BREAK E5_ParkingLights_ON
15 MCU OUT_02 X1:16 SHORT E5_LowBeam_Left_ON
16 MCU OUT_02 X1:16 BREAK E5_LowBeam_Left_ON
17 MCU OUT_03 X1:15 SHORT E5_Indicators_LEFT_ON
18 MCU OUT_03 X1:15 BREAK E5_Indicators_LEFT_ON
19 MCU OUT_04 X1:14 SHORT E7_BrakeLights_ON
20 MCU OUT_04 X1:14 BREAK E7_BrakeLights_ON
21 MCU OUT_05 X1:13 SHORT K15_FrontWiper_Speed_1_ON
22 MCU OUT_05 X1:13 BREAK K15_FrontWiper_Speed_1_ON
23 MCU OUT_06 X1:12 SHORT K5_FrontWiper_Speed_2_ON
24 MCU OUT_06 X1:12 BREAK K5_FrontWiper_Speed_2_ON
25 MCU OUT_07 X1:11 SHORT E8_Indicators_RIGHT_ON
26 MCU OUT_07 X1:11 BREAK E8_Indicators_RIGHT_ON
27 MCU OUT_08 X1:2 SHORT E5_HighBeam_Left_ON
28 MCU OUT_08 X1:2 BREAK E5_HighBeam_Left_ON
29 MCU OUT_09 X1:3 SHORT P8_FlashingReverseLamp_ON
30 MCU OUT_09 X1:3 BREAK P8_FlashingReverseLamp_ON
31 MCU OUT_10 X1:4 SHORT E6_LowBeam_Right_ON
32 MCU OUT_10 X1:4 BREAK E6_LowBeam_Right_ON
33 MCU OUT_11 X1:5 SHORT E20_ReverseLamp_ON
34 MCU OUT_11 X1:5 BREAK E20_ReverseLamp_ON
35 MCU OUT_12 X1:6 SHORT K8_Horn_ON

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Error Description of Error Check

Code
36 MCU OUT_12 X1:6 BREAK K8_Horn_ON
37 MCU OUT_13 X1:7 SHORT E11_WorkLights_Front_ON
38 MCU OUT_13 X1:7 BREAK E11_WorkLights_Front_ON
39 MCU OUT_14 X1:8 SHORT --- Not Available ---
40 MCU OUT_14 X1:8 BREAK --- Not Available ---
41 MCU OUT_15 X1:9 SHORT Q2_EngineFanSpeed_2_mA
42 MCU OUT_15 X1:9 BREAK Q2_EngineFanSpeed_2_mA
43 MCU OUT_00E X2:18 SHORT M2_WashPump_Front_ON
44 MCU OUT_00E X2:18 BREAK M2_WashPump_Front_ON
45 MCU OUT_01E X2:17 SHORT TCU_AuxiliaryHold
46 MCU OUT_01E X2:17 BREAK TCU_AuxiliaryHold
47 MCU OUT_02E X2:16 SHORT E6_HighBeam_RIGHT_ON
48 MCU OUT_02E X2:16 BREAK E6_HighBeam_RIGHT_ON
49 MCU OUT_03E X2:15 SHORT TCU_AuxiliaryRange_inhibit
50 MCU OUT_03E X2:15 BREAK TCU_AuxiliaryRange_inhibit
51 MCU OUT_04E X2:14 SHORT WA4.Q3_DropboxDifflock_engage
52 MCU OUT_04E X2:14 BREAK WA4.Q3_DropboxDifflock_engage
53 MCU OUT_05E X2:13 SHORT WA5.Q4_DropboxLowRange_select
54 MCU OUT_05E X2:13 BREAK WA5.Q4_DropboxLowRange_select
55 MCU OUT_06E X2:12 SHORT WA6.Q5_DropboxHighRange_select
56 MCU OUT_06E X2:12 BREAK WA6.Q5_DropboxHighRange_select
57 MCU OUT_07E X2:11 SHORT WA2.Q6_Syst.Hydr._unloader_valve
58 MCU OUT_07E X2:11 BREAK WA2.Q6_Syst.Hydr._unloader_valve
59 MCU OUT 08E X2:2 SHORT Q27_Exhaust Brake Solenoid
60 MCU OUT 08E X2:2 BREAK Q27_Exhaust Brake Solenoid
61 MCU OUT 09E X2:3 SHORT TCU_RetarderRequest
62 MCU OUT 09E X2:3 BREAK TCU_RetarderRequest
63 MCU OUT 10E X2:4 SHORT S24_Hold_Body Lever_in_LowerPos
64 MCU OUT 10E X2:4 BREAK S24_Hold_Body Lever_in_LowerPos
65 MCU OUT 11E X2:5 SHORT E9_FogLamp_ON
66 MCU OUT 11E X2:5 BREAK E9_FogLamp_ON
67 MCU OUT 12E X2:6 SHORT --- Not Available ---
68 MCU OUT 12E X2:6 BREAK --- Not Available ---
69 MCU OUT 13E X2:7 SHORT Q11_EngineFan_speed
70 MCU OUT 13E X2:7 BREAK Q11_EngineFan_speed
71 MCU OUT 14E X2:8 SHORT WA6.Q8_BodyRaiseValve
72 MCU OUT 14E X2:8 BREAK WA6.Q8_BodyRaiseValve

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 Electrical System 15

Error Description of Error Check

Code
73 MCU OUT 15E X2:9 SHORT WA7.Q9_BodyLowerValve
74 MCU OUT 15E X2:9 BREAK WA7.Q9_BodyLowerValve
75 MCU General internal MCU error
76 MCU PCB WARNING Communications between PCB’s -
temporary fault
77 MCU PCB ERROR Communications between PCB’s - failed
78 ERROR_VBB-R Voltage out of range - Pin 1 Std. side - F23
79 5V REFERENCE VOLTAGE LOW Pin 51 Std. side
80 ERROR_VBB-O Voltage out of range - Pin 19 Std. side - F19
81 ERROR_VBB-1 Voltage out of range - Pin 19 Ext. side - F66
82 ERROR_VBB-2 Voltage out of range - Pin 1 Ext. side - F79
83 ERROR_VBB-3 Voltage out of range - Pin 32 Ext. side - F40
84 ERROR_VBB-4 Voltage out of range - Pin 10 Ext. side - F28
85 ERROR_POWER Voltage out of range - Std. side
86 ERROR_POWER_E Voltage out of range - Ext. side
87 ERROR_TEMPERATURE Internal temperature has exceeded 85 °C
88 ERROR_IO_E Error has occurred in the IO - Ext. side
89 ERROR_VBB-REL_E Voltage out of range - Pin 51 Ext. side - F35
90 --- - - - Not Used - - -
91 --- - - - Not Used - - -
92 --- - - - Not Used - - -
93 --- - - - Not Used - - -
94 --- - - - Not Used - - -
95 --- - - - Not Used - - -
96 --- - - - Not Used - - -
97 --- - - - Not Used - - -
98 --- - - - Not Used - - -
99 --- - - - Not Used - - -
100 --- - - - Not Used - - -
101 --- - - - Not Used - - -
102 --- - - - Not Used - - -
103 --- - - - Not Used - - -
104 --- - - - Not Used - - -
105 --- - - - Not Used - - -
106 --- - - - Not Used - - -
107 MCU IN_X1:22 B2 ThrottlePedal High Volt
108 MCU IN_X1:22 B2 ThrottlePedal Low Volt

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Error Description of Error Check

Code
109 MCU IN_X1:39, 34 B2 ThrottlePedal PLAUSIBILITY
110 --- - - - Not Used - - -
111 GIGA IN_XJ:26 XK:10 S27 BrakePedal PLAUSIBILITY
112 MCU IN_X2:22 S24 BodyRiLoLever. HI VOLT.
113 MCU IN_X2:22 S24 BodyRiLoLever. LO VOLT.
114 MCU IN_X2:40 BREAK B34_BrakeOilTemp
115 MCU IN_X2:40 SHORT B34_BrakeOilTemp
116 MCU IN_X2:35 BREAK B12 DroBxOilPresSensor
117 MCU IN_X2:35 SHORT B12 DroBxOilPresSensor
118 GIGA PIN XJ:18 S14 TransRetSelSwitch PLAUSIBILITY
GIGA PIN XK:12
GIGA PIN XK:13
119 MCU IN_X1:36 M7 BrakeOilCooler_Fault
120 MCU_Input_14_E BREAK IN_B19_DropBox_OilPressure_LOW
121 MCU_Input_14_E SHORT IN_B19_DropBox_OilPressure_LOW
122 MCU IN_X1:35 BREAK IN_B29_HtdraulicOilTemp_SENSOR
123 MCU IN_X2:41 BREAK IN_B15_Body_is_UP_SENSOR
124 --- - - - Not Used - - -
125 --- - - - Not Used - - -
126 --- - - - Not Used - - -
127 --- - - - Not Used - - -
128 --- - - - Not Used - - -
129 --- - - - Not Used - - -
130 --- - - - Not Used - - -
131 --- - - - Not Used - - -
132 --- - - - Not Used - - -
139 MCU OUT_14 X1:8 SHORT Q29_MidAxleDifflock_engage
140 MCU OUT_14 X1:8 BREAK Q29_MidAxleDifflock_engage

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 Electrical System 15

(4) Removal

� 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.
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the 'OFF' position before removing any components. Remove battery
ground cable first, and reconnect last, to avoid damaging electrical components.

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

Numbers in parentheses refer to Figure 15.5, unless otherwise specified.

3,4,5

Ex
Ex

8
St

St
6

1
MOT05276

Figure 15.5 - MCU Mounting

1. Controller Plate 4. Lock-Washer 7. Nut
2. MCU 5. Bolt 8. Bolt
3. Washer 6. Washer 9. Nut

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15 Electrical System

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Operate the treadle valve continuously to discharge the accumulators, block all road
wheels, place the steering lock bar in the 'Locked' position and the battery master switch in
the 'OFF' position.
3. Disconnect the battery ground cable first, then the battery supply cable, before
disconnecting electrical harness from the MCU (2) inside cab.
4. Tag and identify the electrical connections, MCU K18:XL (ST:X1) and K18:XR (EX:X2),
make note of the orientation of the connections. Disconnect both connections K18, cap
connections to prevent ingress of dirt.
5. Remove bolts (5), washers (3) and lock-washers (4) securing the top of the controller
mounting plate (1) to the cab mounting, remove the nuts (7) and washers (6) securing the
bottom of the controller plate (1) to the cab mounting. Remove the controller plate (1)
with the MCU (2) attached.
6. Tag and identify the electrical ground connection (XGND_Cntrlr). Disconnect the GND
terminal.
7. Remove the bolts (8) and nuts (9) securing the MCU to the controller mounting plate.
Remove the MCU.

(5) Installation
Numbers in parentheses refer to Figure 15.5, unless otherwise specified.

� WARNING
• The MCU must be installed with K18:XL (ST:X1) facing the front of the cab and K18:XR
(EX:X2 facing the rear of the cab. Refer to step 4 and, Figure 15.5.

PROCEDURE
1. Secure the MCU (2) to the controller mounting plate (1) with bolts (8) and nuts (9).
2. Identify the electrical ground connection (XGND_Cntrlr). Connect and secure the GND
terminal to the MCU (2)..
3. Secure the controller mounting plate (1) with MCU (2) attached to the cab mounting, with
nuts (7) and washers (6) (bottom) and bolts(5), washers (3) and lock-washers (4) (top).
4. Identify the electrical connections, MCU K18:XL (ST:X1) and K18:XR (EX:X2), make note of
the orientation of the connections. Connect and secure both connections K18.
5. Connect the battery supply cable, and the battery ground cable. Select the battery master
switch to the ‘ON’ position.
6. Turn master switch on, check the dashboard display screen for correct MCU software
(power up screen) and any MCU error codes. Investigate and rectify any error codes
displayed.
7. Place the steering lock bar in the ‘Stowed’ position, remove wheel blocks from all road
wheels.

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 Electrical System 15

(6) Programming
Ensure that the correct software to be loaded has been downloaded from http://tel.ftpstream.com
and is available to be installed.
MCU programming/diagnostic test kit (15505269) is required to perform this task.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Connect portable laptop device to the serial interface connection (RS232) X34 (5, Figure
15.101) using test kit (15505269).
3. Power up the laptop and select the power key switch to ‘ON’.
4. On the laptop desktop display select the ‘DOWNLOAD’ icon.

MOT04782

Figure 15.6 - Step 4

5. From the ‘DOWNLOAD’ screen, select the ‘Interface’ toolbar. Select ‘RS232’.
6. From the ‘RS232’ screen select the relevant ‘COM- Port’ (check in the device manager).

MOT04783 MOT04784

Figure 15.7 - Step 5 Figure 15.8 - Step 6

7. To check good communications, from the ‘DOWNLOAD’ screen, select the ‘Identity’ icon to
check what software version is currently installed. The ‘DOWNLOAD’ screen will show the
software version currently installed.
8. Note software and select ‘OK’ icon.

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15 Electrical System

MOT04785 MOT04786

Figure 15.9 - Step 7 Figure 15.10 - Step 8

9. From the ‘DOWNLOAD’ screen, select the ‘Download’ icon.

10. From the ‘Open’ screen, select the correct software version file to be installed. Select
‘Open’ icon.

MOT04787 MOT04788

Figure 15.11 - Step 9 Figure 15.12 - Step 10

11. Check the status bar at the bottom of the ‘DOWNLOAD’ screen for installation progress.
12. When the software has been installed, a ‘DOWNLOAD’ successful screen will appear.
Select ‘OK’ icon.
MOT04790

MOT04789

Figure 15.13 - Step 11 Figure 15.14 - Step 12

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 Electrical System 15

13. Select the ‘Identity’ icon, check and record the software version installed from the
‘DOWNLOAD’ screen. Select ‘OK’ icon.
14. Select ‘Run’ icon, to execute the program. Select ‘Exit’ icon.

MOT04791 MOT04792

Figure 15.15 - Step 13 Figure 15.16 - Step 14

15. Power down the laptop and select the master key switch to ‘OFF’.
16. Disconnect portable laptop device from the serial interface connection (RS232) X34 (5,
Figure 15.101).
17. Turn master switch on, check the dashboard display screen for correct MCU software
(power up screen) and any MCU error codes. Investigate and rectify any error codes
displayed.

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15 Electrical System

(7) Diagnostics

NOTICE
• Do not open more than one diagnostic screen at the same time.
• Ensure that the correct software has been downloaded from http://tel.ftpstream.com and is
available to be used.
• MCU programming/diagnostic test kit (15505269) is required to perform this task.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Connect portable laptop device to the diagnostic bus connection X36 (1, Figure 15.101)
using test kit (15505269).
3. Power up the laptop and select the power key switch to ‘ON’.
4. On the laptop navigate to the project files, select the required ‘DIAGNOSTICS’ folder.
Refer to Figure 15.17.
5. Select the required machine model folder, the CoDeSys software program will open. Refer
to Figure 15.18.
6. From the CoDeSys project screen (refer toFigure 15.19), Log in:
• User Group - Level 1
• Password - tel
• Select ‘OK’ icon.
7. From the CoDeSys project screen, select ‘Online’ from the menu bar, and ‘Visualisations
from the bottom of the left hand screen. To switch on the system diagnostics, select the
‘SWITCH DIAGNOSTICS PROCESSING’ icon on the main screen. To navigate to a
specific diagnostic page, select the page on the ‘Visualisation’ menu on the left hand side,
or select the page icon on the main screen. Refer to Figure 15.20.

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 Electrical System 15

MOT04793

Figure 15.17 - Step 4

MOT04794

Figure 15.18 - Step 5

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MOT04795

Figure 15.19 - Step 6

MOT04796

Figure 15.20 - Step 7

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 Electrical System 15

Refer to Figure 15.21 to Figure 15.45 inclusive, for diagnostic page display screens.

MOT04797

Figure 15.21 - General System Diagnostics Screen

MOT04798

Figure 15.22 - GIGA Inputs Screen

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15 Electrical System

MOT04799

Figure 15.23 - MCU Input Diagnostics Screen

MOT04800

Figure 15.24 - MCU Output Diagnostics (X1) Screen

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 Electrical System 15

MOT04801

Figure 15.25 - MCU Output Diagnostics (X2) Screen

MOT04802

Figure 15.26 - GIGA Current Date and Time Screen

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MOT04803

Figure 15.27 - GIGA Basic Tests Screen

MOT04804

Figure 15.28 - OMNIA Diagnostics Screen

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 Electrical System 15

MOT04805

Figure 15.29 - ECU Diagnostics (1) Screen

MOT04806

Figure 15.30 - ECU Diagnostics (2) Screen

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MOT048007

Figure 15.31 - TCU Diagnostics Screen

MOT04808

Figure 15.32 - Wipers Diagnostics Screen

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 Electrical System 15

MOT04809

Figure 15.33 - Lights Diagnostics Screen

MOT04810

Figure 15.34 - Work Lights Diagnostics

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MOT04811

Figure 15.35 - Indicators Diagnostics Screen

MOT04812

Figure 15.36 - Warning Buzzer Diagnostics Screen

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 Electrical System 15

MOT04813

Figure 15.37 - Engine Start/Stop Diagnostics Screen

MOT04814

Figure 15.38 - Throttle Pedal Diagnostics Screen

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15 Electrical System

MOT04815

Figure 15.39 - Body Raise/Lower Diagnostics Screen

MOT04816

Figure 15.40 - Difflock Diagnostics Screen

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 Electrical System 15

MOT04817

Figure 15.41 - Park Brake Diagnostics

MOT04818

Figure 15.42 - Engine Brake/Transmission Retarder Diagnostics

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MOT04819

Figure 15.43 - Engine Fan Control

MOT04820

Figure 15.44 - Transmission/Hydraulic Fan Diagnostics

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 Electrical System 15

MOT04821

Figure 15.45 - Error Memory

8. When diagnostics has finished for a specific page, select the ‘EXIT’ icon.
9. To close a complete diagnostics session, select the ‘Online’ icon on the menu bar, and
‘Log Out’.
10. Power down the laptop and select the master key switch to ‘OFF’.
11. Disconnect the portable laptop device from the diagnostic bus connection X36 (1, Figure
15.101).

(8) Special Tools

There are no special tools required for procedures outlined in this section. To obtain IQAN
develop diagnostic software, contact your dealer.

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15 Electrical System

15.3 Transmission Controller Unit (TCU)

6
5
2

1 4 3

MOT04822

Figure 15.46 - TCU Mounting

1. TCU 3. Bolt 5. Nut
2. Mounting Plate 4. Washer 6. Washer

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 Electrical System 15

(1) Description
Numbers in parentheses refer to Figure 15.46, unless otherwise specified.
The transmission control unit (TCU) continually monitors the transmission and shift system
electrical components and warns the operator when a problem develops. It also takes action
to prevent damage to the transmission, and provides the service technician with diagnostic
capabilities so that problems can be corrected quickly and easily.
The TCU is located on the same mounting bracket as the DC/DC Convertor and adjacent to the
PCB, on the rear cab wall. Refer to Figure 15.3.
The TCU (K19) is connect via CAN2 (Powertrain databus) to the MCU and the ECU. The
TCU is also connected to a variety of input and output devices that updates the TCU with the
condition and operation of the transmission and the automatic shift system.
When a fault occurs, a two digit error code will be displayed on the LCD display ( Figure 15.94)
on the dash panel. The error code is also recorded in the transmission TCU, and can be
accessible by the serviceman by plugging in a data reader to extract information relating to the
fault. The error code recorded in the TCU memory will remain until it is erased by a technician.
Refer to (5) Allison 5th Gen Diagnostic Codes on page 6-14.
(2) Removal

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

� WARNING
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the 'OFF' position before removing any components. Remove battery
ground cable first, and reconnect last, to avoid damaging electrical components.

Numbers in parentheses refer to Figure 15.46, unless otherwise specified.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Operate the treadle valve continuously to discharge the accumulators, block all road
wheels, place the steering lock bar in the 'Locked' position and the battery master switch in
the 'OFF' position.
3. Disconnect the battery ground cable first, then the battery supply cable, before
disconnecting electrical harness from the TCU (1) inside cab.
4. Tag and identify the electrical connection TCU K19. Disconnect connection K19, cap
connections to prevent ingress of dirt.
5. Remove the bolts (3) and washers (4) securing the TCU (1) to the mounting plate (2).
Remove the TCU.

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(3) Installation
Numbers in parentheses refer to Figure 15.46, unless otherwise specified.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Secure the TCU (1) to the mounting plate (2) with bolts (3) and washers (4).
2. Identify the electrical connection TCU K21, remove blanking caps. Connect and secure
connection K21.
3. Connect the battery supply cable, and the battery ground cable. Select the battery master
switch to the ‘ON’ position.
4. Turn master switch on, check the dashboard display screen for TCU error codes.
Investigate and rectify any error codes displayed.
5. Place the steering lock bar in the ‘Stowed’ position, remove wheel blocks from all road
wheels.

(4) Diagnostics
If a major fault is detected, it is the operators’ responsibility to shut down the machine as soon
as it is safe to do so. The machine can not be restarted until the fault has been diagnosed and
corrected. Refer to (5) Allison 5th Gen Diagnostic Codes on page 6-14 table for a list of fault
codes and possible cause.
Interrogation of the MCU diagnostic (CoDeSys) system, may also confirm the fault.

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 Electrical System 15

15.4 Dashboard Display

Refer to (2) Displays on page 15-66.
The dashboard display provides the operator with a visual display of the machine functions and
any warnings /alerts that the controller units (MCU, TCU and ECU) generate.
The dashboard panel (COBO) K20 is connected via CAN3 (HMI - databus) to the MCU (refer
to (1) Description on page 15-9. The dashboard panel also has various digital inputs from
sensors/switches, these inputs provide the information on the machine functions to be displayed.
(1) Removal

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

� WARNING
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the 'OFF' position before removing any components. Remove battery
ground cable first, and reconnect last, to avoid damaging electrical components.
• When removing the dashboard panel (Figure 15.47) do not use sharp objects to lever the
panel out as this will result in damage. Kneel on the cab floor, place your hands behind the
panel and apply gentle pressure with your fingers until it releases.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Operate the treadle valve continuously to discharge the accumulators, block all road
wheels, place the steering lock bar in the 'Locked' position and the battery master switch in
the 'OFF' position.
3. Disconnect the battery ground cable first, then the battery supply cable, before
disconnecting electrical harness from the dashboard panel inside cab.
4. Tag and identify the electrical connections dashboard K20.XK and K20.XJ. Disconnect
connections K20.XK and K20.XJ, cap connections to prevent ingress of dirt.
5. To remove the dashboard panel (Figure 15.47) do not use sharp objects to lever the panel
out as this will result in damage. Kneel on the cab floor, place your hands behind the panel
and apply gentle pressure with your fingers until it releases.

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15 Electrical System

Figure 15.47 - Dashboard Panel Removal

(2) Installation

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. To install the dashboard panel, carefully push the panel with finger pressure only into
the dashboard, ensure the panel is secure.
2. Identify the electrical connections dashboard K20.XK and K20.XJ, remove blanking caps.
Connect and secure connections K20.XK and K20.XJ.
3. Connect the battery supply cable, and the battery ground cable. Select the battery master
switch to the ‘ON’ position.
4. Select menu screen to check the dashboard display for correct software version (4, Figure
15.86).
5. Check for any error codes. Investigate and rectify any error codes displayed.
6. Place the steering lock bar in the ‘Stowed’ position, remove wheel blocks from all road
wheels.

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 Electrical System 15

(3) Programming
Ensure that the correct software to be loaded has been downloaded from http://tel.ftpstream.com
and is available to be installed.
GIGA programming test kit (15504874) is required to perform this task.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Connect portable laptop device to the dashboard connection X35 (2, Figure 15.101) using
test kit (15504874).
3. Power up the laptop and select the power key switch to ‘ON’.
4. On the laptop desktop display select the ‘PcanView.exe’ icon.
5. From the Connect screen ensure that 250 kBit/s is selected from the ‘Bit rate:’ drop down
menu. Ensure that ‘Extended’ is selected in the ‘Filter settings’ menu. Select the ‘OK’ icon.

MOT04823 MOT04824

Figure 15.48 - Step 4 Figure 15.49 - Step 5

6. From the ‘PCAN-View’ screen select ‘Receive / Transmit’ data will be displayed and confirm
good connection. Minimise the ‘PCAN-View’ screen.
7. On the laptop desktop display select the ‘Winloader3.21.exe’ icon.

MOT04825 MOT04826

Figure 15.50 - Step 6 Figure 15.51 - Step 7

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15 Electrical System

8. From the ‘WinLoader’ screen ensure ‘CPU0’ selected. Select the ‘Search’ icon.
9. From the ‘Search’ screen, select the ‘Refresh’ icon. Select the ‘OK’ icon.

MOT04827 MOT04828

Figure 15.52 - Step 8 Figure 15.53 - Step 9

10. From the ‘WinLoader’ screen ensure ‘CPU0’ selected. Select the ‘Start Bootloader’ icon.
11. When the ‘Switch unit ON’ screen appears, select the power key switch to ‘OFF’ for
approximately 10 seconds, then re-select back to ‘ON’. If this operation is not successful
repeat Step 10..

MOT04829 MOT04830

Figure 15.54 - Step 10 Figure 15.55 - Step 11

12. From the ‘WinLoader’ screen select the ‘Update Flash’ icon.
13. From the program files, select the correct software file required.

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 Electrical System 15

MOT04831

MOT04832

Figure 15.56 - Step 12 Figure 15.57 - Step 13

14. Ensure the ‘Programming Internal Flash...’ progress bar appears.

15. When the programming is complete the dashboard panel will appear to be ‘OFF’. From the
‘WinLoader’ screen select the ‘Restart Application’ icon.

MOT04833 MOT04834

Figure 15.58 - Step 14 Figure 15.59 - Step 15

16. When the dashboard panel has powered ‘up’ check the dashboard display screen for
correct software version (4, Figure 15.86).
17. From the ‘WinLoader’ screen select the ‘Quit’ icon.
18. Power down the laptop and select the master key switch to ‘OFF’.
19. Disconnect portable laptop device from the dashboard connection X35 (2, Figure 15.101).

(4) Diagnostics
Interrogation of the MCU diagnostic (CoDeSys) system, will aid in the fault diagnostics of the
dashboard display. Refer to (7) Diagnostics on page 15-20.

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15.5 S6 Engine Management System

(1) Diagnostics
Interrogation of the MCU diagnostic (CoDeSys) system, will aid in the fault diagnostics of the S6
EMS system. Refer to (7) Diagnostics on page 15-20.
A brief description and possible cause can also be found in 5.8 List of Fault Codes on page 5-14.
For a detailed fault diagnosis and troubleshooting refer to (2) Scania Diagnos & Programmer
SDP 3 on page 15-44.
(2) Scania Diagnos & Programmer SDP 3
Refer to the Scania User instructions SDP:01
Scania Diagnos & Programmer 3 (SDP3) communicates with Scania vehicles and Scania
industrial and marine engines. The program has been developed to support the electrical
system with CAN communication.
The program is used for troubleshooting, adjusting customer parameters, calibrations,
conversions affecting the electrical system and updating software in control units.
Ensure that the correct software has been downloaded and is available to be used.
SDP3 programming/diagnostic test kit (15504875) is required to perform this task.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Connect portable laptop device to the diagnostic connection C4000 (Figure 15.101 ) using
test kit (15504875). The Scania USB Key should be connected to the laptop device at
this time.
3. Power up the laptop and select the power key switch to ‘ON’. Start the engine and run at
‘Idle’ (refer to 5.11 Starting on page 5-27).
4. On the laptop desktop display, select the ‘SDP3’ icon.
5. Select the ‘Checks and adjustments’ icon. Ensure the ‘Checking and adjusting - Checks
the engine’ screen appears and connection is in progress.

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 Electrical System 15

MOT04837

Info class Internal ET /Scania Academ y /TechnicalTraining /U Frickner

Figure 15.60 - Step 5

6. The following ‘ Screen Shots’ represent typical electrical system display’s:

MOT04838

Info class Internal ET /Scania Academ y /TechnicalTraining /U Frickner

Figure 15.61 - Fault Codes Screen

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15 Electrical System

MOT04839

Info class Internal ET /Scania Academ y /TechnicalTraining /U Frickner

Figure 15.62 - Location Screen

MOT04840

Info class Inte

rnal ET /Scania Academ y /TechnicalTraining /U Frickner

Figure 15.63 - Check Screen

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 Electrical System 15

MOT04841

Info class Inte

rnal ET /Scania Academ y /TechnicalTraining /U Frickner

Figure 15.64 - Adjusting Screen

MOT04842

Figure 15.65 - Components Screen

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15.6 Printed Circuit Board (PCB)

6
4

2,3

2,3

7,8,9
MOT05277

Figure 15.66 - PCB Mounting

1. Cover Plate 4. PCB 7. Bolt
2. Bolt 5. Bracket 8. Lockwasher
3. Washer 6. Strap 9. Washer

Refer to Figure 15.66, Figure 15.67, Figure 15.1 and Figure 15.3.
The Printed Circuit Board (PCB) is installed on the rear of the cabin wall behind the operator’s
seat.
Mounted on the PCB are the fuses and relays that control the distribution of the electrical
power for the machine.
Switch ‘S1’ on the PCB, enables a self test circuit that displays the condition of the PCB
mounted fuses.
Together with the Emergency Mode Key switch ‘S25’ (6, Figure 15.101) jumper links are
installed on the PCB for manual activation of circuits to aid in troubleshooting.

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 Electrical System 15

X20 X34 X21

X29
X23

X33 X32 X30

X22

X24
X27 X26
X28
X25
MOT05326

Figure 15.67 - PCB Rear View

(1) Removal

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

� WARNING
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the 'OFF' position before removing any components. Remove battery
ground cable first, and reconnect last, to avoid damaging electrical components.

Numbers in parentheses refer to Figure 15.66, unless otherwise specified.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Operate the treadle valve continuously to discharge the accumulators, block all road
wheels, place the steering lock bar in the 'Locked' position and the battery master switch in
the 'OFF' position.
3. Disconnect the battery ground cable first, then the battery supply cable, before
disconnecting any electrical connections to the PCB, inside the cab.
4. Position the operator’s seat to the furthest forward position, to gain access to the PCB.
5. Remove bolts (2) and washers (3) securing the cover plate to the PCB. Remove cover (1).
6. Tag and identify the PCB electrical connections X2.a, X7.a, X6.a and X1.a. Disconnect
connections X2.a, X7.a, X6.a and X1.a.
7. Undo / Remove the retaining strap (6).
8. Remove the top two bolts (2) and washers (3), and loosen the bottom (LHS) bolt (2) and
washer (3) securing the PCB assembly to the cab. Carefully raise and tilt forward the
PCB assembly.

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15 Electrical System

9. Tag and identify the PCB harness connections, as follows:

• A1.X20
• A1.X21
• A1.X22
• A1.X23
• A1.X24
• A1.X25
• A1.X26
• A1.X27
• A1.X28
• A1.X29
• A1.X30
• A1.X32
10. Disconnect the harness connections, cap all connections to prevent ingress of dirt.
11. Remove the bottom (LHS) bolt (2) and washer (3) securing the PCB assembly to the cab.
12. Remove the PCB (4) and bracket assembly (5), and transport to a clean maintenance area.

(a) Disassembly
Numbers in parentheses refer to Figure 15.66.

PROCEDURE
1. Remove the bolts (7) washers (9) and spring washers (8) (8 off), securing the PCB (4) to
the bracket assembly (2). Remove the PCB (9).

(b) Assembly
Numbers in parentheses refer to Figure 15.66.

� CAUTION
• Do not over tighten the securing bolts when installing the PCB (4) to the bracket assembly
(5), this may cause damage to the PCB.

PROCEDURE
1. Align the PCB (4) with the bracket assembly (5), secure the PCB to the bracket with bolts
(7) washers (9) and lockwashers (8) (8 off). Do not over tighten the bolts.

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 Electrical System 15

(2) Installation
Numbers in parentheses refer to Figure 15.66, unless otherwise specified.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Align the PCB (4) and bracket assembly (5) with the cab mounting.
2. Install the (LHS) bottom bolt (2) and washer (3), do not fully tighten at this time.
3. Remove the blanking caps from the PCB electrical harness connections, identify and
secure the connections to the PCB as follows:
• A1.X32
• A1.X30
• A1.X29
• A1.X28
• A1.X27
• A1.X26
• A1.X25
• A1.X24
• A1.X23
• A1.X22
• A1.X21
• A1.X20
4. Install and secure the top two bolts (2) and washers (3), secure the (LHS) bottom bolt
(2) and washer (3).
5. Identify the PCB electrical connections X2.a, X7.a, X6.a and X1.a. Connect and secure
connections X2.a, X7.a, X6.a and X1.a.
6. Install bolts (2) and washers (3), and secure the cover plate (1) to the PCB.
7. Install and tighten the retaining strap (6).
8. Return the operators seat to the driving position.
9. Connect the battery supply cable, and the battery ground cable. Select the battery master
switch to the ‘ON’ position.
10. Turn master switch on, check the dashboard display screen for any error codes. Investigate
and rectify any error codes displayed.
11. Place the steering lock bar in the ‘Stowed’ position, remove wheel blocks from all road
wheels.

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15.7 DC/DC Convertor

(1) Description
The DC/DC convertor produces a regulated 12V DC supply, required for various machine
services.

MOT04845

Figure 15.68 - DC/DC Convertor

4
3
MOT05323

Figure 15.69 - DC/DC Convertor Mounting

1. DC/DC Convertor 3. Bolt 4. Washer
2. TCU/DC/DC Bracket

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 Electrical System 15

(2) Removal

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

� WARNING
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the 'OFF' position before removing any components. Remove battery
ground cable first, and reconnect last, to avoid damaging electrical components.

NOTICE
• The DC/DC Convertor is located on the same mounting bracket as the TCU and adjacent
to the PCB, on the rear cab wall.

Refer to Figure 15.69 and Figure 15.68, unless otherwise specified.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Operate the treadle valve continuously to discharge the accumulators, block all road
wheels, place the steering lock bar in the 'Locked' position and the battery master switch in
the 'OFF' position.
3. Disconnect the battery ground cable first, then the battery supply cable, before
disconnecting electrical harness from the convertor inside the cab.
4. Tag and identify the electrical connections to the convertor as follows:
• Cable T1.+12V (‘W149’) from the connection labelled ‘OUTPUT 13.5VDC’
• Cable T1.12V_XGND (‘W155’) from the connection labelled ‘MINUS’
• Cable T1.24V_XGND (‘W156’) from the connection labelled ‘MINUS’
• Cable T1.+24V (‘W148’) from the connection labelled ‘INPUT +18 - 30VDC’
5. Disconnect connections, cap connections to prevent ingress of dirt.
6. Remove the bolts (3) washers (4) securing the convertor (1) to the bracket (2).
7. Transport the convertor to a clean maintenance area.

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15 Electrical System

(3) Installation
Refer to Figure 15.69 and Figure 15.68, unless otherwise specified.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.
• The DC/DC Convertor is located on the same mounting bracket as the TCU and adjacent
to the PCB, on the rear cab wall.

PROCEDURE
1. Secure the convertor (1) to the mounting bracket (2) with bolts (3) and washers (4).
2. Identify the electrical connections to the convertor, remove protective caps and connect
as follows:
• Cable T1.+12V (‘W149’) from the connection labelled ‘OUTPUT 13.5VDC’
• Cable T1.12V_XGND (‘W155’) from the connection labelled ‘MINUS’
• Cable T1.24V_XGND (‘W156’) from the connection labelled ‘MINUS’
• Cable T1.+24V (‘W148’) from the connection labelled ‘INPUT +18 - 30VDC’
3. Connect the battery supply cable, and the battery ground cable. Select the battery master
switch to the ‘ON’ position.
4. Check the dashboard display screen for any error codes. Investigate and rectify any error
codes displayed.
5. Place the steering lock bar in the ‘Stowed’ position, remove wheel blocks from all road
wheels.

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 Electrical System 15

15.8 Battery Box Assembly

MOT04984

MOT05416

Figure 15.70 - Battery Box and Mounting

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15 Electrical System

1. Battery Box Door 20. Bracket - Elect 39. Shim - 4 mm

2. Latch Assembly 21. Bolt 40. Shim - 8 mm
3. Plate 22. Screw 41. Bolt - Hook
4. - 23. Plate - Stiffener 42. Washer
5. Bracket - Door Prop 24. Bulk Head Assy 43. Locknut
6. Bolt 25. Bracket 44. Thread Cover
7. Washer 26. Bolt 45. Clamp - Pad
8. Washer 27. Lockwasher 46. Pad
9. Plate Prop 28. Washer 47. Frame - Cable Entry
10. Bush 29. Washer 48. Frame - Cable Entry
11. Locknut 30. Bolt 49. Kit - Insert
12. Bolt 31. Washer 50. Kit - Insert
13. Washer 32. Locknut 51. Cap Screw
14. Battery Tray Assy 33. Bolt 52. Hinge RH
15. Nylon Strip LH 34. Washer Hardened 53. Hinge LH
16. Nylon Strip RH 35. Bolt 54. Plate - Hinge
17. Seal - Door Assy 36. Locknut 55. Plate - Hinge
18. Plate Bent - Latch 37. Washer 56. Screw
19. Bolt 38. Shim - 2 mm

(1) Description
The Battery Box Assembly is part of the Hydraulic Tank /Battery Box Assembly (refer to, (1)
Description on page 11-25) and is located on the forward Left Hand Side (LHS) of the machine.
The assembly is a sealed/weatherproof compartment containing the following components:
• Two 12 V batteries - C1 and C2.
• Fuse box - F1
• Power relays - KA1, KA2 and K2.
• Battery Master Switch - S1.
• Battery Power LED - P1.
• Hood Raise /Lower Switch - X32.
• Cabin Tilt Hand Pump - (Hand Pump Handle).
• Engine lifting brackets - (Scania supplied).

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(2) Removal

� CAUTION
• When the Battery Master Switch is selected OFF he adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

� WARNING
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the 'OFF' position before removing any components. Remove battery
ground cable first, and reconnect last, to avoid damaging electrical components.

Numbers in parenthesis refer to Figure 15.70, unless otherwise specified.

Also refer to (1) Description on page 11-25.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Operate the treadle valve continuously to discharge the accumulators, block all road
wheels, place the steering lock bar in the 'Locked' position and the battery master switch in
the 'OFF' position.
3. Tag an identify the battery ground connection (- ve) (C1.X-). Disconnect cable (C1.X-) from
the batteries, cap connection to prevent ingress of dirt.
4. Remove the batteries, as required. Refer to (a) Removal on page 15-59.
5. Tag an identify the electrical harness connections to the battery box assembly as follows:
• Cab harness - Hood Switch, S32
• Cab harness - Hood Lift, Fuse Box - F1.3a
• Cab harness - Cabin connector box (X42), Fuse Box - F1.1b
• Cab harness - Cabin connector box (X42), Power Relay - K2..X88a
• Cab harness - Connector (X41) and Ground (XGND1.b) - K2.X1
• Battery ground connection, -ve Power Relay - KA1.X88a
• Starter Motor connection, Fuse Box - F1.30
6. Disconnect harness cables, cap connection to prevent ingress of dirt.
7. Remove bolts (51) and the bolts from top of the cable entry frames (47 and 48), separate
the clamp assemblies and remove the grommet surrounding the harness’s.
8. Carefully feed the disconnected harness’s through the bulkhead.
9. Ensure all harnesses and cables are secure before removing the Hydraulic Tank/Battery
Box assembly. Refer to (3) Removal on page 11-29.

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15 Electrical System

(3) Disassembly
Disassembly of the battery box minor components, are on an as required basis.
Major components are removed for maintenance and for ease of access.

PROCEDURE
1. For removal of the batteries, refer to (a) Removal on page 15-59.
2. For removal of the fuse box, refer to (b) Removal on page 15-62.

(4) Assembly
Major components are installed after maintenance and after removal for access.
Assembly of the battery box minor components, are on a as required basis.

PROCEDURE
1. For installation of the batteries, refer to (b) Installation on page 15-60.
2. For installation of the fuse box, refer to (c) Installation on page 15-64.

(5) Installation
Numbers in parenthesis refer to Figure 15.70, unless otherwise specified.
Also refer to (1) Description on page 11-25.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. For the installation of the Hydraulic Tank/Battery Box assembly to the front frame, refer
to (6) Installation on page 11-36.
2. Carefully feed the cab harness through the whole for cable entry assembly (47), and the
battery ground cable and the starter cable through the whole for cable entry assembly (48).
3. Identify the electrical harness connections to the battery box assembly, remove blanking
caps, connect and secure as follows:
• Starter Motor connection, Fuse Box - F1.30
• Battery ground connection, -ve Power Relay - KA1.X88a
• Cab harness - Connector (X41) and Ground (XGND1.b) - K2.X1
• Cab harness - Cabin connector box (X42), Power Relay - K2..X88a
• Cab harness - Cabin connector box (X42), Fuse Box - F1.1b
• Cab harness - Hood Lift, Fuse Box - F1.3a
• Cab harness - Hood Switch, S32
4. Install the cable entry frame (47 and 48) grommets, install the bolts to the top of the panel
and secure the clamp assemblies.
5. Install bolts (51) and secure the cable entry frames to the battery box bulkhead.

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6. Install batteries if removed, refer to, (b) Installation on page 15-60.

7. Identify the battery ground connection (- ve) (C1.X-). Remove blanking caps, connect cable
(C1.X-) and secure to the battery. Coat the terminal with petroleum jelly if required.
8. Select the Battery Master Switch to the ‘ON’ position. Ensure that the battery LED
indication is illuminated.
9. Check the dashboard display screen for any error codes. Investigate and rectify any error
codes displayed.

(6) Battery
Numbers in parenthesis refer to Figure 15.70, unless otherwise specified.
There are two 12 V batteries electrically connected in series to produce an output of 24 V.
The batteries are located on a tray assembly (5), that is installed on slide assemblies (2, 3)
mounted in the battery box assembly.
The battery tray (5) slides forward to enable access to the batteries.
(a) Removal

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

� WARNING
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the OFF position before removing any components. Remove battery
ground cable first, and reconnect last, to avoid damaging electrical components.

Numbers in parenthesis refer to Figure 15.70, unless otherwise specified.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Operate the treadle valve continuously to discharge the accumulators, block all road
wheels, place the steering lock bar in the 'Locked' position and the battery master switch in
the 'OFF' position.
3. Open door assembly (1) to gain access to the batteries.
4. Ensure the battery master switch is in the ‘OFF’ position and that the battery indicator
LED is extinguished.
5. Tag an identify the electrical ground connection (- ve) (C1.X-). Disconnect cable (C1.X-)
from the batteries, cap connection to prevent ingress of dirt.
6. Remove bolts (21) and washers (13) securing the tray assembly (14) to the battery box
assembly.
7. Carefully slide the tray assembly (14) forward.
8. Tag an identify the electrical connection (+ ve) (C2.X+). Disconnect cable (C2.X+) from the
batteries, cap connection to prevent ingress of dirt.

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15 Electrical System

9. Tag an identify the electrical harness connections (+ ve) (C1.X+) and (- ve) (C2.X-)
connecting the two batteries. Disconnect cables (+ ve) (C1.X+) and (- ve) (C2.X-) from the
batteries, cap connections to prevent ingress of dirt.
10. Remove the clamps securing cables (- ve) (C1.X-) and (+ ve) (C2.X+) to the pad clamp
assemblies (45).
11. Remove thread covers (44) locknuts (43) and washers (42) securing the bolt hooks (41).
Remove the pad clamp assemblies (45) and the bolt hooks (41).
12. Using a suitable lifting device, remove the battery C1 and C2, and transport to a clean
maintenance area.

(b) Installation
Numbers in parenthesis refer to Figure 15.70, unless otherwise specified.

NOTICE
Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Ensure that the battery pads (46) are installed on the battery tray assembly (14) and that
the tray is in the forward position.
2. Using a suitable lifting device, lift the battery C1 and C2, and place on the tray assembly
(14).
3. Install the bolt hooks (41) and pad clamp assemblies (45). Secure with locknuts (43) and
washers (42), torque tighten to 10 Nm (7.4 lbf ft). Install thread covers (44) to bolts hooks
(41).
4. Install the clamps securing cables (- ve) (C1.X-) and (+ ve) (C2.X+) to the pad clamp
assemblies (45).
5. Identify the electrical harness (+ ve) (C1.X+) and (- ve) (C2.X-) connecting the two batteries.
Remove protective caps and connect cables (+ ve) (C1.X+) and (- ve) (C2.X-) to the
batteries. Coat the terminals with petroleum jelly if required.
6. Identify the electrical connection (+ ve) (C2.X+). Remove protective cap and connect cable
(+ ve) (C2.X+) to the battery. Coat the terminal with petroleum jelly if required.
7. Carefully slide the tray assembly (14) into the box assembly.
8. Using bolts (21) and washers (13) secure the tray assembly (14) to the battery box
assembly.
9. Identify the electrical ground connection (- ve) (C1.X-). Remove protective cap and connect
cable (- ve) (C1.X-) to the battery. Coat the terminal with petroleum jelly if required.
10. Select the Battery Master Switch to the ‘ON’ position. Ensure that the battery LED
indication is illuminated.
11. Turn master switch on, check the dashboard display screen for any error codes. Investigate
and rectify any error codes displayed.
12. Ensure that the Alternator Charging warning light (6, Figure 15.74) is not illuminated.

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 Electrical System 15

(c) Maintenance
Check the battery voltage with a multimeter with a minimum 2 figure resolution (i.e. 12.35 V)
Batteries require recharging when the voltage is below 12.40 V.
Battery acid level checks and any necessary filling must be conducted every 500 hours.
Battery levels should be maintained at 7 mm (0.25 in) below the lid-skirt (covering the top of
the separators).
Only distilled and deionized water can be used to top up the battery. Do not use mineral water,
as the constituent impurities are known to accelerate self-discharge and water loss.
At no point during operation or storage should the plates\separators be allowed to be exposed,
above acid level.
Batteries should be allowed to rest for no less than 1 hour after recharge, prior to filling. This
will allow the acid to stabilize in the event that it was gassing off during recharge.
The batteries should be topped up when fully charged, i.e, >12.40 V. Acid expands as the state
of charge increases, so there is a risk of overfilling the battery when filled in a discharged state.
If this is unavoidable and the battery is in a discharged state, add sufficient water to cover the
plates\separators. Once recharged, the acid level should be re-assessed.

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15 Electrical System

(7) Fuse Box

(a) Description

MOT04847

Figure 15.71 - Fuse Box

1. Bolt - Stud 2. Washer 3. Locknut

Refer to Figure 15.70.

The Fuse box is located in the Battery Box Assembly, and is installed on the back plate
assembly (20).
Fuse Box (F1), distributes the electrical power from the batteries to various services on the
machine.
The input to the fuse box (F1.+Ubat) from the battery is via the energized power relay
(KA2.X88a) when the master switch S1 is selected to the ‘ON’ position.
The outputs from the fuse box are as follows:
• Starter Motor M1 - direct connection (F1.30)
• PCB (via TB X42) - via fuse F1.1 (F1.1b)
• Power Relay K2 - via fuse F1.2 (F1.2b)
• Hood Lift Switch S32 - via in-line fuse F1.3 (F1.3a)
• Battery Indication LED P1 - via in-line fuse F2 (X4.1)
(b) Removal

� WARNING
• High electrical current can cause sparks and personal injury from burns. Turn battery
master switch to the OFF position before removing any components. Remove battery
ground cable first, and reconnect last, to avoid damaging electrical components.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

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 Electrical System 15

MOT04848

Figure 15.72 - Fuse Box Connections

Refer to Figure 15.72, unless otherwise indicated.

PROCEDURE
1. Position the machine in a level work area, ensure the body is fully lowered, apply the
parking brake and switch off the engine.
2. Remove the batteries. Refer to (a) Removal on page 15-59.
3. Remove the Fuse Box cover.
4. Tag and identify the Fuse Box connections, as follows:
• Starter Motor M1 - direct connection (F1.30)
• PCB (via TB X42) - via fuse F1.1 (F1.1b)
• Power Relay K2 - via fuse F1.2 (F1.2b)
• Hood Lift Switch S32 - via in-line fuse F1.3 (F1.3a)
• Battery Indication LED P1 - via in-line fuse F2 (X4.1)
• Battery input (F1.+UBat)
5. Disconnect the connections, cap all connections to prevent ingress of dirt.
6. Remove the locknuts and washers (3 and 2, securing the fuse box assembly to the back
plate assembly (20, Figure 15.70). Remove the fuse box assembly and transport to a
clean maintenance area.

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15 Electrical System

(c) Installation
Refer to Figure 15.72 and Figure 15.70.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in 22.3
Standard Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Install the locknuts and washers (3 and 2, Figure 15.71) and secure the fuse box assembly
to the back plate assembly (20, Figure 15.70).
2. Identify the Fuse Box connections, remove protective caps and connect using the hardware
provided, as follows:
• Starter Motor M1 - direct connection (F1.30). Torque tighten to 33 Nm (24.3 lbf ft)
• PCB (via TB X42) - via fuse F1.1 (F1.1b). Torque tighten to 20 Nm (14.7 lbf ft)
• Power Relay K2 - via fuse F1.2 (F1.2b). Torque tighten to 20 Nm (14.7 lbf ft)
• Hood Lift Switch S32 - via in-line fuse F1.3 (F1.3a) and Battery Indication LED P1 - via
in-line fuse F2 (X4.1). Torque tighten to 4 Nm (2.9 lbf ft)
• Battery input (F1.+UBat). Torque tighten to 33 Nm (24.3 lbf ft)
3. Install the Fuse Box cover.
4. Install the batteries. Refer to (b) Installation on page 15-60.
5. Select the Battery Master Switch to the ‘ON’ position. Ensure that the battery LED
indication is illuminated.
6. Check the dashboard display screen for any error codes. Investigate and rectify any error
codes displayed.

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 Electrical System 15

15.9 Control and Display Elements

(1) Controls and Instruments

Figure 15.73 - Controls and Instruments

1. Side Window Demister 14. Trans Diff Lock Request 27. Engine Start / Stop Switch
Switch
2. Accessories Panel 15. Retarder Lever 28. Power Key Switch
3. Hazard Warning Lights 16. Heated Mirrors (Optional) 29. Steering Wheel
4. N/A 17. Rear Working Lights 30. Steering Wheel
(Optional) Adjustment Lock
5. Display Menu Switch 18. Beacon Switch (Optional) 31. 12V / 24V Jack Points
6. Menu Navigation Switch 19. Rear Fog Lamp (Optional) 32. Lights, Wiper / Wash,
Horn, Indicators
7. N/A 20. Park / Emergency Brake 33. Radio Facia
8. Rear Wash / Wipe 21. Heater Vent 34. Heater/Air Conditioner
9. Display Screen 22. Transmission Gear Shift 35. Printed Circuit Board
10. Dropbox LO - HI Switch 23. Body Control Lever 36. Battery Master Switch
11. Transmission Retarder 24. Cup Holder 37. Rear View Camera
Request Switch
12. Engine Exhaust Brake 25. Accelerator Control
Request Switch
13. N/A 26. Service Brake Control

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15 Electrical System

(2) Displays
Operation of the machine is supported by a combined dashboard display. The dashboard
display provides machine information through various gauges and indicators. In addition the
dashboard display also provides up to 36 digital inputs. These inputs are mostly used as inputs
for the rocker switches on the dashboard.
The meanings of all LED Indicators are given in the following pages.
The dashboard display consists of the following:
• Warning lights and symbols
• Instruments
• 3.5” color display and buttons.
(a) Functional Description

Figure 15.74 - Warning Lights and Symbols Figure 15.75 - Warning Lights and Symbols
- Left - Right

Warning Lights and Symbols - Left of Dashboard Display

Engine Coolant Level Low(1) - Illuminates when the coolant level drops below the safe
operating level. Refer to Figure 15.74.
Engine Oil Pressure Low (2) - Illuminates when the engine oil pressure drops below the safe
operating pressure. Refer to Figure 15.74.
Engine Stop Light (3) - When the 'Stop Engine' light comes on, the MCU has detected a major
malfunction in the engine that requires immediate attention. It is the operator’s responsibility to
shut down the engine to avoid serious damage. Refer to Figure 15.74.

NOTICE
• The Fault Codes are displayed in the Diagnostic Display Screen.

Engine Check Light (4) - When the 'Check Engine' light comes on, the MCU has detected
a fault in the engine. The fault must be diagnosed and corrected at the earliest opportunity.
Refer to Figure 15.74.
Engine Exhaust Brake (5) - Indicates that the engine exhaust brake has been requested and
is active. It remains active until the brake is deactivated. Refer to Figure 15.74.
Alternator Charging (6) - Indicates that the system batteries are in a state of undercharging or
battery voltage low. Refer to Figure 15.74.
Parking Brake (7) - Illuminates when the parking brake is applied. Refer to Figure 15.74.

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 Electrical System 15

Air Restriction Filter Indicator (8) - Illuminates to warn of contamination with the engine air
filter. Replace the air filter. Refer to Figure 15.74.
Warning Lights and Symbols - Right of Dashboard Display
Transmission Retarder Active (1) - Illuminates when the transmission retarder is active.
Refer to Figure 15.75.
Engine Over Speed Active (2) - Illuminates when the engine speed rises above the safe
operating speed (Engine Speed > 2300 RPM). The operator must take action to slow the
vehicle. Refer to Figure 15.75.
Hydraulic Oil Level Low (3) - Illuminates when the hydraulic oil drops below a safe operating
level. Stop the truck and fill the oil. Refer to Figure 15.75.
Hydraulic Oil Filter Restriction (4) - Illuminates to warn of contamination within the hydraulic
oil filter. Replace the oil filter. Refer to Figure 15.75.
Rear Brakes Accumulator Pressure Low (5) - Illuminates to warn of low pressure in the rear
brake system accumulator. A buzzer also sounds. If the light illuminates, stop the machine and
investigate the cause. Refer to Figure 15.75.
Body UP Indicator Lamp (6) - Indicates that the body has been raised and it is off the chassis
bed. Transmission upshift is restricted while the light is illuminated. Refer to Figure 15.75.
Front Brakes Accumulator Pressure Low (7) - Illuminates to warn of low pressure in the front
brake system accumulator. A buzzer also sounds. If the light illuminates, stop the machine and
investigate the cause. Refer to Figure 15.75.
Transmission Check Light (8) - Illuminates when a fault has been detected by the TCU. The
fault must be diagnosed and corrected at the earliest opportunity. Refer to Figure 15.75.
Warning Lights and Symbols - Below Dashboard Display

Figure 15.76 - Warning lights and symbols - Figure 15.77 - Control Stock Switch
Below

NOTICE
• The indicator flash is accompanied with an audible buzzing sound.

High Beam (1) - Illuminates when high beam is switched on. Refer to Figure 15.76.
Direction Indicators (2) - Flashes when the indicator lights (left or right) are operating. Refer
to Figure 15.76.
Lights ON (3) - Is ON if the control stock switch is set to headlights ON or working lights
ON. Refer to Figure 15.76 and Figure 15.77.

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15 Electrical System

Instruments

MOT05430

Figure 15.78 - Dashboard Display

Tachometer (1) - Driven from the engine MCU, the tachometer indicates the number of engine
crankshaft revolutions per minute. The needle shows the variations in engine operating speed.
Never accelerate the engine to speeds indicated by the red zone on the dial face. Refer
to Figure 15.78 and Figure 15.79.
Speedometer (2) - The speedometer indicates travel speed in kilometers per hour (displayed
white) and miles per hour (displayed yellow). A digital display is centered at the base of the
speedometer, consisting of a two line LCD. The upper line displays total engine hours or total
distance traveled in kilometers or miles. The lower line indicates trip distance run since last
reset in kilometers or miles. Refer to Figure 15.78 and Figure 15.80.

MOT05431

Figure 15.79 - Tachometer

Figure 15.80 - Speedometer

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 Electrical System 15

Fuel Level Gauge (3) - Indicates fuel level within the tank. If the fuel level drop below 25%
a warning light (3a) on the instrument display illuminates. Fill the tank overnight to minimize
condensation in the tank. Avoid a dry tank condition, as it results in a requirement in bleeding
the fuel system. Refer to Figure 15.78 and Figure 15.81.
Hydraulic Oil Temperature Gauge (4) - Indicates hydraulic oil operating temperature. The
gauge must read in the white zone during normal operation. If the temperature increase (above
80 Degree), a warning light (4a) on the instrument display illuminates. If the gauge reads in the
red zone, stop the machine and investigate the cause. Refer to Figure 15.78 and Figure 15.82.

Figure 15.81 - Fuel Level Gauge Figure 15.82 - Hydraulic Oil Temperature
Gauge

Transmission Oil Temperature Gauge (5) - Indicates transmission oil operating temperature.
The gauge must read in the white zone during normal operation. If the gauge reads in the
red zone and the warning light (5a) on the instrument display illuminates, stop vehicle and
investigate the cause. Refer to Figure 15.78 and Figure 15.83.
Engine Coolant Temp Gauge (6) - This gauge must read in the white zone after the engine
has warmed. If the gauge reads in the red zone the warning light (6a) on the instrument display
illuminates. Stop the engine and investigate the cause. Refer to Figure 15.78 and Figure 15.83.

Figure 15.83 - Transmission Oil Temperature Gauge

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15 Electrical System

(b) Menus
Menu Screen and Buttons

NOTICE
• At all times make sure all gauges, warning lights and controls are working correctly before
operating the machine.
• When removing the Giga Panel (Figure 15.85) do not use sharp objects to lever the panel
out as this will result in damage. Kneel on the cab floor, place your hands behind the panel
and apply gentle pressure with your fingers until it releases.

2 3

MOT05086

Figure 15.84 - Dashboard Display — Giga Panel

Figure 15.85 - Giga Panel Removal

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 Electrical System 15

Menu Screen (1) - above image shows the sequential display in its five possible screens. On
initial starting of the vehicle, the display shows the Power Up Screen and then automatically
scrolls to the Main Screen. Refer to Figure 15.84.
Left Menu Control Button (2) - The "Display-Menu OK Switch" is used to change values
(brightness setup, setting date/time, and so on). It is also used as ‘ENTER / OK’ button in
particular situations. The "Display-Menu OK Switch", also called the "Left Menu Control
Button". Refer to Figure 15.84.
The Dashboard display screen provides a 320 x 240 pixel color display, used as a flexible
operator information device. There are several different screens displayed during power-up,
normal operation, body lift, brightness, and date/time setup and engine and transmission
diagnostics.
Right Menu Control Button (3) - Switching between the different screens is performed
automatically, depending on the current active function. Alternatively a screen can be chosen
manually with the "Display-Menu (+)(-) Switch" (refer to (3) Switches on page 15-75) on
Dashboard or by using "Right Menu Control Button" on the Dashboard display. Refer to Figure
15.84.
Screen - 1:
Power Up Screen
The Date (1) and Time (2) are displayed at the bottom of the screen. Dashboard display
software version (4) and MCU software version (3) are displayed at the top of the screen.
Refer to Figure 15.86.

GIGA V01.05.01 4
TA400
MCU HV008 SV08.08.08
3

88.88.2016 88.88.88

1 2
MOT05087

Figure 15.86 - Power Up Screen Figure 15.87 - Main Screen

Screen - 2:
Main Screen
Main Screen displays several indicators, as shown.
Gear Indicator (1) - The GEAR INDICATOR displays information relating to the transmission
status. The indicator displays the gear selected and drive direction. Colored arrow indicates the
drive direction:
Green = Forward, Red = Reverse.
Refer to Figure 15.87.
Dropbox, High Ratio Selected (2) - Indicates that the dropbox is engaged in high ratio shown
or low ratio. This display flashes and a warning alarm will sound to show and alert that a range
change has been requested. Refer to Figure 15.87.
Dropbox Differential Lock Engaged (3) - Displays once the dropbox differential Lock is
engaged. Refer to Figure 15.87.

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15 Electrical System

Steering Oil Pressure Low (4) - Illuminates to warn of a fault in the steering system supply
pressure. Illuminates when the ignition is turned on and pressure is low. If the light illuminates,
stop the machine and investigate the cause. Refer to Figure 15.87.

NOTICE
• Dropbox High / Low Oil Pressure and Exhaust System Fault Indicator appears alternatively
in about 2-seconds cycle time to warn of a fault in the system.

Dropbox Oil Temperature High (5) - Indicates that dropbox oil temperature is at a level higher
than the prescribed operating range and must be investigated. Refer to Figure 15.87.
Front Windscreen Wiper Intermediate Status Bar (7) - Displays the speed stage at which
the wiper is operating. The front windscreen wiper intermediate Status Bar (8) is shown just
as the control stock wiper switch is set to “Intermediate” position. The intermediate status can
be set from step 1 (slow - 15-sec pause time) to step 6 (fast – 0-sec pause time) by using the
“Display-Menu (+)(-) Switch”. Refer to Figure 15.87.
MCU Error Code (8) - Refer to 5.8 List of Fault Codes on page 5-14 for MCU error codes. The
error codes are displayed in sequence in intervals of 1 sec. Refer to Figure 15.87.
Fuel Consumption Indicator (9)- Displays 3 possible indications on fuel consumption.
1 Total fuel consumption since last reset in liters (Refer to Figure 15.88).
2 Average fuel consumption since last reset in liters / hour (Refer to Figure 15.89).
3 Instantaneous fuel consumption in liters / hour (Refer to Figure 15.90).
A normal short click, on the left menu control button toggles the display between the 3 possible
indications. The indicator can be set to zero by pressing Left Menu Control Button for 2 seconds.

Figure 15.88 - Total Fuel Figure 15.89 - Average Fuel Figure 15.90 - Instantanious
Consumption Consumption Fuel Consumption

Dropbox High / Low Oil Pressure (10) - Indicates that the dropbox oil pressure is above the
prescribed operating range and must be investigated. Refer to Figure 15.87.
Battery Voltage Indicator (11) - Indicates the power supply voltage of the machine. In the
normal condition, the indicator glows green. When the voltage drops below 24 V, the indicator
glows yellow. When the voltage drops below 20 V, the indicator turns red. Recharge the battery
or replace with a new one. Refer to Figure 15.87.
Brake Cooling Oil Temperature (12) - Indicates that brake cooling oil temperature is above
the prescribed operating range and must be investigated. Refer to Figure 15.87.

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 Electrical System 15

Screen - 3:
Body Up Screen
The “Body Up Screen” appears automatically once the body control lever has been activated for
more than 2 seconds. It shows the current state of the body depending on the signal coming
from the body proximity switch. Refer to Figure 15.91.
‘Body Up’ Indicates that the body has been raised and it is off the chassis bed. Transmission
upshift / vehicle movement is restricted while the light is illuminated.
The “Body Up Counter” is incremental after each “regular” body up/down cycle.
A few seconds after the body proximity switch signal has changed from “Body is UP” to “Body is
DOWN” position the display returns to main screen. Refer to Figure 15.92.
Whenever body up screen is displayed, the counter can be set to zero by pressing the “Left
Menu Control Button” on dashboard display for 2 seconds.

Figure 15.91 - Body Up Screen Figure 15.92 - Body Down Screen

Screen - 4:
Brightness and RTC Setup Screen
This screen allows separate setting of the LCD and instruments backlight values of the
dashboard display. There are two different value settings, adjustable for day (Control Stock
Lights Switch OFF) and night (Control Stock Lights Switch ON - 1). Refer to Figure 15.93.
This screen is chosen - by using the “Display-Menu (+)(-) Switch” or the dashboard display’s
“Right Menu Control Button”. When this screen is chosen, pressing the dashboard display’s
“Left Menu Control Button” leads into a deeper menu level. A green arrow appears on the left
and points to the first item “DISPLAY BACKLIGHT”.
Now, the value can be changed circular from 1024,1000,900, … ,100,80,…,20,…1024,… by
tapping the dashboard display’s “Left Menu Control Button”.
The symbol on the right indicates that the “Control Stock Lights Switch” is set to ON. You
can adjust different values for day - Control Stock Lights Switch OFF - and night - Control
Stock Lights Switch ON.
The green arrow can be moved to the next item by pushing the “Right Menu Control Button”.
When the green arrow points to the Date or Time item, the “Right Menu Control Button” moves
to a green underline. The green underline tags the day, month, year, hour, second, minute
value that can be changed with the “Left Menu Control Button”.

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15 Electrical System

NOTICE
• The Trip Distance can be set to zero by pressing Right Menu Control Button for 2 seconds.

The following values in the Odometer LCD correspond to the codes in the LCD mode:
0 - Total engine hours
• Trip distance since last reset (in kilometers)
1 - Total driven distance (in kilometers)
• Trip distance since last reset (in kilometers)
2 - Total engine hours
• Trip distance since last reset (in miles)
3 - Total driven distance (in miles)
• Trip distance since last reset (in miles)

Figure 15.93 - Screen Setup Figure 15.94 - Diagnostic Screen

Screen - 5:
MCU / TCU Diagnostic Screen
The Diagnostic Screen shows the current Fault Status of the engine and the transmission.
ENGINE DIAGNOSTICS is based on the Message sent by the MCU via CAN. The MCU sends
not more than 10 Fault Codes and the status of the amber warning lamp and the red stop lamp.
The amber warning lamp light comes on when the MCU has detected a fault in the engine. The
red stop lamp light comes on when the MCU has detected a major malfunction in the engine
that requires immediate attention. If there is more than 1 fault active, the Suspect Parameter
Number (SPN), Failure Mode Identifier (FMI), and Occurrence Count (OC) displays cyclically
in 1-second interval. Refer to Figure 15.94.
TRANSMISSION DIAGNOSTICS is based on the message sent by the TCU via CAN. The TCU
sends not more than 5 fault codes and the status of amber warning lamp. The amber warning
lamp light comes on when the TCU has detected a fault in the transmission. If there is more
than 1 fault active, the Suspect Parameter Number (SPN) and the Failure Mode Identifier (FMI)
is displayed cyclically in 1-second interval.
The display indicates gear selected in automatic mode and the actual gear active in automatic
mode and the driving direction.

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 Electrical System 15

(3) Switches

� WARNING
• Do not start the engine when the battery master switch is in the OFF position and the light
adjacent to the battery master switch is ON. Refer to Battery Master Switch and Indicator
Light .

NOTICE
• By default the dropbox dfifferential lock is in automatic mode (ON).
• The transmission retarder begins to operate when the engine is operating above 1000 RPM.
• It is only possible to select dropbox HI or LO ratio when certain conditions are met.
• Hazard warning light illumination is possible when the switch is in 0. Refer to Figure 15.99.
• When the Power Key Switch is in the ON position ‘1’ the ‘Display Screen’ starts up.
Sequentially all the indicators are ON and the instruments touch the maximum indicative
value before returning to the minimum.

Figure 15.95 - Left of Instrument Panel Figure 15.96 - Right of Instrument Panel

Hazard Warning Lights (1) -Press the bottom of the switch to make the indicators flash
simultaneously as hazard warning lights. The direction indicator warning lamp on the instrument
panel flashes (ensure that the ignition / power is ON). To switch the hazard lights off, press
the top of the switch. Refer to Figure 15.95.
N/A (2)
Cancellation Buzzer Switch (3) - This switch is used to switch off the buzzer by keeping it
pressed for 4 seconds, when engine is not running. Refer to Figure 15.95.
Display Menu Navigation Switch (4) - Switching between the different screens using this
switch. Refer to Figure 15.95.
N/A (5)
Rear Wash/Wipe (6) - Press the bottom of the switch to operate the rear screen wiper. Press
the switch and hold for wash. To switch off, press the top of the switch. Refer to Figure 15.95.

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15 Electrical System

Engine Exhaust Brake Request Switch (7) - There are 2 positions for the switch. To request
the engine exhaust brake, press the top of the switch. This position applies the engine
exhaust brake when the service brake is applied. Press the bottom of the switch and the
engine exhaust brake activates when the throttle pedal is released. The engine exhaust brake
symbol illuminates on the display screen when the engine exhaust brake is engaged. Refer
to Figure 15.96.
N/A (8)
Dropbox Differential Lock Request Switch (9) - Press the bottom the switch to engage the
dropbox differential lock in manual mode. The differential lock warning lamp on the instrument
panel illuminates when the function is activated. Pressing the switch to the Off position
disengages the differential lock. Refer to Figure 15.96.
Transmission Retarder (manual) Switch (10) - This switch is used to slow the machine or
maintain a steady speed on declines. The retarder prevents the machine 'running away' by
accelerating down the decline. Refer to Figure 15.96 and Figure 15.97.
There are 3 positions for the switch.
Position A
Transmission retarder request OFF.
In this position, there is no transmission retarder.
Position B
Transmission retarder request ON.
This position applies the transmission retarder when service brake is applied.
Position C
Transmission retarder request ON.
This position applies the transmission retarder when throttle pedal is not active
Dropbox HI - LO Switch (11) - Pressing the bottom of the switch engages the low gear ratio in
the dropbox. With the switch in the off position the dropbox defaults to the high ratio. Refer
to Figure 15.96.
The relevant high/low ratio symbol illuminates on the Dashboard display screen.
Retarder Lever (12) - The transmission retarder has six stages of retardation. When the
retarder is engaged, it is at its maximum level when the retarder lever is in its down most
position. When the lever is at its uppermost position, the retarder is Off. Refer to Figure 15.96.
Heated Mirrors (13)- Press the bottom of the switch to activate the heated mirrors. To switch
off, press the top of the switch. Refer to Figure 15.98.

Figure 15.97 - Transmission Retarder Switch Figure 15.98 - Optional Switches

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 Electrical System 15

Rear Working Lights (14) - Press the bottom of the switch to operate the rear working lights.
To switch off, press the top of the switch. Figure 15.98.
Flashing/Rotating Beacon (15) - Press the bottom of the switch to operate the flashing/rotating
beacon. To switch off, press the top of the switch. Figure 15.98.
Rear Fog Lamp (16) - Press the bottom of the switch to operate the rear fog lamp. To switch
off, press the top of the switch. Figure 15.98.
Power Key Switch (17) - The switch is used for switching power ON and OFF. There are two
positions for the switch. Figure 15.99 and Figure 15.100.
'0' - Power switched off. All electrical systems are inoperative.
'1' - Power switched on, instruments, gauges, and warning lights register as appropriate. All
electrical systems are operative. The key must remain in this position while operating the
machine. Refer to Figure 15.99.
Press the Start / Stop switch to start the engine. On pressing the switch again, the engine
stops. Refer to Figure 15.100.

Figure 15.99 - Power Key Switch Figure 15.100 - Start / Stop Button

After a few seconds, the buzzer alarm sounds to indicate that the power is still ON.
On switching the key from 1 to 0, the power goes off. The engine will go to low idle and after 3
seconds the engine stops.
Diagnostic Test Point (18) - Test points are at the right-hand side of the cabin. Refer to Figure
15.101. The test point comprises a 4 plug-in connector for:
1) X36 CAN-4: Diagnostic Bus - For special Diagnostic Equipment
2) X35 CAN-3: HMI Bus - Dash Board, Steering Lever switch
3) X14 CAN-2: Power Train Bus - MCU, TCU
4) X44: For Engine Diagnostics
5) X34: Serial Interface - MCU programming connector (RS232)
6) S25: For manually activating specific circuits in case of emergency
7) X4: Transmission Diagnostic Connector
Battery Master Switch (19) - (Located at the left hand side of the truck in the Battery Box).
Press the cover and the switch down to connect the batteries to the electrical circuits. Lift the
cover and then lift the switch to disconnect the batteries from the electrical circuits. Refer to
Figure 15.102.

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15 Electrical System

Figure 15.101 - Diagnostic Point Figure 15.102 - Battery Master Switch and
Hood Switch

Indicator Light (20) - The red LED comes ON within 5 seconds when the Battery Master
Switch is selected ON. The red LED goes out after 60 seconds when the Battery Master Switch
is selected OFF. Refer to Figure 15.102.
Hood Lift Switch (21) - Controls lifting and lowering of the hood. Refer to Figure 15.102.

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 Electrical System 15

(4) Controls
High Beam Dipper, Direction Indicator, Windscreen Wiper/Washer Headlight/ Parking/ Front
Working Light and Horn are displayed in the text that follows.
1 High Beam Dipper and Flasher: Refer to Figure 15.103,
Neutral Position = Dipped Beam
Control Upwards = High Beam Flash
Control Downward with Lights On = High Beam Continuous
High Beam continuous is possible only if the steering lever switch is set to position 1, 2 or 3
(Lights ON). High Beam Flash is possible in any position.

Figure 15.103 - Control Stock Figure 15.104 - Control Stock

High Beam Dipper and Flasher Direction Indicator

2 Direction Indicator: Refer to Figure 15.104,

Control Rearwards = Left Indicators
Control Forwards = Right Indicators
3 Windscreen Wiper/Washer: Refer to Figure 15.105.
Position 0 = Neutral Position
Position 1 = Intermittent Sweep
Position 2 = Wiper Fast Speed
Position 3 = Windscreen Wash

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15 Electrical System

Figure 15.105 - Control Stock Figure 15.106 - Control Stock

Windscreen Wiper/Washer Headlight, Parking and Front Working
Lights

4 Headlight, Parking, and Front Working Lights. Refer to Figure 15.106.

Position 0 = Light OFF
Position 1 = Parking Light and Headlight ON
Position 2 = Headlight ON
Position 3 = Front Working Light ON
Parking Light stays ON at position 2 and 3
5 Horn: Refer to Figure 15.107.
Button pushed in = Horn Sounds

Figure 15.107 - Control Stock

Horn

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 Electrical System 15

15.10 Switches and Sensors

14

HEADER TANK 13

12

AIR CLEANER 2
9
18
19

3 15 16

BATTERY BOX/
4 DROPBOX COOLANT/HYD. TANK
VALVE
PS1
7
FUEL TANK
MANIFOLD BLOCK
(FONT AXLE) BRAKE LINES

A2
7
5 A1

PS3
7
17
6 7
DROPBOX
MAIN HYDRAULIC 11 TREADLE
PS4
VALVE VALVE
7 10
PS2 5

MOT02130

Figure 15.108 - Layout View of Switches and Sensors

1. Air Flow Sensor 8. Coolant Level Sensor 15. Pressure Switch
2. Air Restriction Sensor 9. Pressure Switch 16. Temperature Sensor
3. Fuel Level Sensor 10. Temperature Sensor 17. Pressure Switch
4. Pressure Switch 11. Adaptor 18. Temperature Sensor
5. Pressure Switch 12. Hyd. Level Sensor 19. Washer - Copper
6. Pressure Switch 13. Washer - Copper
7. Seal - Dowty 14. Restriction Indicator

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15 Electrical System

(1) Description
Numbers in parentheses refer to Figure 15.108, unless otherwise specified.
This section describes the location and function of various switches and sensors installed on
the machine to monitor all major components and systems.
(i) Engine
Sensor - Air Flow (1) - (T126)Mounted externally on the air cleaner Inlet Pipe, this sensor is
connected to the Engine EMS (Scania provide cable) and monitors the inlet air flow.
Sensor - Air Cleaner Restriction (2) - (B4)Mounted externally on the air cleaner pipe, the
restriction sensor indicates the degree of air cleaner element restriction. When the sensor
detects excess contamination, the warning symbol (8, Figure 15.74) illuminates on the left of
dashboard display. The filter elements should be replaced when this warning is illuminated.
Sensor - Engine Coolant Level (8) - (T8)Located in the radiator header tank, the sensor
monitors the coolant level in the header tank. When the coolant level is low a warning light (1,
Figure 15.74) illuminates on the left of dashboard display.
(ii) Fuel
Sensor - Fuel Level (3) - (B5)Located in the fuel tank, the fuel level sensor monitors the fuel
level. Gauge (3, Figure 15.81) indicates the amount of fuel left in the tank. A warning symbol
(3a, Figure 15.81 will illuminate when the fuel level drops below 25%.
(iii) Dropbox
Switch - Dropbox Oil Pressure (9) - (WA7.B19)Located on the dropbox control valve (SW5),
monitors the dropbox oil pressure, when the oil pressure is outside the operating limits warning
symbol (10, Figure 15.87) illuminates on the dashboard display main screen.
Sensor - Dropbox Oil Temperature (10) - (WA1.B6)Located on the front of the dropbox ,
monitors the dropbox oil temperature, when the oil temperature is outside the operating limits
warning symbol (5, Figure 15.87) illuminates on the dashboard display main screen.
(iv) Hydraulic System
Switch - Rear Brake Pressure (5) - (WA9.B13)The Normally Closed (NC) pressure switch,
located in port PS2 of the main hydraulic valve, senses the pressure in the rear brake circuit.
When the pressure is low the symbol (5, Figure 15.75) illuminates on the right of dashboard
display.
Switch - Front Brake Pressure (5) - (WA5.B8)The Normally Closed (NC) pressure switch,
located in port PS3 of the main hydraulic valve, senses the pressure in the front brake circuit.
When the pressure is low the symbol (7, Figure 15.75) illuminates on the right of dashboard
display.
Switch - Parking Brake Pressure (6) - (WA4.B11)The Normally Closed (NC) pressure switch,
located in port PS4 of the main hydraulic valve, senses pressure in the parking brake circuit.
The pressure switch closes at a pressure of 5 bar (70 lbf/in²) parking brake symbol (8, Figure
15.75) illuminates, indicating that the parking brake is applied.
Switch - Steering System Pressure (4) - (WA10.B14)The Normally Closed (NC) pressure
switch is located in port PS1 of the main hydraulic valve. When the pressure is low the warning
symbol (4, Figure 15.87) on the dashboard display main screen.
Sensor - Hydraulic Oil Filter Restriction (14) - (B3)The hydraulic oil filter restriction gauge is
located on top of hydraulic tank. the restriction sensor indicates the degree of oil filter element
restriction. When the sensor detects excess contamination, the warning symbol (4, Figure
15.75) illuminates on the right of dashboard display, the hydraulic filter should be changed.
Sensor - Hydraulic Oil Level (12) - (B28)Located in the hydraulic tank, the oil level sensor
monitors the level of the hydraulic oil. When the level of the oil is low, the warning symbol (3,
Figure 15.75) illuminates on the right of dashboard display.

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 Electrical System 15

Sensor - Hydraulic Oil Temperature (18) - (B29)Located in the hydraulic tank, the sensor
monitors the hydraulic oil temperature. Gauge (4, Figure 15.82) indicates the temperature of the
oil in the tank. When the oil temperature rises above the recommended operating temperature
the warning light (4a, Figure 15.82) illuminates.
(v) Brake System
Switch - OCDB Oil Pressure (15) - (B30)Located on the front axle OCDB manifold block (Port
PS), normally closed (NC) pressure switch. The MCU monitors the OCDB oil pressure.
Sensor - OCDB Oil Temperature (16) - (WA1.B34)Located on the front axle OCDB manifold
block (Port TS1), the sensor measures the temperature of the OCDB oil. Main screen display
(12, Figure 15.87) indicates the temperature.
Solenoid -Brake Unloader Valve (17) - (Q18)Located on the cab bulkhead to the left of the
treadle valve, disengages the dropbox differential lock when excessive braking is applied.

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Intentionally Left Blank

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 Chassis 16

Table of Content
16 Chassis ......................................................................................................16-1
16.1 Frames ......................................................................................................... 16-3
(1) Description............................................................................................... 16-4
(2) Inspection and Maintenance.................................................................... 16-5
16.2 Articulation and Oscillation Pivot .................................................................. 16-7
(1) Description and Operation....................................................................... 16-9
(2) Thru-Drive Driveshaft .............................................................................. 16-9
(a) Removal and Disassembly ................................................................. 16-9
(b) Inspection.......................................................................................... 16-10
(c) Assembly and Installation ................................................................. 16-11
(3) Articulation Components ....................................................................... 16-15
(a) Disconnecting Front and Rear Frames ............................................. 16-15
(b) Disassembly...................................................................................... 16-16
(c) Inspection.......................................................................................... 16-17
(d) Assembly .......................................................................................... 16-17
(e) Connecting Front and Rear Frames ................................................. 16-19
(4) Oscillation Components......................................................................... 16-21
(a) Disconnecting Front and Rear Frames ............................................. 16-21
(b) Disassembly...................................................................................... 16-23
(c) Inspection.......................................................................................... 16-24
(d) Assembly .......................................................................................... 16-24
(e) Connecting Front and Rear Frames ................................................. 16-27
(5) Maintenance .......................................................................................... 16-28
(a) Every 50 Hours ................................................................................. 16-29
(b) Every 250 Hours ............................................................................... 16-29
(c) Drain Gear Oil from the Pivot Assembly ........................................... 16-30
(d) Fill the Pivot Assembly with Gear Oil ................................................ 16-30
(e) Grease the Taper Roller Bearings..................................................... 16-30
(f) Grease the Pivot Assembly Bushes.................................................. 16-30
(6) Special Tools ......................................................................................... 16-31
(7) Special Torque Specifications................................................................ 16-31
16.3 Hood........................................................................................................... 16-32
(1) Removal ................................................................................................ 16-34
(2) Installation ............................................................................................. 16-36
(3) Maintenance .......................................................................................... 16-37
(4) Special Tools ......................................................................................... 16-37
(5) Raising the Hood ................................................................................... 16-38
(6) Lowering the Hood ................................................................................ 16-39
16.4 Mudflaps..................................................................................................... 16-40
(1) Removal ................................................................................................ 16-43
(a) LH Bottom Rear Mudflap .................................................................. 16-43
(b) LH Top Rear Mudflap ........................................................................ 16-44
(c) LH Top Front Mudflap ....................................................................... 16-44
(d) LH Wheel Arch Mudflap .................................................................... 16-44
(e) RH Bottom Rear Mudflap.................................................................. 16-45
(f) RH Top Rear Mudflap ....................................................................... 16-45
(g) RH Top Front Mudflap....................................................................... 16-46
(h) RH Wheel Arch Mudflap ................................................................... 16-46

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16 Chassis

(2) Installation ............................................................................................. 16-47

(a) LH Top Rear Mudflap ........................................................................ 16-47
(b) LH Bottom Rear Mudflap .................................................................. 16-47
(c) LH Top Front Mudflap ....................................................................... 16-48
(d) LH Wheel Arch Mudflap .................................................................... 16-48
(e) RH Top Rear Mudflap ....................................................................... 16-49
(f) RH Bottom Rear Mudflap.................................................................. 16-49
(g) RH Top Front Mudflap....................................................................... 16-50
(h) RH Wheel Arch Mudflap ................................................................... 16-50
16.5 Handrails and Fenders............................................................................... 16-51
(1) Removal ................................................................................................ 16-51
(a) LH Kick Plate .................................................................................... 16-51
(b) LH Handrail Filler Tube ..................................................................... 16-51
(c) LH Forward Outer Handrail............................................................... 16-51
(d) LH Rear Outer Handrail .................................................................... 16-52
(e) LH Rear Inner Handrail ..................................................................... 16-52
(f) LH Lower Step Assembly.................................................................. 16-52
(g) LH Fender Assembly ........................................................................ 16-53
(h) LH Step Support Arm Assembly ....................................................... 16-53
(i) RH Kick Plate.................................................................................... 16-54
(j) RH Forward Outer Handrail .............................................................. 16-54
(k) RH Rear Outer Handrail.................................................................... 16-54
(l) RH Rear Inner Handrail .................................................................... 16-55
(m) RH Lower Step Assembly ................................................................. 16-55
(n) Adblue Cover Assembly.................................................................... 16-55
(o) RH Fender Assembly........................................................................ 16-56
(p) RH Step Support Arm Assembly....................................................... 16-56
(2) Installation ............................................................................................. 16-57
(a) LH Step Support Arm Assembly ....................................................... 16-57
(b) LH Fender Assembly ........................................................................ 16-57
(c) LH Lower Step Assembly.................................................................. 16-58
(d) LH Forward Outer Handrail............................................................... 16-58
(e) LH Rear Outer Handrail .................................................................... 16-58
(f) LH Rear Inner Handrail ..................................................................... 16-59
(g) LH Handrail Filler Tube ..................................................................... 16-59
(h) LH Kick Plate .................................................................................... 16-59
(i) RH Step Support Arm Assembly....................................................... 16-60
(j) RH Fender Assembly........................................................................ 16-60
(k) Adblue Cover Assembly ................................................................... 16-61
(l) RH Lower Step Assembly ................................................................. 16-61
(m) RH Forward Outer Handrail .............................................................. 16-61
(n) RH Rear Outer Handrail.................................................................... 16-62
(o) RH Rear Inner Handrail .................................................................... 16-62
(p) RH Kick Plate.................................................................................... 16-62

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 Chassis 16

16 Chassis
16.1 Frames

17
16
15
1 14

8 6
7
5
4
3 11
10
9
13
12

MOT05286

Figure 16.1 - General Arrangement of Front Frame Assembly

1. Front Frame 8. Bolt 15. Bolt
2. Sump Guard 9. Bolt 16. Hardened Washer
3. Cover 10. Washer 17. Locknut
4. Bolt 11. Locknut
5. Washer 12. Washer
6. Locknut 13. Bolt
7. Washer 14. Cross Member

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16 Chassis

2
1
5
4

MOT05287

Figure 16.2 - General Arrangement of Rear Frame Assembly

1. Rear Frame Assembly 3. Pin - Spring 5. Bolt
2. Pin Assembly 4. Lockwasher

(1) Description
The chassis consists of two separate frame assemblies which provide the articulation of the
unit. The front and rear frames are constructed of all welded high-grade steel fabrications with
rectangular box section beams forming main, side and cross members.
The front frame is fabricated to form a rigid structure which carries the cab, power train and
the front frame suspension system.
The rear frame is fabricated to form a rigid structure which carries the body, body hydraulics,
rear frame suspension and rear drive axles.
Steering is by frame articulation to 45° either side by two widely spaced vertical pivot pins in
taper roller bearings. Oscillation between the front and rear frames is provided by a large
diameter cylindrical coupling, carried on nylon bushes, located in the rear frame. Longitudinal
shocks are absorbed by the thrust faces of the nylon bushes.

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 Chassis 16

(2) Inspection and Maintenance

(a) Inspection
Inspect the frames and attached parts at intervals not exceeding 250 hours for cracked or
broken welds and bending of the frame. Any defects found should be repaired before they
progress into major failures.
(b) Straightening
Hydraulic straightening or aligning of equipment should be used to straighten bent or twisted
frames whenever possible. However, if heat must be applied, never heat the metal beyond a
dull, cherry red color, as too much heat will weaken the metal. When it is necessary to heat the
metal, apply heat uniformly over the area to be straightened and protect the heated surface
from sudden cooling. Frame parts that cannot be straightened should be renewed.
(c) Welding

� WARNING
• Before any welding is done, disconnect the following in this order: Battery earth cable,
battery supply cable, alternator earth cables, alternator supply cables, electrical connections
at the MCU, TCU, body control lever, and cab bulkhead to avoid damage to electrical
components. Turn off the battery master switch to isolate the batteries before disconnecting
any components. After welding, connect all of the above in the reverse order. Always fasten
the welding machines ground cable to the piece/frame being welded, if possible.
• Always fasten the welding machines ground cable to the piece/frame being welded if
possible.
• Before any welding is done ensure all paint has been removed from the area to be welded.
Failure to do so may result in hazardous fumes being given off from the paint.
• Welding and flame cutting cadmium plated metals produce odorless fumes which are toxic.
Recommended industrial hygiene practice for protection of the welding operator from the
cadmium fumes and metallic oxides requires enclosure ventilation specifically designed for
the welding process. A respiratory protective device such as the M.S.A. 'Gasfoe' respirator
with G.M.A. cartridge will provide protection against cadmium fumes and metallic oxides.
The 'Gasfoe' respirator has been approved by the U.S. Bureau of Mines: Approval number
23B-10, and is designed to protect against gases, vapors, and/or metal fumes.
• The current from the welding rod always follows the path of least resistance. If, for example,
the ground clamp is attached to the rear frame when welding is performed on the front
frame, the current must pass a frame connection to return to the welding machine. 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 cause welding blotches on
their wearing surfaces and increase the wear rate of these components.

NOTICE
• Electric arc welding is recommended for all welded frame repairs. Since the nature and
extent of damage to the frame cannot be predetermined, no definite repair procedure
can be established. As a general rule however, if parts are twisted, bent or pulled apart,
or a frame is bent or out of alignment, no welding should be done until the parts are
straightened or realigned.
• Successfully welded repairs will depend to a great extent upon the use of proper equipment,
materials and the ability of the welder. The customer support department can be consulted
regarding the feasibility of welding repairs.

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16 Chassis

(d) Reinforcement
Frame reinforcement can be made with a channel or an angle or a flat structural stock.
Whenever possible, the reinforcement should extend well beyond the bent, broken or cracked
area. The reinforcement stock thickness should not exceed that of the frame stock and the
material should be of the same tensile strength.
(e) Painting

� CAUTION
• Welding, burning, heating or dressing surfaces previously painted using polyurethane paint
produces fumes which are toxic. Surfaces must be prepared using paint stripper prior to
area being reworked. Recommended industrial hygiene and safety rules should be followed
for protection of the welding operator from the fumes.

A check of the condition of the paint should be made approximately twice a year and chassis
repainted if necessary.
To keep rust and corrosion to a minimum, periodic painting of abrasions and other exposed
metal areas on the frames is highly recommended.
If painting of a frame is required, thoroughly clean the areas to be painted. Apply a primer coat
of polyurethane red oxide and then a finish coat of polyurethane enamel.

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 Chassis 16

16.2 Articulation and Oscillation Pivot

52

13
23
22

24
51

13
21

19
12

24
26

18
29

15

13,4

13,4
11

31
10

4
2

14
9
5

10
7 20 6

45
47
28
45
47

28

37
37
43

30

34
38
35
36
39
41

30
42

32

27
44

45
46
31
46
45

8
15
17
29
26
40

25
36
A

38

33

16
50
49

51
3

48

23

MOT05004

Figure 16.3 - Articulation and Oscillation Pivot

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16 Chassis

1. Pivot Assembly 22. Bolt 38. Shim (0.040 in)

2. Bush 23. Bolt 38. Shim (0.003 in)
3. Breather Pipe 24. Hose Assembly 38. Shim (0.006 in)
Assembly
4. Grease Fitting 25. Shim (0.080 in) 38. Shim (0.020 in)
5. Gasket 25. Shim (0.040 in) 39. Spacer
6. Plate 25. Shim (0.020 in) 40. Upper Pin Assembly
7. Bolt 25. Shim (0.008 in) 41. Washer
8. Taper Roller Bearing 25. Shim (0.004 in) 42. Nut
Cup and Cone
9. Plug 25. Shim (0.002 in) 43. Lower Pin Assembly
10. V Ring 26. O-Ring 44. Hardened Washer
11. Thrust Nut 27. Bolt 45. Washer
12. Lockplate 28. Plug 46. Bolt
13. Elbow 29. O-Ring 47. Bolt
14. Pivot Shaft 30. Taper Roller Bearing 48. Bushing
15. Seal 31. Retainer 49. Connector
16. Pivot Shaft Collar 32. Seal Housing 50. Elbow
17. Pivot Shaft Front Yoke 33. Seal Housing 51. Tab Washer
18. Parking Brake Yoke 34. Housing 52. Shim (0.25mm)
19. Thrust Collar 35. Housing 52. Shim (0.5mm)
20. Washer 36. Seal 52. Shim (1mm)
21. Washer 37. Seal 52. Shim (3mm)

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 Chassis 16

(1) Description and Operation

The articulation and oscillation pivot allows the front frame and the rear frame to rotate
horizontally (articulation) and tilt laterally (oscillation) with respect to each other. It is also the
main load bearing coupling between the two frames. The pivot assembly houses the driveshaft
connecting the drive between the front and rear frames. Articulation bearings, oscillation
bushes, pivot driveshaft bearing and associated parts can be removed, inspected and replaced
or renewed by following the procedures outlined in this section.
(2) Thru-Drive Driveshaft
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure wheel blocks are properly secured
and of adequate capacity to do the job safely.
• When necessary to drive out or drive on components during disassembly/assembly, be sure
to use a soft drift to prevent property damage and personal injury.

NOTICE
• Tighten all fasteners without special torques specified to torques listed in 22.3 Standard
Bolt and Nut Torque Specifications on page 22-5.
• Take extra care when handling drivelines as any deformity on a rotating mass creates
vibration and excessive wear during any operation.
• Take care when releasing the parking brake as the actuator adjuster is spring tensioned.
• If either bearing assembly cup or cone (30) need replacing, they must be replaced as a set.
• When cleaning bearings, DO NOT spin with compressed air.

(a) Removal and Disassembly

Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

PROCEDURE
1. The procedure that follows assumes that only the thru-drive components require repair.
2. Position the machine on a level work area, apply parking brake and block all wheels
securely.
3. Raise the body and install the body safety prop to secure body in raised position. Refer to
(3) Deploy the Body Prop on page 21-12.
4. Shut down engine. Refer to 5.12 Stopping on page 5-28
5. Position the battery master switch in the OFF position. Refer to Figure 15.102
6. Remove the dropbox to pivot point driveline:
a. Identify the dropbox to pivot point driveline (4). Refer to Figure 8.1.
b. Remove the driveline. Refer to (2) Removal on page 8-3.
7. Remove wheel blocks, start engine and steer machine into a full left-hand lock. Shut down
engine and block all wheels securely.
8. Release the parking brake by turning the hex-head on the parking brake actuator fully
anticlockwise. Refer to (1) Description on page 14-93.

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16 Chassis

9. Remove the parking brake assembly. Refer to (2) Removal on page 14-95.
10. Remove the pivot point to centre axle driveline:
a. Locate the 8.5C pivot point to centre axle driveline (1). Refer to Figure 8.4.
b. Remove the driveline. Refer to (2) Removal on page 8-11.
11. Remove the parking brake disc from the yoke (18).(2) Removal on page 14-95
12. Drain gear oil from the pivot assembly (1). Refer to (c) Drain Gear Oil from the Pivot
Assembly on page 16-30.
13. Remove bolts (23), tab washer (51) and pivot shaft collar (16).
14. Remove and discard O-rings (26 & 29) from pivot shaft collar (16).
15. Place a suitable container under the front of the pivot assembly (1) and pull pivot shaft
front yoke (17) forward from pivot shaft (14).
16. Remove breather pipe assembly (3) from pivot assembly (1):
a. Disconnect pipe assembly (3) from elbow (50).
b. Remove elbow (50), connector (49) and bushing (48) from pivot assembly (1).
17. Withdraw pivot shaft (14) from housing by pulling rearwards on parking brake yoke (18). If
necessary, tap front end of pivot shaft (14) to ease removal, take care to avoid damaging
threads. Place pivot shaft (14) assembly on work bench for further disassembly.
18. Temporarily install pivot shaft front yoke (17) fully onto front of pivot shaft (14) and suitably
restrain to resist rotation.
19. Remove bolts (23), tab washer (51) and thrust collar (19) and parking brake yoke (18)
from pivot shaft (14).
20. Identify front and rear ends of pivot shaft (14).
21. Remove and discard o-rings (26 & 29) from thrust collar (19).
22. Praise out and discard front and rear seals (15) from the pivot assembly (1).
23. If front and rear taper roller bearings (8) need replacing, use a suitable puller to remove
from the pivot assembly (1).
24. If front and rear retainers (31) need replacing, use a suitable drift or puller to remove from
the pivot assembly (1).

(b) Inspection
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

PROCEDURE
1. Clean all parts with a suitable solvent and let dry. Place bearings on a clean surface,
cover with a lint free cloth and allow to dry.
2. Check taper roller bearings (8) for wear or damage. Renew as necessary.
3. Inspect splines of pivot shaft (14) and yokes (17 & 18) for nicks, burrs or excessive wear.
Replace if wear is excessive or splines are nicked. Burrs may be removed with a fine
file or medium India stone.
4. Check yokes (17 & 18) for damage in region polished by oil seal lip; even slight damage in
this area can cause leakage. Very slight marks may be polished out with fine emery cloth
but it is essential that polishing marks are parallel to the seal lip.
5. Replace all seals and O-rings with new parts.

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 Chassis 16

(c) Assembly and Installation

Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

PROCEDURE
1. Install retainers (31) in their seats in the pivot assembly (1) and press home firmly .
2. Install the taper roller bearing (8) cups:
a. Use a freezer to cool the taper roller bearing (8) cups.
b. Use a suitable assembly mandrel to install (cooled from freezer) taper roller bearing
(8) cups firmly in their seats in the front frame and the rear frame ends of the pivot
assembly (1).
c. Ensure a 0.05 mm (0.002 in) feeler gauge cannot be inserted between the taper roller
bearing (8) and the mating face.
3. Install a taper roller bearing (8) cone to the tractor end of the pivot shaft (14):
a. Support the pivot shaft (14) vertically in a suitable fixture with the front frame end up.
b. Using a tubular mandrel, tap one taper roller bearing (8) cone onto the tractor end of
pivot shaft (14) 55 mm (2.16 in) from the spline end face. Refer to Figure 16.4.

Figure 16.4 - Pre assembly of bearing

4. Install the pivot shaft (14) into the front frame end of the pivot assembly (1) until the taper
roller bearing (8) cone seats firmly in the taper roller bearing (8) cup.
5. Install seal (15) to the front frame end of the pivot assembly (1):
a. Apply Loctite 648.
b. Install seal (15) over pivot shaft (14) with the lip to the taper roller bearing (8).
c. Press home the seal (15) firmly using a suitable mandrel.
6. Apply multi-purpose grease to the spline and light oil to the seal diameters of both yokes
(17 & 18).
7. Slide pivot shaft front yoke (17) onto front frame end of pivot shaft (14) and install two long
bolts into pivot shaft front yoke (17) and place a wooden packer onto fixture to prevent the
yoke from turning.

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8. Before installing the pivot shaft collar (16), measure and record the following:
Refer to Figure 16.5.
a. Value ‘A’ – width of pivot shaft collar (16).
b. Value ‘B’ – inner bore depth of pivot shaft collar (16), using a depth micrometer.
c. Value ‘C’ – recess dimension if possible, alternatively subtract ‘B’ from ‘A’.

‘A’ 2 1
‘D’
‘C’

‘B’ 3
‘E’ (D-C) MOT03951

Figure 16.5 - Measurements / various

1. Shaft 2. Depth Micrometer 3. Shim Area

9. Temporarily install pivot shaft collar (16) to front frame end of pivot shaft (14):
a. Install pivot shaft collar (16) without o-rings (29 & 26) against pivot shaft front yoke (17).
b. Ensure collar holes align with shaft holes.
c. Install one bolt (23) to hold pivot shaft collar (16) in place.
10. Install the rear frame end taper roller bearing (8) cone:
a. Using an induction heater set to 75°C, heat the rear frame end taper roller bearing (8)
cone for approximately 75 secs.
b. Apply oil to the bearing diameter of the rear frame end of pivot shaft (14).
c. Install the heated taper roller bearing (8) cone onto the pivot shaft (14).
11. Temporarily install the parking brake yoke (18) and thrust collar (19) to the rear frame end
of pivot shaft (14):
a. Install the parking brake yoke (18) and the thrust collar (19), ensuring collar holes
align with pivot shaft (14) holes.
b. Install end bolts (23) finger tight.
c. Tighten the bolts (23) alternately 1/4 - 1/2 turns to draw the pivot shaft (14) hard
against the inner face of thrust collar (19) until the pivot shaft (14) is visible through
inspection hole on the thrust collar (19).
d. Torque tighten bolts (23) to 54 Nm (39 lbf ft).
12. Allow the rear frame end taper roller bearing (8) cone to cool for a few minutes.
13. Remove the parking brake yoke (18) and thrust collar (19) from rear frame end of pivot
shaft (14):
a. Remove the bolts (23).
b. Remove the thrust collar (19) and parking brake yoke (18) from the pivot shaft (14).
14. Install a seal (15) to the rear frame end of the pivot assembly (1):
a. Apply Loctite 648.
b. Install seal (15) over pivot shaft (14) with the lip to the taper roller bearing (8).
c. Press home the seal (15) firmly using a suitable mandrel.

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15. Remove the wooden packer and two long bolts from pivot shaft front yoke (17). Refer
to Step 7.
16. Reinstall the parking brake yoke (18) and thrust collar (19) to trailer end of pivot shaft (14):
a. Install the parking brake yoke (18) onto pivot shaft (14).
b. Install o-rings (26 & 29) to thrust collar (19).
c. Install the thrust collar (19) onto pivot shaft (14).
d. Ensure thrust collar (19) holes align with pivot shaft (14) holes.
e. Install tab washer (51) and bolts (23) finger tight.
f. Tighten the bolts (23) alternately 1/4 - 1/2 turns.
g. Torque tighten bolts (23) to 54 Nm (39 lbf ft).
h. Spin the parking brake yoke (18) several times to ‘feel‘ the preload.
17. Install the second bolt (23) to the pivot shaft collar (16):
a. Install the second bolt (23) finger tight.
b. Tighten the bolts (23) sequentially.
c. Torque tighten bolts (23) to 30 Nm (22 lbf ft).
d. Spin the parking brake yoke (16) several times to ‘feel‘ the preload.
18. Use a torque meter to ensure that the taper rollers (8) are seated properly by checking that
the rolling torque value at the trailer end of the pivot shaft (14) is between a value of 4-7 Nm
(3-5 lbf ft). If a value of 4 Nm (3 lbf ft) is not achieved, increase the torque in increments
until a value of 4 Nm (3lbf ft) is achieved.
19. Measure and record value ‘D’ – the distance between outer face of the pivot shaft collar
(16) and the end face of the tractor end of the pivot shaft (14), using a depth micrometer via
the hole in the pivot shaft collar (16). Refer to .
20. Calculate value 'E' = 'D' - 'C' – the actual free air space to be shimmed between end face
of the tractor end of the pivot shaft (14) and compression face of the pivot shaft collar
(16). Refer to , Step 19.and Figure 16.5.
21. Calculate value 'F' = 'E' + 0.6 mm (0.024 in) to allow for oversize shims. (End float will be
determined by subtraction.)
22. Remove bolts (23) and pivot shaft collar (16) from tractor end of the pivot shaft (14).
23. Tap tractor end of the pivot shaft (14) to free tapper rollers (8).
24. Calculate the nominal combination of minimum number of shims (25) to achieve the size
nearest to value 'F'. Record the appropriate part numbers and total nominal thickness value.
25. Select the shims (25) and measure the total actual thickness of the combination (shim
pack). Record this value.
26. Install the shim (25) pack in the pivot shaft collar (16) to the tractor end of the pivot shaft (14):
a. Place the selected shims (25) in the pivot shaft collar (16).
b. Install a lock to the pivot shaft front yoke (17).
c. Install bolts (23).
d. Torque tighten bolts (23) to 54 Nm (39 lbf ft).
e. Remove the lock from the pivot shaft front yoke (17).
f. Spin the parking brake yoke (16) several times to ensure free pivot shaft (14) rotation.
27. Measure and record value 'G' – pivot shaft front yoke (17) float movement:
a. Locate a magnetic clock gauge on the flange of pivot assembly (1).
b. Setup the needle of the magnetic clock gauge to the end face of the pivot shaft collar
(16).
c. Spin the pivot shaft front yoke (17) by turning the parking brake yoke (16).
d. Record value 'G' observed whilst pivot shaft front yoke (17) was turned.

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28. Calculate value 'H' by taking value 'G' and subtracting a figure sufficient to give a value (the
end float) in the range of 0.05 mm - 0.15 mm (0.002 in - 0.006 in). The thickness of the
shim (25) pack will have to be adjusted accordingly by the value 'H'.
29. Remove bolts (23), pivot shaft collar (16) and shims (25) from the front frame end of the
pivot shaft (14).
30. Calculate the nominal combination of minimum number of shims (25) to achieve the size
nearest to value 'H'. Record the appropriate part numbers and total nominal thickness value.
31. Select the shims (25) and measure the total actual thickness of the combination (shim
pack). Record this value.
32. Install the shim (25) pack in the pivot shaft collar (16) to the front frame end of the pivot
shaft (14):
a. Place the selected shims (25) in the pivot shaft collar (16).
b. Install a lock to the pivot shaft front yoke (17).
c. Install o-rings (26 & 29) to thrust collar (19).
d. Install the thrust collar (19) onto pivot shaft (14).
e. Ensure thrust collar (19) holes align with pivot shaft (14) holes.
f. Install tab washer (51) and bolts (23) finger tight.
g. Tighten the bolts (23) alternately 1/4 - 1/2 turns.
h. Torque tighten bolts (23) to 54 Nm (39 lbf ft).
i. Remove the lock from the pivot shaft front yoke (17).
33. Use the clock gauge to confirm that the pivot shaft (14) end float is in the range 0.05 mm -
0.15 mm (0.002 in - 0.006 in) by moving the pivot shaft front yoke (17) fore and aft.
34. Adjust and refit the shim (25) pack as necessary.
35. Use the clock gauge to ensure that the parking brake yoke (18) run out value does not
exceed 0.203 mm (0.008 in ). If the run out value exceeds 0.203 mm (0.008 in), the end
float procedure needs to be revisited and individual components checked for conformance.
36. Install breather pipe assembly (3) to pivot assembly (1):
a. Install bushing (48), connector (49) and elbow (50) to pivot assembly (1).
b. Connect pipe assembly (3) to elbow (50).
37. Install the parking brake disc on parking brake yoke (18). Refer to (6) Installation on
page 14-100.
38. Install the parking brake assembly. Refer to (6) Installation on page 14-100.
39. Install the pivot point to centre axle driveline. Refer to (6) Installation on page 8-8.
40. Apply parking brake by turning the hex-head on the parking brake actuator fully clockwise.
Refer to (6) Installation on page 14-100.
41. Install the dropbox to pivot point driveline. Refer to (6) Installation on page 8-8.
42. Fill the pivot assembly with gear oil. Refer to (d) Fill the Pivot Assembly with Gear Oil
on page 16-30.
43. Remove the body safety prop and lower body. Refer to (4) Lower the Body Prop on page
21-13.
44. Put the battery master switch in the ON position. Refer to Figure 15.102
45. Remove wheel blocks.

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 Chassis 16

(3) Articulation Components

Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure wheel blocks are properly secured
and of adequate capacity to do the job safely.
• When necessary to drive out or drive on components during disassembly/assembly, be sure
to use a soft drift to prevent property damage and personal injury.

NOTICE
• The following procedures assume that only components associated with articulation require
repair.
• It is essential that the grease used for articulation components is Extreme Pressure Lithium
Complex No. 2 (23), as specified in (1) Recommended Lubricants on page 4-16.
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.

(a) Disconnecting Front and Rear Frames

Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

NOTICE
• The front and rear frames can be separated sufficiently to permit disassembly/assembly of
the articulation components without disconnecting hydraulic lines or electrical wiring.
• Take care when releasing the parking brake as the actuator adjuster is spring tensioned.
• When removing the upper pin (40) it may be necessary to relieve binding between the pin
and pin bores by raising or lowering the pivot/ rear frame assembly.
• Only separate the frames sufficient to permit removal of the articulation bearings or damage
to hydraulic and electrical connections could result.

PROCEDURE
1. Position the machine on a level work area, apply parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove steering cylinders. Refer to (2) Removal on page 12-7.
5. Remove the dropbox to pivot point driveline:
a. Identify the dropbox to pivot point driveline (4). Refer to Figure 8.1
b. Remove the driveline. Refer to (2) Removal on page 8-3
6. Support the front frame at front and rear with suitably placed stands or timbers so the tractor
will remain level during and after disconnection.
7. Release the parking brake by turning the hex-head on the parking brake actuator fully
anticlockwise. Refer to (2) Removal on page 14-95.

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8. Attach suitable lifting equipment to the rear frame. Lifting equipment must prevent the rear
frame from oscillating after separation, and be capable of pulling the rear frame clear of the
front frame. Raise lifting equipment to support the rear frame.
9. Remove the upper pin assembly (40):
a. Remove large nut (42) and washer (41) securing upper pin assembly (40).
b. Remove upper pin assembly (40). If necessary tap upper pin assembly (40) to ease
removal taking care to avoid damaging the pin.
10. Remove lower pin assembly (43):
a. Remove bolt (27) and hardened washer (44) securing lower pin assembly (43).
b. Remove lower pin assembly (43). If necessary tap lower pin assembly (43) to ease
removal taking care to avoid damaging the pin.
11. Separate the front frame from the rear frame:
a. Remove blocks from rear wheels securing the rear frame.
b. Use lifting equipment to move the rear frame clear of the front frame.
c. After moving, block all the rear frame wheels securely.

(b) Disassembly
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

NOTICE
• Upper and lower pivot assemblies are not interchangeable.
• Bearing assemblies (6) and spacers are a matched set, never interchange cups, cones
or spacers between sets.

(i) Upper Pivot Assembly

PROCEDURE
1. Mark, identify and note the orientation of all pivot assembly components to ensure correct
location on assembly/installation.
2. Remove bolts (46 & 47), washers (45).
3. Remove spacer (39) and seals (36).
4. Remove seal housings (32 & 33).
5. Remove shims (38) pack.
6. Remove taper roller bearing (30).

(ii) Lower Pivot Assembly

PROCEDURE
1. Mark, identify and note the orientation of all pivot assembly components to ensure correct
location on assembly/installation.
2. Remove bolts (46 & 47), washers (45).
3. Remove seals (37).
4. Remove seal housings (34 & 35).

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 Chassis 16

5. Remove shims (38) pack.

6. Remove taper roller bearing (30).

(c) Inspection
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

NOTICE
• Bearing assemblies (6) and spacers must be renewed as a matched set.
• When drying components after cleaning, DO NOT spin bearings with compressed air.

PROCEDURE
1. Clean all parts with a suitable solvent and let dry. Place bearings on a clean surface,
cover with a lint free cloth and allow to dry.
2. Check upper and lower pivot taper roller bearings (30) and spacers for wear or damage.
Renew as necessary.
3. Check upper pin assembly (40) and lower pin assembly (43) for wear or damage. Renew
as necessary.
4. Replace all seals and o-rings with new parts.

(d) Assembly
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

NOTICE
• Bearing assemblies (6) and spacers are a matched set, never interchange cups, cones
or spacers between sets.

(i) Upper Pivot Assembly

PROCEDURE
1. Using bolts (46 & 47), install seal (36) and lower seal housing (33). Tighten bolts (46 & 47)
to secure lower seal housing (33).
2. Install first taper roller bearing (30) cup into the pivot bore.
3. Using a suitable driver, seat the taper roller bearing (30) cup until it is flush with lower
seal housing (33).
4. Apply grease to the two taper roller bearing (30) cones. Refer to (1) Recommended
Lubricants on page 4-16.
5. Install taper roller bearing (30) cones into the pivot bore.
6. Install second taper roller bearing (30) cup into the pivot bore.
7. Using a suitable driver, seat the taper roller bearing (30) cup until it is flush with the top of
the pivot bore.
8. Remove bolts (46 & 47), lower seal housing (33) and seal (36).

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9. Using bolts (46 & 47) and washers (45), install seals (36) and lower and upper seal
housings (33 & 32).
10. Torque tighten bolts (46 & 47) to 27 Nm (20 lbf ft).
11. Use feeler gauges, as shown in Figure 16.6, to measure the gap between the inner pivot
face and lower seal housing (33). Measure at 3 positions equally spaced around the
retainer to determine the average gap, this is the size of shims (38) pack required.

Figure 16.6 - Determining Shim Thickness

12. Remove bolts (46 & 47), washers (45), upper and lower seal housings (32 & 33) and seals
(36).
13. Install shims (38) pack as required with a tolerance of + 0.00 mm, – 1.90 mm (+ 0.00
in, – 0.075 in ).
14. Apply Loctite 243 to threads of bolts (46 & 47).
15. Apply anti-seize compound (Rocol J-166) to the shafts of bolts (46 & 47).
16. Reinstall seals (36) and lower and upper seal housings (33 & 32), using bolts (46 & 47)
and washers (45).
17. Torque tighten bolts (46 & 47) to 106 - 116 Nm (78 - 86 lbf ft).

(ii) Lower Pivot Assembly

PROCEDURE
1. Using bolts (46 & 47), install seal (37) and lower seal housing (34). Tighten bolts (46 & 47)
to secure lower seal housing (34).
2. Install first taper roller bearing (30) cup into the pivot bore.
3. Using a suitable driver, seat the taper roller bearing (30) cup until it is flush with lower
seal housing (33).
4. Apply grease to the two taper roller bearing (30) cones. Refer to (1) Recommended
Lubricants on page 4-16.
5. Install taper roller bearing (30) cones into the pivot bore.
6. Install second taper roller bearing (30) cup into the pivot bore.
7. Using a suitable driver, seat the taper roller bearing (30) cup until it is flush with the top of
the pivot bore.
8. Remove bolts (46 & 47), lower seal housing (34) and seal (37).

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 Chassis 16

9. Using bolts (46 & 47) and washers (45), install seals (37) and lower and upper seal
housings (34 & 35).
10. Torque tighten bolts (46 & 47) to 27 Nm (20 lbf ft).
11. Using feeler gauges, as shown in Figure 16.6, measure the gap between the inner pivot
face and upper seal housing (35). Measure at 3 positions equally spaced around the
retainer to determine the average gap, this is the size of shims (38) pack required.
12. Remove bolts (46 & 47), washers (45), upper and lower seal housings (35 & 34) and seals
(37).
13. Install shims (38) pack as required with a tolerance of + 0.00 mm, – 1.90 mm (+ 0.00
in, – 0.075 in).
14. Apply Loctite 243 to threads of bolts (46 & 47).
15. Apply anti-seize compound (Rocol J-166) to the shafts of bolts (46 & 47).
16. Reinstall seals (37) and lower and upper seal housings (34 & 35), using bolts (46 & 47)
and washers (45).
17. Torque tighten bolts (46 & 47) to 106 - 116 Nm (78 - 86 lbf ft).

(e) Connecting Front and Rear Frames

Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

NOTICE
• It may be necessary to relieve binding between the pin and pin bores by raising or lowering
pivot/rear frame assembly.
• Lube fittings (38) are stored on pad on side of pivot assembly (1).
• Take extra care when handling drivelines as chips, dents, burrs or deformity on any rotating
mass creates vibration and excessive wear during any operation.
• Take care when releasing the parking brake as the actuator adjuster is spring tensioned.

PROCEDURE
1. Align rear frame bearing bores and front frame pin bores:
a. If necessary, attach suitable lifting equipment to the rear frame. Lifting equipment must
prevent the rear frame from oscillating and be capable of pulling the rear frame to align
the rear frame bearing bores and front frame pin bores. Raise lifting equipment to
support the rear frame.
b. Remove blocks from rear wheels and blocking from the rear frame assembly.
c. Using lifting equipment, pull the rear frame to align pivot bearing bores and the front
frame pin bores.
d. Block wheels and block the rear frame to remain level and stationary.
2. Install the upper pin assembly (40):
a. Freeze upper pin (40) to ease installation.
b. Apply Extreme Pressure Lithium Complex No. 2 grease to the upper pivot bearings and
pin bores and the shaft of the upper pin assembly (40).. Refer To (1) Recommended
Lubricants on page 4-16.
c. Apply anti-seize compound (Rocol J-166) to the threads of the upper pin assembly (40).
d. Install spacer (39) in upper pivot assembly.

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e. Install pin assembly (40), washer (41) and nut (42) to the upper pivot, tighten nut to pull
assembly into position.
f. Torque tighten Nut (42) to 1425 Nm (1 051 lb ft).
g. Using 8 mm Ø 90° cutting angle drill, spot drill to a maximum of 4 mm (0.16 in) upper
pin assembly (40) through access hole in nut (42).
h. Install locking grub screw (part of item 42) to pin assembly (40). Torque tighten grub
screw to 70 Nm (52 lbf ft).
3. Install the lower pin assembly (43):
a. Freeze lower pin (43) to ease installation.
b. Apply anti-seize compound (Rocol J-166) to the threads of bolt (27).
c. Install lower pin (43) to the lower pivot assembly, secure using bolt (27) and washer (44).
d. Torque tighten bolt (27) to 73 Nm (54 lbf ft).
4. Grease the taper roller bearings (30) in the upper and lower pivot assemblies. Refer to (e)
Grease the Taper Roller Bearings on page 16-30.
5. Apply the parking brake by turning the hex-head on the parking brake actuator fully
clockwise. Refer to (6) Installation on page 14-100.
6. Install dropbox to pivot point driveline. Refer to (6) Installation on page 8-8.
7. Install steering cylinders. Refer to (6) Installation on page 12-25.
8. Remove lifting equipment from the rear frame.
9. Remove stands or timbers from the front frame.
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Remove wheel blocks.

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 Chassis 16

(4) Oscillation Components

Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

� 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.
• When necessary to drive out or drive on components during disassembly/assembly, be sure
to use a soft drift to prevent property damage and personal injury.
• Hydraulic fluid pressure will remain within the braking system after engine shut down.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the braking system or serious injury could result.

NOTICE
• The following procedure assumes that only components associated with oscillation require
repair.
• It is necessary to disconnect the front and rear frames at the articulation point to service the
oscillation components.
• It is essential that the grease used for oscillation components is Extreme Pressure
Multipurpose Grease (26), as specified in (1) Recommended Lubricants on page 4-16.
• Tighten all the fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.

(a) Disconnecting Front and Rear Frames

Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

NOTICE
• Take care when releasing the parking brake as the actuator adjuster is spring tensioned.
• It may be necessary to relieve binding between the pin and pin bores by raising or lowering
the trailer.

PROCEDURE
1. Position the machine on a level work area, apply parking brake and block all wheels
securely.
2. Raise body and install body safety prop to secure body in partially raised position. Refer to
(3) Deploy the Body Prop on page 21-12.
3. Shut down engine. Refer to 5.12 Stopping on page 5-28
4. Position the battery master switch in the OFF position. Refer to Figure 15.102
5. Depressurize the brake system:
a. Depress and release brake pedal continuously to relieve the pressure in the braking
system.
b. Check at diagnostic points DP20, DP21 and DP22, that the brake pressure has been
released.
6. Remove the Dropbox to Pivot Point Driveline:

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a. Identify the Dropbox to Pivot Point Driveline (4). Refer to Figure 8.1.
b. Remove the driveline. Refer to (2) Removal on page 8-3.
7. Drain the hydraulic tank. Refer to (3) Removal on page 11-29.
8. Remove steering cylinders. Refer to (2) Removal on page 12-7.
9. At the rear frame, identify and tag all hydraulic hoses between the front and rear frames to
ensure correct assembly/installation.
10. At the rear frame, disconnect body system (refer to Figure 13.1) hoses:
a. Position a suitable container under the front of the rear frame.
b. Disconnect raise hose (1). Refer to (a) Main Hydraulic Valve Body Raise Hose on
page 13-5.
c. Disconnect lower hose (2) Refer to (b) Main Hydraulic Valve Body Lower Hose on
page 13-6.
d. Cap all connections to prevent ingress of dirt.
11. At the rear frame, disconnect braking system (refer to 14.1 Description on page 14-4) hoses:
a. Position a suitable container under the front of the rear frame.
b. Disconnect centre and rear axle brake hose (8).
c. Disconnect diff-lock centre axle hose (9).
d. Disconnect parking brake hose (9).
e. Cap all connections to prevent ingress of dirt.
12. Disconnect wiring harnesses:
a. At the front of the rear frame, identify and tag the electrical wiring harnesses between
the front and rear frames to ensure correct assembly/installation.
b. Disconnect electrical connector X20.
c. Disconnect the rear camera harness connector WA2.B32.X1.
d. Cap all connections to prevent ingress of dirt.
13. Support the umbilical hoses’ assembly in preparation to disconnecting the front and rear
frames.
14. Release the parking brake by turning the hex-head on the parking brake actuator fully
anticlockwise. Refer to (2) Removal on page 14-95.
15. Support front frame at front and rear with suitably placed stands or timbers so the front
frame will remain level during and after disconnection.
16. Attach suitable lifting equipment to the rear frame. Lifting equipment must prevent the rear
frame from oscillating after separation, and be capable of pulling the rear frame clear of the
front frame. Raise lifting equipment to support the rear frame.
17. Remove the upper pin assembly (40):
a. Remove large nut (42) and washer (41) securing upper pin assembly (40).
b. Remove upper pin assembly (40). If necessary tap upper pin assembly (40) to ease
removal taking care to avoid damaging the pin.
18. Remove lower pin assembly (43):
a. Remove bolt (27) and hardened washer (44) securing lower pin assembly (43).
b. Remove lower pin assembly (43). If necessary tap lower pin assembly (43) to ease
removal taking care to avoid damaging the pin.
19. Separate the rear frame from the front frame:
a. Remove blocks from rear wheels securing the rear frame.
b. Use lifting equipment move the rear frame clear of the front frame.
c. After moving, block all the rear frame wheels securely.

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 Chassis 16

(b) Disassembly
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure wheel blocks are properly secured
and of adequate capacity to do the job safely.

PROCEDURE
1. Remove the thru-drive driveshaft. Refer to (a) Removal and Disassembly on page 16-9.
2. Disconnect the front frame from the rear frame. Refer to (a) Disconnecting Front and Rear
Frames on page 16-21.
3. Disconnect the grease hose assemblies (24) from the top of the rear frame pivot assembly
housing:
a. Disconnect the grease hose assembly (24) from the elbow (13).
b. Disconnect the elbow (13) from the grease fitting (4).
c. Remove the grease fitting (4) from the top of the rear frame pivot assembly housing.
d. Repeat steps (a) thru (c) for the second hose assembly (24).
4. Remove lockplate (12).
a. Remove bolts (22) and washers (21) securing lockplate (12).
b. Remove lockplate (12) from thrust nut (11).
5. Restrain pivot assembly (1) to prevent it oscillating:
a. Place a heavy bar between the steering cylinder mountings. Refer toFigure 16.7.

Figure 16.7 - Preventing Pivot Assembly From Oscillating

b. Lock bar in position using suitable trestles or stands.
6. Insert an M20 eyebolt into tapped pad provided on top of pivot assembly (1).
7. Attach suitable lifting equipment to eyebolt.
8. Remove thrust nut (11):
a. Use a suitable tool to remove thrust nut (11) from end of pivot assembly (1).
b. Remove and discard V-ring (10) from thrust nut (11).
9. Remove pivot restraining bar.

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16 Chassis

10. Using lifting equipment, carefully pull pivot assembly (1) clear of bushes (2) and rear frame
pivot assembly housing.
11. Remove and discard V-ring (10) from pivot assembly (1).
12. Move pivot assembly (1) to a suitable work area.
13. If necessary, remove bushes (2) from rear frame pivot assembly housing:
a. Make an axial cut along the bush (2).
b. Lever the bush (2) in order to collapse it.
c. Pull the bush (2) out of the rear frame pivot assembly housing.
d. Repeat steps (a) thru (c) for the second bush (2).

(c) Inspection
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

PROCEDURE
1. Clean bushes (2) with a suitable solvent and allow to dry.
2. Inspect bushes (2) for wear, scoring, erosion and 'out of round'. Pay particular attention
to the thrust faces of the bushes which should also be inspected for cracking/splitting.
Renew if required.
3. Replace V-rings (10) with new parts.
4. Inspect thrust nut (2) wear area for damage. If damaged replace.

(d) Assembly
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure wheel blocks are properly secured
and of adequate capacity to do the job safely.

NOTICE
• Tighten all fasteners without special torques specified to torques listed in 22.3 Standard
Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Install bushes (2) to rear frame pivot assembly housing:
a. Freeze bushes (2) for approximately 3 hours at -40º to -60° C.
b. Ensure there is no paint on the sealing faces of the pivot assembly housing.
c. Wipe bush housing clean using a suitable solvent and allow to dry.
d. Apply Loctite 648 and Loc Quick Primer to bush (2).
e. Align bush (2) with grease hole and identification paint spot (1) at top dead centre.
Refer to Figure 16.8.

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 Chassis 16

Figure 16.8 - Installing Oscillation Bushes

1. Paint Spot
f. Install bush (2) into bore of rear frame pivot assembly housing.
g. Drift bush (2) into housing using soft faced hammer for protection.
h. Check that grease hole in bush (2) aligns with hole in rear frame pivot assembly
housing.
i. Repeat steps (c) thru (g) for second bush (2).
2. Apply extreme pressure grease, to the rubbing faces of the pivot assembly (1) spindle,
V-rings (10) and bushes (2).
3. Install V ring (10), with lip towards rear, on pivot assembly (1) spindle.
4. If necessary, insert an M20 eyebolt into tapped pad provided on top of pivot assembly (1).
5. Attach suitable lifting equipment to eyebolt.
6. Using lifting equipment and taking care to prevent damaging bushes (2), carefully push
pivot assembly (1) into bushes (2) and rear frame pivot assembly housing.
7. Ensure that the V-ring (10) is installed correctly between pivot assembly (1) and rear frame
pivot assembly housing.
8. Restrain pivot assembly (1) to prevent it oscillating:
a. Place a heavy bar between the steering cylinder mountings. See Figure 16.7.
b. Lock bar in position using suitable trestles or stands.
9. Install thrust nut (11) to seat bushes (2):
a. Using a micrometer or caliper, measure value 'DTN', the depth of thrust nut (11).
b. Record value 'DTN.
c. Install thrust nut (11).
d. Using a suitable tool tighten thrust nut (11) to seat bushes (2).
10. Determine the shim (52) pack to be installed:
a. Using a depth micrometer, measure values 'D1' and 'D2', the depths through the two
holes to be found in the thrust nut (11) to the end face of the pivot assembly (1) spindle.
b. Record values 'D1' and 'D2'.
c. Calculate value 'DAV', an average value by adding 'D1' and 'D2' and dividing by 2
(DAV = D1+D2/2).
d. Calculate value 'DSP', the shim (52) pack thickness by subtracting 'DAV' from 'DTN'
('DSP'= 'DTN'-'DAV').
e. Calculate the nominal combination of minimum number of shims (52) to achieve the
size nearest to value 'DSP' to achieve an end float between a minimum of 0.2 mm
and maximum of 0.5 mm. Record the appropriate part numbers and total nominal
thickness value.

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16 Chassis

f. Select the shims (52) and measure the total actual thickness of the combination (shim
pack). Record this value.
MOT05316
D1

D1 D2
D tn

D2

Figure 16.9 - Calculating Shim Pack Thickness

11. Using a suitable tool, remove thrust nut (11) from end of pivot assembly (1).
12. Install shim (52) pack and thrust nut (11):
a. Install shim (52) pack to pivot assembly (1) spindle.
b. Install V-ring (10), with lip towards front, on the thrust nut (11).
c. Apply Rocol J-166 anti-seize compound to the threads of the thrust nut (11).
d. Install thrust nut (11).
e. Using a suitable tool tighten thrust nut (11) until there is no end float/clearance at thrust
face of either bush (2).
f. Ensure that the V-ring (10) is installed correctly between the thrust nut (11) and bush (2).
13. Install lockplate (12).
a. Slacken thrust nut (11) until pin of the lockplate (12) can be inserted in the first available
hole in the thrust nut (11).
b. Fit lockplate (12) to thrust nut (11).
c. Install bolts (22) and washers (21) securing lockplate (12).
d. Torque tighten bolts (22) to 94 Nm (69 lbf ft).
14. Remove pivot restraining bar.
15. Connect the grease hose assemblies (24) to the top of the rear frame pivot assembly
housing:
a. Install the grease fitting (4) to the top of the rear frame pivot assembly housing.
b. Connect the elbow (13) to the grease fitting (4).
c. Connect the grease hose assembly (24) to the elbow (13).
d. Repeat steps (a) thru (c) for the second hose assembly (24).
16. Grease bushes (2). Refer to (f) Grease the Pivot Assembly Bushes on page 16-30.

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 Chassis 16

17. Install the thru-drive driveshaft. Refer to (c) Assembly and Installation on page 16-11.
18. Connect the trailer to the tractor. Refer to (e) Connecting Front and Rear Frames on page
16-27.

(e) Connecting Front and Rear Frames

Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

NOTICE
• It may be necessary to relieve binding between the pin and pin bores by raising or lowering
pivot/rear frame assembly.
• Lube fittings (38) are stored on pad on side of pivot assembly (1).
• Take extra care when handling drivelines as chips, dents, burrs or deformity on any rotating
mass creates vibration and excessive wear during any operation.
• Take care when releasing the parking brake as the actuator adjuster is spring tensioned.

PROCEDURE
1. Align trailer bearing bores and tractor pin bores:
a. If necessary, attach suitable lifting equipment to the rear frame. Lifting equipment
must prevent to the rear frame from oscillating and be capable of pulling to the rear
frame to align to the rear frame bearing bores and front frame pin bores. Raise lifting
equipment to support trailer.
b. Remove blocks from rear wheels and blocking from the rear frame.
c. Using lifting equipment, pull the rear frame to align pivot bearing bores and the front
frame pin bores.
d. Block wheels and block the rear frame so that it will remain level and stationary.
2. Install the upper pin assembly (40):
a. Freeze upper pin (40) to ease installation.
b. Apply Extreme Pressure Lithium Complex No. 2 grease to the upper pivot bearings and
pin bores and the shaft of the upper pin assembly (40).. Refer to (1) Recommended
Lubricants on page 4-16.
c. Apply anti-seize compound (Rocol J-166) to the threads of the upper pin assembly (40).
d. Install spacer (39) in upper pivot assembly.
e. Install pin assembly (40), washer (41) and nut (42) to the upper pivot, tighten nut to pull
assembly into position.
f. Torque tighten Nut (42) to 1425 Nm (1 051 lb ft).
g. Using 8 mm Ø 90° cutting angle drill, spot drill to a maximum of 4 mm (0.16 in) upper
pin assembly (40) through access hole in nut (42).
h. Install locking grub screw (part of item 42) to pin assembly (40). Torque tighten grub
screw to 70 Nm (52 lbf ft).
3. Install the lower pin assembly (43):
a. Freeze lower pin (43) to ease installation.
b. Apply anti-seize compound (Rocol J-166) to the threads of bolt (27).
c. Install lower pin (43) to the lower pivot assembly, secure using bolt (27) and washer (44).
d. Torque tighten bolt (27) to 73 Nm (54 lbf ft).
4. Grease the taper roller bearings (30) in the upper and lower pivot assemblies. Refer to (e)
Grease the Taper Roller Bearings on page 16-30.
5. At the rear frame, connect body system (refer to Figure 13.1) hoses:

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16 Chassis

a. Position a suitable container under the front of the rear frame.

b. Remove blanking caps.
c. Connect raise hose (1). Refer to (a) Main Hydraulic Valve Body Raise Hose on page
13-5.
d. Connect lower hose (2) Refer to (b) Main Hydraulic Valve Body Lower Hose on page
13-6.
e. Torque tighten hoses (1&2) to 160 Nm (118 lbf ft).
6. At the rear frame, connect braking system (refer to 14.1 Description on page 14-4) hoses:
a. Position a suitable container under the front of the rear frame.
b. Remove blanking caps.
c. Connect centre and rear axle brake hose (8).
d. Torque tighten brake hose (8) to 55 Nm (41 lbf ft).
e. Connect diff-lock centre axle hose (9).
f. Torque tighten to 24 Nm (18 lbf ft).
g. Connect parking brake hose (9).
h. Torque tighten parking brake hose (9) to 35 Nm (26 lbf ft).
7. Connect wiring harnesses:
a. Remove blanking caps.
b. Connect electrical connector X20.
c. Connect the rear camera harness connector WA2.B32.X1.
8. Install steering cylinders. Refer to (6) Installation on page 12-25.
9. Fill hydraulic tank with hydraulic oil as described in (1) Recommended Lubricants on page
4-16. Ensure area around fill area is clean. Install filler cap on hydraulic tank. Refer to (1)
Checking Oil Level on page 11-70.
10. Bleed the braking system. Refer to (7) Bleeding the Service Brakes on page 14-61.
11. Apply the parking brake by turning the hex-head on the parking brake actuator fully
clockwise. Refer to (6) Installation on page 14-100.
12. Install dropbox to pivot point driveline. Refer to (6) Installation on page 8-8.
13. Remove lifting equipment from to the rear frame.
14. Remove stands or timbers from the front frame.
15. Place the battery master switch in the ‘ON’ position.
16. Start the engine. Refer to 5.11 Starting on page 5-27.
17. Raise body and stow body prop. Refer to (4) Lower the Body Prop on page 21-13.
18. Operate the brake, body and steering systems.
19. Check hydraulic lines and fittings for leaks. Tighten where required.
20. Check hydraulic tank oil level and replenish if required. Refer to (1) Checking Oil Level
on page 11-70.
21. Remove wheel blocks.

(5) Maintenance
Numbers in parentheses refer to Figure 16.3, unless otherwise specified.

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 Chassis 16

NOTICE
• A practical method of establishing the effective adjustment of the thrust nut is to use
movement of the machines body in the raised position. Move the body from fully raised
to almost fully raised while watching the effect of this action on the frame and pivot
arrangement. Any slackness between the thrust nut and thrust faces will be clearly visible
movement of the frame.
• It is essential that the grease used for articulation components is Extreme Pressure Lithium
Complex No. 2 grease. Refer to (1) Recommended Lubricants on page 4-16.
• Lube fittings (38) are stored on pad on side of pivot assembly (1).

Follow the procedures given below to check the oil level in the driveshaft bearing housing, and,
lubricate the articulation and oscillation bearings.
(a) Every 50 Hours

PROCEDURE
1. Position the machine on a level work area, apply parking brake and block all wheels
securely.
2. Raise body and install body safety prop to secure body in partially raised position. Refer to
(3) Deploy the Body Prop on page 21-12.
3. Shut down engine. Refer to 5.12 Stopping on page 5-28
4. Position the battery master switch in the OFF position. Refer to Figure 15.102
5. If fitted, remove the parking brake disc protective guard. Refer to .
6. Drain the pivot assembly (1) of oil. Refer to (c) Drain Gear Oil from the Pivot Assembly
on page 16-30.
7. Fill the pivot assembly with oil. Refer to (d) Fill the Pivot Assembly with Gear Oil on page
16-30.
8. If fitted, install the parking brake disc protective guard. Refer to.
9. Raise body and stow body prop. Refer to (4) Lower the Body Prop on page 21-13.
10. Place the battery master switch in the ‘ON’ position.
11. Start the engine. Refer to 5.11 Starting on page 5-27.
12. Remove wheel blocks.

(b) Every 250 Hours

PROCEDURE
1. Position the machine on a level work area, apply parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Grease the taper roller bearings (30) in the upper and lower pivot assemblies. Refer to (e)
Grease the Taper Roller Bearings on page 16-30.
5. Place the battery master switch in the ‘ON’ position.
6. Start the engine. Refer to 5.11 Starting on page 5-27.

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16 Chassis

7. Remove wheel blocks.

(c) Drain Gear Oil from the Pivot Assembly

PROCEDURE
1. Place a suitable container under the rear frame pivot assembly (1) housing.
2. Remove bolts (7), washers (20), plate (6) and gasket (5) from bottom of rear frame pivot
assembly housing to gain access to filler/level plug (9).
3. Remove filler/level plug (9).

(d) Fill the Pivot Assembly with Gear Oil

PROCEDURE
1. Install filler/level plug (9) into filler/level hole on bottom of rear frame pivot assembly
housing .
2. Install gasket (5) and plate (6) on bottom of rear frame pivot assembly housing and secure
with washers (20) and bolts (7).
3. Remove bolts (7), washers (20), plate (6) and gasket (5) from side of rear frame pivot
assembly housing to gain access to filler/level plug (9).
4. Remove filler/level plug (9).
5. Add SAE 80W - 90 E. P. gear oil through filler/level hole in side of rear frame pivot assembly
housing until the oil is level with the bottom of filler/level hole.
6. Install filler/level plug (9) into filler/level hole on side of rear frame pivot assembly housing .
7. Install gasket (5) and plate (6) on side of rear frame pivot assembly housing and secure
with washers (20) and bolts (7).

(e) Grease the Taper Roller Bearings

PROCEDURE
1. Locate the plugs (28) installed in the side of the upper and lower pivot assemblies.
2. Remove plugs (28).
3. Locate the grease fittings (4) installed in the pad on the side of the pivot assembly (1).
4. Install grease fittings (4) into the holes where the plugs (28) were installed.
5. Fill bearing housings with Extreme Pressure Lithium Complex No. 2 grease , through
grease fittings (4), until excess grease starts to escape from pivot assemblies.
6. Remove grease fittings (4) from the side of the upper and lower pivot assemblies.
7. Reinstall plugs (28).
8. Reinstall grease fittings (4) in the pad on the side of the pivot assembly (1).

(f) Grease the Pivot Assembly Bushes

PROCEDURE
1. Locate grease fittings connected to grease hose assemblies (24).

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 Chassis 16

2. Fill bushes (2) with Extreme Pressure Lithium Complex No. 2 grease, through grease
fittings, until excess grease starts to escape from bushes (2).

(6) Special Tools

Refer to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5 for part numbers of the
thrust nut tool and general service tools and adhesives required for procedures outlined in this
section. These tools and adhesives are available from your dealer.
(7) Special Torque Specifications
ITEM TORQUE
FIG. No. ITEM NAME
No. Nm lbf ft
Figure 16.3 22 Bolt 94 69
Figure 16.3 23 Bolt 54 39
Figure 16.3 27 Bolt 73 54
Figure 16.3 42 Nut 1 425 1 050
Figure 16.3 46/47 Bolt 106–116 78–86

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 16.3

Page 16-32
15-Sep-2017
16 Chassis

Hood

37
36
1 67,69 34 2

48
14 69
13
4 68
12
52
22 43,44
53 51 58
55
57 20
54
32
26 37
5 29
27 45,46 36
35 34

Revision 1.0
67
16 17 69 47
15
31 69
42
31 68
14,13 13
B 14 7,8
23

Figure 16.10 - Hood Installation

18 31 32
25
39 33 31
54
19 18
60 14
38 13
57
A 21
56 12
35
50 59 6 31
40 4
41 24,33
10,11 28 20 58,55
65,66 31 51
65,66 12 30
3 27 53
63,64 62 63,64 13
14 56 60 29
61 62 61 9 26
59 49 45,46

MOT05415

TA400 Tier2
Maintenance Manual
 Chassis 16

1. Hood Assembly 24. LHS Baffle 47. LHS Hood Mounting

2. Hood 25. RHS Baffle 48. RHS Hood Mounting
3. Reinforcement 26. Plate 49. Plate
Assembly
4. Joining Plate 27. Bolt 50. Plate
5. Grille 28. Bolt 51. Plate
6. Reinforcement 29. Washer 52. Strap
Assembly
7. Bolt 30. Hardened Washer 53. Pin
8. Nut 31. Bulk Seal 54. Washer
9. Adjustment Rod 32. Lip Seal 55. Bolt
10. Washer 33. Beading 56. Bolt
11. Nut 34. V Mount Assembly 57. Bolt
12. Bolt 35. Torx Screw 58. Washer
13. Spring Washer 36. Nut 59. Hardened Washer
14. Hex Nut 37. Washer 60. Seal
15. Bolt 38. Brace Tube 61. Hinge Plate Assembly
16. Washer 39. Brace Tube 62. Bolt
17. Nut 40. Brace Tube 63. Washer
18. Bolt 41. Brace Tube 64. Locknut
19. Washer 42. Angle Plate 65. Bolt
20. Pin 43. RHS Light Pod 66. Washer
21. LHS Light Pod 44. Grille 67. Bolt
22. Air Intake Plate 45. Actuator 68. Locknuts
23. Top Baffle 46. Seal Kit 69. Washers

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16 Chassis

(1) Removal
Numbers in parentheses refer to Figure 16.10, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

NOTICE
• If for any reason, electrical power is disabled from the electric actuator (47) , the actuator
can be raised manually. Taking a suitable ball end allen key (6 mm) with extension, remove
the cap covering the hand wind socket from the base end of the actuator (45).
• The actuator (45) ram can be extended and retracted manually. Using a suitable 6 mm ball
end allen key, first remove the cap covering the hand wind socket from the base end of
the actuator (45) and then either turn the hand wind socket clockwise to extend the ram or
anticlockwise to retract the ram.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove the grille (5):
a. Remove bolts (57) and washers (54) securing the grille (5) to the hood.
b. Lift the grille (5) from the hood assembly (1).
c. Move the grille (5) to a clean maintenance area.
5. Place the battery master switch in the ‘ON’ position.
6. Raise the hood assembly (1). Refer to (5) Raising the Hood on page 16-38.
» Raise the hood assembly (1) sufficiently that suitable lifting equipment can be attached.
7. Attach suitable lifting equipment to the hood assembly (1).
» Lifting equipment must secure the full length of the hood assembly (1) from front to back,
prevent hood assembly (1) from swinging after separation and be capable of pulling
hood assembly (1) clear.
8. Raise the hood assembly (1). Refer to (5) Raising the Hood on page 16-38.
» Raise the hood assembly (1) completely.
9. Place the battery master switch in the ‘OFF’ position.
10. Remove the brake oil cooler from the hood. Refer to (b) Cooler on page 18-16
a. Using suitable lifting equipment, support the brake oil cooler (1, Figure 18.5).

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 Chassis 16

b. Remove the three bolts, locknuts, washers and rubber mounts (5, 8, 9 and 10, Figure
18.5) from the cooler mounting brackets (12, 13, Figure 18.5).
c. Using suitable lifting equipment, carefully remove the brake cooler (1, Figure 18.5)
from the hood (2). If the brake oil is still hot, great care must be taken when handling
the cooler.
d. Place the brake oil cooler (1, Figure 18.5) on a suitable support on the LH fender.
11. Disconnect wiring harness:
a. Identify and tag the hood electrical harness connection X17.
b. Disconnect electrical connector X19.
c. Cap all connections to prevent ingress of dirt.
12. Disconnect the actuators (45) from the hood assembly (1):
a. Locate the plate (26).
b. Remove the bolts (27) and washers (29) from the plate (26).
c. Remove the plate (26).
d. Remove the pin (20) from hood assembly (1) structure to disconnect the rod end of
the actuator (45).
e. Repeat steps (a) thru (d) for the second actuator (45).
13. Using standard lifting equipment, support the weight of the hood assembly (1).
14. Disconnect the strap (52):
a. Locate the strap (52).
b. Locate the bolt (12), washer (13) and nut (14) attaching the strap (52) to the hood
assembly (1).
c. Remove the bolt, washer and nut.
d. Restrain the strap (52).
15. Disconnect the adjustment rods (9):
a. Locate the hinge plate assembly (61) and bolt (62).
b. Remove the locknut (64) and washer (63).
c. Remove the bolt (62) securing the adjustment rod (9) to the hinge plate assembly (61).
d. Repeat steps (a) thru (c) for the second adjustment rod (9).
16. Using standard lifting equipment, lift the hood assembly (1) away from the tractor.
17. Move the hood assembly (1) to a clean maintenance area.

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16 Chassis

(2) Installation
Numbers in parentheses refer to Figure 16.10, unless otherwise specified.

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

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Place the battery master switch in the ‘OFF’ position.
2. Attach suitable lifting equipment to the hood assembly (1).
» Lifting equipment must secure the full length of the hood assembly (1) from front to
back, prevent hood assembly (1) from swinging and be capable of lowering the hood
assembly (1) into position.
3. Using standard lifting equipment, lower the hood assembly (1) into position until the
adjustment rods (9) are aligned with the hinge plate assemblies (61).
4. Using standard lifting equipment, support the weight of the hood assembly (1).
5. Connect the adjustment rods (9):
a. align the adjustment rod (9) with the hinge plate assembly (61).
b. Install the bolt (62) securing the adjustment rod (9) to the hinge plate assembly (61).
c. Install the washer (63) and locknut (64).
d. Repeat steps (a) thru (c) for the second adjustment rod (9).
e. Torque tighten locknuts (64) to 45 Nm (33 lbf ft).
6. Connect the strap (52):
a. Release the strap (52).
b. Position the end of strap (52) to its attachment point on the hood assembly (1).
c. Install the bolt (12), washer (13) and nut (14) attaching the strap (52) to the hood
assembly (1).
7. Connect the actuators (45) to the hood assembly (1):
a. Locate the attachment point for the rod end of the actuator (45).
b. Install the pin (20) to hood assembly (1) structure to connect the rod end of the actuator
(45).
c. Install the plate (26).
d. Install the washers (29) and bolts (27) to the plate (26).
e. Repeat steps (a) thru (d) for the second actuator (45).
f. Torque tighten the bolts (27) to 5 Nm (lb ft).
8. Connect wiring harness:
a. Locate hood electrical harness connection X17.
b. Remove blanking caps.
c. Connect electrical connector X19.
9. Place the battery master switch in the ‘ON’ position.

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 Chassis 16

10. Lower the hood assembly (1). Refer to (6) Lowering the Hood on page 16-39.
11. Check installation:
a. Check that the hood clears the transmission oil cooler pipes.
b. Check that there is a sufficient parallel gap between the hood assembly (1) and the
front frame. Gap to be approximately 20 mm. Adjust as required by adjusting the
adjustment rods (9).
c. Check that the V mount assemblies (34) engage the hood mountings (47 and 48)
correctly. Adjust as required. Adjust by either adjusting the V mount assemblies (34) or
moving the hood mountings (47 and 48).
12. Lower the hood assembly (1). Refer to (6) Lowering the Hood on page 16-39.
13. Operate three times, the raise and lower function of the hood to ensure correct installation.
Refer to (5) Raising the Hood on page 16-38 and (6) Lowering the Hood on page 16-39.
14. Place the battery master switch in the ‘OFF’ position.
15. Install the grille (5):
a. Lift the grille (5) into position at the front of the hood assembly (1).
b. Install washers (54) and bolts (57) to secure the grille (5) to the hood assembly (1).
16. Remove wheel blocks.

(3) Maintenance

PROCEDURE
1. Periodically check bolts, washers and locknuts and tighten when necessary.
2. Replace any damaged or defective lights.
3. Periodically check all brackets for cracks or damage and replace when necessary.

(4) Special Tools

There are no special tools required for procedures outlined in this section. Refer to 22.2 Service
Tools on page 22-4 for part numbers of general service tools and adhesives required. These
tools and adhesives are available from your dealer.

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TA400 Tier2 Page 16-37
16 Chassis

(5) Raising the Hood

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• To prevent damage, at all times, make sure the hood is raised before tilting or lowering the
cab.

NOTICE
• The hood can be tilted to any angle from fully lowered to fully raised. When the hood
has reached the fully raised position, the actuators will continue to operate until the hood
switch is released.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Open the battery box.
4. Place the battery master switch in the ‘ON’ position.
5. Locate the hood switch in the battery box to the left of the master battery disconnect switch.
6. Press and hold the top of the hood switch.
» The hood starts to tilt.
7. Release the hood switch once the hood has tilted to the angle required.
8. Place the battery master switch in the ‘OFF’ position.
9. Close the battery box.

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 Chassis 16

(6) Lowering the Hood

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• To prevent damage, at all times, make sure the hood is raised before tilting or lowering the
cab.

NOTICE
• The hood can be tilted to any angle from fully lowered to fully raised. When the hood has
reached the fully lowered position, the actuators will continue to operate until the hood
switch is released.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Open the battery box.
4. Place the battery master switch in the ‘ON’ position.
5. Locate the hood switch in the battery box to the left of the master battery disconnect switch.
6. Press and hold the bottom of the hood switch.
» The hood starts to lower.
7. Release the hood switch once the hood has lowered to the angle required.
8. Place the battery master switch in the ‘OFF’ position.
9. Close the battery box.

Maintenance Manual Revision 1.0 15-Sep-2017

TA400 Tier2 Page 16-39
 16.4

Page 16-40
15-Sep-2017
16 Chassis

33 9
34
Mudflaps

10
11
26
32 12
31
5
3

30
31 26 36
LHS
2
26
21 32
29 31
26
26
34
30

Revision 1.0
17 7 31
23 4 8 30
6
13 25 27 23
15 33 24 22
1 30 31
18 40
42

Figure 16.11 - LHS Fender Assembly

31 30 16
30 26 40
29 31 26 28 38 41
49
14 26 19 20 53
34 37 55
30
39
26 47
30 31 45 52 50
30
26 29 31 26 43
29 31 26 44
32
31 26 46
31
35 30 26 31 51 52

MOT05417

TA400 Tier2
Maintenance Manual
TA400 Tier2
Maintenance Manual
87 87
57 94 94
88 92 92
98
86
90
91 83 89
RHS 60

58 56

100 88
96 98
90 99 95
93

79 59 77 63 92
93 62 90

67
66 90

Revision 1.0
87 92 64 112 116
84 118
81
61 106
87 87 97 104
94 102 105 113
92 73
117
76 119
80
82 101 103

Figure 16.12 - RHS Fender Assembly

65 74 111
116 114
78
85 96 92 87

109 90
90 87 75 92 110 108
92 88 92 97 87
107
90
92 97 87 116
115

MOT05418

Page 16-41
15-Sep-2017
Chassis 16
16 Chassis

1. LH Fender Assembly 41. LH Mudflap Mounting 81. RH Mudflap Clamping Plate

Bracket
2. LH Rear Outer 42. LH Bracket 82. RH Mudflap Mounting Plate
Handrail
3. Diagnostic Box Plate 43. LH Bottom Rear 83. Washer
Mudflap
4. LH Bush 44. LH Clamping Angle 84. Foam
5. LH Rear Inner 45. LH Clamping Plate 85. Bolt
Handrail
6. LH Step Support Arm 46. LH Mudflap Clamping 86. Bolt
Assembly Plate
7. Clamp Washer 47. LH Side Washer 87. Bolt
Clamp
8. Thrust Washer 48. Bolt 88. Bolt
9. Screw 49. Bolt 89. Nut
10. Retainer 50. Bolt 90. Lock Nut
11. Receptacle 51. Bolt 91. Washer
12. Diagnostic Box Cover 52. Washer 92. Washer
13. LH Kick Plate 53. Washer 93. Washer
14. LH Top Front Mudflap 54. Nut 94. Lock Washer
15. LH Wheel Arch 55. Nut 95. Washer
Mudflap Reinforcing
Plate
16. LH Mudflap Clamping 56. RH Fender Assembly 96. Washer
Plate
17. LH Wheel Arch 57. RH Rear Outer 97. Washer
Mudflap Handrail
18. LH Top Rear Mudflap 58. RH Rear Inner 98. Washer
Handrail
19. LH Mudflap Mounting 59. RH Step Support Arm 99. Bolt
Plate Assembly
20. LH Mudflap Mounting 60. RH Forward Outer 100. Bolt
Plate Handrail
21. LH Forward Outer 61. RH Mudflap Mounting 101. RH First Step
Handrail Plate
22. Bolt 62. Thrust Washer 102. RH Second Step
23. Washer 63. RH Bush 103. RH Step Support Strip
24. Lockwasher 64. RH Top Rear Mudflap 104. RH Side Support
25. Locknut 65. Adblue Platform 105. RH Mudflap Mounting
Assembly Bracket
26. Bolt 66. Door 106. RH Bracket
27. Washer 67. Latch 107. RH Bottom Rear Mudflap
28. LH Kick Plate 68. 108. RH Clamping Angle

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 Chassis 16

29. Washer 69. 109. RH Clamping Plate

30. Locknut 70. 110. RH Mudflap Clamping Plate
31. Washer 71. 111. RH Side Washer Clamp
32. Lockwasher 72. 112. Bolt
33. Bolt 73. RH Mudflap Clamping 113. Bolt
Plate
34. Washer 74. RH Wheel Arch 114. Bolt
Mudflap Reinforcing
Plate
35. LH Mudflap Mounting 75. RH Wheel Arch 115. Bolt
Plate Mudflap
36. LH Handrail Filler 76. RH Top Front Mudflap 116. Washer
Tube
37. LH First Step 77. Bolt 117. Washer
38. LH Second Step 78. RH Mudflap Mounting 118. Nut
Plate
39. LH Step Support Strip 79. RH Kick Plate 119. Nut
40. LH Side Support 80. Spacer

(1) Removal
Numbers in parentheses refer to Figure 16.11 and Figure 16.12, unless otherwise specified.

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

(a) LH Bottom Rear Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove bolts (51) and washers (52) and LH mudflap clamping plates (46) securing the LH
first step (37) and LH second step (38) to the LH bottom rear mudflap (43).
5. Remove nuts (55), bolts (49) and washers (53) securing the LH mudflap mounting brackets
(41) to the LH bottom rear mudflap (43).
6. Remove nuts (55), bolts (49) and washers (53) securing the LH clamping angle (44) and
LH clamping plate (45) to the LH bottom rear mudflap (43).
7. Separate the LH bottom rear mudflap (43) from the LH lower step assembly.
8. Move the LH bottom rear mudflap (43) to a clean maintenance area.

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TA400 Tier2 Page 16-43
16 Chassis

(b) LH Top Rear Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove the LH bottom rear mudflap (43). Refer to (a) LH Bottom Rear Mudflap on page
16-43.
5. Remove locknuts (30), bolts (26), washers (29) and washers (31) securing the LH top
rear mudflap (18) with the LH mudflap mounting plates (19) and (20) to the LH wheel
arch mudflap (17).
6. Remove locknuts (30), bolts (26) and washers (31) securing the LH top rear mudflap (18)
with the LH mudflap mounting plates (19) and (20) and mudflap clamping plate (16) to the
LH step support arm assembly (6) and LH fender assembly (1).
7. Separate the LH top rear mudflap (18) from the LH step support arm assembly (6) and
LH fender assembly (1).
8. Move the LH top rear mudflap (18) to a clean maintenance area.

(c) LH Top Front Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove locknuts (30), bolts (26), washers (29) and washers (31) securing the LH top front
mudflap (14) with the LH mudflap mounting plate (35) to the LH wheel arch mudflap (17).
5. Remove locknuts (30), bolts (26) and washers (31) securing the LH top front mudflap
(14) with the LH mudflap mounting plate (35) and LH mudflap clamping plate (28) to the
LH fender assembly (1).
6. Separate the LH top front mudflap (14) from the LH fender assembly (1).
7. Move the LH top front mudflap (14) to a clean maintenance area.

(d) LH Wheel Arch Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove the wheel. Refer to (3) Removing Tire and Rim Assembly from Machine on page
9-125.
5. Remove the LH Top Front Mudflap (14). Refer to (c) LH Top Front Mudflap on page 16-44.

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 Chassis 16

6. Remove the LH Top Rear Mudflap (18). Refer to (b) LH Top Rear Mudflap on page 16-44.
7. Support LH wheel arch mudflap (17).
8. Remove bolts (26) and washers (29).
9. Separate the LH wheel arch mudflap (17) from the LH fender assembly (1).
10. If necessary, remove locknuts (30), bolts (26), washers (29) and washers (31) to separate
the LH wheel arch mudflap reinforcing pate (15) from the LH wheel arch mudflap (17).
11. Move the LH wheel arch mudflap (17) to a clean maintenance area.

(e) RH Bottom Rear Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove bolts (115) and washers (116) and RH mudflap clamping plates (110) securing the
RH first step (101) and RH second step (102) to the RH bottom rear mudflap (107).
5. Remove nuts (119), bolts (113) and washers (117) securing the RH mudflap mounting
brackets (105) to the RH bottom rear mudflap (107).
6. Remove nuts (119), bolts (113) and washers (117) securing the RH clamping angle (108)
and RH clamping plate (109) to the RH bottom rear mudflap (107).
7. Separate the RH bottom rear mudflap (107) from the RH lower step assembly.
8. Move the RH bottom rear mudflap (107) to a clean maintenance area.

(f) RH Top Rear Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove the RH bottom rear mudflap (107). Refer to (e) RH Bottom Rear Mudflap on
page 16-45.
5. Remove locknuts (90), bolts (87), washers (97) and washers (92) securing the RH top
rear mudflap (64) with the RH mudflap mounting plates (78) and (61) to the RH wheel
arch mudflap (75).
6. Remove locknuts (90), bolts (87) and washers (92) securing the RH top rear mudflap (64)
with the RH mudflap mounting plates (78) and (61) and mudflap clamping plate (81) to the
RH step support arm assembly (59) and RH fender assembly (56).
7. Separate the RH top rear mudflap (64) from the RH step support arm assembly (59) and
RH fender assembly (56).
8. Move the RH top rear mudflap (64) to a clean maintenance area.

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TA400 Tier2 Page 16-45
16 Chassis

(g) RH Top Front Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove locknuts (90), bolts (87), washers (92) and washers (97) securing the RH top front
mudflap (76) with the RH mudflap mounting plate (82) to the RH wheel arch mudflap (75).
5. Remove locknuts (90), bolts (87) and washers (92) securing the RH top front mudflap
(76) with the RH mudflap mounting plate (82) and RH mudflap clamping plate (73) to the
RH fender assembly (56).
6. Separate the RH top front mudflap (76) from the RH fender assembly (56).
7. Move the RH top front mudflap (76) to a clean maintenance area.

(h) RH Wheel Arch Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine. Refer to 5.12 Stopping on page 5-28
3. Position the battery master switch in the OFF position. Refer to Figure 15.102
4. Remove the wheel and tyre assembly. Refer to (3) Removing Tire and Rim Assembly from
Machine on page 9-125.
5. Remove the RH Top Front Mudflap (76). Refer to (g) RH Top Front Mudflap on page 16-46.
6. Remove the RH Top Rear Mudflap (64). Refer to (f) RH Top Rear Mudflap on page 16-45.
7. Support RH wheel arch mudflap (75).
8. Remove bolts (87) and washers (97).
9. Separate the RH wheel arch mudflap (75) from the RH fender assembly (56).
10. If necessary, remove locknuts (90), bolts (87), washers (92) and washers (97) to separate
the RH wheel arch mudflap reinforcing pate (74) from the RH wheel arch mudflap (75).
11. Move the RH wheel arch mudflap (75) to a clean maintenance area.

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Page 16-46 TA400 Tier2
 Chassis 16

(2) Installation
Numbers in parentheses refer to Figure 16.11 and Figure 16.12 unless otherwise specified.

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

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

(a) LH Top Rear Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Position the battery master switch in the OFF position. Refer to Figure 15.102
3. Gain access to the work area.
4. Lift the LH top rear mudflap (18) into position.
5. Align the LH top rear mudflap (18) with LH step support arm assembly (6) and LH fender
assembly (1).
6. Install bolts (26), washers (31) and locknuts (30) securing the LH top rear mudflap (18) with
the LH mudflap mounting plates (19) and (20) and mudflap clamping plate (16) to the LH
step support arm assembly (6) and LH fender assembly (1).
7. Install bolts (26), washers (29), washers (31) and locknuts (30) securing the LH top rear
mudflap (18) with the LH mudflap mounting plates (19) and (20) to the LH wheel arch
mudflap (17).
8. Torque tighten the bolts (26).
9. Install the LH bottom rear mudflap (43). Refer to (b) LH Bottom Rear Mudflap on page
16-47.

(b) LH Bottom Rear Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Position the battery master switch in the OFF position. Refer to Figure 15.102
3. Gain access to the work area.
4. Lift the LH bottom rear mudflap (43) into position.
5. Align the LH bottom rear mudflap (43) with the LH lower step assembly.
6. Install bolts (49), washers (53) and nuts (55) securing the LH clamping angle (44) and LH
clamping plate (45) to the LH bottom rear mudflap (43).

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TA400 Tier2 Page 16-47
16 Chassis

7. Install bolts (51) and washers (52) and LH mudflap clamping plates (46) securing the LH
second step (38) and LH first step (37) to the LH bottom rear mudflap (43).
8. Install bolts (49), washers (53) and nuts (55) securing the LH mudflap mounting brackets
(41) to the LH bottom rear mudflap (43).
9. Torque tighten the bolts (49) and (51).

(c) LH Top Front Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Position the battery master switch in the OFF position. Refer to Figure 15.102
3. Gain access to the work area.
4. Lift the LH top front mudflap (14) into position.
5. Align the LH top front mudflap (14) with LH fender assembly (1).
6. Install bolts (26), washers (31) and locknuts (30) securing the LH top front mudflap (14)
with the LH mudflap mounting plate (35) and LH mudflap clamping plate (28) to the LH
fender assembly (1).
7. Install bolts (26), washers (29), washers (31) and locknuts (30) securing the LH top front
mudflap (14) with the LH mudflap mounting plate (35) to the LH wheel arch mudflap (17).
8. Torque tighten the bolts (26).

(d) LH Wheel Arch Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Position the battery master switch in the OFF position. Refer to Figure 15.102
3. Gain access to the work area.
4. If necessary, install bolts (26), washers (29), washers (31) and locknuts (30) to attach the
LH wheel arch mudflap reinforcing pate (15) to the LH wheel arch mudflap (17).
5. Lift the LH wheel arch mudflap (17) into position.
6. Align the LH wheel arch mudflap (17) with LH fender assembly (1).
7. Install bolts (26) and washers (29).
8. Torque tighten the bolts (26).
9. Install the LH Top Rear Mudflap (18). Refer to (a) LH Top Rear Mudflap on page 16-47.
10. Install the LH Top Front Mudflap (14). Refer to (c) LH Top Front Mudflap on page 16-48.
11. Install the wheel. Refer to (7) Mounting Tire and Rim Assembly on Machine on page 9-129.

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 Chassis 16

(e) RH Top Rear Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Position the battery master switch in the OFF position. Refer to Figure 15.102
3. Gain access to the work area.
4. Lift the RH top rear mudflap (64) into position.
5. Align the RH top rear mudflap (64) with RH step support arm assembly (59) and RH fender
assembly (56).
6. Install bolts (87), washers (92) and locknuts (90) securing the RH top rear mudflap (64) with
the RH mudflap mounting plates (78) and (61) and mudflap clamping plate (81) to the RH
step support arm assembly (59) and RH fender assembly (56).
7. Install bolts (87), washers (92), washers (97) and locknuts (90) securing the RH top rear
mudflap (64) with the RH mudflap mounting plates (78) and (61) to the RH wheel arch
mudflap (75).
8. Torque tighten the bolts (87).
9. Install the RH bottom rear mudflap (107). Refer to (f) RH Bottom Rear Mudflap on page
16-49.

(f) RH Bottom Rear Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Position the battery master switch in the OFF position. Refer to Figure 15.102
3. Gain access to the work area.
4. Lift the RH bottom rear mudflap (107) into position.
5. Align the RH bottom rear mudflap (107) with the RH lower step assembly.
6. Install bolts (113), washers (117) and nuts (119) securing the RH clamping angle (108) and
RH clamping plate (109) to the RH bottom rear mudflap (107).
7. Install bolts (115) and washers (116) and RH mudflap clamping plates (110) securing the
RH second step (102) and RH first step (101) to the RH bottom rear mudflap (107).
8. Install bolts (113), washers (117) and nuts (119) securing the RH mudflap mounting brackets
(105) to the RH bottom rear mudflap (107).
9. Torque tighten the bolts (113) and (115).

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TA400 Tier2 Page 16-49
16 Chassis

(g) RH Top Front Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Position the battery master switch in the OFF position. Refer to Figure 15.102
3. Gain access to the work area.
4. Lift the RH top front mudflap (76) into position.
5. Align the RH top front mudflap (76) with RH fender assembly (56).
6. Install bolts (87), washers (92) and locknuts (90) securing the RH top front mudflap (76)
with the RH mudflap mounting plate (82) and RH mudflap clamping plate (73) to the RH
fender assembly (56).
7. Install bolts (87), washers (92), washers (97) and locknuts (90) securing the RH top front
mudflap (76) with the RH mudflap mounting plate (82) to the RH wheel arch mudflap (75).
8. Torque tighten the bolts (87).

(h) RH Wheel Arch Mudflap

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Position the battery master switch in the OFF position. Refer to Figure 15.102
3. Gain access to the work area.
4. If necessary, install bolts (87), washers (92), washers (97) and locknuts (90) to attach the
RH wheel arch mudflap reinforcing pate (74) to the RH wheel arch mudflap (75).
5. Lift the RH wheel arch mudflap (75) into position.
6. Align the RH wheel arch mudflap (75) with RH fender assembly (56).
7. Install bolts (87) and washers (97).
8. Torque tighten the bolts (87).
9. Install the RH Top Rear Mudflap (64). Refer to (e) RH Top Rear Mudflap on page 16-49.
10. Install the RH Top Front Mudflap (76). Refer to (g) RH Top Front Mudflap on page 16-50.
11. Install the wheel. Refer to (7) Mounting Tire and Rim Assembly on Machine on page 9-129.

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Page 16-50 TA400 Tier2
 Chassis 16

16.5 Handrails and Fenders

(1) Removal
Numbers in parentheses refer to Figure 16.11 and Figure 16.12, unless otherwise specified.

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

(a) LH Kick Plate

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the nuts (25), bolts (33) and washers (27).
5. Separate the Left Hand (LH) kick plate (13) from LH forward outer handrail (21) and LH
rear outer handrail (2) mounting brackets.
6. Move the LH kick plate (13) to a clean maintenance area.

(b) LH Handrail Filler Tube

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the nuts (30) bolts (26) and washers (31).
5. Separate the LH handrail filler tube (36) from LH forward outer handrail (21) and LH rear
outer handrail (2).
6. Move the LH handrail filler tube (36) to a clean maintenance area.

(c) LH Forward Outer Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the LH kick plate (13). Refer to (a) LH Kick Plate on page 16-51.
5. Remove the LH handrail filler tube (36). Refer to (b) LH Handrail Filler Tube on page 16-51.
6. Remove the bolts (26), lockwashers (32) and washers (31).

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16 Chassis

7. Remove the LH forward outer handrail (21) from the mounting pads on the LH fender
assembly (1).
8. Move the LH forward outer handrail (21) to a clean maintenance area.

(d) LH Rear Outer Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the LH kick plate (13). Refer to (a) LH Kick Plate on page 16-51.
5. Remove the LH handrail filler tube (36). Refer to (b) LH Handrail Filler Tube on page 16-51.
6. Remove the bolts (26), lockwashers (32) and washers (31).
7. Remove the LH rear outer handrail (2) from the mounting pads on the LH fender assembly
(1).
8. Move the LH rear outer handrail (2) to a clean maintenance area.

(e) LH Rear Inner Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the bolts (26), lockwashers (32) and washers (31).
5. Remove the LH rear inner handrail (5) from the mounting pads on the LH fender assembly
(1).
6. Move the LH rear inner handrail (5) to a clean maintenance area.

(f) LH Lower Step Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the LH bottom rear mudflap. Refer to (a) LH Bottom Rear Mudflap on page 16-43.
5. Remove the locknuts (30), bolts (7), washers (23), thrust washers (8) and washers (31).
6. Keep the bushes (4) for installation.
7. Separate the LH lower step assembly from the LH step support arm assembly (6).
8. Move the LH lower step assembly to a clean maintenance area.

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 Chassis 16

(g) LH Fender Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the handrails. Refer to (c) LH Forward Outer Handrail on page 16-51, (d) LH Rear
Outer Handrail on page 16-52and (e) LH Rear Inner Handrail on page 16-52.
5. Remove the wheel. Refer to (3) Removing Tire and Rim Assembly from Machine on page
9-125.
6. Remove the LH wheel arch mudflap (17). Refer to (d) LH Wheel Arch Mudflap on page
16-44.
7. Attach suitable lifting equipment to LH fender assembly (1).
8. Remove the bolts (26), washers (34) and locknuts (30) from the LH step support arm
assembly (6) and hydraulic tank fender attachment point (refer to 8, Figure 11.11).
9. Using lifting equipment, carefully separate the LH fender assembly (1) from the LH step
support arm assembly (6) and hydraulic tank fender attachment point (refer to 8, Figure
11.11).
10. Move the LH fender assembly (1) to a clean maintenance area.

(h) LH Step Support Arm Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the LH lower step assembly. Refer to (f) LH Lower Step Assembly on page 16-52.
5. Remove LH fender assembly (1). Refer to (g) LH Fender Assembly on page 16-53.
6. Attach suitable lifting equipment to LH step support arm assembly (6).
7. Remove the bolts (22), lockwashers (24) and washers (23).
8. Using lifting equipment, separate the LH step support arm assembly (6) from the front frame.
9. Move the LH step support arm assembly (6) to a clean maintenance area.

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16 Chassis

(i) RH Kick Plate

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the nuts (89), bolts (86), washers (91) and washers (83).
5. Separate the Right Hand (RH) kick plate (79) from RH forward outer handrail (60) and RH
rear outer handrail (57) mounting brackets.
6. Move the RH kick plate (79) to a clean maintenance area.

(j) RH Forward Outer Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the RH kick plate (79). Refer to (i) RH Kick Plate on page 16-54.
5. Remove the bolts (87), lockwashers (94) and washers (92).
6. Remove the RH forward outer handrail (60) from the mounting pads on the RH fender
assembly (56).
7. Move the RH forward outer handrail (60) to a clean maintenance area.

(k) RH Rear Outer Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the RH kick plate (79). Refer to (i) RH Kick Plate on page 16-54.
5. Remove the bolts (87), lockwashers (94) and washers (92).
6. Remove the RH rear outer handrail (57) from the mounting pads on the RH fender
assembly (56).
7. Move the RH rear outer handrail (57) to a clean maintenance area.

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 Chassis 16

(l) RH Rear Inner Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the bolts (87), lockwashers (94) and washers (92).
5. Remove the RH rear inner handrail (58) from the mounting pads on the RH fender
assembly (56).
6. Move the RH rear inner handrail (58) to a clean maintenance area.

(m) RH Lower Step Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the RH bottom rear mudflap. Refer to (e) RH Bottom Rear Mudflap on page 16-45.
5. Remove the locknuts (90), bolts (77), washers (93), thrust washers (62) and washers (92).
6. Keep the bushes (63) for installation.
7. Separate the RH lower step assembly from the RH step support arm assembly (59).
8. Move the RH lower step assembly to a clean maintenance area.

(n) Adblue Cover Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the RH forward outer handrail (60). Refer to (j) RH Forward Outer Handrail on
page 16-54.
5. Remove the bolts (100) and (85) and washers (96).
6. Separate the adblue cover assembly (65) from the RH fender assembly (56) and fuel tank.
7. Move the adblue cover assembly (65) to a clean maintenance area.

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16 Chassis

(o) RH Fender Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the handrails. Refer to (j) RH Forward Outer Handrail on page 16-54, (k) RH Rear
Outer Handrail on page 16-54 and (l) RH Rear Inner Handrail on page 16-55.
5. Remove the adblue cover assembly (65). Refer to (n) Adblue Cover Assembly on page
16-55.
6. Remove the wheel. Refer to (3) Removing Tire and Rim Assembly from Machine on page
9-125.
7. Remove the RH wheel arch mudflap (75). Refer to (h) RH Wheel Arch Mudflap on page
16-46.
8. Attach suitable lifting equipment to RH fender assembly (56).
9. Remove the bolts (88), washers (98) and locknuts (90) from the RH step support arm
assembly (59) and fuel tank fender attachment point.
10. Using lifting equipment, carefully separate the RH fender assembly (56) from the RH step
support arm assembly (59) and fuel tank fender attachment point.
11. Move the RH fender assembly (1) to a clean maintenance area.

(p) RH Step Support Arm Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Shut down engine.
3. Place the battery master switch in the ‘OFF’ position.
4. Remove the RH lower step assembly. Refer to (m) RH Lower Step Assembly on page 16-55.
5. Remove RH fender assembly (56). Refer to (o) RH Fender Assembly on page 16-56.
6. Attach suitable lifting equipment to RH step support arm assembly (59).
7. Remove the bolts (99), lockwashers (95) and washers (93).
8. Using lifting equipment, separate the RH step support arm assembly (59) from the front
frame.
9. Move the RH step support arm assembly (59) to a clean maintenance area.

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 Chassis 16

(2) Installation
Numbers in parentheses refer to Figure 16.11 and Figure 16.12, unless otherwise specified.

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

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

(a) LH Step Support Arm Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Attach suitable lifting equipment to LH step support arm assembly (6).
5. Using lifting equipment, align the LH step support arm assembly (6) with its attachment
point on the front frame.
6. Install the bolts (22), lockwashers (24) and washers (23).
7. Torque tighten the bolts (22).
8. Install LH fender assembly (1). Refer to (b) LH Fender Assembly on page 16-57.
9. Install the LH lower step assembly. Refer to (c) LH Lower Step Assembly on page 16-58.

(b) LH Fender Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Attach suitable lifting equipment to LH fender assembly (1).
5. Using lifting equipment, carefully align the LH fender assembly (1) with the LH step support
arm assembly (6) and hydraulic tank fender attachment point (refer to 8, Figure 11.11).
6. Install the bolts (26), washers (34) and locknuts (30) to the LH step support arm assembly
(6) and hydraulic tank fender attachment point (refer to 8, Figure 11.11).
7. Torque tighten the bolts (26).
8. Install the LH wheel arch mudflap (17). Refer to (d) LH Wheel Arch Mudflap on page 16-48.
9. Install the wheel. Refer to (7) Mounting Tire and Rim Assembly on Machine on page 9-129.

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16 Chassis

10. Install the handrails. Refer to (d) LH Forward Outer Handrail on page 16-58, (e) LH Rear
Outer Handrail on page 16-58 and (f) LH Rear Inner Handrail on page 16-59.

(c) LH Lower Step Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the LH lower step assembly into position.
5. Align the LH lower step assembly with the LH step support arm assembly (6).
6. Install the bolts (7), washers (23), thrust washers (8), washers (31) and locknuts (30).
7. Torque tighten the bolts (7).
8. Install the LH bottom rear mudflap (43). Refer to (b) LH Bottom Rear Mudflap on page
16-47.

(d) LH Forward Outer Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the LH forward outer handrail (21) into position.
5. Align the LH forward outer handrail (21) with the mounting pads on the LH fender assembly
(1).
6. Install the bolts (26), lockwashers (32) and washers (31).
7. Torque tighten the bolts (26).
8. Install the LH handrail filler tube (36). Refer to (g) LH Handrail Filler Tube on page 16-59.
9. Install the LH kick plate (13). Refer to (h) LH Kick Plate on page 16-59.

(e) LH Rear Outer Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the LH rear outer handrail (2) into position.
5. Align the LH rear outer handrail (2) with the mounting pads on the LH fender assembly (1).
6. Install the bolts (26), lockwashers (32) and washers (31).

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 Chassis 16

7. Torque tighten the bolts (26).

8. Install the LH handrail filler tube (36). Refer to (g) LH Handrail Filler Tube on page 16-59.
9. Install the LH kick plate (13). Refer to (h) LH Kick Plate on page 16-59.

(f) LH Rear Inner Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the LH rear inner handrail (5) into position.
5. Align the LH rear inner handrail (5) with the mounting pads on the LH fender assembly (1).
6. Install the bolts (26), lockwashers (32) and washers (31).
7. Torque tighten the bolts (26).

(g) LH Handrail Filler Tube

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the LH handrail filler tube (36) into position with the LH forward outer handrail (21) and
LH rear outer handrail (2).
5. Align the LH handrail filler tube (36) with the LH forward outer handrail (21) and LH rear
outer handrail (2) mounting brackets.
6. Install the bolts (26), washers (31) and nuts (30).
7. Torque tighten the bolts (26).

(h) LH Kick Plate

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the Left Hand (LH) kick plate (13) into position with the LH forward outer handrail (21)
and LH rear outer handrail (2).
5. Align the LH kick plate (13) with the LH forward outer handrail (21) and LH rear outer
handrail (2) mounting brackets.
6. Install the bolts (33), washers (27) and nuts (25).

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16 Chassis

7. Torque tighten the bolts (33).

(i) RH Step Support Arm Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Attach suitable lifting equipment to RH step support arm assembly (59).
5. Using lifting equipment, align the RH step support arm assembly (59) with its attachment
point on the front frame.
6. Install the bolts (99), lockwashers (95) and washers (93).
7. Torque tighten the bolts (99).
8. Install RH fender assembly (56). Refer to (j) RH Fender Assembly on page 16-60.
9. Install the RH lower step assembly. Refer to (l) RH Lower Step Assembly on page 16-61.

(j) RH Fender Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Attach suitable lifting equipment to RH fender assembly (56).
5. Using lifting equipment, carefully align the RH fender assembly (56) with the RH step
support arm assembly (59) and fuel tank fender attachment point.
6. Install the bolts (88), washers (98) and locknuts (90) to the RH step support arm assembly
(59) and fuel tank fender attachment point.
7. Torque tighten the bolts (88).
8. Install the RH wheel arch mudflap (17). Refer to (h) RH Wheel Arch Mudflap on page 16-50.
9. Install the wheel. Refer to (7) Mounting Tire and Rim Assembly on Machine on page 9-129.
10. Install the adblue cover assembly (65). Refer to (k) Adblue Cover Assembly on page 16-61.
11. Install the handrails. Refer to (m) RH Forward Outer Handrail on page 16-61,(n) RH Rear
Outer Handrail on page 16-62 and x(o) RH Rear Inner Handrail on page 16-62.

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 Chassis 16

(k) Adblue Cover Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the adblue cover assembly (65) into position.
5. Align the adblue cover assembly (65) with RH fender assembly (56) and fuel tank.
6. Install the bolts (100) and (85) and washers (96).
7. Torque tighten the bolts (100) and (85).
8. Install the RH forward outer handrail (60). Refer to (m) RH Forward Outer Handrail on
page 16-61.

(l) RH Lower Step Assembly

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the RH lower step assembly into position.
5. Align the RH lower step assembly with the RH step support arm assembly (59).
6. Install the bolts (77), washers (93), thrust washers (62), washers (92) and locknuts (90).
7. Torque tighten the bolts (77).
8. Install the RH bottom rear mudflap. Refer to (f) RH Bottom Rear Mudflap on page 16-49.

(m) RH Forward Outer Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the RH forward outer handrail (60) into position.
5. Align the RH forward outer handrail (60) with the mounting pads on the RH fender assembly
(56).
6. Install the bolts (87), lockwashers (94) and washers (92).
7. Torque tighten the bolts (87).
8. Install the RH kick plate (79). Refer to (p) RH Kick Plate on page 16-62.

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16 Chassis

(n) RH Rear Outer Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the RH rear outer handrail (57) into position.
5. Align the RH rear outer handrail (57) with the mounting pads on the RH fender assembly
(56).
6. Install the bolts (87), lockwashers (94) and washers (92).
7. Torque tighten the bolts (87).
8. Install the RH kick plate (79). Refer to (p) RH Kick Plate on page 16-62.

(o) RH Rear Inner Handrail

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the RH rear inner handrail (58) into position.
5. Align the RH rear inner handrail (58) with the mounting pads on the RH fender assembly
(56).
6. Install the bolts (87), lockwashers (94) and washers (92).
7. Torque tighten the bolts (87).
8. Install the RH kick plate (79). Refer to (p) RH Kick Plate on page 16-62.

(p) RH Kick Plate

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. Lift the Right Hand (RH) kick plate (79) into position with the RH forward outer handrail (60)
and RH rear outer handrail (57).
5. Align the RH kick plate (79) with the RH forward outer handrail (60) and RH rear outer
handrail (57) mounting brackets.
6. Install the bolts (86), washers (91) and nuts (89).
7. Torque tighten the bolts (86).

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 Suspension System 17

Table of Content
17 Suspension System..................................................................................17-1
17.1 Front Suspension ......................................................................................... 17-2
(1) Description............................................................................................... 17-3
(2) Removal .................................................................................................. 17-3
(a) Linkage ............................................................................................... 17-4
(b) Shock Absorber and Mount ................................................................ 17-4
(c) Bracket Assembly ............................................................................... 17-5
(3) Installation ............................................................................................... 17-6
(a) Bracket Assembly ............................................................................... 17-6
(b) Linkage ............................................................................................... 17-7
(c) Shock Absorber and Mount ................................................................ 17-8
(4) Adjustments........................................................................................... 17-10
(5) Special Torque Specifications................................................................ 17-11
17.2 Rear Suspension........................................................................................ 17-12
(1) Description............................................................................................. 17-15
(2) Removal ................................................................................................ 17-15
(a) Linkage ............................................................................................. 17-15
(b) Mount ................................................................................................ 17-16
(c) Equalizer Beam................................................................................. 17-17
(d) Bracket Assembly ............................................................................. 17-17
(3) Installation ............................................................................................. 17-18
(a) Equalizer Beam................................................................................. 17-18
(b) Bracket Assembly ............................................................................. 17-19
(c) Mount ................................................................................................ 17-20
(d) Linkage ............................................................................................. 17-21
(4) Maintenance .......................................................................................... 17-23
(5) Special Torque Specifications................................................................ 17-23

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17 Suspension System

17 Suspension System
17.1 Front Suspension
16
38 17 35
37 36
15
9 11 24 37
11 37
7 8 8,9,10,11
7
14 12,13,14,15
19 38 34 16,17,28,34
13 35,36
26
10
3 28
37 38
12 19
25 24 26
18
3
21,22 1
37
2

5,6 23
25 24 30
24
31 25
18 5,6 24 27
33
32 29
23
24
25 30
5,6 20
25 30
31 20

33 5,6 4
32 23

MOT05353

Figure 17.1 - Exploded View of Front Suspension

1. Bracket Assembly 14. Suspension Bush 27. Bolt
LHS
2. Bracket Assembly 15. Washer 28. Spacer
RHS
3. Plate 16. Nut 29. Bolt
4. Bolt 17. Washer 30. Hardened Washer
5. Control Link 18. Bolt 31. Guard Plate
6. Bushing 19. Bolt 32. Bolt
7. Shock Absorber 20. Nut 33. Washer
8. Front Suspension 21. Panhard Rod 34. Circlip
Mount
9. Rebound Mount 22. Bush 35. Bolt
(Rubber)
10. Chain 23. Bolt 36. Nut
11. Adjusting Screw 24. Locknut 37. Outer Bushing
12. Pin 25. Hardened Washer 38. Inner Bushing
13. Pin 26. Washer

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 Suspension System 17

(1) Description
Numbers in parentheses refer to Figure 17.1, unless otherwise specified.
The front axle assembly is mounted on the suspension brackets (assemblies 1 and 2), which
in turn are linked to the chassis frame through a system of shock absorbing/rubber mount
assemblies through the vertical axis.
Suspension is provided by two heavy duty rubber suspension mounts (8 and 9) mounted on the
central plate of brackets (1 and 2) which have internal chain (10) assemblies to provide extra
retention on rebound. Additional damping is provided by four heavy duty double acting shock
absorbers (7) (two on each side) to ensure operator comfort.
A panhard rod (21) provides the traverse link between the left and right hand sides of the
suspension assembly, while control links (5) provide the means of retaining longitudinal control
over the length of the tractor frame, between the suspension and the front frame pivot.
(2) Removal
Numbers in parentheses refer to Figure 17.1.

� WARNING
, unless otherwise specified.
• 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.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• All components should be thoroughly cleaned and inspected for serviceability when they
are removed from the vehicle.

PROCEDURE
1. Before carrying out any work to the vehicle, position it on a level work area, apply the
parking brake and securely block all road wheels.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.
3. Install body safety prop to secure the body in a partially raised position. Refer to (3) Deploy
the Body Prop on page 21-12.
4. Switch off the engine. Refer to 5.12 Stopping on page 5-28.
5. Turn the steering wheel several times to relieve any pressure in the steering system.
6. Place the steering lock bar in the 'Locked' position. Refer to (1) Fit the Steering Lock
on page 12-29
7. Turn the battery master switch to the 'OFF' position.

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17 Suspension System

(a) Linkage

PROCEDURE
1. Remove both front tire and rim assemblies. Refer to (3) Removing Tire and Rim Assembly
from Machine on page 9-125.
2. With suitably placed stands or timbers, support the front frame at the front and rear so
that the tractor will remain level.
3. If required, remove the bolt (32) and washer (33) securing the guard plate (31) to the
frame (1, Figure 16.1).
4. Remove the guard plate (31).
5. Support the linkage (control link (5) or panhard rod (21)) prior to removal.
6. Remove the bolt (23) and washer (25) securing the linkage (5, 21) to the frame (1, Figure
16.1).
7. Remove the bolt (4, 18, 23 as required), washer (25) and nut (24) securing the linkage (5,
21) to the bracket assembly (1, 2).
8. Remove the linkage (5, 21).
9. Repeat the procedure as required to remove more control links (5) or the panhard rod (21).

(b) Shock Absorber and Mount

PROCEDURE
1. Remove the wheel arch mudflaps (17, Figure 16.11or 75, Figure 16.12). Refer to (1)
Removal on page 16-43.
2. With suitably placed stands or timbers, support the front frame (1, Figure 16.1) at front and
rear so the tractor will remain level.
3. Remove the bolts (19) and washers (26) securing the shock absorber plate (3) to the
bracket assemblies (1 and 2).
4. Remove the locknut (24) and outer bushing (37) securing the shock absorbers (7) to the
chassis frame (1, Figure 16.1).
5. Using suitable lifting equipment and jacks, lower the axle/suspension assembly to give
sufficient clearance to remove the shock absorbers (7).
6. Remove the shock absorbers (7). Separate the shock absorbers (7) from the mounting
plate (3) if necessary.
7. Remove nuts (16) and washer (17), securing the rebound mounts (9) to the chassis frame
(1, Figure 16.1).
8. Remove the rebound mounts (9) and washers (15).
9. Using suitable lifting equipment and jacks, lower the axle/suspension assembly to give
sufficient clearance to remove the suspension mount (8).
10. Raise the front suspension mount (8) to expose the pin (12) securing the chains (10) to
the bracket assemblies (1 and 2).
11. Using a wooden dowel or brass drift, remove the chain retaining pin (12).
12. Raise the adjusting screw (11) and remove the front suspension mount (8).
13. Lower the adjusting screw (11) and remove from the chassis frame (1, Figure 16.1).
14. If necessary, remove the suspension bush (14) from the adjusting screw (11) and pin (13)
to detach the chain (10).

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 Suspension System 17

(c) Bracket Assembly

PROCEDURE
1. Remove the Control Links and Panhard Rod. Refer to (a) Linkage on page 17-4
2. Remove the Front Suspension Mounts and Shock Absorbers. Refer to (b) Shock Absorber
and Mount on page 17-4
3. With suitably placed stands or timbers, support the front axle (1, Figure 9.7).
4. Remove the jacks from beneath the bracket assemblies.
5. Remove bolts (27 and 29), washers (30) and nuts (20) from the bracket assemblies.
6. Remove the LHS and RHS bracket assemblies (1 and 2) from the front axle (1, Figure 9.7).

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17 Suspension System

(3) Installation
Numbers in parentheses refer to Figure 17.1, unless otherwise specified.

� WARNING
• To prevent personal injury and property damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job safely.
• Before refitting the suspension components, ensure that the vehicle is in a condition that
allows the work to be carried out safely. The battery master switch should be in the OFF
position, wheel blocks should be in position and the vehicle and axles should be properly
supported.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in Standard
Bolt and Nut Torque Specifications section (5) Special Torque Specifications on page 17-11.
• All components should be cleaned and inspected for serviceability before they are installed
on the vehicle.

(a) Bracket Assembly

PROCEDURE
1. Ensure that the axle (1,Figure 9.7) is suitably supported to allow reassembly of the
suspension prior to installation to the bracket assemblies (1 and 2).
2. Ensure that the mating surfaces of the axle (1,Figure 9.7) and bracket assemblies (1 and 2)
are clean and free from corrosion and that all previous traces of sealant have been removed.
3. Coat the mating surfaces of the axle (1,Figure 9.7) and bracket assemblies (1 and 2) with
a suitable grease to aid installation and prevent corrosion. Refer to (1) Recommended
Lubricants on page 4-16.
4. Fit the bracket assemblies (1 and 2) in their respective positions on the front axle (1,Figure
9.7.
5. Secure bracket assemblies (1 and 2) in place using the bolts (27 and 29), washers (30)
and nuts (20).
6. Torque tighten the bolts (27 and 29). Refer to (5) Special Torque Specifications on page
17-11.
7. Using a cloth or rag, remove excess grease from the axle (1, Figure 9.7) and bracket
assemblies (1 and 2).
8. Apply silicone sealant around the joint between the axle (1, Figure 9.7) and bracket
assemblies (1 and 2) to prevent the ingress of dirt and water.

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 Suspension System 17

(b) Linkage

PROCEDURE
1. If required, fit the bracket assemblies (1 and 2) to the front axle (1,Figure 9.7). Refer to (a)
Bracket Assembly on page 17-6
2. Ensure that the axle (1,Figure 9.7) is suitably supported to allow reassembly of the
suspension before attempting to install the suspension linkages (5 and 21). Jacks or other
suitable lifting equipment should be used to reposition the axle (1, Figure 9.7) as required.
3. Ensure that the mating surfaces of the linkages (5 and 21) and bracket assemblies (1
and 2) are clean and free from corrosion.
4. Position the panhard rod (21) between the bracket assembly (1) and bracket on the frame
(1, Figure 16.1).
5. Secure the panhard rod (21) to the bracket assembly LHS (1) using two bolts (4), washers
(25) and nuts (24).
6. Torque tighten the bolts (4). Refer to (5) Special Torque Specifications on page 17-11.
7. Secure the panhard rod (21) to the frame (1, Figure 16.1) using two bolts (23), washers
(25) and nuts (24).
8. Torque tighten the bolts (23). Refer to (5) Special Torque Specifications on page 17-11.
9. Install the upper control links (5) and secure them to the bracket assemblies (1 and 2) using
two bolts (18), washers (25) and nuts (24) on each side.
10. Torque tighten the bolts (18). Refer to (5) Special Torque Specifications on page 17-11.
11. Secure the upper control links (5) to the frame (1, Figure 16.1) using two bolts (23), washers
(25) and nuts (24) on each side.
12. Torque tighten the bolts (23). Refer to (5) Special Torque Specifications on page 17-11.
13. Install the lower control links (5) to the frame (1, Figure 16.1) and bracket assemblies (1
and 2) using four bolts (23), washers (25) and nuts (24) on both sides.
14. Torque tighten the bolts (23). Refer to (5) Special Torque Specifications on page 17-11.
15. Secure the guard assemblies (21) to the frame (1, Figure 16.1) using two bolts (32) and
washers (33) on each side.
16. If the front suspension has been completely reassembled and all parts refitted to the
vehicle, mount the wheel and tire assemblies ((3) Removing Tire and Rim Assembly from
Machine on page 9-125) onto the axle. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
17. Using suitable lifting equipment, raise the tractor frame sufficiently to remove all of the
supporting equipment from the front axle (1,Figure 9.7) and tractor frame (1, Figure 16.1).
18. Lower the vehicle to the ground and remove the lifting equipment.
19. Torque tighten all wheel nuts. Refer to (16) Special Torque Specification on page 9-137.
20. Place the steering lock bar in the 'Stowed' position. Refer to (2) Stow the Steering Lock
on page 12-29.
21. Remove the wheel blocks from the rear road wheels.
22. Check serviceability of the vehicle. Refer to (4) Operation Safety on page 2-19 and (a)
Every 10 Hours of Operation on page 4-3.
23. Torque tighten the wheel nuts after ten hours of operation. Refer to (b) After First 10 Hours
of Operation or Rebuilt Components on page 4-4.

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17 Suspension System

(c) Shock Absorber and Mount

PROCEDURE
1. If required, fit the bracket assemblies (1 and 2) to the front axle (1,Figure 9.7. Refer to (a)
Bracket Assembly on page 17-6.
2. If required, fit the suspension linkages (5 and 21). Refer to (b) Linkage on page 17-7.
3. Ensure that the axle (1,Figure 9.7) is suitably supported and positioned with enough
clearance to allow reassembly of the suspension before attempting to install the shock
absorbers (7) and suspension mounts (8 and 9). Jacks or other suitable lifting equipment
should be used to reposition the axle (1, Figure 9.7) as required.
4. Ensure that the mating surfaces of the spacer (28) and bracket assemblies (1 and 2) are
clean and free from corrosion.
5. Coat the mating surface of the bracket assemblies (1 and 2) for the spacer (28) with a
suitable grease to prevent corrosion. Refer to (1) Recommended Lubricants on page 4-16.
6. Fit the spacers (28) onto the bracket assemblies (1 and 2).
7. Connect the chain (10) to the adjusting screw (11) using the pin (13) and fit the circlip
(34) to secure.
8. Fit the suspension bush (14) to the adjusting screw (11).
9. Pull the adjusting screw (11) up through the front frame (1, Figure 16.1) bracket.
10. With the adjusting screw (11) fully raised, feed the chain (10) through the centre hole in the
suspension mount (8) and position the mount (8) over the spacer (28).
11. With the suspension mount (8) supported to provide access to the chain locating point on
the bracket assemblies (1 and 2), secure the bottom link of the chain (10) to the bracket
assemblies (1 and 2) using the pin (12).
12. Lower the suspension mount (8) onto the spacer (25)
13. Place two shock absorbers (7) upside down in a suitable jig or fixture.
14. Remove the nut (24), outer bushing (37) and inner bushing (38) from the bottom of each
shock absorber.
15. Fit the mounting plate (3) over the shock absorbers.
16. Re-fit the nut (24), outer bushing (37) and inner bushing (38) to each shock absorber.
17. Turn over and remove nut (24) and outer bushing (37) from top end of each shock absorber
(7).
18. Secure the plate (3) with the attached shock absorbers (7) to the axle bracket (1 and 2)
using four bolts (19) and washers (26) on each side.
19. Torque tighten the bolts (19). Refer to (5) Special Torque Specifications on page 17-11.
20. Using jacks or other suitable lifting equipment, raise the axle (1,Figure 9.7) up to the chassis
frame to set the initial ride height. Ensure that the threaded ends of the shock absorbers (7)
locate in their mounting holes on the chassis frame (1, Figure 16.1) as the axle (1,Figure
9.7) is raised. Damage to the screw threads can occur if they are not properly located.
21. Secure the shock absorbers (7) to the front frame (1, Figure 16.1) mounting points by
refitting the nut (24) and outer bushing (37) to each shock absorber (7).
22. Fit the rebound mount (9) over the adjusting screw (11).
23. Fit the washers (15 and 17) over the adjusting screw (11) and on top of the rebound
mount (9).
24. Fit a single nut (16) to the adjusting screw (11) threaded end.

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 Suspension System 17

25. Tighten a single nut (16) on the end of the adjusting screw (11), and set the pre-compressed
length of the rebound mount (9) to the value shown in Figure 17.2. Do not over tighten
the lower nut (16).

Figure 17.2 - Rebound Mount Length

26. Fit the second nut (16) to the adjustment screw (11).
27. Apply Loctite Threadlocker 243™ to the threads above the lower nut (16).
28. Torque tighten the second nut (16) against the first nut, making sure that the inner nuts (16)
do not move. Refer to (5) Special Torque Specifications on page 17-11.
29. Fit the bolt (35) and two nuts (36) to the top of the adjustment screw (11).
30. Using a cloth or rag, remove excess grease from around the spacer (28) and on bracket
assemblies (1 and 2).
31. Fit the wheel arch mudflaps (17 Figure 16.11 or 75, Figure 16.12). Refer to (2) Installation
on page 16-47.
32. If the front suspension has been completely reassembled and all parts refitted to the
vehicle, mount the wheel and tyre assemblies ((3) Removing Tire and Rim Assembly from
Machine on page 9-125) onto the axle. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
33. Place the steering lock bar in the 'Stowed' position. Refer to (2) Stow the Steering Lock
on page 12-29
34. Remove the wheel blocks from the rear road wheels
35. Check serviceability of the vehicle. Refer to (4) Operation Safety on page 2-19 and (a)
Every 10 Hours of Operation on page 4-3.
36. Torque tighten the wheel nuts after ten hours of operation. Refer to (b) After First 10 Hours
of Operation or Rebuilt Components on page 4-4.

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17 Suspension System

(4) Adjustments
Numbers in parentheses refer to Figure 17.1, unless otherwise specified.

� 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.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• All components should be thoroughly cleaned and inspected for serviceability when they
are removed from the vehicle.

PROCEDURE
1. Remove the wheel arch mudflaps (17, Figure 16.11or 75, Figure 16.12). Refer to (1)
Removal on page 16-43.
2. With suitably placed stands or timbers, support the front frame (1, Figure 16.1) at front and
rear so the tractor will remain level.
3. Inspect the suspension components for serviceability and replace as necessary.
4. Loosen the nuts (16) on the rebound mount adjusting screw (11) until there is no load
on the rebound mount (9).
5. Ensure the washer (15) is loose.
6. Tighten the lower nut (16) to take up the clearance between the washer (15) and rebound
mount (9). Do not over tighten the lower nut (16).
7. Measure and record the dimension between the underside of the washer (15) at the top
of the rebound mount (9) and the base plate. Ensure that the dimension is approximately
200 mm.
8. Tighten the lower nut (16) on the end of the adjusting screw (11), and set the
pre-compressed length of the rebound mount (9) to the value shown in Figure 17.2. Do not
over tighten the lower nut (16).
9. Apply Loctite Threadlocker 243™ to the threads above the lower nut (16).
10. Torque tighten the second nut (16) against the first nut, making sure that the inner nuts (16)
do not move. Refer to (5) Special Torque Specifications on page 17-11.
11. Fit the wheel arch mudflaps (17 Figure 16.11 or 75, Figure 16.12). Refer to (2) Installation
on page 16-47.
12. Place the steering lock bar in the 'Stowed' position. Refer to (2) Stow the Steering Lock
on page 12-29
13. Remove the wheel blocks from the rear road wheels
14. Check serviceability of the vehicle. Refer to (4) Operation Safety on page 2-19 and (a)
Every 10 Hours of Operation on page 4-3.
15. Torque tighten the wheel nuts after ten hours of operation. Refer to (b) After First 10 Hours
of Operation or Rebuilt Components on page 4-4.

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 Suspension System 17

(5) Special Torque Specifications

TORQUE
FIG. NO. ITEM NO. ITEM NAME
Nm lbf ft
Figure 17.1 4 Bolt 570 420
Figure 17.1 18 Bolt 570 420
Figure 17.1 23 Bolt 570 420
Figure 17.1 16 Nut 250 183
Figure 17.1 19 Bolt 169 125
Figure 17.1 27 Bolt
Figure 17.1 29 Bolt
- - Wheel Nut 730 540

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17 Suspension System

17.2 Rear Suspension

18
3
27
26
17
24
7A

22
3
4
27
17 16

26 17
18 29
2
5,6

21
22
89
10
23
28 5,6
9
1 8
19
20
13,14,15
30 25
8 28
10
12
22
5,6
21
19 28
20

13 14 15
MOT05360
Figure 17.3 - Exploded Views of Rear Axle Suspension
3
16
17
7B 27
24
17
22

18
29
26
3

27
17
26

5,6 23
18
21 22

30
2
13
14 19
15 20
5,6
13
14
15 19
21 22
5,6 20

25
MOT05361
MOT05361
Figure 17.4 - Exploded Views of Centre Axle Suspension

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 Suspension System 17

21,22
40
23

27
17
22

38 39 41 2
31 32 35 37
36 26
33 29 9 10
34 3
14

18 21 22 25 3
1 30 12 8 28 13 15 5,6

21 22 25

MOT05362

Figure 17.5 - Suspension Component Location

1
47
BRACKET RH

48 41
43

41 49
42
44
41 18 41 45,46
1
47
41 50

18

51
BRACKET LH

47 TRAILER CHASSIS
LH FRAME RAIL

P11580B

Figure 17.6 - Rear Suspension Lubrication Lines

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17 Suspension System

1. Bracket Assembly 19. Spherical Bearing 37. Bolt

2. Bracket Assembly 20. Internal Snap Ring 38. Washer
3. Bracket Assembly 21. Wear Ring 39. Bracket Assembly
4. Equalizer Beam 22. Bushing 40. Bolt
5. Control Link 23. Plate 41. Elbow
6. Bushing 24. Washer 42. Elbow
7. Interleaf Mount 25. Bolt 43. Grease Nipple
8. Bolt 26. Cover Plate 44. Manifold Plate
9. Hardened Washer 27. Bolt 45. Bolt
10. Locknut 28. Lube Fitting 46. Washer
11. Bolt 29. Lockwasher 47. P-Clip
12. Hardened Washer 30. Bolt 48. Hose Assembly
13. Retainer 31. Locknut 49. Hose Assembly
14. Locknut 32. Bolt 50. Hose Assembly
15. Bolt 33. V-ring Seal 51. Hose Assembly
16. Bolt 34. V-ring Seal
17. Washer 35. Rear Suspension Pin
18. Panhard Rod 36. Lockwasher

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 Suspension System 17

(1) Description
Numbers in parentheses refer to Figure 17.3 unless otherwise specified.
Each axle is coupled to the chassis by three rubber bushed leading or trailing control links (5)
which provide longitudinal restraint. Lateral restraint is by transverse panhard rods (18).
Loads acting on the centre and rear axles are balanced by centrally pivoting equalizer beams
(4) with rubber cushioning interleaf mounts (7) between axles and beam ends. Interleaf mounts
(7) are rubber/steel laminated compression units with chain link ties.
Lubrication of spherical bearings (19) in panhard rods (31) is through remote mounted lube
fittings (43, Figure 17.6) secured to manifold plate (44, Figure 17.6). Lubrication of bushings
(22) in equalizer beams (4) is through lube fittings (28).
(2) Removal
Numbers in parentheses refer to Figure 17.1.

� WARNING
, unless otherwise specified.
• 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.

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• All components should be thoroughly cleaned and inspected for serviceability when they
are removed from the vehicle.

PROCEDURE
1. Before carrying out any work to the vehicle, position it on a level work area, apply the
parking brake and securely block all road wheels.
2. Raise the body. Refer to (6) Raise the Body on page 21-8.
3. Install body safety prop to secure the body in a partially raised position. Refer to (3) Deploy
the Body Prop on page 21-12.
4. Switch off the engine. Refer to 5.12 Stopping on page 5-28.
5. Turn the steering wheel several times to relieve any pressure in the steering system.
6. Place the steering lock bar in the 'Locked' position. Refer to (1) Fit the Steering Lock
on page 12-29
7. Turn the battery master switch to the 'OFF' position.

(a) Linkage

PROCEDURE
1. Remove the tyre and rim assemblies (1, (3) Removing Tire and Rim Assembly from
Machine on page 9-125) as required. Refer to (3) Removing Tire and Rim Assembly from
Machine on page 9-125.

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17 Suspension System

2. With suitably placed stands or timbers, support the rear frame (1, Figure 16.2 at the front
and rear so that the trailer will remain level.
3. If required, disconnect grease lines (48, 49, 50 & 51 Figure 17.6) from elbows (41 & 42,
Figure 17.6), on both panhard rods (18).
4. Cap lines and fittings.
5. If required, remove elbows (41 & 42 , Figure 17.6) from panhard rods (18).
6. If required, remove p-clips (47) and manifold bracket (44) from the chassis frame (1,Figure
16.2). Refer to Figure 17.6.
7. Move lubrication lines to a clean, dry area.
8. Support the control link (5) or Panhard rod (18) prior to removal.
9. To detach the control links (5), remove the bolt (30), washer (25) and nut (24) securing the
linkage (5) to the bracket assembly (1, 2, 3 or 39). Refer to detail A in Figure 17.3.
10. Remove the bolt (15, 30) and washer (12) securing the link (5) to the frame (1, Figure
16.2). Refer to details A and C in Figure 17.3
11. Remove the linkage (5).
12. To detach the panhard rods (18), remove the bolt (37), lockwasher (36) and washer (12)
securing the rear suspension pin (35) to the bracket assembly (1). Refer to detail B in
Figure 17.3
13. Remove the rear suspension pin (35) from the bracket assembly (1).
14. Remove the bolt (37), lockwasher (36) and washer (12) securing the rear suspension
pin (35) to frame (1, Figure 16.2).
15. Remove the rear suspension pin (35) from the frame (1, Figure 16.2).
16. Remove the panhard rod (18).
17. Remove the retainer (13) and v-ring seal (34) from the panhard rod (18).
18. Repeat the procedure as required to remove more control links (5) or panhard rods (18).

(b) Mount

PROCEDURE
1. Remove the tire and rim assemblies (1, (3) Removing Tire and Rim Assembly from
Machine on page 9-125) as required. Refer to (3) Removing Tire and Rim Assembly from
Machine on page 9-125.
2. With suitably placed stands or timbers, support the rear frame (1, Figure 16.2 at the front
and rear so that the trailer will remain level.
3. Using suitable blocking equipment, block equalizer beams to prevent movement during
disassembly.
4. Remove bolts (32), locknuts (31) and lockwashers (29) securing the interleaf mounts (7) to
equalizer beam (4).
5. Remove the two bolts (16) and lockwashers (29) securing the Brake Guard (20, Figure
14.2) and interleaf mount (7) to equalizer beam (4).
6. Remove the Brake Guard (20, Figure 14.2).
7. Remove the remaining two bolts (16) and lockwashers (29) securing the interleaf mount
(7) to equalizer beam (4).

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 Suspension System 17

8. Using suitable lifting equipment and jacks, lower the axle/suspension assembly to give
sufficient clearance to remove the interleaf mount (7).
9. Remove the interleaf mount (7) from the axle (1, Figure 9.59 or 1, Figure 9.172).
10. Repeat this procedure for the other mounts (7) as required.

(c) Equalizer Beam

PROCEDURE
1. Remove all four interleaf mounts (7). Refer to (b) Mount on page 17-16.
2. Remove blocking equipment from the equalizer beams (4).
3. Remove bolts (27) and washers (17) securing the cover plate (26) to the equalizer beam
(4). Refer to detail D.
4. Remove the cover plate (26).
5. Remove the bolts (24) and washers (25) securing the retaining plate (23) to the frame
shaft (1, Figure 16.2).
6. Remove the retaining plate (23).
7. Using suitable lifting equipment, support the equalizer beam (4) and remove from the
shaft on the rear frame (1, Figure 16.2).
8. Remove the bushing (22) from the equalizer beam (4).
9. Remove the wear ring (21) and 'V' ring seal (33) from the frame shaft (1, Figure 16.2).
10. Remove the lube fitting (28) from the cover plate (26).
11. Repeat the procedure to remove the opposite equalizer beam (4).

(d) Bracket Assembly

PROCEDURE
1. Remove suspension linkages as required (5, 18). Refer to (a) Linkage on page 17-15
2. To remove the lower bracket assemblies (1, 3), remove locknuts (10), hardened washers
(9) and bolts (8, 40) securing the bracket assembly (1, 3) to the axle (1, Figure 9.59 or 1,
Figure 9.172).
3. Using a sharp knife, cut the silicone bead between the bracket assembly (1, 3) and the axle
(1, Figure 9.59 or 1, Figure 9.172).
4. Remove bracket assembly (1, 3).
5. To remove the upper bracket assemblies, remove the bolts, lockwashers and hardened
washers securing the manifold block to the bracket assemblies.
6. Detach the manifold block (9, 10) from the upper bracket assemblies (2, 39). Refer to
Figure 18.3 and Figure 18.4.
7. Remove the bolts (11) and hardened washers (12) securing the bracket assembly (2, 39) to
the axle (1, Figure 9.59 or 1, Figure 9.172).
8. Using a sharp knife, cut the silicone bead between the bracket assembly (2, 39) and the
axle (1, Figure 9.59 or 1, Figure 9.172).
9. Remove the bracket assembly (2, 39).

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17 Suspension System

(3) Installation
Numbers in parentheses refer to Figure 17.3, unless otherwise specified.

� WARNING
• To prevent personal injury and property damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job safely.
• Before refitting the suspension components, ensure that the vehicle is in a condition that
allows the work to be carried out safely. The electrical master switch should be in the off
position, wheel chocks should be in position and the vehicle and axles should be properly
supported.

NOTICE
• Tighten all fasteners without special torques specified to standard torques listed in Standard
Bolt and Nut Torque Specifications section (5) Special Torque Specifications on page 17-23.
• All components should be cleaned and inspected for serviceability before they are installed
on the vehicle.

(a) Equalizer Beam

Numbers in parentheses refer to Figure 17.3, unless otherwise specified.

PROCEDURE
1. Using a suitable solvent, clean equalizer beam (4) on the frame shaft (1, Figure 16.2).
2. Ensure mounting holes on the ends of the shaft are clean and free from debris.
3. Install new 'V' ring seal (13) and new wear ring (21) on the frame shaft (1, Figure 16.2) with
the flange to the inside.
4. Using a suitable solvent, clean the bore of equalizer beam (4).
5. Install new bushings (22) in the equalizer beam (4) bore.
6. Align the holes in bushings (22) with the holes in the equalizer beam (4).
7. Using suitable lifting equipment, carefully fit the equalizer beam (4) onto the frame shaft
(1, Figure 16.2).
8. Apply Loctite 243 to the retaining plate bolts (24).
9. Secure the retaining plate (23) to the frame shaft (1,Figure 16.2) with bolts (24), washers
(25).
10. Torque tighten the bolts (24). Refer to (5) Special Torque Specifications on page 17-23.
11. Apply Loctite 243 to the cover plate bolts (27).
12. Install the cover plate (26) to equalizer beam (4) and secure with bolts (27) and washers
(17).
13. Torque tighten the bolts (27). Refer to (5) Special Torque Specifications on page 17-23
14. Apply Loctite 243 to the lube fitting (28) and install in the cover plate (25).
15. Lubricate with grease until excess lubrication is seen. Refer to (1) Recommended
Lubricants on page 4-16.
16. Using a cloth or rag, remove excess grease from the equalizer beam (4).

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 Suspension System 17

17. Repeat the procedure to install the opposite equalizer beam (4).
18. If required, fit the interleaf mounts (7) to the axles (1, Figure 9.59 and 1, Figure 9.172).
Refer to (c) Mount on page 17-20.
19. Ensure that the mating surfaces of the equalizer beams (4) and interleaf mounts (7) are
clean and free from corrosion.
20. Coat the mating surfaces of the equalizer beams (4) and interleaf mounts (7) with a suitable
grease to aid installation and prevent corrosion. Refer to (1) Recommended Lubricants
on page 4-16.
21. Using suitable lifting equipment and jacks, raise the axle/suspension assembly so that the
interleaf mounts (7) and equalizer beams (4) make contact.
22. If fitted to the axle (1, Figure 9.59 or 1, Figure 9.172), secure the interleaf mounts (7) to the
equalizer beams (4) with bolts (32), lockwashers (29) and locknuts (31).
23. Torque tighten the bolts (32). Refer to (5) Special Torque Specifications on page 17-23.
24. Using a cloth or rag, remove excess grease from the equalizer beams (4) and interleaf
mounts (7).
25. If the rear suspension has been completely reassembled and all parts refitted to the
vehicle, mount the wheel and tire assemblies ((3) Removing Tire and Rim Assembly from
Machine on page 9-125) onto the axle. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
26. Using suitable lifting equipment, raise the trailer frame sufficiently to remove all of the
supporting equipment from the axles (1, Figure 9.59 or 1, Figure 9.172) and tractor frame
(1, Figure 16.2).
27. Lower the vehicle to the ground and remove the lifting equipment.
28. Torque tighten all wheel nuts. Refer to (16) Special Torque Specification on page 9-137
29. Place the steering lock bar in the 'Stowed' position. Refer to (2) Stow the Steering Lock
on page 12-29.
30. Remove the wheel blocks from the rear road wheels
31. Check serviceability of the vehicle. Refer to (4) Operation Safety on page 2-19 and (a)
Every 10 Hours of Operation on page 4-3.
32. Torque tighten the wheel nuts after ten hours of operation. Refer to (b) After First 10 Hours
of Operation or Rebuilt Components on page 4-4.

(b) Bracket Assembly

PROCEDURE
1. Ensure that the axle (1, Figure 9.59 or 1, Figure 9.172) is suitably supported to allow
reassembly of the suspension prior to installation to the bracket assemblies (1, 2, 3 and 39).
2. Ensure that the mating surfaces of the axle (1, Figure 9.59 or 1, Figure 9.172) and bracket
assemblies (1, 2, 3 and 39) are clean and free from corrosion and that all previous traces
of sealant have been removed.
3. Coat the mating surfaces of the axle (1, Figure 9.59 or 1, Figure 9.172) and bracket
assemblies (1, 2, 3 and 39) with a suitable grease to aid installation and prevent corrosion.
Refer to (1) Recommended Lubricants on page 4-16.
4. Fit the bracket assembly (1, 2, 3 or 39) in its respective position on the axle (1, Figure
9.59 or 1, Figure 9.172).

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17 Suspension System

5. To secure the upper bracket assemblies (2 and 39) in place, use bolts (11) and hardened
washers (12).
6. Torque tighten the bolts (11). Refer to (5) Special Torque Specifications on page 17-23.
7. Ensure that the mating surfaces of the upper bracket assemblies (2 and 39) and the
manifold block (9, 10 ) are clean and free from corrosion.
8. Secure the manifold block (9, 10) to the upper bracket assemblies (2 and 39) with bolts
(28), lockwashers (29) and hardened washers (30). Refer to Figure 18.3 and Figure 18.4.
9. To secure the lower bracket assemblies (1 and 3) in place, use bolts (8 and 40), hardened
washers (9) and locknuts (10).
10. Torque tighten the bolts (8 and 40). Refer to (5) Special Torque Specifications on page
17-23.
11. Using a cloth or rag, remove excess grease from the axles (1, Figure 9.59 or 1, Figure
9.172) and bracket assemblies (1, 2, 3 and 39).
12. Apply silicone sealant around the joint between the axles (1, Figure 9.59 or 1, Figure 9.172)
and bracket assemblies (1, 2, 3 and 39) to prevent the ingress of dirt and water.
13. Repeat this procedure for the other bracket assemblies (1, 2, 3 and 39) as required.

(c) Mount

PROCEDURE
1. Ensure that the axle (1, Figure 9.59 or 1, Figure 9.172) is suitably supported to allow
reassembly of the suspension prior to installation to the interleaf mounts (7).
2. Ensure that the mating surfaces of the axle (1, Figure 9.59 or 1, Figure 9.172), equalizer
beams (4) and interleaf mounts (7) are clean and free from corrosion.
3. Coat the mating surfaces of the axle (1, Figure 9.59 or 1, Figure 9.172), equalizer beams
(4) and interleaf mounts (7) with a suitable grease to aid installation and prevent corrosion.
Refer to (1) Recommended Lubricants on page 4-16.
4. Fit the interleaf mount (7) in its respective position on the axle (1, Figure 9.59 or 1, Figure
9.172).
5. Secure the interleaf mount (7) in place with bolts (16) and lockwashers (29).
6. Torque tighten the bolts (16). Refer to (5) Special Torque Specifications on page 17-23.
7. Using suitable lifting equipment and jacks, raise the axle/suspension assembly so that the
interleaf mounts (7) and equalizer beams (4) make contact.
8. Secure the interleaf mounts (7) to the equalizer beams (4) with bolts (32), lockwashers (29)
and locknuts (31).
9. Torque tighten the bolts (32). Refer to (5) Special Torque Specifications on page 17-23.
10. Using a cloth or rag, remove excess grease from the equalizer beams (4) and interleaf
mounts (7).
11. Repeat this procedure for the other mounts (7) as required.
12. If the rear suspension has been completely reassembled and all parts refitted to the
vehicle, mount the wheel and tire assemblies ((3) Removing Tire and Rim Assembly from
Machine on page 9-125) onto the axle. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
13. Using suitable lifting equipment, raise the trailer frame sufficiently to remove all of the
supporting equipment from the axles (1, Figure 9.59 or 1, Figure 9.172) and tractor frame
(1, Figure 16.2).

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 Suspension System 17

14. Lower the vehicle to the ground and remove the lifting equipment.
15. Torque tighten all wheel nuts. Refer to (m) Special Torque Specifications on page 9-108
16. Place the steering lock bar in the 'Stowed' position.
17. Remove the wheel blocks from the rear road wheels.
18. Check serviceability of the vehicle. Refer to (4) Operation Safety on page 2-19 and (a)
Every 10 Hours of Operation on page 4-3.
19. Torque tighten the wheel nuts after ten hours of operation. Refer to (b) After First 10 Hours
of Operation or Rebuilt Components on page 4-4.

(d) Linkage

PROCEDURE
1. If required, fit the bracket assemblies (1, 2, 3 or 39) to the axles (1, Figure 9.59 or 1, Figure
9.172). Refer to (b) Bracket Assembly on page 17-19.
2. Ensure that the mating surfaces of the linkages (5 and 18) and bracket assemblies (1, 2, 3
and 39) are clean and free from corrosion.
3. Install the control link (5) between the axle mounting bracket (1 or 3) and frame (1, Figure
16.2) mounting point.
4. Secure the control link (5) to the bracket assembly (1, 2, 3 or 39) with bolts (30), hardened
washers (12) and locknuts (14). Refer to detail “A”.
5. Torque tighten the bolts (30). Refer to (5) Special Torque Specifications on page 17-23.
6. If necessary and using jacks or other suitable lifting equipment, adjust the position of the
axle (1, Figure 9.59 or 1, Figure 9.172) to allow the control rod (5) to make contact with
the frame (1, Figure 16.2) mounting point. Damage to the screw threads can occur if they
are not properly located.
7. Secure the control link (5) to the frame (1, Figure 16.2) with bolts (30), hardened washers
(12) and locknuts (14). Refer to detail “A”.
8. Torque tighten the bolts (30). Refer to (5) Special Torque Specifications on page 17-23.
9. If required, repeat Steps 1 to 8 for more control links (5).
10. Using a suitable solvent, clean each bore of panhard rod (18).
11. Clean the frame (1, Figure 16.2) mounting point.
12. Install new bushings (19) in the panhard rod (18) bore.
13. Install new snap rings (20) in the panhard rod (18) bore.
14. Ensuring that the panhard rod (18) is orientated to allow the correct fitment of lubrication
lines (48, 49, 50 and 51), fit the panhard rod (18) between the bracket assembly (1) on axle
(1, Figure 9.59 or 1, Figure 9.172) and the frame (1, Figure 16.2) mounting point. Refer
to Figure 17.6
15. Insert new seals (34) and retainers (13) into the bracket assembly (1) mounting point.
16. Insert the pin (35) into the bracket assembly (1) through the retainers (13) and the bore of
the panhard rod (18). Refer to detail “B”.
17. Secure the pin (35) in place with washers (38), lockwashers (36) and bolts (37). Refer to
detail “B”.
18. Torque tighten the bolts (37). Refer to (5) Special Torque Specifications on page 17-23.

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17 Suspension System

19. If necessary and using jacks or other suitable lifting equipment, adjust the position of the
axle (1, Figure 9.59 or 1, Figure 9.172) to align the panhard rod (18) bore with the frame
(1, Figure 16.2) mounting point.
20. Insert new seals (34) and retainers (13) into the frame (1, Figure 16.2) mounting point .
21. Insert the pin (35) into the frame (1, Figure 16.2) mounting point through the retainers (13)
and the bore of the panhard rod (18). Refer to detail “E”.
22. Secure the pin (35) in place with washers (38), lockwashers (36) and bolts (37). Refer to
detail “E”.
23. Torque tighten the bolts (37). Refer to (5) Special Torque Specifications on page 17-23.
24. If required, repeat Steps 10 to 23 for the opposite panhard rod (18).
25. If required, install p-clips (47) and manifold bracket (44) to the chassis frame (1, Figure
16.2). Refer to Figure 17.6.
26. If required and using a suitable solvent, clean each elbow (41, 42 and 43, Figure 17.6).
27. If required, fit the elbows (41, 42 and 43, Figure 17.6) to the panhard rods (18) and manifold
bracket (44).
28. If required, fit the grease lines (48, 49, 50 & 51 Figure 17.6) to the p-clips (47) on the
chassis frame (1, Figure 16.2).
29. Remove line caps.
30. If required, connect the grease lines (48, 49, 50 & 51 Figure 17.6) to the elbows (41 and
43, Figure 17.6) on the manifold bracket (44, Figure 17.6).
31. Connect the grease lines (48, 49, 50 & 51 Figure 17.6) to the elbows (41 and 42, Figure
17.6) on the panhard rods (18).
32. Lubricate with grease until excess lubrication is seen. Refer to (1) Recommended
Lubricants on page 4-16.
33. Using a cloth or rag, remove excess grease.
34. If the rear suspension has been completely reassembled and all parts refitted to the
vehicle, mount the wheel and tire assemblies ((3) Removing Tire and Rim Assembly from
Machine on page 9-125) onto the axle. Refer to (7) Mounting Tire and Rim Assembly on
Machine on page 9-129.
35. Using suitable lifting equipment, raise the trailer frame sufficiently to remove all of the
supporting equipment from the axles (1, Figure 9.59 or 1, Figure 9.172) and tractor frame
(1, Figure 16.2.
36. Lower the vehicle to the ground and remove the lifting equipment.
37. Torque tighten all wheel nuts. Refer to (m) Special Torque Specifications on page 9-108
38. Place the steering lock bar in the 'Stowed' position. Refer to (2) Stow the Steering Lock
on page 12-29.
39. Remove the wheel blocks from the rear road wheels
40. Check serviceability of the vehicle. Refer to (4) Operation Safety on page 2-19 and (a)
Every 10 Hours of Operation on page 4-3.
41. Torque tighten the wheel nuts after ten hours of operation. Refer to (b) After First 10 Hours
of Operation or Rebuilt Components on page 4-4.

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 Suspension System 17

(4) Maintenance
Numbers in parentheses refer to Figure 17.3, unless otherwise specified.
Every 250 Hours:
1 Lubricate equalizer beam bushings (22) through lube fittings (28, Figure 17.3) with grease
specified in Lubricants, Oils and Fluids Chapter, until excess lube is seen.
2 Lubricate panhard rod bushings (19) through lube fittings (43, Figure 17.3) on the frame
with grease specified in Lubricants, Oils and Fluids Chapter, until excess lube is seen.
3 Using a cloth or rag, remove excess grease from around the bushings.
(5) Special Torque Specifications
Table 17.1 - Special Torque Specifications
TORQUE
FIG. NO. ITEM NO. ITEM NAME
Nm lbf ft
Figure 17.3 8 & 40 Bolt 790 583
Figure 17.3 11 Bolt 457 337
Figure 17.3 15 & 30 Bolt 531 392
Figure 17.3 16, 24 & 32 Bolt 169 125
Figure 17.3 27 Bolt 73 54

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17 Suspension System

Intentionally Left Blank

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 Cooling System 18

Table of Content
18 Cooling System.........................................................................................18-1
18.1 Description ................................................................................................... 18-2
18.2 Brake Cooling............................................................................................... 18-4
(1) Description............................................................................................. 18-10
(2) Operation............................................................................................... 18-10
(3) Drain the System ................................................................................... 18-12
(a) Oil Cooled Disc Brakes ..................................................................... 18-13
(b) Cooler ............................................................................................... 18-13
(c) Cooling Lines .................................................................................... 18-14
(d) Cooling Oil Tank................................................................................ 18-15
(4) Removal ................................................................................................ 18-15
(a) Oil Cooled Disc Brakes ..................................................................... 18-16
(b) Cooler ............................................................................................... 18-16
(c) Brake Cooling Lines.......................................................................... 18-16
(d) Triple Pump....................................................................................... 18-17
(e) Ancillaries.......................................................................................... 18-18
(5) Disassembly .......................................................................................... 18-21
(a) Triple Pump....................................................................................... 18-21
(b) Relief Valve ....................................................................................... 18-24
(6) Inspection .............................................................................................. 18-25
(7) Assembly ............................................................................................... 18-26
(a) Triple Pump....................................................................................... 18-26
(b) Relief Valve ....................................................................................... 18-27
(8) Installation ............................................................................................. 18-28
(a) Oil Cooled Disc Brakes ..................................................................... 18-28
(b) Cooler ............................................................................................... 18-28
(c) Brake Cooling Lines.......................................................................... 18-29
(d) Triple Pump....................................................................................... 18-30
(e) Ancillaries.......................................................................................... 18-30
(f) Priming.............................................................................................. 18-31
(9) Fault Diagnosis...................................................................................... 18-33
(10) Special Tools ......................................................................................... 18-33
(11) Special Torque Specifications................................................................ 18-34

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18 Cooling System

18 Cooling System
18.1 Description
Numbers in parentheses refer to Figure 18.1, unless otherwise specified.
The vehicle cooling system consists of several separate cooling subsystems:
• Oil Cooled Disc Brakes (OCDB) Cooling
• Charge Air Cooling (CAC)
• Engine Cooling
• Hydraulic Oil Cooling
• Transmission Cooling.
The main cooling package (2) and fan is mounted to the front of the tractor chassis frame, in
front of the engine. The cooling package (2) consists of a charge air cooler mounted at the top,
an engine water radiator in the middle and the oil cooler at the bottom. The air conditioning
condenser (1) is mounted to the front of the cooling package (2) on its own frame.
Beneath the cooling package (2) is the transmission coolers (4) which are plate type heat
exchangers. Hot oil from the gearbox, dropbox and transmission retarder is fed into the heat
exchangers where excess heat is transferred to the engine’s wet cooling system.
The brake cooler (5) and fan is mounted to the inside of the hood. Brake cooling oil is distributed
via a hydraulic triple pump (8).

11
3

7
10

8
2
5

1
FRONT
4 6

MOT05376

Figure 18.1 - Cooling System General Arrangement

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 Cooling System 18

1. AC Condenser 5. Brake Cooler 9. Manifold Block

2. Cooling Package 6. LHS Fender (inc. 10. Main Hydraulic Valve
Hydraulic Tank, Brake
Oil Cooling Tank and
Battery Box)
3. Header Tank 7. Engine 11. Tractor Manifold Plate
4. Transmission Coolers 8. Triple Pump Assembly

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TA400 Tier2 Page 18-3
18 Cooling System

18.2 Brake Cooling

OCDB System

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19

TRACTOR TRAILER

MOT05372

Figure 18.2 - OCDB Component General Arrangement

1. OCDB Filter 8. Centre Axle Manifold 15. Hydraulic Tank
Block
2. Motor/triple Pump 9. Centre Right Brake 16. Front Left Brake
Assembly Assembly
3. Tee Piece 10. Rear Axle Manifold 17. Main Hydraulic Control
Block Valve
4. Front Axle Manifold 11. Rear Right Brake 18. Centre Left Brake
Block Assembly Assembly
5. Front Right Brake 12. Battery Box 19. Rear Left Brake
Assembly Assembly
6. Tractor Manifold Plate 13. Brake Cooling Oil Tank
7. Trailer Manifold Plate 14. Relief Valve

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TA400 Tier2
DETAIL A

Maintenance Manual
15
Cooler feed 57,56,55 16
32 9
R.H. BRAKE
Cooler feed lines 20
32 33 19
10
DETAIL B 22
TOP BTM 70
39 34,38 53
31 72,73
35 25 21
COOLER 7
25 71 16
Cooler return 17
8
59 30,40 58 6
19 18
41 Main hydraulic pressure
48
Pump motor feed

63 RELIEF VALVE Pump motor return 24 60

13 57,56,54 50 51 23
14
11 Manifold block return lines
33 62
52 P P1 1 Front manifold block feed MANIFOLD

Revision 1.0
A. TRACTOR
T T
49
61 4
66 Rear axle feed 74
52 5 65 60 36
Manifold block return
MOTOR / 3
Pump feed TRIPLE PUMP
Hydraulic tank
return 6
C. 67 68 7 69 37
12
67 75
25 DETAIL D
60 2 67 25
52 OCDB FILTER 26 LH
HYDRAULIC TANK 27 RH

Figure 18.3 - OCDB Cooling Line Diagram — Front

OCDB CAP Centre axle feed
ASSEMBLY
29 HYDRAULIC
DETAIL C 42 42 43 28 CONTROL VALVE
L.H. BRAKE
48 WB
44 45
46
Main hydraulic pressure
64

47
MOT05377

Page 18-5
15-Sep-2017
Cooling System 18
18 Cooling System

1. Hose Assembly 26. Support Bracket LHS 51. Hose Assembly

2. Hose Assembly 27. Support Bracket RHS 52. Elbow
3. Hose Assembly 28. Bolt 53. Strap
4. Hose Assembly 29. Washer 54. Bracket
5. Hose Assembly 30. Clamp 55. Bracket
6. Hose Assembly 31. Clamp 56. Bolt
7. Hose Assembly 32. Elbow 57. Washer
8. Hose Assembly 33. Tee Piece 58. Bracket
9. Hose Assembly 34. Clamp 59. Bracket
10. Hose Assembly 35. Clamp 60. Adaptor
11. Hose Assembly 36. Elbow 61. Adaptor
12. Hose Assembly 37. Elbow 62. Elbow
13. Hose Assembly 38. Clamp 63. Elbow
14. Manifold Block 39. Locking Plate 64. Adaptor
15. Bolt 40. Clamp 65. Adaptor
16. Washer 41. Hose Assembly 66. Elbow
17. Nut 42. Adaptor 67. Adaptor
18. Bolt 43. Reducer 68. Adaptor
19. Washer 44. Split Flange 69. Manifold Plate
20. Nut 45. Bolt 70. Bracket
21. Bolt 46. Lock Washer 71. Mounting Bracket
22. Lock Washer 47. O-Ring 72. Clamp
23. Bleed Screw 48. Hose Assembly 73. Clamp
24. Dust Cap 49. Hose Assembly 74. Lockwasher
25. Adaptor 50. Hose Assembly 75. Lockwasher

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TA400 Tier2
Maintenance Manual
CENTRE AXLE REAR AXLE
52,60,51 52,60,51 R.H. BRAKES
52,60,51
58 55 52,60,51
56,57 56,57 59
53 53
54 53

21 24 1 1 14 12 1 1
13

11
20

25 2
20 23 22
4 3 10 9
5
DETAIL A

Revision 1.0
6
5 5 28
MANIFOLD - TRACTOR 34 5 7,8 3 29
39,40,41 28 30
42,43 29 4
33 MANIFOLD - TRAILER
(L.H. FRAME RAIL)
30 2 19

38 18
35 16 15
32
31 1 1 1
44 17 1
48

Figure 18.4 - OCDB Cooling Line Diagram — Rear

35 27
61 37
62 36
35 46 47 L.H. BRAKES
61 49 50
62
26
45,49
MOT05378

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15-Sep-2017
Cooling System 18
18 Cooling System

1. Adaptor 22. Hose Assembly 43. Bolt

2. Elbow 23. Hose Assembly 44. Bolt
3. Adaptor 24. Hose Assembly 45. Bolt
4. Elbow 25. Tee Piece 46. Bolt
5. Adaptor 26. Bulkhead Elbow 47. Bolt
6. Elbow 27. Tee Piece 48. Washer
7. Diagnostic 28. Bolt 49. Washer
8. Dustcap 29. Lockwasher 50. Washer
9. Rear Axle Manifold 30. Washer 51. Stacking Screw
10. Centre Axle Manifold 31. Hose Assembly 52. Clamp
11. Hose Assembly 32. Hose Assembly 53. Clamp
12. Hose Assembly 33. Hose Assembly 54. Clamp
13. Hose Assembly 34. Hose Assembly 55. Bracket
14. Hose Assembly 35. Reducer 56. Bolt
15. Hose Assembly 36. Bracket Assembly 57. Lockwasher
16. Hose Assembly 37. Cover Assembly 58. Bracket
17. Hose Assembly 38. Cover Assembly 59. Bracket
18. Hose Assembly 39. Clamp 60. Locking Plate
19. Hose Assembly 40. Bushing 61. Reducer
20. Hose Assembly 41. Stacking Nut 62. Nut
21. Hose Assembly 42. Thread Adaptor

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 Cooling System 18

OCDB Components

2
3

MOT00467

16

Figure 18.5 - OCDB Cooler and Mounting

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18 Cooling System

1. Oil Cooler Assembly 7. Bolt 13. Cooler Mounting

Bracket
2. Radiator Element 8. Bolt 14. Duct
3. Steel Housing 9. Locknut 15. Spring Washer
4. Fan 10. Washer 16. Bleed Cap
5. Rubber Mount 11. Washer
6. Seal 12. Cooler Mounting
Bracket

(1) Description
Numbers in parentheses refer to Figure 18.2, unless otherwise specified.
The hydraulic braking system is a closed circuit design, in which constant pressure is stored in
accumulators and is regulated as required to retard or stop the machine. The service brakes are
enclosed, forced oil cooled multiple discs. Refer to (1) Description and Operation on page 14-27.
The discs within the brake assemblies are immersed in cooling oil which is pumped through a
cooling circuit as shown in Figure 18.3 and Figure 18.4.
The oil is stored in the brake cooling oil tank (13) which is located in the front LH fender between
the main hydraulic tank (13) and the battery box (12). A hydraulically powered triple pump (2)
distributes the cooling oil to each axle via separate cooling circuits (front: 2, 3, 4 and 5, Figure
18.3; rear: 20 and 23, Figure 18.4). Hydraulic power is regulated by a relief valve (14).
The cooling oil to the front brakes travels through a filter (1) to the front manifold block (4) where
it is distributed to the brake assemblies (5 and 16) within the wheel hubs. Cooling oil to the
centre and rear axles is distributed via the tractor and trailer manifold plates (6 and 7) to the
manifold blocks (8 and 10) on to the brake assemblies in their respective axles (9, 11, 18 and
19). The hot oil from the brake assemblies follows the same route (front: 8, 9 and 10, Figure
18.3; rear: 21, 24 and 31, Figure 18.4) via the manifold blocks (4, 8 and 10) and into the brake
oil cooler (5, Figure 18.1) located inside the hood (1, Figure 16.10).
The manifold blocks (3, 7 and 9, Figure 18.2) contain a 1 Bar pressure switch (7, Figure 18.12)
on the inlet that returns excess pressure to the brake oil tank (12, Figure 18.2) via the manifold
block return lines (front: 11, 12 and 13, rear: 19, 22 and 32 Figure 18.4). The front manifold
block (4) contains an additional temperature transmitter (7, Figure 18.12).
(2) Operation

Figure 18.6 - Relief Unloader Valve Schematic Figure 18.7 - Motor/Triple Pump- Solenoid
Energized.

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 Cooling System 18

Figure 18.8 - Motor/Triple Pump- Solenoid De-Energized.

Numbers in parentheses refer to Figure 18.6, Figure 18.7 and Figure 18.8, unless otherwise
specified.
The motor is supplied with hydraulic oil from the brake cooling section of the triple gear pump
(2, Figure 18.2) via the disc brake oil cooler (5, Figure 18.1). The motor and pump elements
are connected by a common shaft, therefore motor rotation causes pump elements to draw
brake cooling oil from brake coolant tank (13, Figure 18.2). Cooling oil flows to the brake
packs via manifold blocks on front, centre and rear axles (4, 8 and 10, Figure 18.2). A sealing
arrangement within the assembly prevents cross contamination of hydraulic oil from the triple
gear pump (2, Figure 18.2) with brake cooling oil from brake coolant tank (12, Figure 18.2).
The OCDB relief valve (14, Figure 18.2) controls the brake cooling pump (2, Figure 18.2). Main
hydraulic supply pressure is delivered from the main hydraulic valve assembly (15,Figure 18.2),
via the 'WB' port. The valve, within the OCDB relief unloader valve, limits the pressure through
the motor to 26 bar (377 lbf/in²) at a flow rate of 10 l/min.
A solenoid integral to the OCDB relief unloader valve (3, Figure 18.7) controls the output of
the motor/triple pump (2, Figure 18.2), by controlling the flow of hydraulic oil to the motor side
of the assembly. When brake cooling oil is below 50 °C (122 °F) solenoid (A) is energized,
which limits the flow from the main hydraulic valve entering the relief unloader, by causing it
to bleed through a throttle by-pass around the solenoid valve. There will be limited cooling
from the pumps to the brake packs.
When brake cooling oil reaches 50 °C (122 °F) solenoid (A) is de-energized, thereby directing
all of the hydraulic oil through the motor, increasing motor speed therefore increasing pump
output. Refer to Figure 18.8.

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18 Cooling System

(3) Drain the System

� DANGER
• Avoid direct contact of hot oil with your skin. Hot oil will cause serious personal injury.

� 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.
• Oils present a serious slip hazard. To prevent personal injury and property damage, ensure
that any spilled oil is cleaned up immediately.
• Oils and lubricants can cause skin irritation. Use barrier cream and the appropriate
personal protective equipment.
• Escaping fluids under pressure can penetrate your skin.
• When the battery master switch is selected to the OFF position the adjacent red LED
remains ON for a further 60 seconds. When the LED is ON electrical power remains
connected to the truck.

NOTICE
• All components should be thoroughly cleaned and inspected for serviceability when they
are removed from the vehicle.
• Oil which has a milky appearance is contaminated with water and must be replaced.
Affected lines must be cleaned and the source of the contamination investigated.

General Preparation
1 Before carrying out any work to the vehicle, position it on a level work area and apply
the parking brake.
2 Raise the body. Refer to (6) Raise the Body on page 21-8.
3 Install body safety prop to secure the body in a partially raised position. Refer to (3) Deploy
the Body Prop on page 21-12.
4 Switch off the engine. Refer to 5.12 Stopping on page 5-28.
5 Turn the steering wheel several times to relieve any pressure in the steering system.
6 Block all wheels securely.
7 Place the steering lock bar in the 'Locked' position. Refer to (1) Fit the Steering Lock
on page 12-29.
8 Tilt the hood. Refer to (5) Raising the Hood on page 16-38.
9 Turn the battery master switch to the 'OFF' position.
10 Prepare the work area with drip trays and suitable absorbent materials to soak up any
spilled fluids.

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 Cooling System 18

(a) Oil Cooled Disc Brakes

Numbers in parentheses refer to Figure 18.9.

2
1
6 8
7

11
10

5 3
4

6 7
MOT05379

Figure 18.9 - OCDB Outer Casing

1. Brake Housing 5. Vent Valve 9. Bolt
2. Sealing Holder 6. Plug 10. Screw Plug
3. Screw Neck 7. O-ring 11. O-ring
4. O-ring 8. Bracket Anchor Plate

PROCEDURE
1. Using a pressure washer, thoroughly clean the brake housing (1) and anchor plate (8).
2. Place a suitable container under the brake housing (1) to collect the oil. If the wheel is fitted
to the axle, use a piece of cardboard or plastic to create a gutter to direct the flow of oil
into the container rather than let it run along the wheel rim.
3. Remove the plug (6) from the bottom of the brake housing (1) and allow the oil to drain into
the container. If the brake oil is still hot, great care must be taken when draining the oil.
4. When the oil has emptied from the brake housing (1), refit the plug (6) and o-ring (7),
replacing the o-ring (7) if required.
5. Repeat as necessary for the other brakes.
6. Clean up any spilled oil in accordance with local regulations.

(b) Cooler
Numbers in parentheses refer to Figure 18.5.

PROCEDURE
1. If required, tilt the hood fully. Refer to (5) Raising the Hood on page 16-38.
2. Identify the inlet (10, Figure 18.3) and outlet (41, Figure 18.3) hoses on the brake oil cooler
(5, Figure 18.1).
3. Using suitable lifting equipment, support the brake oil cooler (1).
4. Remove the three bolts, locknuts, washers and rubber mounts (5, 8, 9 and 10) from the
cooler mounting brackets (12, 13).
5. Using suitable lifting equipment, carefully remove the brake cooler (1) from the hood. If the
brake oil is still hot, great care must be taken when handling the cooler.

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18 Cooling System

6. Place the brake oil cooler (1) on a block or similar support on the LH fender.
7. Place a suitable container underneath the lower port of the brake oil cooler (1).
8. Loosen the fitting (32, Figure 18.3) at the outlet hose (41, Figure 18.3) until brake cooling oil
begins to flow. If the brake oil is still hot, great care must be taken when draining the oil.
9. Remove the bleed cap (16) at the top of the brake oil cooler (1).
10. Remove the fitting (32, Figure 18.3) at the outlet hose (41, Figure 18.3) and ensure that all
oil empties into the container. Do not attempt to empty the brake oil directly into the brake
oil tank (13, Figure 18.2), contamination of the brake cooling oil can occur and the tank
is very likely to overflow, causing a spillage. If the brake oil is still hot, great care must
be taken when draining the oil.
11. Be aware that spilled oil presents a slip hazard and any spills should be cleaned up
immediately.
12. When the oil has stopped draining into the container, if required, refit the bleed cap (16)
and outlet hose fitting (32, Figure 18.3) to the cooler (1).
13. If required, using suitable lifting equipment, fit the brake oil cooler (1) to the hood.
14. If required, fit the three bolts, locknuts, washers and rubber mounts (5, 8, 9 and 10) in the
cooler mounting brackets (12, 13).
15. Clean up any spilled oil in accordance with local regulations.

(c) Cooling Lines

PROCEDURE
1. Identify the brake oil cooling line to be drained. Refer to Figure 14.1 and Figure 14.2.
2. If required, tilt the hood. Refer to (5) Raising the Hood on page 16-38.
3. If required, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
4. If required, remove the sump guard (2, Figure 16.1). Refer to (procedure pending).
5. Identify the fittings at either end of the cooling line and mark if necessary.
6. If required, thoroughly clean the components.
7. Place a suitable container underneath the lower brake line fitting to collect the oil.
8. Disconnect the lower fitting and direct the oil flow into the container. If the brake oil is still
hot, great care must be taken when draining the oil.
9. When the oil has stopped flowing, disconnect the fitting at the other end of the cooling line.
10. If required, use compressed air to flush residual oil from the brake oil cooling line.
11. Either reconnect the line fittings or cap the lines and ports as required.
12. If required, torque tighten the fittings. Refer to (11) Special Torque Specifications on page
18-34.
13. Repeat as necessary for the other brake oil cooling lines.
14. Clean up any spilled oil in accordance with local regulations.

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 Cooling System 18

(d) Cooling Oil Tank

Numbers in parentheses refer to Figure 18.2.

PROCEDURE
1. Using a pressure washer, thoroughly clean the front LH fender.
2. Place a suitable container under the tank drain located on the underside of the brake
cooling oil tank (13) to collect the oil.
3. Remove the tank drain cap.
4. Using a hose with a quick-drain fitting and with one end in the oil collection container,
connect the hose to the tank drain. If the brake oil is still hot, great care must be taken
when draining the oil.
5. When the oil has emptied from the brake oil tank (13), refit the cap.
6. Clean up any spilled oil in accordance with local regulations.

(4) Removal

� DANGER
• Avoid direct contact of hot oil with your skin. Hot oil will cause serious personal injury.

� 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.
• Oils present a serious slip hazard. To prevent personal injury and property damage, ensure
that any spilled oil is cleaned up immediately.
• Oils and lubricants can cause skin irritation. Use barrier cream and the appropriate
personal protective equipment.
• Escaping fluids under pressure can penetrate your skin.
• When the battery master switch is selected to the OFF position the adjacent red LED
remains ON for a further 60 seconds. When the LED is ON electrical power remains
connected to the truck.

NOTICE
• All components should be thoroughly cleaned and inspected for serviceability when they
are removed from the vehicle.
• Oil which has a milky appearance is contaminated with water and must be replaced.
Affected lines must be cleaned and the source of the contamination investigated.

General Preparation
1 Before carrying out any work to the vehicle, position it on a level work area and apply
the parking brake.
2 Raise the body. Refer to (6) Raise the Body on page 21-8.

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18 Cooling System

3 Install body safety prop to secure the body in a partially raised position. Refer to (3) Deploy
the Body Prop on page 21-12.
4 Switch off the engine. Refer to 5.12 Stopping on page 5-28.
5 Turn the steering wheel several times to relieve any pressure in the steering system.
6 Block all wheels securely.
7 Place the steering lock bar in the 'Locked' position. Refer to (1) Fit the Steering Lock
on page 12-29.
8 Tilt the hood. Refer to (5) Raising the Hood on page 16-38.
9 Turn the battery master switch to the 'OFF' position.
10 Prepare the work area with drip trays and suitable absorbent materials to soak up any
spilled fluids.
(a) Oil Cooled Disc Brakes
Remove the oil cooled disc brakes (OCDB). Refer to (2) Removal and Disassembly on page
14-29.
(b) Cooler
Numbers in parentheses refer to Figure 18.5.

PROCEDURE
1. Drain the brake oil cooler (1), but do not refit the cooler (1) to the hood (2, Figure 16.10) or
reconnect the inlet hose (10, Figure 18.3). Refer to (b) Cooler on page 18-13.
2. Drain the cooler feed hose (10, Figure 18.3). Refer to (c) Cooling Lines on page 18-14.
3. If required, reconnect the inlet (10, Figure 18.3) and outlet (41, Figure 18.3) hoses to the
tee piece (33, Figure 18.3) and brake oil tank (13, Figure 18.2) respectively.
4. Cap the ends of the hoses (10 and 41, Figure 18.3) that connect to the cooler (1).
5. Disconnect the cooling fan (4) power lead.
6. Remove any fasteners (Detail B, Figure 18.3) holding the inlet (10, Figure 18.3) and outlet
(41, Figure 18.3) hoses and wiring to the brake oil cooler (1) and separate.
7. Using suitable lifting equipment, carefully remove the brake cooler (1) from the vehicle. Be
aware that there may be residual cooling oil in the cooler (1) which could spill while it is being
removed. If the brake oil is still hot, great care must be taken when handling the cooler.
8. Clean up any spilled oil in accordance with local regulations.

(c) Brake Cooling Lines

Numbers in parentheses refer to Figure 18.3.

PROCEDURE
1. Identify the brake oil cooling line to be removed. Refer to Figure 18.3 and Figure 18.4.
2. If required, tilt the hood. Refer to (5) Raising the Hood on page 16-38.
3. If required, tilt the cab.(4) Tilting the Cab on page 19-12
4. If required, remove the sump guard (2, Figure 16.1). Refer to (procedure pending).
5. Drain the cooling line. Refer to (c) Cooling Lines on page 18-14.
6. Cap the ends of the cooling line.
7. Identify the fasteners (Detail B) for the cooling line, label if necessary.

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 Cooling System 18

8. Remove or loosen fasteners (Detail B) as required to free the cooling line.

9. Remove the cooling line from the vehicle.
10. Either refit the fasteners (Detail B) or label removed fasteners so that they can be refitted
later in the correct location.
11. Repeat as necessary for the other brake oil cooling lines. If more than one line is removed
from the vehicle, the route of the line should be suitably labeled in the vehicle to ensure that
the replacement is fitted correctly.
12. Clean up any spilled oil in accordance with local regulations.

(d) Triple Pump

Numbers in parenthesis refer to Figure 18.3.
7

1 8

6
5
4

3
MOT05380

Figure 18.10 - Motor/Triple Pump

1 Motor/Triple Pump 4 Washer 7 Bolt
2 Mounting Bracket 5 Lockwasher 8 Lockwasher
3 Mounting Bracket 6 Bolt

PROCEDURE
1. If required, tilt the hood. Refer to (5) Raising the Hood on page 16-38.
2. Remove the sump guard (2, Figure 16.1). Refer to (procedure pending).
3. Place rag or absorbent material around the pressure relief valve (14, Figure 18.2) which is
mounted inside the engine bay on the wall of the hydraulic tank (15, Figure 18.2).
4. Relieve the hydraulic line pressure to the pump motor by disconnecting the feed line
between the hydraulic control valve (port WB, 17, Figure 18.2) and the pressure relief valve
(14, Figure 16.1) by removing the elbow (52) from port P on the pressure relief valve (1,
Figure 18.14). Great care must be taken during the removal of the elbow (52).
5. Place a suitable container underneath the triple pump (2, Figure 18.2) to collect the
hydraulic oil.
6. Remove the fittings for the pump motor feed (66) and return (68) lines from the triple pump
(2, Figure 18.10) and drain the hydraulic fluid into the container.
7. Cap the lines (50, 51) and the ports on the pump motor (1, Figure 18.10).
8. Clean up any spilled hydraulic oil to reduce the potential for cross contamination of oils.

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18 Cooling System

9. Drain the brake cooling oil tank. Refer to (d) Cooling Oil Tank on page 18-15. If the oils are
to be reused, do not empty the brake cooling oil into the same container as the hydraulic
fluid. Their properties are different and mixing them will render them unserviceable.
10. Place a suitable container underneath the triple pump (2, Figure 18.2) to collect the brake
cooling oil.
11. Remove the pump feed line (1) fitting (65) from the inlet port of the pump (26, Figure 18.13)
and drain the oil into the container. If the oils are to be reused, do not empty the brake
cooling oil into the same container as the hydraulic fluid. Their properties are different and
mixing them will render them unserviceable.
12. When the oil has stopped flowing, remove the three axle feed lines (2, 3, 4) fittings (67)
from the outlet ports of the triple pump (1, Figure 18.10).
13. Cap all lines (1, 2, 3, 4, 50, 51) and label if required.
14. Remove the four screws (7, Figure 18.10) and lockwashers (8, Figure 18.10) securing the
pump (1, Figure 18.10) to the frame (1, Figure 16.1).
15. Remove the triple pump (1, Figure 18.10) from the vehicle.
16. Move the triple pump (1, Figure 18.10) to a suitable clean and dry area if required.
17. Clean up any spilled oil in accordance with local regulations.

(e) Ancillaries
4
5
6

HOSE LINES
1
& FITTINGS
2

7
8

MOT00451

Figure 18.11 - OCDB Filter Assembly

1 Filter Assembly 4 Bolt 7 Bolt
2 Filter Element 5 Lockwasher 8 Washer
3 Indicator Gauge 6 Bracket

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 Cooling System 18

3
4

9
5

8
7

MOT05384

Figure 18.12 - Axle Manifold Blocks

Numbers in parentheses refer to manifold block port numbers. Refer to Appendix B Hydraulic
System Schematic Diagram on page B-1.
1 Cooling Oil inlet Port 4 Cooling Oil Outlet Ports 7 Temperature
(A1) (B1, X) Transmitter (TS1, front
axle only)
2 Pressure Switch (PS) 5 Service Brake Outlet 8 Cooling Oil Return
Ports (C1, C2) Outlet Port (A2)
3 Service Brake Inlet Port 6 Cooling Oil Return Inlet 9 Coolant Tank Return
(B3) Ports (B2, Y) Port (T)

Table 18.1 - Ancillary Locations

Item Location Reference
Tee (cooler feed lines: 8, 9 (3) Underside of chassis 33, Figure 18.3
and 10) frame (1, Figure 16.1),
inboard and forward of
suspension mount.
Tee (manifold block return (3) Underside of chassis 33, Figure 18.3
lines: 11, 12 and 13) frame (1, Figure 16.1),
inboard and to the rear of the
suspension mount.
Tee (manifold block return: On top of centre axle manifold 25, Figure 18.4
19 and 23, Figure 18.4) block (8).
Pressure Relief Valve Side of hydraulic tank (15), Figure 18.14
LHS of engine bay.
OCDB Filter Chassis frame (1, Figure 1, Figure 18.11
16.1), above triple pump (2).
OCDB Manifold Block — Underside of chassis frame Figure 18.12
Front Axle (1, Figure 16.1), bracket on
suspension beam (4).
OCDB Manifold Block — (8) Centre axle bracket Figure 18.12
Centre Axle assembly.

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18 Cooling System

Item Location Reference

OCDB Manifold Block — (10) Rear axle bracket Figure 18.12
Rear Axle assembly.
Tractor Manifold Plate Above articulation pivot on Detail A, Figure 18.4
the tractor (6).
Trailer Manifold Plate On cover assembly (37, Detail A, Figure 18.4
Figure 18.4) above oscillation
pivot on the trailer (7).

Numbers in parentheses refer to Figure 18.3.

PROCEDURE
1. If required, tilt the hood. Refer to (5) Raising the Hood on page 16-38.
2. If required, tilt the cab. Refer to (4) Tilting the Cab on page 19-12.
3. If required, remove the sump guard (2, Figure 16.1). Refer to (1) Removal on page 16-51.
4. Identify the ancillary to be removed. Refer to Table 18.1.
5. If required, disconnect any electrical connections from the ancillary.
6. Disconnect the cooling lines from the ancillary. Refer to (c) Brake Cooling Lines on page
18-16.
7. For the three OCDB manifold blocks, also disconnect the service brake hoses. Refer to (5)
Hose Removal on page 14-42. If the oils are to be reused, do not empty the brake cooling
oil into the same container as the brake hydraulic fluid. Their properties are different and
mixing them will render them unserviceable.
8. Cap the ends of the cooling lines and label if required.
9. Cap the ports of the ancillary and label if required.
10. Identify the fasteners (Detail B of (5) Hose Removal on page 14-42) securing the ancillary
to the vehicle. Refer to Table 18.1.
11. Remove the fasteners (Detail B of Figure 18.3) from the ancillary and label if required.
12. Remove the ancillary from the vehicle.
13. Move the ancillary to a suitable clean and dry area if required.
14. Clean up any spilled oil in accordance with local regulations.

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 Cooling System 18

(5) Disassembly

� DANGER
• Avoid direct contact of hot oil with your skin. Hot oil will cause serious personal injury.

� 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.
• Oils present a serious slip hazard. To prevent personal injury and property damage, ensure
that any spilled oil is cleaned up immediately.

NOTICE
• All components should be thoroughly cleaned and inspected for serviceability when as they
are disassembled.
• Seals are normally replaced during disassembly and reassembly, ensure that the correct
seal kit is available before commencing work.
• Prepare the work area with suitable absorbent materials to soak up any oil spills.

(a) Triple Pump

Numbers in parentheses refer to Figure 18.13.

� WARNING
• The machined surfaces of the assembly are easily damaged.
• Do not clamp the vice on the machined surfaces of the assembly at any time.
• Do not attempt to pry the motor/triple pump (1) assembly apart with a large screwdriver
or pry bar.

If required, prepare a suitable work area for disassembling the triple pump:
• Absorbent material should be laid out to soak up excess oil.
• Suitable containers should be used to organise parts as the pump is disassembled to aid
part identification when it is reassembled. It is very important that the pump gears remain
with their respective pump bodies. Label if required.
• Suitable solvents and other cleaning materials should be available to clean the parts as
they are removed.
• Compressed air can be used to supplement the cleaning process. Eye protection should
be worn in this case.
• For more detailed information, refer to the manufacturer’s literature.

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TA400 Tier2 Page 18-21
Page 18-22
15-Sep-2017
19 24

MOT03734
17
23 16 21
18 Cooling System

2 16
19
1 16
16 16 23
6 20 21
8
6
5 16
16 16
24
28 15

27
5
13 15 14
11
16
16

18 10

Revision 1.0
16 20
22
16
3 22
18 10 7
12
7
16 20 25

16

Figure 18.13 - Motor/Triple Pump Assembly

9 7
12 4 15 29
7
27
25
26 31
15 27
28
3
7 30
12
7

TA400 Tier2
Maintenance Manual
 Cooling System 18

1. Hydraulic Motor/Triple 12. Driven Gear 23. Dowel Pin

Pump Assembly
2. Body 13. Screw 24. Dowel Pin
3. Body 14. Nut 25. Dowel Pin
4. Body 15. Washer 26. Special Adapter
5. Rear Cover 16. Seal Kit 27. Lockwasher
6. Thrust Plate 17. Ring 28. Bolt
7. Thrust Plate 18. Flange 29. Plate Assembly
8. Drive Gear 19. Flange 30. Plate Assembly
9. Drive Gear 20. Coupling 31. Bolt
10. Drive Gear 21. Back-up Washer
11. Driven Gear 22. Support Plate

PROCEDURE
1. Place the motor/triple pump assembly (1) on a suitable work area.
2. If required, place the pump assembly (1) in a soft jawed vice and apply the vice clamp to
the body.
3. If required, remove any remaining fittings from the pump assembly (1).
4. Remove the nuts (14), washers (15) and support plate (22) securing the rear cover (5) to
the pump assembly.
5. Remove the rear cover (5) and clean with a suitable solvent.
6. Carefully remove the body (3) and clean with a suitable solvent.
7. Inspect the body (3) and body seals (16) for damage and excessive wear.
8. If required, remove the body seals (16) from the body (3) and dispose.
9. Place the pump body (3) in a suitable container.
10. Remove the thrust plates (7) and pump gears (10 and 12).
11. Clean with a suitable solvent and inspect the parts for damage and excessive wear.
12. Place the parts in the container with the pump body (3).
13. Remove the dowel pins (25).
14. Clean with a suitable solvent and place the pins (25) in the container with the pump body (3).
15. Remove the flange plate (18) and coupling (20).
16. Clean with a suitable solvent and inspect the parts for damage and excessive wear.
17. Repeat step 6 to step 16 for the remaining pump bodies. The individual pump assemblies
should be kept in separate containers as they are removed.
18. Remove both flange plates (19) from the end of pump motor (2) together.
19. Separate the flange plates (19) and clean with a suitable solvent..
20. Inspect the seals (16) and rings (17) for damage and excessive wear.
21. If required, dispose of the seals (16).
22. Place the flange plates (19) and associated components in a suitable container.
23. Remove the pump motor body (2) and clean with a suitable solvent.

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18 Cooling System

24. Inspect the motor body (3) and body seals (16) for damage and excessive wear.
25. If required, remove the body seals (16) from the body (2) and dispose.
26. Place the motor body (2) in a suitable container.
27. Remove the thrust plates (6), thrust seals (16) and motor gears (8 and 11).
28. Clean with a suitable solvent and inspect the parts for damage and excessive wear.
29. If required, remove the thrust seals (16) from the thrust plates (6) and discard.
30. Place the parts in the container with the motor body (2).
31. Remove the screws (13), washers (15) and support plate (22) from the motor cover (5).
32. Clean up any spilled oil in accordance with local regulations.

(b) Relief Valve

Numbers in parentheses refer to Figure 18.14.

NOTICE
It is not recommended that any of the cartridge assemblies (2 & 3) are disassembled for routine
maintenance purposes. If they are removed, ensure that valve assembly is cleaned prior to
removal of any components and that no contaminant is allowed to enter the internal galleries.
For more detailed information, refer to the manufacturer’s literature.

1
2

5 6 3

P11855

Figure 18.14 - Relief Valve

1. OCDB Relief Valve 3. Seal Kit 5. Coil
2. Seal Kit 4. Seal Kit 6. Solenoid Cartridge

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 Cooling System 18

PROCEDURE
1. Note location and position of all hydraulic connectors and adaptors prior to removing them
from valve body (1).
2. Remove unloader relief valve. Check for wear, scoring or contamination.
3. Remove relief valve (2). Check for wear, scoring or contamination.
4. If necessary, remove solenoid valve assembly (5 and 6). Check for wear, scoring or
contamination.
5. If necessary, remove flow regulator (3). Check for wear, scoring or contamination.
6. Ensure all O-Rings are checked and replaced when re-assembly is carried out. Check parts
book for relevant kit information.

(6) Inspection
Numbers in parentheses refer to Figure 18.13.

PROCEDURE
1. Clean all parts in a suitable solvent and dry with compressed air.
2. Examine all bushings and thrust plates (6 and 7) carefully for scoring, spalling or pitting.
Lightly oil the bushings and spin a shaft by hand to check for roughness of operation and
excess play. Replace bushings and thrust plates if necessary.
3. Examine the seals (16) for wear or damage and replace if necessary.
4. Examine gear housings (2, 3 and 4) carefully for wear. 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.
5. Check the centre of thrust plates (6 and 7) at the point of meshing of gears (8 and 11) and
(10 and 12). Erosion indicates contaminated oil. Pitted thrust plates indicate cavitation or
aeration of the oil supply. Discoloured thrust plates are a sign of pump overheating.
6. Check thrust plate surface wear against the size of new thrust plates. If worn more than
0.05 mm (0.002 in), replace the thrust plates. Thrust plate side wear permits oil to bypass
gears and allows internal oil slippage and reduced pump efficiency.
7. Check the driveshafts (20) and gear (8 and 10) for wear or damage to splines and seal
areas. Replace the driveshaft (20) and driven gear matched set if wear is detectable by
touch or measures in excess of 0.05 mm (0.002 in) at the seal or drive areas. Excessive
spline wear requires driveshaft and matching gear replacement.
8. Examine gears carefully for wear. Scoring, grooving or burring of the gear teeth OD
requires gear replacement. Nicked, grooved or fretted gear tooth 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. When gears are
replaced, their bushings must also be replaced.

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18 Cooling System

(7) Assembly

� WARNING
• The machined surfaces of the assembly are easily damaged.
• Do not clamp the machined surfaces of the assembly at any time.

NOTICE
• Parts should be cleaned thoroughly with a suitable solvent and inspected for damage, wear
and serviceability before assembly. Refer to (6) Inspection on page 18-25.
• Great care should be taken when fitting seals during assembly. Incorrect fitting can damage
the seals and cause leakage.

If required, prepare a suitable work area for assembling the cooling system components:
• The work area should be clean, dry and well lit.
• Absorbent material should be laid out to soak up excess oil.
• Suitable solvents and other cleaning materials should be available to clean the parts before
they are assembled.
• Compressed air can be used to supplement the cleaning process and to dry parts after
being cleaned. Eye protection is strongly advised in this case.
(a) Triple Pump
Numbers in parentheses refer to Figure 18.13.

NOTICE
• Pump parts should be identified prior to assembly and kept together for each chamber of
the motor/pump. It is very important that the pump gears remain with their respective
pump bodies. Label if required.
• For more detailed information, refer to the manufacturer’s literature.

PROCEDURE
1. Collect the pump motor seals (16) and apply a coat of hydraulic oil. Do not use brake
cooling oil to coat these seals.
2. Fit the thrust plates (6) onto the drive gear (8) and driven gear (11).
3. Fit the seals (16) to the motor body (2) and thrust plates (6).
4. Fit the dowel pins (23) to the motor body (2).
5. Insert the assembled gears (8 and 11) and thrust plates (6) into the pump body (2).
6. Ensuring that the pump motor seals (16) remain correctly seated, fit the flange plate (19)
to the assembled motor components (2).
7. Fit two of the screws (13) through the support plate (22).
8. Fit the washers (15) to the four screws (13).
9. Fit the screws (13) to the rear cover (5), ensuring that the support plate (22) is correctly
oriented.

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 Cooling System 18

10. Fit the assembled screws (13) and rear cover (5) to the assembled motor body (2) and
flange plate (19), taking care that the pump motor seals (16) remain correctly seated.
11. If required, mount the assembly (1) horizontally in a soft jawed vice.
12. Fit the seals (16), washers (21), rings (17), coupling (20) and dowel pins (23 and 24) to the
pump flange plate (19).
13. Fit the assembled pump flange plate (19) onto the screws (13) of the assembled pump
motor (2), taking care that the seals (16) are correctly seated.
14. Collect the pump body seals (16) and apply a coat of brake cooling oil. Do not use
hydraulic oil to coat these seals.
15. Fit the pump body seals (16) to the pump body (3).
16. Assemble the pump gears (9 and 12) and thrust plates (7).
17. Insert the assembled gears (9 and 12) into the pump body (3).
18. Fit the dowel pins (25), coupling (20) and pump flange plate (18) to the assembled pump
body (3), taking care that the seals (16) are correctly seated.
19. Fit the assembled pump body (3) onto the screws (13) of the pump assembly (1), taking
care that the seals (16) are correctly seated.
20. Repeat Step 14. to Step 19. for the remaining pump bodies (3 and 4), fitting the rear
cover (5) when complete.
21. Fit two washers (15) followed by the support plate (22) onto the screws (13) of the triple
pump assembly (1), ensuring that they are fitted to the same screws (13) as those at the
motor end (2) of the pump assembly (1). Refer to Step 9..
22. Fit four washers (15) and nuts (14) to the screws (13) of the triple pump assembly (1).
23. Inspect the gaps between the pump bodies (2, 3 and 4) to ensure that the seals (16) are
correctly seated.
24. Carefully torque tighten the nuts (14). Refer to (11) Special Torque Specifications on page
18-34.
25. If required, refit the hose fittings to the pump assembly (1).
26. If available, test run the pump (1) using a portable hydraulic supply. Check for correct
functioning of the pump (1) and for any leaks from the motor and pump bodies (2, 3 and 4).
27. Cap the ports on the pump (1) to prevent dirt or contamination entering the motor (2) or
pump (3 and 4) bodies.

(b) Relief Valve

Numbers in parentheses refer to Figure 18.14.
For more detailed information, refer to the manufacturer’s literature.

PROCEDURE
1. If required, replace the seals on hydraulic connectors and adaptors.
2. Replace all seals on unloader relief valve body (1), relief valve (2), solenoid coil/spool (4
and 5) and flow regulator (3) valve prior to assembly.
3. Install the hose fittings (52, Figure 18.3) to the correct ports and orientation.
4. Torque tighten the fittings. Refer to (11) Special Torque Specifications on page 18-34.
5. Fit relief valve (2), flow regulator (3) and solenoid valve assembly to valve body (1) at
correct ports.

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18 Cooling System

(8) Installation

� 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.
• Oils present a serious slip hazard. To prevent personal injury and property damage, ensure
that any spilled oil is cleaned up immediately.
• Escaping fluids under pressure can penetrate your skin.

NOTICE
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• Prepare the work area with drip trays and suitable absorbent materials to soak up any
oil spills.
• All components should be thoroughly cleaned and inspected for serviceability before they
are installed on the vehicle.

1 Before carrying out any work to the vehicle, ensure that it is on a level work area and the
parking brake is applied.
2 Ensure that all wheels are blocked securely.
3 If required, raise the body. Refer to (6) Raise the Body on page 21-8.
4 If required, install body safety prop to secure the body in a partially raised position. Refer to
(3) Deploy the Body Prop on page 21-12.
5 Turn the steering wheel several times to relieve any pressure in the steering system.
6 Ensure that the steering lock bar is in the 'Locked' position. Refer to (1) Fit the Steering
Lock on page 12-29.
7 If required, tilt the hood. Refer to (5) Raising the Hood on page 16-38.
8 Ensure that the battery master switch is in the 'OFF' position.
9 Prepare the work area with drip trays and suitable absorbent materials to soak up any
oil spills.
(a) Oil Cooled Disc Brakes
Install the oil cooled disc brakes (OCDB). Refer to (3) Assembly and Installation on page 14-34.
(b) Cooler
Numbers in parenthesis refer to Figure 18.2.

PROCEDURE
1. If required, tilt the hood (2, Figure 16.10) fully. Refer to (5) Raising the Hood on page 16-38.
2. Ensure that the bleed cap (16) is fitted to the cooler (1). Fit if required.
3. Using suitable lifting equipment, fit the brake oil cooler (1) into place on the hood (2,
Figure 16.10).
4. Secure the brake oil cooler (1) to the hood (2, Figure 16.10) with the three bolts, locknuts,
washers and rubber mounts (5, 8, 9 and 10) in the cooler mounting brackets (12, 13).

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 Cooling System 18

5. Identify the inlet (10, Figure 18.3) and outlet (41, Figure 18.3) hoses for the brake oil
cooler (1).
6. Ensure that the inlet and outlet hose fittings (32, Figure 18.3) are attached. Fit if required.
7. Remove caps from the inlet (10, Figure 18.3) and outlet (41, Figure 18.3) hoses
8. Fit inlet and outlet hose fittings (32, Figure 18.3) to the cooler (1).
9. Torque tighten the fittings (32). Refer to (11) Special Torque Specifications on page 18-34.
10. Using heat resistant cable ties, secure the cooler return line (41) and associated wiring to
the outer rim of the fan motor assembly (4, Figure 18.2).
11. Connect the fan motor power cable (4, Figure 18.2) to the wiring harness.
12. Check the functionality of the cooling fan.
13. Clean up any spilled oil in accordance with local regulations.
14. If the brake cooling system has been completely reassembled, prime the brake cooling
system. Refer to (f) Priming on page 18-31.
15. Lower the hood. Refer to (6) Lowering the Hood on page 16-39.
16. Check serviceability of the vehicle. Refer to (4) Operation Safety on page 2-19 and (a)
Every 10 Hours of Operation on page 4-3.

(c) Brake Cooling Lines

Numbers in parenthesis refer to Figure 14.1.

PROCEDURE
1. Identify the brake oil cooling line to be fitted. Refer to Figure 14.1 and Figure 14.2.
2. If required, tilt the hood. Refer to (5) Raising the Hood on page 16-38.
3. If required, tilt the cab.(4) Tilting the Cab on page 19-12
4. If required, remove the sump guard (2, Figure 16.1). Refer to (1) Removal on page 16-51.
5. Identify the route of the cooling line and the fittings at either end, mark if necessary.
6. Identify the fasteners (Detail B, Figure 18.3) for the cooling line, label if necessary.
7. If required, clean the cooling lines, fittings and fasteners (Detail B, Figure 18.3).
8. Test fit the cooling line along its route, holding it loosely in position with the fasteners (Detail
B, Figure 18.3).
9. Place suitable containers underneath the cooling line fittings to collect any residual oil.
10. Remove caps from the cooling line fittings and their respective ports on the vehicle.
11. Connect the line fittings.
12. Torque tighten the fittings. Refer to (11) Special Torque Specifications on page 18-34.
13. Adjust the position of the cooling line along its length to ensure that it is not under excess
strain or in a position that could cause it to rub or be damaged.
14. Where appropriate, torque tighten the fasteners (Detail B, Figure 18.3). Refer to (11)
Special Torque Specifications on page 18-34.
15. Repeat as necessary for the other brake oil cooling lines.
16. Clean up any spilled oil in accordance with local regulations.
17. If the brake cooling system has been completely reassembled, prime the brake cooling
system. Refer to (f) Priming on page 18-31.

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18 Cooling System

(d) Triple Pump

Numbers in parenthesis refer to Figure 14.1.

PROCEDURE
1. If required, tilt the hood. Refer to (5) Raising the Hood on page 16-38.
2. If required, remove the sump guard (2, Figure 16.1). Refer to (1) Removal on page 16-51.
3. Ensure that the mounting area for the triple pump (2, Figure 18.2) is clean and free from
corrosion.
4. Ensure that the fittings (65, 66, 67 and 68) are still in place and are capped. If a cap is
not in place then that brake cooling line should be flushed to ensure that it is clean and
free from contamination.
5. If required, refit the hose fittings (65, 66, 67 and 68).
6. Place a suitable container underneath the triple pump (2, Figure 18.2) to collect any oil spills.
7. If required, fit the mounting plates (2 and 3, Figure 18.10) to the chassis frame (1, Figure
16.1) using four bolts (6, Figure 18.10), lockwashers (5, Figure 18.10) and washers (4,
Figure 18.10)
8. Attach the triple pump assembly (1, Figure 18.10) to the mounting plates (2 and 3, Figure
18.10) using four bolts (7, Figure 18.10) and lockwashers (8, Figure 18.10).
9. Remove the caps from the pump motor feed and return fittings (66 and 68) and from the
ports on the pump motor body (2, Figure 18.13)
10. If required, replace the seals on the fittings.
11. Reconnect the pump motor (2, Figure 18.13).
12. Torque tighten the fittings (66 and 68). Refer to(11) Special Torque Specifications on page
18-34.
13. Clean up any spilled hydraulic oil to prevent contamination of the brake cooling oil.
14. Remove the caps from the triple pump feed and return fittings (65 and 67) and from the
ports on the pump bodies (3 and 4, Figure 18.13)
15. If required, replace the seals on the fittings.
16. Reconnect the pump (1, Figure 18.13).
17. Torque tighten the fittings (65 and 67). Refer to (11) Special Torque Specifications on
page 18-34.
18. Clean up any spilled oil in accordance with local regulations.
19. If the brake cooling system has been completely reassembled, prime the brake cooling
system. Refer to (f) Priming on page 18-31.

(e) Ancillaries
Numbers in parentheses refer to Figure 18.3.
Refer to Table 18.1 for a list of ancillary locations.

PROCEDURE
1. If required, tilt the hood. Refer to (5) Raising the Hood on page 16-38.
2. If required, tilt the cab.(4) Tilting the Cab on page 19-12

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 Cooling System 18

3. If required, remove the sump guard (2, Figure 16.1). Refer to (1) Removal on page 16-51.
4. Identify the ancillary to be installed. Refer to Table 18.1.
5. Ensure that the mounting area for the ancillary is clean and free from corrosion.
6. Fit the ancillary into the vehicle.
7. Using the appropriate bolts, washers and nuts, secure the ancillary to the vehicle. Refer
to Table 18.1.
8. If required, torque tighten the bolts. Refer to(11) Special Torque Specifications on page
18-34.
9. Ensure that the fittings are still in place and are capped. If a cap is not in place then that
brake cooling line should be flushed to ensure that it is clean and free from contamination.
10. Place a suitable container underneath the ancillary to collect any oil spills.
11. Remove caps from the cooling line fittings and their respective ports on the ancillary.
12. If required, refit the hose fittings.
13. Connect the hose fittings to the ancillary.
14. Torque tighten the fittings. Refer to (11) Special Torque Specifications on page 18-34.
15. Repeat as necessary for the other ancillaries.
16. If required, connect any electrical connections to the ancillary.
17. Clean up any spilled oil in accordance with local regulations.
18. If the brake cooling system has been completely reassembled, prime the brake cooling
system. Refer to (f) Priming on page 18-31.

(f) Priming
Numbers in parenthesis refer to Figure 18.2.

� DANGER
• To prevent serious injury or death, DO NOT go under the vehicle when the engine is
running. Rotating shafts are dangerous. You can snag clothes, skin, hair, hands, etc.

� WARNING
• Escaping fluids under pressure can penetrate your skin.

PROCEDURE
1. Place drip trays and suitable absorbent materials underneath any components that have
been refitted.
2. Ensure that the brake cooling oil tank (13) drain cap is fitted.
3. Ensure that the hydraulic tank (15) and brake cooling oil tank (13) are full. Replenish if
required.
4. If required, lower the cab. Refer to (5) Lowering the Cab on page 19-14.
5. Disconnect the cable from the solenoid (5, Figure 18.14) on the relief valve (14).
6. Start the engine. Refer to 5.11 Starting on page 5-27.

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18 Cooling System

7. Monitor the fluid levels in both the hydraulic tank (15) and brake cooling oil tank (13).
Replenish as required, ensuring that there is no cross contamination of the two fluids.
8. With the engine running and using a torch if required, inspect the brake cooling lines for
leaks. DO NOT go under the vehicle while the engine is running.
9. If leaks are discovered, stop the engine (refer to 5.12 Stopping on page 5-28) and refer to
the appropriate section and refit, tighten or replace the part as necessary.
10. When the brake cooling oil level remains constant, loosen the bleed cap (16, Figure 18.5) at
the top of the brake oil cooler (1, Figure 18.5) until a hissing noise can be heard or brake
cooling oil begins to flow. Do not remove the cap completely.
11. With a rag or other absorbent material in place to soak up brake cooling oil, monitor the oil
as it flows from the bleed cap (16, Figure 18.5).
12. When the brake cooling oil runs clear with no bubbles, tighten the bleed cap (16, Figure
18.5).
13. Be aware that spilled oil presents a slip hazard and any spills should be cleaned up
immediately.
14. Check the fluid levels in both the hydraulic tank (15) and brake cooling oil tank (13).
Replenish as required.
15. When the brake cooling oil level remains constant, stop the engine. Refer to 5.12 Stopping
on page 5-28.
16. Using a torch if required, inspect the brake cooling lines, fittings and components for leaks.
17. If leaks are discovered, refer to the appropriate procedure and refit, tighten or replace the
part or connections as necessary.
18. Reconnect the cable to the solenoid (5, Figure 18.14) on the relief valve (14).
19. Clean up any spilled oil in accordance with local regulations.
20. If required, return to the appropriate installation procedure.
21. Lower the hood. Refer to (6) Lowering the Hood on page 16-39.
22. Place the steering lock bar in the 'Stowed' position. Refer to (2) Stow the Steering Lock
on page 12-29.
23. Remove the wheel blocks from the rear road wheels

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 Cooling System 18

(9) Fault Diagnosis

Identifiers in parentheses refer to Figure 18.7 and Figure 18.8.
Refer to the following Fault Diagnosis chart. As stated previously, it is not recommended that
the relief valve (B) cartridge assembly is disassembled for maintenance purposes. Ensure
that the motor/ triple pump is cleaned off prior to removal of any components and that no
contaminant is allowed to enter the internal galleries.
If investigation shows that the relief valve (B) is in good clean condition and fit for use, the seals
should be renewed, prior to re-assembly. Any damage to the motor section or to any of the
pump elements would necessitate renewal of the motor/triple pump assembly.
Table 18.2 - Brake cooling fault diagnosis
CONDITION REASON ACTION
Non rotation of shaft No oil supply. Check the pressure at the motor
section of the triple pump.
Pressure should be 26 bar (377 psi)
at 2 100 rpm, when oil is at operating
temperature.
Brake packs overheating Relief valve faulty. Check relief valve functionality.
Pump elements Inspect and replace parts or
damaged. motor/triple pump as required. Refer
to (6) Inspection on page 18-25.
Brake oil contamination. Inspect oil condition. Clean or
replace as required. Refer to (3)
Drain the System on page 18-12.

(10) Special Tools

Refer to 22.2 Service Tools on page 22-4, for part numbers of general service tools and
consumables required. These tools and consumables are available from your dealer.
Table 18.3 - Special Tools List
Item Tool Part No. (Supplier)
1 Seal driver (25.4–30mm dia) N/A
2 Motor seal installation tool. DM3–418S0–1 (Parker Denison)

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18 Cooling System

(11) Special Torque Specifications

Table 18.4 - Special torque specifications
Item Reference Torque setting
Relief Valve fittings 52, Figure 18.3 35 Nm (25.8 Ibf-ft)
Manifold block cooling oil port B1, B2, X, Y, Figure 18.12 110 Nm (81.1 lbf-ft)
fittings
Manifold block cooling oil A1, T, Figure 18.12 160 Nm (118 lbf-ft)
return fitting
Manifold block service brake B3, Figure 18.12 110 Nm (81.1 lbf-ft)
inlet fitting
Manifold block service brake C1, C2, Figure 18.12 60 Nm (44.25 lbf-ft)
outlet fitting
Manifold block temperature TS1, Figure 18.12 25 Nm (18.4 lbf-ft)
transmitter
Manifold block pressure PS, Figure 18.12 Max 40 Nm (29.5 lbf-ft)
switch

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 Operator's Compartment 19

Table of Content
19 Operator's Compartment .........................................................................19-1
19.1 Cab............................................................................................................... 19-2
(1) Description............................................................................................... 19-7
(2) Removal .................................................................................................. 19-8
(3) Installation ............................................................................................. 19-10
(4) Tilting the Cab........................................................................................ 19-12
(5) Lowering the Cab .................................................................................. 19-14
(6) Mirror Arms............................................................................................ 19-15
(a) Removal............................................................................................ 19-15
(b) Installation......................................................................................... 19-15
(7) Replacing Glass .................................................................................... 19-16
(a) Water Leaks ...................................................................................... 19-17
(8) Maintenance .......................................................................................... 19-17
(9) Service Tools ......................................................................................... 19-17
19.2 Operator's Seat .......................................................................................... 19-18
(1) Description............................................................................................. 19-18
(2) Adjustment............................................................................................. 19-20
(3) Operation............................................................................................... 19-21
(4) Removal ................................................................................................ 19-22
(5) Disassembly .......................................................................................... 19-22
(a) Horizontal Shock Absorber ............................................................... 19-23
(b) Vertical Shock Absorber.................................................................... 19-24
(c) Compressor ...................................................................................... 19-25
(d) Level Controller................................................................................. 19-26
(6) Inspection .............................................................................................. 19-27
(7) Assembly ............................................................................................... 19-27
(8) Installation ............................................................................................. 19-28
(9) Maintenance .......................................................................................... 19-28
(10) Special Torque Specifications................................................................ 19-28
19.3 Instructor's Seat ......................................................................................... 19-29
(1) Description............................................................................................. 19-29
(2) Removal ................................................................................................ 19-31
(3) Installation ............................................................................................. 19-32
(4) Maintenance .......................................................................................... 19-32

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19 Operator's Compartment

19 Operator's Compartment
19.1 Cab

42

42
7 8
9

MOT04619
Figure 19.1 - Cab Installation
1. Cab Locating Pin 15. Washer 29. Bolt
2. Hinge Pin 16. Spring 30. Locknut
3. Locating Pin 17. Locknut 31. Cab Mud Flap (RH)
4. Washer 18. Multi Purpose Grease 32. Plate
5. Spring Pin 19. Window Guard 33. Bolt
6. Bolt 20. Bolt 34. Washer
7. Cab Prop 21. Washer 35. Lockwasher
8. Pin Assembly 22. Storage Box 36. Silent Block Support (LH)
9. Bolt 23. Front Floor Mat 37. Isolation Mount
10. Nut 24. Left Rear Mat 38. Clamp Bar
11. Mirror Arm 25. Right Rear Mat 39. Mirror Mounting Bar
12. Mirror Exterior Convex 26. Under Seat Mat 40. Bolt
13. Mirror 27. Silent Block Support 41. Lockwasher
(RH)
14. Ball 28. Isolation Mount 42. Washer

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 Operator's Compartment 19

13
22 17,27 23
1 2 10
9
11

16
28,26
6

7 8
24

12
15

14 4
26
3

18
25
21 19
20
MOT05419A

Figure 19.2 - Cab Assembly

1. Cap Assembly 11. Rear Lower Trimming 21. Noise Insulation
2. Safety Hammer 12. Extension Lining 22. Roof Trim
3. Left Front Trim 13. Strap 23. Rear Profile Cover
4. Extension Lining 14. Left Rear Lower Trim 24. Left C-Post Cover
5. Extension Lining 15. Left B-Post Cover 25. Noise Insulation
6. Extension Lining 16. Right B-Post Cover 26. Screw
7. Extension Lining 17. Coat Hanger 27. Screw
8. Extension Lining 18. Noise Insulation 28. Washer
9. Extension Lining 19. Noise Insulation
10. Extension Lining 20. Noise Insulation

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19 Operator's Compartment

13,41
13,30 27

21
23 5,36

34 21
3
16 15
5,36
13,7 4 11 24
14
10 8
7
20,40 7
6

10
12 7

37 38
28 17 25
10 30
32 28 26
30 36
44 29,39 31 28
29,35,42 18,39,9 30
29,35,42 31 30 22
31

33,35
43

45 46
30 1

MOT05426

Figure 19.3 - Cab Interior

1. Electrical Duct 17. Plate 33. Screw
2. Footrest 18. Dashboard Support 34. Clip
3. Interior Light 19. Dashboard Support 35. Washer
4. Seal 20. Front Dashboard 36. Screw
5. Speaker 21. Vent 37. Dashboard Fixing
6. Thread Clip 22. Fuse Box Plate 38. Seal
7. Washer 23. Document Shelf 39. Seal
8. Screw 24. Fuse Box Cover 40. Seal
9. Nut 25. Right Side Console 41. Cap
10. Screw 26. Gear-Shift Support 42. Nut
11. Screw 27. Instrument Panel 43. Closing Plate
12. Ash Tray 28. Bolt 44. PCB Cover
13. Screw 29. Nut 45. Plastic Head Bolts
14. Handle 30. Washer 46. Washer
15. Socket 31. Washer
16. Decal 32. Insert

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 Operator's Compartment 19

11
2

14
5
8

1
6
9
7
4

2
12

13

10

MOT05427

Figure 19.4 - Cab Windows

1. Foam Seal 6. Sliding Rear Glass 11. Right Rear Window
2. Rear Corner Protectors 7. Fixed Front Glass 12. Left Rear Window
3. Sliding Window 8. Frame 13. Left Front Window
4. Lock Assembly 9. Rear Latch 14. Rear Window
5. Slide and Seal Kit 10. Front Window

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19 Operator's Compartment

31 26
28,33 31 B B
32 27 32
27,28 27,28 B
33 33
35 35
34 34
A B 3 38
C
13 A
8
4 7
A
12 23
27 6 41
37 40
42
6 5
10

7 39
9
1
18
19 2,24
42 11 20
22,23,36 17
48 45 3
15
50 43
52 16 44
18
C
47 46
14
21
29,30
46 50 47
49,51

MOT05428

Figure 19.5 - Cab Accessories

1. Lock Protection 19. Washer 37. Screw
2. Door Lock 20. Cap Nut 38. Cap Nut
3. Aerial 21. Bracket 39. Seal
4. Bent Pipe Connection 22. Bolt 40. Pipe
5. Cover Plate 23. Washer 41. Grommet
6. Working Light Harness 24. Washer 42. Pipe
7. Wiper Blade 25. Screen Washer Valve 43. Centering
8. Wiper Arm 26. Cap Nut 44. Washer
9. Wiper Arm 27. Washer 45. Top Seal Baffle
10. General Cab Harness 28. Washer 46. Side Seal Baffles
11. Front Screen Wiper 29. Washer 47. Side Seal Baffle Plates
Motor
12. Rear Screen Wiper 30. Bolt 48. Top Seal Baffle Plate
Motor
13. Sunblind 31. Nut 49. Bolt
14. Push Button 32. Sealing Nut 50. Seal
15. Washer 33. Washer 51. Washer
16. Screw 34. Protection Socket 52. Seal
17. VDU Cable 35. Screw
18. Nut 36. Cap

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 Operator's Compartment 19

(1) Description
Numbers in parentheses refer to Figure 19.1, unless otherwise specified.

� CAUTION
• The protection offered by the roll over and falling object protective structure may be
impaired if it has been subjected to any change or damage.
• Do not operate the machine while the cab is tilted. At all times make sure the cab is fully
lowered and correctly secured before operating the machine.

NOTICE
• Access from the cab, in the case of an emergency, can be gained by breaking one of the
windows using the hammer provided (mounted on the back pillar).

The cab is fully insulated and mounted on cab mount assembly to decrease structure-borne
noise and vibration. The cab complies with the ISO, ROPS (Roll Over Protective Structure) -
ISO 3471 and FOPS (Falling Object Protective Structure) ISO 3449 requirements as standard.
The cab assembly can be tilted for better accessibility to components below the cab, including
the transmission and main hydraulic valve. A hydraulic hand pump (1, Figure 19.6), located
inside the battery box and a cab raise cylinder (7, Figure 19.6) are used to raise the cab.
The cab interior is spacious and offers outstanding visibility through large areas of tinted safety
glass. Access to the cab assembly is from the left hand side with open tread steps, platform
and handrail.
The cab interior, trimmed with noise-absorbent material, is extensively thermally insulated
and a heater/filter/pressurizer and a de-misting unit keeps the internal air fresh and dust free.
Sliding windows provide additional ventilation. Air conditioning is fitted as standard. Refer to (1)
Description on page 20-6.

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19 Operator's Compartment

(2) Removal
Numbers in parentheses refer to Figure 19.1, unless otherwise specified.

� DANGER
• Air conditioning refrigerant will rapidly freeze all objects with which it comes into contact. It
can cause serious and permanent damage to the eyes and skin.

� WARNING
• To prevent personal injury and property damage, be sure the wheel blocks, blocking
materials and the lifting equipment are correctly secured and of adequate capacity to do
the job safely.
• Do not work near or under an unblocked or unsupported cab. When working in theses
circumstances the cab safety prop must de used, every time.

� CAUTION
• Hydraulic fluid pressure will remain within the system after engine shutdown. Operate the
brake pedal continuously until the pressure is released before disconnecting any hoses.
• To prevent damage, make sure the hood is raised before tilting or lowering the cab.
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Operate the brake pedal continuously to release pressure in the system.
3. Block all the road wheels.
4. Raise the hood. Refer to (5) Raising the Hood on page 16-38.
5. Place the battery master switch in the 'OFF' position.
6. Identify and tag all cables, harnesses, lines and linkages disconnected from cab assembly
during removal to aid in installation.
7. Disconnect the electrical cables in the following order to prevent damage to the electrical
components:
a. Battery negative cable (C1.X-).
b. Battery positive cable (C2.X+).
c. Rear view camera connection (WA1.B32.X2).
d. Rear frame harness connector (X18).
e. Engine harness connector (X3).
f. Front frame harness connectors (X15 and X16).
g. Battery sense connector (X43), located inside the cab.
h. Terminal block connections (X42.X1a and X42.X2a), located inside the cab.
i. Ground connection (XGND2.a).
j. Remove bolts securing the feedthrough panel to the cabin bulkhead.
k. Remove bolts from top of feedthrough panel, separate the clamp assemblies and
remove the grommet surrounding the cab harness’s.

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 Operator's Compartment 19

l. Carefully feed the disconnected cab harness’s through the bulkhead/firewall. Feed the
camera harness through the bulkhead into the cab, and the terminal block connections
outwards from the cab.
m. Identify and remove the header tank harness p-clips securing the harness to the cab.
8. Empty the refrigerant from the air conditioning system, tag and disconnect the hoses (17
and 20, Figure 20.5). Fit blanking caps to all open lines and fittings.
9. Identify, tag and with suitable containers available to catch leakage, disconnect the heater
lines (10 and 12, Figure 20.3). Fit blanking caps to open line ends and fittings.
10. Identify, tag and disconnect the treadle valve hose connections. Refer to (3) Removal
on page 14-14.
11. Remove the front right hand tire and rim assembly, for access. Refer to 9.6 Wheel Rim
and Tire on page 9-123.
12. Tilt the cab (refer to (4) Tilting the Cab on page 19-12) to get access to the steering valve
below the cab, and secure with the cab safety prop. Make sure all lines are identified for
ease of installation and with suitable containers available to catch leakage, disconnect and
remove the steering valve hoses. Fit blanking caps to open line ends and fittings. Refer
to (3) Removal on page 12-13.
13. Attach suitable slings to the cab lifting points and raise the lifting equipment to take up
the slack.
14. Disconnect the cab raise cylinder (7) from the cab floor by removing bolt (21), washer (22)
and nut (15). Refer to Figure 19.6.
15. Tag and disconnect any other harnesses and hoses that may be affected by the cab
removal. Disconnect the earth strap at rear right hand cab support.
16. Lower the cab safety prop and place in the stowed position, then using the lifting equipment,
slowly lower the cab until it is horizontal.
17. Remove spring pins to allow the hinge pins to be driven out from the cab mounts using a
suitable driver.
18. Remove the bush and bolt securing the locating pin to the cab mount. Remove the locating
pin.
19. Check to make sure all necessary disconnections have been made, before lifting the cab
assembly. Taking care to prevent damaging the insulating material, lift the cab assembly
from the frame and place on suitable stands. Transport to a suitable clean maintenance
area.

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19 Operator's Compartment

(3) Installation
Numbers in parentheses refer to Figure 19.1, unless otherwise specified.

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

� CAUTION
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

NOTICE
• Tighten all fasteners without special torques specified to torques listed in Table 22.1.

PROCEDURE
1. Inspect the cab mounts (27 and 36) for damage and replace if necessary. Check and
torque tighten bolts (29) to 457 Nm (337 lbf ft).
2. Attach suitable slings to the cab lifting points and raise and position the cab on the frame.
3. Using lifting equipment, raise the cab.
4. Secure the cab raise cylinder (7) to the bracket on the cab floor using bolt (14), washer (17)
and nut (15). Refer to Figure 19.6.
5. Secure the cab in raised position with the cab safety prop (7).
6. Install and connect the steering valve hoses. Refer to Installation , page 12-17. Connect
the earth strap at the rear right hand cab support.
7. Place the cab safety prop (7) in the stowed position. Using a hand pump (1, Figure 19.6)
to control lowering of cab, gently lower the cab until the cab brackets align with the cab
mounts (27 and 36).
8. Secure the cab assembly to the cab mounts (27) with hinge pins (2) and spring pins (5).
9. Apply Loctite to bushes (4) and bolts (6), secure the cab assembly to the cab mounts (36)
with locating pins (1), bushes (4) and bolts (6). Torque tighten bolts to 457 Nm (337 lbf ft).
10. Remove slings and all lifting equipment.
11. Install the front right hand tire and rim assembly. Refer to Mounting Tire and Rim Assembly
on Machine , page 9-129.
12. Identify and connect the treadle valve hose connections. Refer to (6) Installation on page
14-20.
13. Remove blanking caps, identify and connect the heater lines (10 and 12, Figure 20.3).
Torque tighten clamps (23, Figure 20.3) to 7 Nm (5 lbf ft).
14. Remove blanking caps, identify and connect air conditioning hoses (8 and 9, Figure 20.5).
Trque tighten to 28 Nm (21 lbf ft).
15. Identify and connect the electrical cables and harness in the following order:
a. Install the header tank harness p-clips securing the harness to the cab.

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 Operator's Compartment 19

b. Carefully feed the cab harness’s through the bulkhead/firewall. Feed the camera
harness through the bulkhead from the cab, and the terminal block connections into
the cab.
c. Install the grommet and surround the cab harness’s, secure the clamp assemblies and
install bolts to the top of feedthrough panel.
d. Install bolts and secure the feedthrough panel to the cabin bulkhead.
e. Ground connection (XGND2.a).
f. Terminal block connections (X42.X1a and X42.X2a), located inside the cab.
g. Battery sense connector (X43), located inside the cab.
h. Front frame harness connectors (X15 and X16).
i. Engine harness connector (X3).
j. Rear frame harness connector (X18).
k. Rear view camera connection (WA1.B32.X2).
l. Battery positive cable (C2.X+).
m. Battery negative cable (C1.X-).
16. Charge the air conditioning system. Refer to (b) Charging New or Completely Empty
Systems on page 20-14.
17. Re-start the air conditioning system. Refer to (3) Re-Start Procedure on page 20-15.
18. Place the battery master switch in the 'ON' position, start the engine and check for leaks.
Tighten fittings as necessary. Allow the engine to warm up and recheck all connections for
leaks. Ensure the electrical systems and gear shifts are functioning properly.
19. Lower the hood. Refer to (6) Lowering the Hood on page 16-39.
20. Ensure the parking brake is applied and remove the wheel blocks from all road wheels.

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19 Operator's Compartment

(4) Tilting the Cab

TO CAB BRACKET

15
17

17
14

7,8
6

11
12
10
15
17
22
5
9
3 16
18 19
1
TO FRAME
21,22 BRACKET
18
13
4

2 BRACKET TO
HYD/BATTERY BOX
20

MOT04606

Figure 19.6 - Cab Tilt Mechanism

1. Hand Pump Assembly 9. Flow Control Valve 17. Washer (Hardened)
2. Hydraulic Tank (1 litre) 10. Adaptor 18. Washer
3. Hand Pump 11. Elbow 19. Adaptor
4. Gasket 12. Hose Assembly 20. Clamp
5. Elbow 13. Bolt 21. Bolt
6. Lever 14. Bolt 22. Washer
7. Cab Raise Cylinder 15. Locknut
8. Breather 16. Locknut

Numbers in parentheses refer to Figure 19.6, unless otherwise specified.

� DANGER
• Do not work near or under an unblocked or unsupported cab. At all times use the cab
safety prop.

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 Operator's Compartment 19

� WARNING
• To prevent damage, at all times, make sure the hood is raised before tilting or lowering the
cab.
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.

PROCEDURE
1. Position the machine in a level work area, apply the parking brake, switch off the engine
and block all road wheels.
2. Operate the brake pedal continuously to relieve pressure in the hydraulic system.
3. Raise the hood assembly. Refer to (5) Raising the Hood on page 16-38.
4. Place the battery master switch in the 'OFF' position. Refer to Figure 15.102.
5. Insert lever (6), located in the battery box, into the cab hand pump (1).
6. Using the hand pump (1), charge the cab raise cylinder (7) sufficiently to allow locating pins
(25, refer to Figure 19.1) to be removed. Hold the cylinder (7) in this position by locking the
hand valve on the hand pump (1).
7. Remove bolts and bushes (27 & 26, refer to Figure 19.1), then drive out the locating pins
(25, refer to Figure 19.1). Carefully raise or lower the cab as necessary to facilitate removal
of pins (25, refer to Figure 19.1).
8. Once the locating pins (25, refer to Figure 19.1) have been safely removed, continue to raise
the cab using hand pump (1) until the cab safety prop (1, refer to Figure 19.7) can be fitted.
9. Remove the pin assembly (17, refer to Figure 19.1) to allow the cab safety prop (1, refer to
Figure 19.7) to swing down to a vertical position on top of the front left hand cab leg.
10. Lock the cab safety prop (1, refer to Figure 19.7) in position using pin assembly (17, Refer
to Figure 19.1), locating through holes on the bracket at the front left hand cab leg.
11. Lock off the hand valve on the hand pump (1). Remove lever (6) from the pump (1) and
place in the stowed position.

Figure 19.7 - Cab Secured In Raised Position

1. Cab Safety Prop 2. Cab Support 3. Cab Raise Cylinder

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19 Operator's Compartment

(5) Lowering the Cab

Numbers in parentheses refer to Figure 19.6, unless otherwise specified.

� DANGER
• Do not work near or under an unblocked or unsupported cab. At all times use the cab
safety prop.

� WARNING
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.
• To prevent damage, at all times make sure the hood is raised before tilting or lowering the
cab.

PROCEDURE
1. Remove the pin assembly (8, refer to Figure 19.1) from the bracket at the front left hand
cab leg. Place the cab safety prop (1, refer to Figure 19.7) in stowed position by locating
the pin assembly (8, refer to Figure 19.1) in the bracket under the cab.
2. Slowly open the hand valve on the hand pump (1) to allow the cab to gently lower. Rate of
descent is controlled by the hand valve on the pump (1).
3. Lower the cab until holes in the cab brackets line up with the holes in the cab supports (2,
refer to Figure 19.1). Hold the cylinder (7) in this position by locking the hand valve on
the hand pump (1).
4. Install the locating pins (1) through the cab brackets. Secure the locating pins (1) in position
with bushes (4) and bolts (6)
5. Lower the hood and place the battery master switch in the 'ON' position before closing
the battery box.
6. Ensure parking brake is applied and remove wheel blocks from all road wheels.

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 Operator's Compartment 19

(6) Mirror Arms

(a) Removal
Numbers in parentheses refer to Figure 19.1, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure blocking materials and lifting
equipment are correctly secured and of adequate capacity to do the job safely.

PROCEDURE
1. Support the mirror arm (11) bracket and remove the locknuts (17), hardened washers (15)
and springs (16) securing the mirror arm assembly to the mounting brackets.
2. Remove the mirror arm (11) bracket and ball bearings (14) from the mounting brackets.
3. Repeat steps 1 and 2 for the opposite mirror arm (11) bracket.

(b) Installation
Numbers in parentheses refer to Figure 19.1, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure blocking materials and lifting
equipment are correctly secured and of adequate capacity to do the job safely.

NOTICE
• Tighten all fasteners without special torques specified to torques listed in Section, Standard
Bolt and Nut Torque Specifications.

PROCEDURE
1. Coat ball bearings (14) with grease (18) and locate in the mounting brackets.
2. Position the mirror arm (11) bracket to the mounting brackets and install hardened washers
(15), springs (16) and locknuts (17) as shown in Figure 19.1.
3. Set the mirror bracket spring (16) pressure as follows;
a. Rotate the mirror arm (11) until the ball bearings (14) are out of their detent.
b. Tighten the locknut (17) until the spring (16) is almost completely compressed (typical
two places).
c. Swing the arm until it seats in the detent.
d. Check the other two detent positions
e. Repeat steps 1, 2 and 3 for the opposite mirror arm (11) bracket.

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(7) Replacing Glass

1 4

2
12,15

5 7 10

13
6
14
3
11

8
MOT04621

Figure 19.8 - Cabin Door

1. Door Assembly-LH 6. Handle-Door 11. Lock Assembly-LH
2. Door-Welded 7. Key Cab-Door 12. Slide and Seal Kit
3. Door Trim 8. Stop-Door 13. Glass Rear-Fixed
4. Strut-Gas 9. Lock-Door 14. Glass Front-Sliding
5. Handle-Inside 10. Window Sliding-Door 15. Frame

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 Operator's Compartment 19

Numbers in parentheses refer to Figure 19.4, unless otherwise specified.

NOTICE
• When replacing broken glass, it is the user’s responsibility to ensure that the replacement
glass meets the required specifications. Replacement glass can be purchased from your
dealer.
• Ensure the glass is supported adequately before starting to cut the adhesive seal.

The rear window (62) glass, left and right hand side glasses (57, 58, 61, 106 and 107), door
glasses (13 and 14, Figure 19.8) and front windscreen (105) are held in place by a bonding
adhesive.
To replace a glass assembly, proceed as follows:

PROCEDURE
1. Using a pointed tool, pierce a hole in the adhesive seal, it is advisable to start at the top
edge of the glass. Unscrew one handle of the special tool and feed the wire through the
opening. Pierce a second hole in the adhesive on the side directly opposite the first.
2. From inside the cab pull the wire through and feed it back out through the second hole.
3. Re-fit the handle on the special tool. Pull both handles outwards until wire is taut.
4. Maneuver the special tool around the edge of the glass, keeping the wire taut, to cut the
adhesive seal. Ensure the glass is supported adequately before completing the cut.
5. Clean the remains of the adhesive from the edge of the panel opening using a suitable
solvent.
6. Coat the edge of the replacement glass with primer and apply adhesive around the lip of
the window aperture, as per the manufacturers recommendations.
7. Position the glass onto the panel opening, pressing firmly so that the adhesive bonds
sufficiently to allow the glass to be moved or straightened up as required.
8. Ensuring the glass is adequately supported, allow the sealing adhesive to set properly.
9. Clean off any excess adhesive using a suitable solvent.

(a) Water Leaks

Test for leaks by directing a stream of water along the adhesive seal, while an assistant marks
the spot of leakage inside the cab. Care should be taken to note whether the leak is between
adhesive and the glass. Then apply a sealing compound from the outside. Start from a point
near the leak and continue applying the sealer until well beyond the suspected point of entry.
This should stop the leak immediately, but since some sealing compounds should be allowed
to set before getting wet, wait a few minutes before testing.
(8) Maintenance
Ensure that hand pump hydraulic tank (2, refer to Figure 19.6) is filled with clean hydraulic oil as
specified in (1) Recommended Lubricants on page 4-16. Capacity is 0.75 litre (0.2 US gallon).
(9) Service Tools
Refer to 22.2 Service Tools on page 22-4, for part numbers of the glass removal tool, adhesive
bonding kit and other general service tools required. These tools are available from your dealer.

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19 Operator's Compartment

19.2 Operator's Seat

(1) Description

MOT04935

Figure 19.9 - Exploded View of Operator Seat

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 Operator's Compartment 19

1. Seat Assembly-Driver 20. Resilient Kit 39. Bellows-Complete

2. Backrest 21. Bracket Kit 40. Compressor-Complete
3. Cushion 22. Side Cover Kit 41. Shock Absorber-Complete
4. Head Rest 23. Adjuster-Seat Depth 42. Air Reservoir-Complete
5. Bushing 24. Adjustment-Rail Set 43. DA. Adjuster-Complete
6. Lumber Support 25. Fixing Part-Rail Set 44. DA. Handle-Complete
7. Actuator-Front 26. Cable 45. HV. Handle-Complete
Lumber
8. Handle Kit-Lumber 27. Seat Belt 46. Adaptor Cable-Complete
Support
9. Handle Complete 28. Arm Rest 47. Secondary Belt-Complete
Assembly-LH
10. Actuator-Front/Back 29. Arm Rest 48. Bowden Cable
Rest Assembly-RH
11. Backrest-Bearing Kit 30. Cushion Set 49. Inner Tube-Complete
12. Stop 31. Cover Complete 50. Bowden Cable
13. Glide 32. Lever 51. Bowden Cable
Control-Complete
14. Seat Pan 33. Suspension 52. Operation Unit
Upper-Complete
15. Back Rest 34. Harness-Complete 53. Cover
16. Actuator-Front 35. Air Spring-Complete 54. Adjustment-Complete
Cushion
17. Kit Resilient Sheet 36. Kit-Wear Parts 55. Longitudinal Horizon
18. Adjuster-Seat Angle 37. Suspension 56. Mounting Parts-Suspension
Assembly-Complete Assembly
19. Lever 38. Suspension
Lower-Complete

Numbers in parentheses refer to Figure 19.9, unless otherwise specified.

� WARNING
• By Law, seat belts must be provided. Always wear seat belts when travelling in the vehicle.
• Do not attempt to adjust the seat or seat belt while the machine is moving. Loss of control
will result. Stop the machine; apply the brakes; then adjust.

The seat assembly consists of a seat cushion (3) and backrest cushion (2) mounted to back rest
(15) and seat pan (14). Seat pan (14) is attached to a cab seat base by means of a suspension
assembly (37). The air seat only reacts when the driver sits on the seat. When unoccupied,
the seat sinks to the lowest position to allow easier access.
A retractable seat belt (27) is secured to the seat assembly using nuts and spacers. A push
button allows quick release of seat belt (27).

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19 Operator's Compartment

(2) Adjustment

10

14

15
9

12
11 13 2

3
6 4
2 7
5
3
4
MOT04955

Figure 19.10 - Operator Seat Controls

1. Operator Seat 6. Forward and Aft 11. Damper Adjustment
Adjustment
2. Bolt 7. Locking Lever 12. Seat Depth Adjustment
Forward and Aft
Isolator
3. Lockwasher 8. Seat Belt 13. Seat Cushion Angle
Adjustment
4. Washer 9. Back Rest Angle 14. Lumber Support Adjustment
Adjustment
5. Height and Weight 10. Back Rest Height 15. Armrest Adjustment
Adjustment Adjustment

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 Operator's Compartment 19

(3) Operation
Numbers in parentheses refer to Figure 19.10, unless otherwise specified.

NOTICE
• All controls should be set to operators own personal comfort.

To achieve the most comfortable driving position, adjust the seat as follows;

PROCEDURE
1. Sit in seat.
2. Pull up and release height and weight adjustment (5) handle - this will reset the seat to
the predetermined height setting - 'bounce' lightly until a 'click' is heard, the seat position
in now engaged properly.
3. Pull up forward and aft adjustment handle (6) and move seat forwards or backwards,
release handle when required position is achieved.
4. Pull up (or push down) height and weight adjustment (5) handle and hold until the require
height position is achieved, release handle - 'bounce' lightly until a 'click' is heard, the seat
position in now engaged properly.
5. Pull handle (12) to adjust seat depth position. Hold and pull handle (8) until desired position
is achieved.
6. Pull handle (13) to adjust seat cushion angle, hold and pull until desired angle is achieved.
Ensure cushion is locked into position. This procedure is better performed when operator
is off seat.
7. Pull up handle (9) and adjust backrest to the required angle, release handle when required
position is achieved.
8. Pull up (or push down) backrest (10) to the required height.
9. Turn lumber support adjustment (14) until desired pressure if felt on operators back.
10. Set damper adjustment (11) position to suit driving conditions, (4 positions; forward position
- hardest setting, rearmost position - softest setting).
11. Set fore/aft isolator (7) position to suit driving conditions, (forward position - unlocked,
rearmost position - locked).
12. Turning armrest adjustment (15) alters the height of armrests.
13. Engage seat belt (8).

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19 Operator's Compartment

(4) Removal
Numbers in parentheses refer to Figure 19.10, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure wheel chocks and lifting
equipment are properly secured and of adequate capacity to perform the task safely.

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels and place the battery master switch in the 'OFF' position.
3. Disconnect harness connector at the rear of the seat (26, Figure 19.9).
4. Push down height and weight adjustment (5) handle to release the air from the seat air
suspension system.
5. Remove bolts (2), lockwashers (3) and washers (4) securing complete seat assembly to the
cab seat base. Remove seat assembly from machine using suitable lifting equipment.

(5) Disassembly
Numbers in parentheses refer to Figure 19.9, unless otherwise specified.

NOTICE
• The disassembly and assembly procedures will cover only basic sub-assemblies due to
the multitude of parts. If a sub-assembly must be disassembled, use the exploded view in
Figure 19.9 for reference.

PROCEDURE
1. Remove cover (31) from seat assembly. Remove nuts and spacers securing lap belt (27)
to seat assembly. Remove lap belt (27).
2. Pull up and remove headrest (4) from seat frame (1).
3. Remove screws securing backrest cushion (2) to seat frame (1). Remove backrest cushion
(2).
4. Remove screws securing seat cushion (3) to seat frame (1). Remove seat cushion (3).
5. Pull up forward and aft (6, Figure 19.10) lever and slide seat assembly rearwards. Hold
captive nuts using a suitable spanner and remove front allen screws.
6. Pull up forward and aft adjustment (6, Figure 19.10) lever and slide seat assembly forwards.
Hold captive nuts using a suitable spanner and remove rear allen screws.
7. Remove seat assembly from suspension base.

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 Operator's Compartment 19

(a) Horizontal Shock Absorber

Figure 19.11 - Exploded View of Horizontal Shock Absorber

1. Buttons Pop-Out 3. Circlip 5. Spacer
2. Cover Access 4. Shock Absorber

Numbers in parentheses refer to Figure 19.11, unless otherwise specified.

PROCEDURE
1. Remove seat assembly. Refer to (4) Removal on page 19-22.
2. Remove pop-out buttons (1) and remove access cover (2) to allow access to suspension
assembly.
3. Unclip hooked end of shock absorber (4) from horizontal spring assembly.
4. Remove circlip (3) and lever out shock absorber (4) from rocker shaft and slide off of
mounting pin.
5. Remove spacer (5) from mounting pin.
6. Reassembly is done in the reverse order.

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19 Operator's Compartment

(b) Vertical Shock Absorber

Figure 19.12 - Exploded View of Vertical Shock Absorber

1. Button Pop-Out 4. Mounting Pin 7. Shock Absorber
2. Cover Access 5. Bowden Wire 8. Spacer
3. Circlip 6. Adjuster Damper

Numbers in parentheses refer to Figure 19.12, unless otherwise specified.

NOTICE
• Inscription must face upwards when assembling shock absorber (7).

PROCEDURE
1. Remove seat assembly. Refer to (4) Removal on page 19-22.
2. Remove pop-out buttons (1) and remove access cover (2) to allow access to suspension
assembly.
3. Unhook Bowden wire (5) and damper adjuster (6) assembly from the top of shock absorber
(7).
4. Remove circlips (3) and lever out shock absorber (7) from mounting pins (4).
5. Remove spacers (8) from lower mounting pin (4).
6. Reassembly is done in the reverse order.

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 Operator's Compartment 19

(c) Compressor

Figure 19.13 - Exploded View of Compressor and Mounting

1. Button Pop-Out 5. Airline Pressurised 9. Nut
2. Cover Access 6. Compressor 10. Screw Micro-Cylinder
3. Button Pop-Out 7. Cable Electrical 11. Clamp
4. Suspension Skirt 8. Cable Electrical 12. Mat Felt

Numbers in parentheses refer to Figure 19.13, unless otherwise specified.

NOTICE
• Replace micro encapsulated cylinder screw (10).
• Centralise compressor (6) and felt mat (12) between rocker arms.

PROCEDURE
1. Remove seat assembly. Refer to (4) Removal on page 19-22.
2. Remove pop-out buttons (1) and remove access cover (2) to allow access to suspension
assembly.
3. Remove pop-out buttons (3) and push down suspension skirt (4) to allow further access
to suspension assembly.
4. Remove pressurised airline (5) from compressor (6).
5. Identify, tag and disconnect electrical plug connections (7 & 8). Unfasten cable tie on
the rocker.
6. Pull suspension assembly up to its highest position and block securely.
7. Unscrew lower nut (9) and remove micro encapsulated cylinder screw (10) and retaining
clamp (11).
8. Remove compressor (6) and felt mat (12) from suspension base.
9. Reassembly is done in the reverse order.

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19 Operator's Compartment

(d) Level Controller

Figure 19.14 - Exploded View of Level Controller and Mounting

1. Button Pop-Out 7. Level Controller 13. Pin
2. Cover Access 8. Cable Electrical 14. Nut
3. Button Pop-Out 9. Cable Electrical 15. Screw
4. Suspension Skirt 10. Airline Pressurised 16. Retainer Bowden Wire
5. Bowden Wire 11. Air Suspension Unit 17. Belt Roll-Up
6. Bowden Wire 12. Screw

Numbers in parentheses refer to Figure 19.14, unless otherwise specified.

NOTICE
• Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).

PROCEDURE
1. Remove seat assembly. Refer to (4) Removal on page 19-22.
2. Remove pop-out buttons (1 and 3) and remove access cover (2) and push down suspension
skirt, to allow access to suspension assembly.
3. Pull suspension assembly up to its highest position and block securely.
4. Unhook bowden wires (5 and 6) from level controller (7).
5. Identify and tag and disconnect electrical plug connections (8 & 9).
6. Identify and tag and disconnect pressurised airlines (10) from air suspension unit (11).
Unfasten cable tie on the rocker.
7. Remove screw (12), push out pin (13) and release roll up belt (17).
8. Remove nuts (14) and manoeuvre level controller (7) until studs are free from mounting
holes.
9. Remove screws (15) and remove bowden wire (16) retainer from level controller (7).
10. Remove level controller (7) from suspension base.
11. Reassembly is done in the reverse order.

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 Operator's Compartment 19

(6) Inspection
Numbers in parentheses refer to Figure 19.9, unless otherwise specified.

PROCEDURE
1. Inspect air lines, shock absorber (41), compressor (40), level controller (32) and air spring
(35) for leaks and damage and replace if required.
2. Check all brackets and frame for cracks and/or damage. Repair or replace as necessary.
3. Check springs for fatigue or damage and replace as required.

(7) Assembly
Numbers in parentheses refer to Figure 19.9, unless otherwise specified.

NOTICE
• Tighten all fasteners without special torques specified to torques listed in 22.3 Standard
Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Position seat assembly onto suspension base. Hold captive nuts using a suitable spanner
and install rear allen screws. Tighten allen screws to a torque of 25 Nm (18 lbf ft).
2. Pull up forward and aft adjustment (6, Figure 19.10) lever and slide seat assembly
rearwards. Hold captive nuts using a suitable spanner and install front allen screws. Tighten
allen screws to a torque of 25 Nm (18 lbf ft).
3. Install seat cushion (3) to seat frame (1) and secure using screws.
4. Install backrest cushion (2) to seat frame (1) and secure using screws.
5. Refit headrest (4) to seat frame (1).
6. Position lap belt (27) to seat assembly and secure using nuts and spacers. Tighten nuts to
a torque of 50 Nm (36 lbf ft). Refit cover (31).

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19 Operator's Compartment

(8) Installation
Numbers in parentheses refer to Figure 19.10, unless otherwise specified.

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

NOTICE
• Tighten all fasteners without special torques specified to torques listed in 22.3 Standard
Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Using suitable lifting equipment, position seat assembly on the cab seat base and secure
using bolts (2), lockwashers (3) washers (4).
2. Reconnect harness at the rear of the seat (26, Figure 19.9).
3. Place battery master switch in the 'ON' position, start the engine and charge the air system.
Check seat for proper operation, refer to (3) Operation on page 19-21.
4. Remove wheel chocks from road wheels.

(9) Maintenance
Numbers in parentheses refer to Figure 19.9, unless otherwise specified.
The care of the upholstery on seat cushion (3) and backrest cushion (2) is a relatively simple,
but important matter. Accumulation of dirt on the surface eventually turns into a hard gritty
substance which cuts into the surface of the upholstery.
To clean seat cushion (3) and backrest cushion (2), use warm water and a mild soap, such
as Castile. Work up thin soap suds on a piece of soft cloth and rub the upholstery briskly.
Remove the suds with a damp cloth, using no soap, and finish by wiping the upholstery dry
with a soft, dry cloth.
Lap belt (27) assembly should be inspected by the user on a regular basis. Replace lap belt
(9) immediately if hardware is worn or damage, straps are nicked or frayed, buckle is not
functioning correctly, loose stitching is found, or if the strap material has lost strength due to the
effects of ultraviolet rays.
(10) Special Torque Specifications
Table 19.1 - Special Torque Specifications
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
Figure 19.9 # Nut 50 36
Figure 19.9 # Allen Screw 25 18
Figure 19.14 14 Nut 25 18

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 Operator's Compartment 19

19.3 Instructor's Seat

(1) Description

MOT04611

3 4 5

Figure 19.15 - Exploded View of Instructor Seat

1. Instructor Seat 3. Bolt 5. Washer
2. Seat Belt 4. Lockwasher

Figure 19.16 - Instructor Seat, Hinged Back and Base Operations

Numbers in parentheses refer to Figure 19.15, unless otherwise specified.

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19 Operator's Compartment

� CAUTION
• By Law, seat belts must be provided. Always wear seat belts when travelling in the machine.

The instructor seat (1) is located adjacent to the left hand side of the operator’s seat, and
is secured to tapped bosses on the rear wall of the cab with bolts (3), washers (4) and
lockwashers (5). The seat (1) comprises a seat cushion and back cushion mounted to a seat
frame. Seat frame is attached to seat base by means of a hinge at the front end and locked at
the rear by a spring loaded latch arrangement. Located below the seat base is a storage box,
below which is a cavity containing a number of electrical harnesses, the transmission ECU,
the MCU, the wash/wipe relay, the CPU and the busbar assembly, all of which are described
elsewhere. Access to the equipment below the seat requires pivoting of the base cushion into a
vertical attitude, then securing it to the back rest by means of the strap provided, as shown on
steps 1 and 2 on Figure 19.16. The back rest can be pivoted to the horizontal position when
not in use, by first unlocking the release catch on the right-hand side, then rotating it down
as shown on steps 3 and 4 of Figure 19.16.
The diagnostic interface socket and the hood control switch are both fitted adjacent to the
right-hand side of the instructor seat.
A retractable lap seat belt (2) is secured to drilled lugs on the rear wall of the cab. A release
button allows quick release of the seat belt (2).

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 Operator's Compartment 19

(2) Removal
Numbers in parentheses refer to Figure 19.15, unless otherwise specified.

� CAUTION
• To prevent personal injury and property damage, be sure wheel chocks, blocking materials
and lifting equipment are properly secured and of adequate capacity to perform the task
safely.
• High electrical current. Turn the ignition key switch and the battery master switch 'OFF'
before disconnecting any electrical components. Disconnect electrical connections in the
correct order given to prevent damage to the electrical components.
• When the Battery Master Switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and shut down the
engine.
2. Turn the steering wheel in both directions several times to relieve any pressure in the
steering system. Block all road wheels.
3. Pivot the base cushion to the vertical position, then secure it to the back rest using the strap
provided, thus allowing access to the seat mounting hardware.
4. Undo and remove the bolts (3), lockwashers (4) and washers (5) securing the seat
assembly (1) to the rear wall of the cab.
5. Lift the entire seat assembly (1) out of the cab and remove it to a clean maintenance area.

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19 Operator's Compartment

(3) Installation
Numbers in parentheses refer to Figure 19.15, unless otherwise specified.

NOTICE
• Tighten all fasteners without special torques specified to torques listed in 22.3 Standard
Bolt and Nut Torque Specifications on page 22-5.

PROCEDURE
1. Position the instructor seat assembly (1) against the internal rear wall of the cab, correctly
orientated such that the three holes in the rear of the seat frame align with the tapped
holes in the bosses of the rear cab wall.
2. Secure the instructor seat assembly (1) to the rear wall of the cab using the bolts (3),
lockwashers (4) and washers (5), tightened evenly and securely.
3. Support the base cushion, then undo the strap holding it in a vertical attitude. Carefully
pivot the base cushion to the horizontal position.
4. Remove the wheel chocks from the road wheels.

(4) Maintenance
Numbers in parentheses refer to Figure 19.15, unless otherwise specified.
The care of the upholstery on the base cushion and back rest is relatively simple, but an
important matter. Accumulation of dirt on the surface eventually turns into a hard gritty
substance which cuts into the surface of the upholstery.
To clean the base cushion and back rest, use warm water and a mild soap, such as Castile.
Work up thin soap suds on a piece of soft cloth and rub the upholstery briskly. Remove the suds
with a damp cloth, using no soap, and finish by wiping the upholstery dry with a soft, dry cloth.
The seat belt (2) assembly should be inspected by the user on a regular basis. Replace the
seat belt (2) immediately if the hardware is worn or damage, straps are nicked or frayed, release
mechanism is not functioning correctly, loose stitching is found, or if the strap material has lost
strength due to the effects of ultraviolet rays.

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 Heating, Ventilation and Air Conditioning 20

Table of Content
20 Heating, Ventilation and Air Conditioning..............................................20-1
20.1 HVAC Cab Distribution ................................................................................. 20-2
(1) Description............................................................................................... 20-2
20.2 HVAC Combi-unit ......................................................................................... 20-4
(1) Description............................................................................................... 20-4
20.3 Heating......................................................................................................... 20-5
(1) Description............................................................................................... 20-5
20.4 Air Conditioning............................................................................................ 20-6
(1) Description............................................................................................... 20-6
(2) Maintenance .......................................................................................... 20-10
(a) Discharging the System .................................................................... 20-12
(b) Charging New or Completely Empty Systems .................................. 20-14
(c) Final Charging of the System............................................................ 20-15
(3) Re-Start Procedure................................................................................ 20-15
(4) Troubleshooting ..................................................................................... 20-16

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20 Heating, Ventilation and Air Conditioning

20 Heating, Ventilation and Air Conditioning

20.1 HVAC Cab Distribution
(1) Description
Numbers in parentheses refer to Figure 20.1, unless otherwise specified.
Heating, Ventilation and Air Conditioning (HVAC) is distributed throughout the operator’s cab
by a system consisting of:
• the HVAC (ELITE) combi-unit (1), installed inside the cab, under the dashboard at the front
LHS. Refer to (1) Description on page 20-4.
• three adjustable ventilation mouths (38, 39 and 40) installed in the LHS of the dashboard
• two adjustable ventilation mouths (36 and 37) installed in the RHS of the dashboard
• two windscreen de-misters (22) installed at the front of the dashboard
• an inlet air filter (29) mounted to the exterior of the cab at the front RHS
• a hose from the inlet air filter (29) to the combi-unit (1)
• five hoses from the combi-unit (1) to the adjustable ventilation mouths
• two hoses from the combi-unit to the windscreen de-misters (22).

23 37
36
22
3 38
4
22 40
39
30
31 21
13
32,33 3
4 24 16
34 14 13
35 17
13 18
14
11,14 19,15
3 41
4 12,13 42
20 25
29 15
28
27 A 3
4
43
3 44
4
10,15 45,46
8
7
26 A
3
4 47
6
5 48
1

49,50
2 53,54
55
2 3
9 1
49,51
52,53
54
49,50,52,53,54

MOT05425

Figure 20.1 - HVAC Cab Distribution

1. HVAC Unit 21. Hose 41. Caps
2. Foam 22. De-misters 42. Screws
3. Washers 23. Screws 43. Control Panel
4. Screws 24. Hose 44. Control Panel Plate
5. Harness 25. Screws 45. Radio Panel Plate

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 Heating, Ventilation and Air Conditioning 20

6. Harness 26. Front Panel 46. Nuts

7. Clamp 27. Interior Cover 47. Control Panel Harness
8. Stick Pads 28. Seal 48. Control Panel Film
9. Cover Plate 29. Air Filter 49. Caps
10. Hose 30. Air Filter Door 50. Two Position Switches
11. Hose 31. Stopper 51. Fan Switch
12. Hose 32. Lock 52. 24V Lamp
13. Double Collars 33. Screws 53. Washers
14. Rings 34. Washers 54. Nuts
15. Double Collars 35. Nuts 55. Control Panel Film
16. Hose 36. Adjustable Ventilation
17. Hose 37. Adjustable Ventilation
18. Hose 38. Adjustable Ventilation
19. Hose 39. Adjustable Ventilation
20. Hose 40. Adjustable Ventilation

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20.2 HVAC Combi-unit

(1) Description
Numbers in parentheses refer to Figure 20.2, unless otherwise specified.
The HVAC (ELITE) combi-unit is installed inside the cab, under the dashboard at the front
LHS and consists of:
• Cover (5)
• the blower filter (4)
• the blower (2)
• the evaporator
• an expansion valve
• the air conditioning supply connection
• the air conditioning return connection
• the heating supply connection
• the heating return connection
The combi-unit is part of the HVAC cab distribution. Refer to (1) Description on page 20-2.

8
7
6
2
3
4
5

MOT05429

Figure 20.2 - HVAC Combi-unit

1. HVAC Combi-unit 4. Filter 7. Control Panel Plate
2. Blower 5. Cover 8. Radio Panel Plate
3. Filter Frame 6. Control Panel

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 Heating, Ventilation and Air Conditioning 20

20.3 Heating
(1) Description
The Heating System consists of: Refer to Heating System Hoses , page 20-5
• Hose (4) from the engine outlet to ball valve (13)
• Supply ball valve (13).
• Hose (2) from the ball valve (13) to HVAC Combi-unit
• HVAC Combi-unit. Refer to (1) Description on page 20-4.
• Hose (3) from HVAC Combi-unit to ball valve (13)
• Return ball valve (13).
• Hoses (5 and 1) from the ball valve (13) to engine inlet.

MOT05423

Figure 20.3 - Heating System Hoses

1. Heater Hose 9. Lockwasher 17. Hose Clamp
2. Heater Hose 10. Bolt 18. Clamp
3. Heater Hose 11. Lockwasher 19. Clamp
4. Heater Hose 12. Nipple 20. Spacer
5. Heater Hose 13. Ball Valve 21. P-clip
6. Bracket 14. Elbow 22. P-clip
7. Bracket 15. Nipple 23. Bolt
8. Bolt 16. Plate 24. Nut

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20 Heating, Ventilation and Air Conditioning

20.4 Air Conditioning

(1) Description
Numbers in parentheses refer to Figure 20.5, unless otherwise specified.
The Air Conditioning System consists of:
• Condenser (2)
• Pipe (8) from the condenser (2) to compressor
• Compressor.
• Pipe (7) from the compressor to HVAC Combi-unit
• HVAC unit.
• Pipe (10) from HVAC unit to receiver drier (1)
• Receiver drier (1)
• Pipe (9) from the receiver drier to the condenser.

NOTICE
• R-134a refrigerant is used this air conditioning system.

Condenser
The purpose of the condenser (2) is to radiate enough heat energy from the compressed high
pressure vaporized R-134a so that the R-134a changes from vapor to liquid. During normal
operation all the high pressure section of the system will be warm or hot, but large quantities
of heat should be radiating from the condenser. Nothing should be permitted to stop or slow
down this radiation of heat. Cooling fins are located on the condenser tubes and fans are used
to circulate cool air around the condenser tubes. Keep all leaves, paper, dirt, etc. clear from
the condenser and condenser filter. The cooling fins should be straight to permit free flow
of air. The condenser is located ahead of the engine radiator and the blockage of air flow
through the radiator also affects the condenser. Bent fan blades, slipping fan drive, inoperable
condenser fan motors, or any other fault that lessens the amount of cool air circulated through
the condenser, should be corrected. The oil, dirt, or antifreeze will act as an insulator that will
inhibit the radiation of heat.
Since the purpose of the condenser is to radiate heat energy, anything that prevents or inhibits
this action 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 and the result will be
pressure that is too high. The condenser, hoses, connections and seals can be damaged by the
high pressure. Pressure sensing safety switches may be activated by the high pressure caused
by the condenser not radiating enough heat.
Compressor
The compressor is designed to compress vapor and can be damaged by non-compressibles
such as dirt, moisture, liquid refrigerant (R-134a), etc. The compressor draws vaporized R-134a
from the evaporator (which maintains the low pressure necessary for proper evaporation)
and compresses the vapor to a high pressure, which is necessary for condensation. The
high pressure vapor then moves into the condenser where heat can be radiated to change
the R-134a back to liquid.
Temperature Control Switch
A thermostat switch senses the temperature of the evaporator and engages or disengages the
compressor drive clutch. The control for this switch is located in the cab.

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 Heating, Ventilation and Air Conditioning 20

Compressor Drive Clutch

The R-134a compressor systems uses a electronically actuated clutch to engage and
disengage drive to the compressor. The drive belt pulley is mounted on a bearing and is free to
rotate without turning the compressor crankshaft any time the electrical power is disconnected.
The compressor will not operate when the pulley is freewheeling. The field coil is energized by
supplying electrical current to the exposed wire. The other end of the coil winding is grounded
to the compressor and equipment frame. Energizing the coil creates a magnetic force that locks
the driven disk to the pulley and drives the compressor.
Receiver Drier
The high pressure liquid R-134a moves from the condenser to the receiver drier (1), where the
R-134a is stored and filtered. Moisture is the major enemy of the air conditioning system and the
desiccant inside the receiver drier will absorb only a small amount. The container of desiccant
inside the receiver drier may break open and contaminate the system if any attempt is made to
dry the desiccant, or, if more moisture is inside the system than the desiccant can absorb.
All efforts should be made to remove all moisture from the system and install a new receiver
drier if its condition is questionable. Installation of a new receiver drier is recommended each
time any part of the R-134a system is open to the atmosphere. Bubbles are observed in the
sight glass on top of the receiver drier during the charging procedure.
A filter screen is located in the receiver drier to stop solid contaminates from leaving the
unit. Blockage of the filter will result in a drop in pressure that will be indicated by a drop
in temperature. Connections of the new receiver drier should be securely capped before
installation to prevent the entrance of moisture (air) while in storage.
Thermostatic Expansion Valve
An expansion valve is installed in the system to lower the pressure before the R-134a enters
the evaporator. The reduction in pressure is done by passing the R-134a through a small hole
(orifice). The size of the orifice must be controlled to compensate for changes in pressure and
temperature. The temperature of R-134a leaving the evaporator is sensed by a thermostatic
sensor that moves the valve seat via a diaphragm and actuating pin.
Evaporator - Heat/Cool
The evaporator (5) is the low pressure, low temperature component where liquid R-134a
absorbs heat from surrounding air. The expansion valve bleeds high pressure R-134a into the
low pressure evaporator. 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 over
the evaporator coil fins. The exchange of heat from the air to the R-134a depends upon the
difference in temperature. During high heat load, such as usually encountered when the system
is first turned on, the temperature difference is great and the R-134a will absorb heat quickly.
The blower fan can be set at its highest setting to circulate large quantities of warm air around
the evaporator. After the cab has cooled, the fan speed should be reduced so that the already
cool air will have a longer time to yield heat to the R-134a as it passes the evaporator coils. The
heater circuits utilize engine coolant at approximately 82 °C (180 °F).
High Pressure and Low Pressure Switches
The pressure switches are electric switches that monitor air conditioner operation. The high
pressure and low pressure switches are activated at preset pressures and engage and
disengage the compressor clutch.

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20 Heating, Ventilation and Air Conditioning

1 3 IN
D

S OUT
4

6
5

MOT05424

Figure 20.4 - Typical Air Conditioning Flow Diagram

1. Compressor 3. Receiver Drier 5. Evaporator
2. Condenser 4. HVAC Combi-unit 6. Expansion Valve

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 Heating, Ventilation and Air Conditioning 20

13
CAB
6
11
19
24
13
18
13 7 25
10 5 11

26,23 4
17
21,26 15,16
20,22

COMPRESSOR
2
12
3

8
12

12
9 1
14

MOT05165

Figure 20.5 - Air Conditioner Lines

1. Receiver Drier 11. Clamp 21. Screw
2. Condenser 12. Clamp 22. Nut
3. Bracket 13. Clamp 23. Nut
4. Bracket 14. Clamp 24. Washer
5. Bracket 15. P-Clip 25. Washer
6. Bracket 16. P-Clip 26. Washer
7. Pipe Assembly 17. Spacer
8. Pipe Assembly 18. Bolt
9. Pipe Assembly 19. Bolt
10. Pipe Assembly 20. Bolt

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20 Heating, Ventilation and Air Conditioning

(2) Maintenance

� CAUTION
• Always wear goggles or glasses to protect your eyes when working around R-134a. R-134a
boils at sea level temperatures of -29.8 °C (-21.6 °F), which means that direct contact with
your skin will produce frostbite. Be very careful when handling R-134a. If R-134a contacts
your skin, wash immediately with plenty of warm water. Remove any contaminated clothing
with caution as it may adhere to the skin. If blistering or continued irritation occurs obtain
immediate medical attention.
• 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 petroleum jelly followed by boric acid rinse. Report
to a hospital or doctor as soon as possible.
• The chemicals of R-134a when burned produce gases that will damage the respiratory
system if inhaled. NEVER SMOKE in an area where R-134a is used or stored. Use hot
water or an approved heated charge cylinder as a heat source if required to force R-134a
into the system. If using water, do not exceed 52 °C (125 °F). Never use direct flame or
electric heaters in direct contact with the R-134a container. High temperatures may result in
raising the pressure to a dangerous level.

NOTICE
• Unit can operate with some bubbles visible, but not milky looking.

1 Periodically clean the condenser coil of debris and dirt using water or air pressure. A
partially blocked condenser coil can reduce the life of the compressor belt and/or clutch.
2 If the system has a heater in the same location as the air conditioning evaporator core,
heater valves should be closed.
3 To check the refrigerant level, run the engine at 1200 rev/min with fans on high speed
and thermostat fully open for a minimum of five minutes. If the clutch is engaged in this
situation, there should be very few bubbles visible in the receiver-drier sight glass.
4 Ensure all hoses and hose clamps are free from contact with sharp metal, moving parts or
near to manifolds.
5 Inspect the condensation drain lines for debris, sharp bends or breaks.
6 Inspect the clutch wire from the thermostat for bare spots.
7 Inspect bolts and nuts on the compressor and the mounting bracket for proper tightness.
8 Check for any air blockages within the system. Clean recirculation filter periodically, by
shaking off dust or by washing in soapy water.
9 If the refrigerant system is broken and there is gas loss due to mechanical damage or there
is any other reason to suspect foreign material ingress, then the receiver/drier should be
replaced.
10 Every 4000 hours, drain, flush and refill the compressor with refrigerant oil specified in (1)
Recommended Lubricants on page 4-16.

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 Heating, Ventilation and Air Conditioning 20

Refrigerant Oil

� CAUTION
• To prevent personal injury always wear rubber gloves when handling refrigerant oils.
• Too much refrigerant oil will dampen the cooling effect and too little refrigerant oil may lead
to compressor failure. If in doubt flush the system.

Oil is required to lubricate the compressor. The oil mixes with the refrigerant and is carried
around the system. The compressor is supplied with an oil charge. However, additional oil is
required, the amount depending on the length of refrigerant hose being used. The quantity
added should be calculated using the following equation:
Amount of oil to add in fl oz. (0.47 x total length of hoses in m) - 2.15

If any component is replaced the following amount of oil should be added to the system;
Condenser add 1 fl oz (28.4 ml)
Drier add 1 fl oz (28.4 ml)
Evaporator add 3 fl oz (85.2 ml)
Compressor add 4.4 fl oz (125 ml)

The oil should be added to the oil filling port of the compressor before the evacuation procedure
is started or by using an oil injector when the system is being charged, observing the following
good practises:
• Only pour the amount required from the container straight into a CLEAN measuring jug and
immediately pour the oil into the compressor.
• Re-cap the container tightly as soon as the required amount has been taken (never leave
an oil container open).
• Do not mix different oils.
Only new oil should be used, because oil that has been exposed to the air will have absorbed
water (hygroscopic).
Use only refrigerant oil as specified in (1) Recommended Lubricants on page 4-16.
System Leak Testing
Recommended Equipment Required: Electronic Leak Detector
Switch off the engine and check all connections throughout the system for leaks. A large leak
point will have an oily or greasy appearance. The refrigerant carries compressor oil with it and
deposits it around the leak area. Check all such points for loose connections and tighten.
Using a suitable leak detector, search for leaks around all joints, connections, seals and control
devices. If a leak is located, purge the system of refrigerant and repair. Fully evacuate and
charge the system to make it operational.

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20 Heating, Ventilation and Air Conditioning

(a) Discharging the System

Recommended Equipment Required: Portable High Vacuum Charging Station Suitable
Canister or Standard Service Manifold (Refer to Figure 20.6)

Figure 20.6 - Standard Service Manifold

A. Vacuum Gauge 1. Vacuum Pressure 5. Refrigerant Liquid Port
B. Low Pressure Gauge 2. Suction Line 6. Vacuum Connection
C. High Pressure Gauge 3. Discharge Line
D. Charging Cylinder 4. Refrigerant Gas
Pressure

To eliminate system contaminants from an air conditioning system the entire system must be
discharged. This means removing all of the refrigerant and cleansing all contamination (air and
moisture) from the system components. If any of the major system components are to be
repaired or replaced, the system must also be completely discharged.

� WARNING
• The machine must not be running during this procedure. Be sure to have adequate
ventilation during this operation. Do not discharge refrigerant near an open flame.

NOTICE
• Refer to all WARNINGS listed in (8) Maintenance Safety on page 2-25 prior to discharging
the system.

Numbers and letters in parentheses refer to Figure 20.6, unless otherwise specified.

PROCEDURE
1. Position the machine in a level work area, apply the parking brake and switch off the engine.
2. Block all road wheels and place the battery master switch in the 'OFF' position.
3. Raise the hood. Refer to (3) Switches on page 15-75
4. Connect the service hose (yellow) to the centre access port on the manifold gauge and to
the vacuum connection (6) on the vacuum pump. Ensure that the system is empty before
connecting the vacuum so that refrigerant does not enter the pump.

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 Heating, Ventilation and Air Conditioning 20

5. Tighten down (turn clockwise) both high and low side valves on the gauge manifold to the
closed position. Remove protective caps from the service ports on the compressor.
6. Connect both service hoses from the two fittings (2 & 3) in the bottom of the manifold to the
two service ports on the compressor. High side (red) to compressor discharge valve, low
side (blue) to compressor suction valve.
7. Switch vacuum pump on, open vacuum pressure valve (1) until less than 6 mb is reached
on vacuum gauge (A). The vacuum gauge (A) should remain at this value when the vacuum
pressure valve (1) is closed to indicate that there are no leaks.
8. Open the low side hand valve on the manifold and the vacuum pressure valve (1) and
watch that the gauges start to register that a vacuum is being drawn. If the gauges do not
register the vacuum then a blockage is present. Open the high side and pump down until
a vacuum of 10 mb is achieved.
9. After 10 - 15 minutes close the vacuum pressure valve (1) and allow the system to settle,
the vacuum gauge (A) should not alter. If the vacuum is held, no leaks or refrigerant
contaminated oil is present. If not, open the vacuum pressure valve (1) and continue
pumping, checking at regular intervals. If there is a leak, check all fittings and tighten if
necessary.
10. Tighten down (turn clockwise) both high and low side valves on the gauge manifold to the
closed position, remove the service hose (yellow) from the vacuum connection (6) on the
vacuum pump and switch the pump 'OFF’.
11. Connect the service hose (yellow) to the R-134a cylinder. Open the cylinder valve and then
purge air from the hose at the manifold connection.
12. Open the low side hand valve on the manifold slowly, until the low pressure gauge (B) is
at bottle pressure. Watch the high pressure gauge (C) rise to ensure that no blockage is
present. Close the manifold valve and cylinder, then disconnect the hose from the cylinder.
13. Connect the service hose (yellow) to the Nitrogen cylinder. Open the neck valve on the
cylinder and set the regulator pressure such that it is higher than the system pressure, then
purge the hose. Open the low pressure valve on the manifold, as the pressure rises open
the high pressure valve on the manifold and allow a system pressure of 10 bar (150 psig) to
be reached. Close all the valves. Using a suitable electronic leak detector, check all joints
in the air conditioning system for leaks. Tighten any loose joints and re-test if necessary.
14. Vent the refrigerant mix to atmosphere by removing the service hose (yellow) from the
Nitrogen cylinder and opening the low pressure valve on the manifold. Re-evacuate the
system to below 6 mb (steps 7 to 10).
15. Lower the hood assembly and remove wheel blocks.

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20 Heating, Ventilation and Air Conditioning

(b) Charging New or Completely Empty Systems

Recommended Equipment Required: Portable High Vacuum Charging Station Electronic
Leak Detector or Standard Service Manifold.

NOTICE
• Refer to all WARNINGS listed in (8) Maintenance Safety on page 2-25 prior to charging
the system.
• The charging procedure must be done in ambient temperatures above 15.5 °C (60 °F) with
the R-134a canister temperature equal to the outside ambient temperature.
• Never charge with liquid R-134a. Charge on the low pressure side only.

Numbers and letters in parentheses refer toFigure 20.6, unless otherwise specified.

PROCEDURE
1. Shut off engine and block all road wheels.
2. Raise the hood. Refer to (3) Switches on page 15-75
3. Remove protective caps from 'quick coupler' valves on the rear of the compressor.
4. Connect the low pressure gauge hose (blue hose and gauge) to suction or low side fitting
on the compressor. The suction side can be identified by the size of the hose connected to
the fitting. This will be the largest diameter hose of the system.
5. Connect the high pressure gauge hose (red hose and gauge) to discharge or high side
fitting on the compressor.
6. Connect the yellow supply hose to the suction port on the vacuum pump.
7. Open both sides of the gauges, low and high, completely.
8. Start the vacuum pump to evacuate the complete air conditioning system.
9. Run the vacuum pump for approximately 30 minutes. Ideal gauge readings should be
29.92 inches of mercury. The pressure will vary with altitude; it will be approximately 0.03
bar (0.5 lbf/in²) less for each 305 m (1000 ft) of elevation.
10. Before disconnecting the power supply from the vacuum pump, close both high and low side
gauges. Remove the yellow hose from the vacuum pump and connect to R-134a source.
11. Open R-134a source. Loosen, but do not remove, the yellow supply hose at manifold on
gauges to remove all air in the yellow supply hose, replacing the air with R- 134a. This is
done in a few seconds. Tighten the yellow supply hose.
12. Open the low side of R-134a gauges slowly. When the gauge reads zero open both sides
completely. Vacuum in the system will draw R-134a gas into the system. Hold until both
gauge readings equalize.

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 Heating, Ventilation and Air Conditioning 20

(c) Final Charging of the System

NOTICE
• It is normal for bubbles to increase during clutch cycling or system start-up.
• Some R-134a will escape as the hoses are being removed.

PROCEDURE
1. Start the engine and run at engine idle speed.
2. Turn the air conditioning system on with the thermostat set on maximum cooling and fan
on high speed.
3. At this point a visual inspection must be made of the sight glass on top of the receiver-drier.
Allow charging to continue until 1.1 kg (2.43 lbs) of refrigerant has been added. The
charging process can be speeded up by running the engine at a fast idle.
4. The sight glass on top of the receiver/drier will be substantially free of bubbles.
5. With the system completely charged, shut off the 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 from the filling ports on the compressor.
6. The system is completely charged when.
a. The suction pressure on the gauge is approx. 20 - 30 psig at 25 °C ambient.
b. The correct weight of refrigerant has been added i.e. 1.1 kg (2.43 lbs).
c. The correct sub-cooling can be measured at the condenser, approx. 5 - 7 °C.
7. Replace the protective caps on the hoses and valve fittings.
8. Lower the hood assembly, refer to (3) Switches on page 15-75 and remove wheel blocks.

(3) Re-Start Procedure

If the machine has been idle for an extended period of time (2 weeks), the refrigerant in the
air conditioning unit converts from a gas to a liquid. This puts the compressor unit under a
great deal of strain trying to compress a liquid instead of a gas, and could cause a failure in
the air conditioning unit. The following commissioning procedure allows the air conditioning
unit to achieve normal operating parameters.

PROCEDURE
1. Start the machine and allow it to run until the engine is at a normal operating temperature of
80 °C (176 °F)
2. Turn the blower control to setting 1.
3. Turn on the air conditioning unit on for 5 seconds then off for 5 seconds.
4. Repeatedly switch the air conditioning on and off for at least 1 minute. There should be at
least 12 repetitions.
5. Commissioning the air conditioning unit is complete and ready for use.

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20 Heating, Ventilation and Air Conditioning

(4) Troubleshooting
Preliminary Checks
Before any checks are carried out on the refrigerant circuit the following checks should be made:
1 Check if the compressor drive belt is serviceable and correctly tensioned.
2 Check if the condenser and engine radiator are not blocked by debris. Clean with
compressed air or water if necessary.
3 Check that the condenser fins are not flattened or damaged, the fins must allow air to
pass freely.
4 Check the cab fresh air inlet filter for blockage.
5 Check that, with the ignition switch on (engine not running), the blower operates over
whole speed range.
6 Check that, with the ignition switch on (engine not running), the blower and air conditioning
is switched on, the compressor clutch engages.
Charge level: It is not possible to check refrigerant charge level with R134a systems. Any
bubbles seen at the sight glass on the receiver drier may be bubbles of oil and are perfectly
normal.
Table 20.1 - Air Conditioning Troubleshooting
Condition Problem Remedy
1 - Belt Trouble
Slipping Loose Adjust belt to 10 mm
(0.39 in) depression
Overcharge Correct the charge
Air in system Evacuate and re-charge
Excessive wear Pulley not aligned Align pulley
Belt too tight Adjust or replace
Bad idler bearing Replace idler bearing
Belt wrong width Replace with correct belt
2 - Vibration/Noise
in Compressor
Vibration/noise Stuck compressor or clutch Replace
Vibration Overcharge Correct the charge
Air in system Evacuate system and re-charge
Compressor mounting Tighten
or belts loose
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 Clutch loose Tighten
or disengaged
Noise Clutch rubbing field coil Align clutch
Faulty belt Replace belt
Compressor oil level low Add oil

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 Heating, Ventilation and Air Conditioning 20

Condition Problem Remedy

Chatter/Knock Valve plate broken Repair or replace
3 - Noise - Evaporator
Rubbing/scraping Fan blade or blower Repair or replace
Hissing Low charge/leak Correct charge/repair leak
Chatter/Knocking Expansion valve Replace
Noisy case Loose brackets/screws Tighten
Motor squeal Dry bearings Tighten
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 Replace. Clean and tighten
or bad wiring connections connections
motor inoperable
Tight motor bearing Repair or replace motor
Switch open or shorted Repair or replace switch
Blown fuse Check fuse, replace if necessary
Motor seized Check rotors are free to turn
Loose wire/connection Check connectors at blower.
Check there is power across
terminals
Motor failure Remove and replace blower
Faulty control Check system with replacement
Module damaged Check system with replacement
module inside main weldment
Slow running blower Shaft binding Replace motor - worn bearings
Wheel misaligned Replace
Bad blower switch Replace blower
Insufficient current Install larger alternator
Clutch inoperable Defective relay Replace
Loose connection Clean and tighten connection
Broken wire - ground Repair wire
Shorted or open field Replace field
Blown fuse Check fuse, replace if necessary
Faulty freeze protection When temperature is above
thermostat cutoff temp, thermostat should
be closed. If faulty, replace
thermostat

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20 Heating, Ventilation and Air Conditioning

Condition Problem Remedy

Faulty compressor If compressor clutch is being
fed power then it should be
engaged. If not, check wiring.
Replace the compressor if faulty
Faulty pressure switch If the binary pressure switch
detects pressure within range,
circuit should be closed. If
the switch is not in a closed
circuit it indicates incorrect
pressure or faulty
6 - Air Conditioning System
Trouble - Gauges must
be connected
High head pressure Overcharge of refrigerant Purge system as necessary
Air in system Evacuate and re-charge
Condenser clogged Clean condenser
Low head pressure Undercharge of refrigerant Complete charge
Bad compressor valve plate Repair or replace
or gasket
Low suction pressure Restriction in drier Replace drier
Restriction in lines Clean lines
Restriction in expansion valve Replace expansion valve
and drier
Improper expansion valve Replace expansion valve
in charge
Refrigerant leak Inspect lines and fittings.
Tighten, repair or replace

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 Body 21

Table of Content
21 Body...........................................................................................................21-1
21.1 Body and Mounting ...................................................................................... 21-2
(1) Description............................................................................................... 21-3
(2) Operation................................................................................................. 21-4
(3) Removal .................................................................................................. 21-5
(4) Installation ............................................................................................... 21-6
(5) Body Shimming ....................................................................................... 21-7
(6) Raise the Body ........................................................................................ 21-8
(7) Lower the Body........................................................................................ 21-9
21.2 Body Prop .................................................................................................. 21-10
(1) Removal ................................................................................................ 21-10
(2) Installation ............................................................................................. 21-11
(3) Deploy the Body Prop............................................................................ 21-12
(4) Lower the Body Prop ............................................................................. 21-13
21.3 Proximity Switch......................................................................................... 21-15
(1) Description............................................................................................. 21-15
(2) Removal ................................................................................................ 21-15
(3) Installation ............................................................................................. 21-16
21.4 Mudflaps..................................................................................................... 21-18
(1) Description............................................................................................. 21-18
(2) Removal ................................................................................................ 21-18
(3) Installation ............................................................................................. 21-19
21.5 Chain Operated Tailgate Option................................................................. 21-20
(1) Description............................................................................................. 21-20
(2) Removal ................................................................................................ 21-22
(3) Installation ............................................................................................. 21-23
(4) Maintenance .......................................................................................... 21-25

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21 Body

21 Body
21.1 Body and Mounting
17

2
1 8

10
7
4 3
6 12
5
11

30
28
29
26
6

1
27
6
25

14
13
21
20

18

1
22
15
16 20
23 19
24
MOT04351_p

Figure 21.1 - Body and Mounting

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 Body 21

1. Body Assembly 11. Bolt 21. Locknut

2. Bushing 12. Washer 22. Pin
3. Shim 13. Spacer 23. Nut
4. Shim 14. Guide Plate 24. Bolt
5. Bolt 15. Washer 25. Locknut
6. Washer 16. Bolt 26. Bolt
7. Locknut 17. Shim 27. Bolt
8. Body Pad 18. Body Prop 28. Plate
9. Hinge Pin 19. Bolt 29. Plate
10. Grease Fitting 20. Washer 30. Proximity Switch

(1) Description
The standard body is an all welded construction with all wear plates fabricated from high
hardness (min. 360 BHN) 1000 MPa (145 000 lbf/in²) yield strength material. Angled lower
body sides reduce body impacts when loading and a tail chute angle of 25° provides good load
retention when travelling without a tailgate. Refer to 3.2 Carrying Capacity on page 3-3.
The body is pivoted at the rear of the trailer frame and is operated by two single stage, double
acting body cylinders which are cushioned at both ends of the stroke to reduce impact shocks.
The body cylinders raise the body to a tipping angle of 65° in 12.5 seconds and power down the
body in 8 seconds.
Table 21.1 - Plate Thicknesses
Plate Thickness
Floor and Tailchute 15 mm (0.58 in)
Sides 12 mm (0.47 in)
Front 8 mm (0.39 in)

Table 21.2 - Volume

Volume
Struck (SAE) 17.44 m3 (22.8 yd.3)
Heaped 2:1 (SAE) 23.00 m3 (30.3 yd.3)

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21 Body

(2) Operation

� CAUTION
• The body control lever must remain in the 'NEUTRAL ' position until it is necessary to
operate the body again. Failure to comply to this could result in overheating the hydraulic
oil and failure of the hydraulic system components

NOTICE
• A proximity switch (30) prevents the body (1) being fully powered down on to the chassis.
At a predetermined height, the sensor automatically defaults the body control valve to the
'FLOAT' condition. Refer to Figure 21.1.

The body control lever is mounted on the right hand side dash panel, next to the transmission
shift controller.
When the body control lever is operated, a voltage is sent to the MCU, which converts voltage
to current. This current controls the body raise and lower proportional pressure control valves,
producing a pilot pressure to shift the control spool in the main hydraulic valve. This allows
the flow of oil to reach the body cylinders, to either raise or lower the body. Refer to 13.1
Description on page 13-2.
The three operating positions of the lever from front to rear are:
• Lower Push the lever forward to this position to lower (power-down) the body. Keep the
lever pushed forward until the body has fully lowered then release the lever and the lever
will return to the Neutral position. If the body is above the proximity switch, releasing the
lever will stop lowering and the lever will return to the Neutral position. When the body
reaches the proximity switch, the lever springs back the Neutral position and power down
is ramped back to allow the body to float down onto the chassis.
• Neutral The middle default position of the lever. The lever will return to this position when
released during raising or lowering and will remain in this position when released. The
body should be fully lowered and in the Neutral position while the machine is in motion.
If the body is above the proximity switch, the body will stop raising or lowering and hold
the body at any desired height. If the body is below the proximity switch, the body will
float down onto the chassis.
• Raise Pull the lever back to this position to raise the body. Keep the lever pulled back until
the body has fully raised to 65° then release the lever and the lever will return to the Neutral
position. If the body is above the proximity switch, releasing the lever will stop raising and
the lever will return to the Neutral position.

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 Body 21

(3) Removal
Numbers in parentheses refer to Figure 21.1, unless otherwise specified.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• The approximate weight of the body (1) is 5 400 kg (11 905 lb).
• Do not remove body pads (8) and shims (3 and 4) unless the body pads are being renewed.

PROCEDURE
1. Position the vehicle in a level work area, ensure the body is fully lowered, apply the parking
brake and switch off the engine. Turn steering wheel several times to relieve any pressure
in the steering circuit.
2. Block all road wheels and place the battery master switch the 'OFF' position.
3. Remove the upper pins securing the body cylinders to the body (1) and secure the body
cylinders clear of the body (1). Also refer to (1) Description on page 13-19.
4. Using suitable lifting equipment, sling the body (1) assembly at the four lifting points and
take an initial strain.
5. Remove the bolts (35) and washers (36) securing the body hinge pins (9) through the body
(1) and pin mounting bores (via bushing, 2).
6. Remove the body hinge pins (9) and shims (17) from the body (1) and remove the body (1)
assembly from the vehicle. If necessary, remove the bushing (2) from the pin mounting
bores.
7. If required, remove the locknuts (7), washers (6) and bolts (5) securing the body pads
(8) and shims (3 and 4) to the body (1) assembly. Remove and discard the body pads
(8) and shims (3 and 4).

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21 Body

(4) Installation
Numbers in parentheses refer to Figure 21.1, unless otherwise specified.

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

NOTICE
• Tighten all the fasteners to the standard torques listed in Standard Bolt and Nut Torque
Specifications section.
• The approximate weight of the body (1) assembly is 5 400 kg (11 905 lb).

PROCEDURE
1. If removed, install the bushings (2) in the pin mounting bores.
2. Using suitable lifting equipment, sling the body (1) assembly and position it over the trailer
frame.
3. Align the body hinge pin (9) shafts in the body (1) with bushing (2) bores in the trailer
frame. Install the body hinge pins (9) and shims (17), and secure them with the bolts (35)
and washers (36).
4. Secure the body cylinders to body (1) assembly with pins and mounting hardware removed
during removal. Refer to (6) Installation on page 13-24.
5. Lubricate the body hinge pins (9) and body cylinder pins with lubricant specified in (1)
Recommended Lubricants on page 4-16. Lubricate slowly until excess lubricant is observed.
6. If removed, install body pads (8) and body guide plates (14) on the body (1). Refer to
(5) Body Shimming on page 21-7.
7. Remove the lifting equipment from the body (1) and the wheel blocks from all road wheels.
8. Place the battery master switch in the ‘ON’ position.
9. Start the engine. Refer to 5.11 Starting on page 5-27.
10. Check for correct operation of the body (1) assembly, by raising and lowering the body
several times. Refer to (6) Raise the Body on page 21-8 and (7) Lower the Body on page
21-9

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 Body 21

(5) Body Shimming

Numbers in parentheses refer to Figure 21.1, unless otherwise specified.

NOTICE
• Tighten all fasteners to 22.3 Standard Bolt and Nut Torque Specifications on page 22-5.
• When it becomes necessary, body pads (8) should be replaced as a set to maintain load
distribution along the chassis. Existing body pads will have taken a compression 'set' and a
new pad shimmed to match existing pads will not carry its share of the load, resulting in
uneven load distribution along the chassis.

PROCEDURE
1. Raise the body (1) clear of the trailer frame. Refer to (6) Raise the Body on page 21-8.
2. Lay the body pads (8) (metal face down), roughly in position on the frame.
3. Lower the body (1) on to the body pads (8). Refer to (7) Lower the Body on page 21-9.
4. Centralize the body (1) to the frame and place shims (3 and 4) under the front two body
pads (8) until all other pads are clear of the body (1).
5. Slide shims (3 and 4) under the other body pads (8) until they just make contact with the
body (1).
6. Raise the body (1).
7. Install the body pads (8) and shim packs (3 and 4) to their relative brackets on the body (1)
securing them with bolts (5), washers (6) and locknuts (7).
8. Lower the body (1).
9. Check the shimming.
10. Install the body guide plates (14) with spacers (37) to the mounting brackets on the body (1)
setting the gap between plates (14) and the frame at 5 - 10 mm (0.2 - 0.4 in).
11. Secure the plates (14) and spacers (37) to the mounting brackets with the bolts (16) and
washers (15).

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21 Body

(6) Raise the Body

Numbers in parentheses refer to Figure 21.1, unless otherwise specified. Also refer to (1)
Description on page 13-15.

� WARNING
• Before raising the body make sure that the body is empty.
• Never place yourself under an unsupported body due to the potential for crush.

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘ON’ position.
3. Check that the parking brake is applied.
4. Start the engine.
5. Ensure transmission is in neutral.
6. Pull the body control lever back to the raise position.
» The body raises and the body up screen displays on the menu screen of the dashboard
display.
7. Once the body is fully raised, release the body control lever.
» The body stops raising and the body control lever returns to the neutral position.
8. If the body is to remain raised, Deploy the Body Prop. Refer to (3) Deploy the Body Prop
on page 21-12. Or, if the body is to be immediately lowered, lower the body. Refer to
(7) Lower the Body on page 21-9
9. Switch off the engine.
10. Remove the ignition key.
11. Attach ‘Do Not Operate’ or similar sign to the ignition switch.
12. Put the battery master switch to the OFF position.

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 Body 21

(7) Lower the Body

Numbers in parentheses refer to Figure 21.1, unless otherwise specified. Also refer to (1)
Description on page 13-15.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Place the battery master switch in the ‘ON’ position.
2. Check that the parking brake is applied.
3. Remove ‘Do Not Operate’ or similar sign from the ignition switch.
4. Start the engine.
5. Ensure transmission is in neutral.
6. If the body (1) has been left raised, raise the body (1) off the deployed body prop (18) and
lower the body prop (18). Refer to (4) Lower the Body Prop on page 21-13.
7. Push the body control lever forward to the lower position.
» The body lowers.
8. Once the body is fully lowered, release the body control lever.
» The body stops lowering, the body control lever returns to the neutral position and the
body down screen displays on the menu screen of the dashboard display.
9. Switch off the engine.
10. Remove the ignition key.
11. Put the battery master switch to the OFF position.

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21 Body

21.2 Body Prop

(1) Removal
Numbers in parentheses refer to 21.1 Body and Mounting on page 21-2 unless otherwise
specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘ON’ position.
3. Check that the parking brake is applied.
4. Start the engine.
5. Ensure transmission is in neutral.
6. Raise the Body (1). Refer to (6) Raise the Body on page 21-8.
7. Attach suitable lifting equipment to the body (1) and take the weight.
8. Shut down engine.
9. Place the battery master switch in the ‘OFF’ position.
10. Gain access to the work area.
11. Attach suitable lifting equipment to the body prop (18) and take an initial strain.
12. Pull the pin (22) to release the body prop (18).
13. Remove the locknut (21), bolt (19) and washers (20).
14. Using standard lifting equipment, lift the body prop (18) from the trailer.
15. Move the body prop (18) to a clean maintenance area.

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 Body 21

(2) Installation
Numbers in parentheses refer to 21.1 Body and Mounting on page 21-2 unless otherwise
specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘ON’ position.
3. Check that the parking brake is applied then start the engine.
4. Ensure transmission is in neutral.
5. Raise the Body (1). Refer to (6) Raise the Body on page 21-8.
6. Attach suitable lifting equipment to the body (1) and take the weight.
7. Shut down engine.
8. Place the battery master switch in the ‘OFF’ position.
9. Gain access to the work area.
10. Attach suitable lifting equipment to the body prop (18).
11. Using lifting equipment, align the body prop (18) with its attachment point on the rear
chassis.
12. Install and torque tighten the bolt (19), washers (20) and locknut (21) .
13. Install the pin (22) to secure the body prop (18).
14. Detach the lifting equipment from the body (1).

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21 Body

15. Place the battery master switch in the ‘ON’ position.

16. Start the engine.
17. Lower the Body (1). Refer to (7) Lower the Body on page 21-9.
18. Shut down engine.

(3) Deploy the Body Prop

Numbers in parentheses refer to 21.1 Body and Mounting on page 21-2 unless otherwise
specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

� WARNING
• Before raising the body make sure that the body is empty.
• Never place yourself under an unsupported body due to the potential for crush.

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘ON’ position.
3. Check that the parking brake is applied.
4. Start the engine.
5. Ensure transmission is in neutral.
6. Raise the body (1). Refer to .(6) Raise the Body on page 21-8.
7. Gain access to the work area.
8. Pull the pin (22) to release the body prop (18).
9. Raise the body prop (18) from its stowed position flush to the chassis to its deployed
position (past the vertical). Refer to Figure 21.2

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 Body 21

Figure 21.2 - Raise the Body Prop

10. Lower the body (1) onto the deployed body prop (18). Refer to (7) Lower the Body on
page 21-9.
11. Switch off the engine.
12. Remove the ignition key.
13. Attach ‘Do Not Operate’ or similar sign to the ignition switch.
14. Put the battery master switch to the OFF position.

(4) Lower the Body Prop

Numbers in parentheses refer to 21.1 Body and Mounting on page 21-2 unless otherwise
specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.

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21 Body

2. Place the battery master switch in the ‘ON’ position.

3. Check that the parking brake is applied.
4. Remove ‘Do Not Operate’ or similar sign from the ignition switch.
5. Start the engine.
6. Ensure transmission is in neutral.
7. Raise the body (1) off the deployed body prop (18). Refer to (6) Raise the Body on page
21-8.
8. Gain access to the work area.
9. Lower the body prop (18) from its deployed position to its stowed position flush with the
chassis.
10. Install the pin (22) to secure the body prop (18).
11. Lower the body (1) onto the chassis. Refer to (7) Lower the Body on page 21-9.
12. Switch off the engine.
13. Put the battery master switch to the OFF position.

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 Body 21

21.3 Proximity Switch

(1) Description
Numbers in parentheses refer to 21.1 Body and Mounting on page 21-2 unless otherwise
specified.
A proximity switch (30) installed on the chassis monitors movement of the body (1) when in
close proximity to the chassis. When the body (1) is being:
• Raised the switch prevents raising being stopped until the body has cleared the switch.
• Lowered the switch prevents the body (1) being fully powered down onto the chassis by
allowing the body (1) to float down to the chassis over the last few centimeters of travel.
(2) Removal
Numbers in parentheses refer to 21.1 Body and Mounting on page 21-2 unless otherwise
specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Raise the Body (1). Refer to (6) Raise the Body on page 21-8.
3. Shut down engine.
4. Place the battery master switch in the ‘OFF’ position.
5. Gain access to the work area.
6. Disconnect electrical connector (WA1.B15).
7. Remove the proximity switch (30):
a. Remove the bolts (26) and washers (6).
b. Separate the plate (28) from its attaching point on the chassis.
c. Separate the proximity switch (30) from the plate (28).
8. If necessary remove the plate (29):
a. Remove the nut (25), bolt (27) and washers (6).

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21 Body

b. Separate the plate (29) from its attachment point on the bottom of the body (1).

(3) Installation
Numbers in parentheses refer to 21.1 Body and Mounting on page 21-2 unless otherwise
specified.

� DANGER
• Never place yourself under an unsupported body due to the potential for crush.

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

� CAUTION
• When the battery master switch is selected OFF the adjacent red LED remains ON for a
further 60 seconds. When the LED is ON electrical power is still connected to the truck.
• Hydraulic fluid pressure will remain within the body hoist system after engine shutdown.
Operate the treadle pedal continuously until the pressure has dissipated before carrying out
any work on the hydraulic system or serious injury could result.

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. If necessary, raise the body (1). Refer to (6) Raise the Body on page 21-8.
3. Shut down engine.
4. Place the battery master switch in the ‘OFF’ position.
5. Gain access to the work area.
6. If necessary, install the plate (29):
a. Align the plate (29) with its attachment point on the bottom of the body (1).
b. Install the bolts (27), washers (6) and nuts (25).
c. Torque tighten the bolts (27).
7. Install the proximity switch (30):
a. Fit the proximity switch (30) to the plate (28).
b. Align the plate (28) with its attaching point on the chassis.
c. Install the bolts (26) and washers (6).
d. Torque tighten the bolts (26).

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 Body 21

8. Disconnect electrical connector (WA1.B15).

9. Place the battery master switch in the ‘ON’ position.
10. Start the engine.
11. Lower the Body (1). Refer to (7) Lower the Body on page 21-9.
12. Shut down engine.
13. Place the battery master switch in the ‘OFF’ position.
14. Ensure the gap between the proximity switch (30) and the plate (29) is no more than 15 mm.

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21 Body

21.4 Mudflaps
(1) Description

1 1
5 6 6 4

7 6 8 4

2
2

MOT04607_p

Figure 21.3 - Trailer Mudflaps

1. Mounting Strip 4. Nut 7. Bolt
2. Stiffener 5. Bolt 8. Washer
3. Mudflap 6. Washer

(2) Removal
Numbers in parentheses refer to Figure 21.3 unless otherwise specified.

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

NOTICE
• The procedure to remove the LH and RH are identical. The procedure for the LH is detailed
below; the RH procedure is identical.
• Stiffener (2) is also used to retain mudflap (3) in the stowed position for transportation.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.

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 Body 21

2. Shut down engine.

3. Place the battery master switch in the ‘OFF’ position.
4. Support LH mudflap (3).
5. Remove nuts (4), bolts (5) and washers (6) from the mounting strips (1) securing the LH
mudflap (3) to the body.
6. Separate the LH mudflap (3) from the body.
7. If necessary, remove nuts (4), bolts (7), washers (6) and washers (8) to separate the
stiffeners (2) from the LH mudflap (3).
8. Move the LH mudflap (3) to a clean maintenance area.

(3) Installation
Numbers in parentheses refer to Figure 21.3 unless otherwise specified.

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

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.

PROCEDURE
1. Position the machine on a level work area, apply the parking brake and block all wheels
securely.
2. Place the battery master switch in the ‘OFF’ position.
3. Gain access to the work area.
4. If necessary, install bolts (7), washers (6), washers (8) and nuts (4) to attach the stiffeners
(2) to the LH mudflap (3).
5. Lift the LH mudflap (3) into position.
6. Align the LH mudflap (3) with the body.
7. Install bolts (5), washers (6), nuts (4) and mounting strips (1) to secure the LH mudflap
(3) to the body.
8. Torque tighten the bolts (5).

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21 Body

21.5 Chain Operated Tailgate Option

(1) Description

22 26

16,19
15

15

A
11
25

30
31

17
21
12
27

20 29
23

10
9
26
25
24

2
7

18 13
4
8

14
5
28

15
16
15

19
7

5
6

3
1
9
20 10
12

18 14
11

13

MOT05420

Figure 21.4 - Chain Operated Tailgate Assembly (Option)

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 Body 21

1. LH Tailgate Arm 12. Washer 23. Tie Plate

2. RH Tailgate Arm 13. Bolt 24. Bolt
3. Rear Tailgate 14. Locknut 25. Washer
4. Locking Plate 15. Shackle 26. Nut
5. Stub Shaft 16. Chain 27. Bolt
6. Bolt 17. Grease Fitting 28. Lifting Lug
7. Lockwasher 18. Washer 29. Adaptor
8. Shim 19. Spiral Wrap 30. Elbow
9. Spherical Bearing 20. Bolt Locking Plate 31. Hose Assembly
10. Thrust Plate 21. Coupling
11. Bolt 22. Support Assembly

Numbers in parentheses refer to Figure 21.4, unless otherwise specified.

The chain operated tailgate assembly, when fitted, features a rear tailgate (3), two tailgate
side arms (1 and 2), trunnion mounted to the stub shafts (5) on the sides of the body. Side
chain assemblies connect the front ends of the side arms (1 and 2) to support assemblies
(22) bolted to the suspension equalization frames. As the body is lifted, the chains rotate the
side arms (1 and 2) about the axes of the stub shafts (5), thus maintaining the side arms in
an approximately horizontal attitude, and opening up a gap between the rear tailgate (3) and
the rear end of the body.

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21 Body

(2) Removal
Numbers in parentheses refer to Figure 21.4, unless otherwise specified.

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

� CAUTION
• The light goes out after 60 seconds when the Battery Master Switch is selected OFF. When
the light is ON electrical power is still connected to the truck.

PROCEDURE
1. Position the vehicle in a level work area, ensure the body is fully lowered, apply the parking
brake and switch off the engine. Turn steering wheel several times to relieve any pressure
in the steering circuit.
2. Block all road wheels and place the battery master switch the 'OFF' position.
3. Attach lifting tackle to the attachment point on the top of the tailgate (3) and take up the
slack.
4. Undo and remove the bolts (13) with nuts (14) and washers (18) securing the locking plates
(4), tailgate side arms (1 and 2) and rear tailgate (3) together, and remove the locking plates
(4), if necessary. The side arms (1 and 2) are applied with a retaining compound (Loctite™
648) on assembly to the tailgate (3), and may not readily be separated from the tailgate (3).
5. Remove the rear tailgate (3) to a prepared area.
6. Transfer the lifting tackle to one of the tailgate side arms (1 or 2) and take up the slack.
7. Disconnect the shackle (15) at the lower end of the respective chain (16) from the location
on the respective support assembly (22).
8. Bend down the corners of the locking plate (20) to allow the bolts (11) and washers (12) to
be removed. Remove the adapter (29) from the locking plate. Undo and remove elbow
(30), hose (31) and coupling (21). Undo and remove the bolts (11), washers (12), locking
plate (20), thrust plate (10). Discard the locking plate (20) and fit a new one on assembly.
9. Carefully manipulate the tailgate side arm (1 or 2) off the stub shaft (5), and remove it
to a prepared area.
10. Remove the spherical bearing (9) from the aperture of the tailgate side arm (1 or 2), if
required. The spherical bearing is an interference fit in the arm and therefore it will be
necessary to use a bearing puller to assist in the removal process.
11. Transfer the lifting tackle to the other tailgate side arm (2 or 1) and take up the slack.
12. Disconnect the shackle (15) at the lower end of the respective chain (16) from the location
on the respective support assembly (22).
13. Bend down the corners of the locking plate (20) to allow the bolts (11) and washers (12) to
be removed. Undo and remove the bolts (11), washers (12), locking plate (20), thrust plate
(10). Discard the locking plate (20) and fit a new one on assembly.
14. Carefully manipulate the tailgate side arm (1 or 2) off the stub shaft (5), and remove it
to a prepared area.

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 Body 21

15. Remove the bush (9) from the aperture of the tailgate side arm (1 or 2), if required. The
bush is an interference fit in the arm and therefore it will be necessary to use a bearing
puller to assist in the removal process.
16. Remove the bolt (24) with nut (26) and washer (25) securing one of the tie plates (23) to
the lug on the bottom of the respective equalization beam.
17. Support the weight of the tie plate (23), then undo and remove the bolt (27) with nut (26)
and washer (25) securing the tie plate (23) to the support assembly (22). Remove the
tie plate (23) to a prepared area.
18. Support the weight of the support assembly (22), then undo and remove the bolts (24) with
nuts (26) and washers (25) securing the support assembly (22) to the lugs on the top of the
equalization beam. Remove the support assembly (22) to a prepared area. Repeat steps
16 - 18 for the other support assembly (22) and tie plate (23).
19. Undo and remove the four bolts (6) with lock washers (7) securing one of the stub shafts
(5) to the side of the body. Remove the stub shaft to prepared area. Repeat this step for
the stub shaft on the other side arm (1 or 2 respectively).

(3) Installation
Numbers in parentheses refer to Figure 21.4, unless otherwise specified.

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

NOTICE
• Tighten all the fasteners to the standard torques listed in 22.3 Standard Bolt and Nut Torque
Specifications on page 22-5.
• The spherical bearings (9) may be a tight fit in the LH and RH side arms (1 and 2). Take care
not to damage the bearings if using mechanical assistance during the installation process.

PROCEDURE
1. Apply Loctite™ 243 (anaerobic thread lock) to bolts (6), then secure both stub shafts (5) to
the side walls of the body using the bolts (6) and lock washers (7).
2. Attach the support assemblies (22) to the lugs on the top of the left-hand and right-hand
equalization beams using the bolts (24), washers (25) and nuts (26).
3. Attach the tie plates (23) to the support assemblies (22) and to the lugs on the bottom of
the equalization beams.
4. Install a spherical bearing (9) to each of the two tailgate side arms (1 and 2 respectively).
5. Lift both tailgate side arms (1 and 2) into position on their respective stub shafts (5),
correctly orientated. Measure the linear distance between the two side arms (1 and 2),
which should be in accordance with the reference dimension identified on Figure 21.5. If
necessary, remove the side arms (1 and 2) and insert sufficient shims (8) over the stub
shafts (5), in order to achieve the reference dimension of 3 374 mm, then refit the side arms
(1 and 2) and check the dimension again.

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21 Body

Figure 21.5 - Side Arm Check Size

6. Fit a thrust plate (10) to each stub shaft (5), orientated as shown on Figure 21.6 below,
securing them with the locking plates (20), bolts (11) and washers (12). Ensure that the
thrust plates (10) are secured to the stub shafts (5) and NOT to the side arms (1 &and 2
respectively). If a thrust plate is impinging on a side arm, undo the bolts (11), remove the
bolts (11), washers (12), locking plate (20) and thrust plate (10), then fit a shim (8), and
finally re-fit the thrust plate, (10), locking plate (20), bolts (11) and washers (12). There
must be a clearance between each side arm (1 and 2) and their respective thrust plate (10)
of 0.3 - 1.3 mm. Bend up the corners of the locking plates (20) against the flats of the
bolts (11) on completion.
7. Refer to Figure 21.6. Fit the two grease lubrication hoses (3) complete with elbows (2) and
adapters (1) to the stub shafts (5, Figure 21.4). Fit the couplings and grease nipples (17,
Figure 21.4) to the bottom of the hoses (3, Figure 21.6).

Figure 21.6 - Orientation of Thrust Plates Figure 21.7 - Retaining Compound Application
Areas

8. Apply retaining compound (Loctite™ 638) to the areas of the tailgate (3) identified on Figure
21.7 below, at BOTH ENDS of the tailgate (3).
9. Transfer the lifting tackle to the rear tailgate (3) and lift it into position at the rear of the body.
Loosely assemble the rear tailgate (3) with the side arms (1 and 2) and the locking plates
(4), using the bolts (13), washers (18) and lock-nuts (14).
10. Manipulate the rear tailgate (3) until it makes contact with the rear lip of the body. Tighten
the bolts (13) with washers (18) and lock-nuts (14), in accordance with 22.3 Standard Bolt
and Nut Torque Specifications on page 22-5.
11. Manually operate the side arms (1 and 2) to ensure that the rear tailgate (3) operates
correctly, and does not impinge on the top of the body in its lifted position.

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 Body 21

12. Lubricate the rear tailgate (3) via the grease nipples (17), until excess lubricant can be
observed exiting the spherical bearings (9).
13. Fit the support assemblies (22) to the respective equalization beams using the bolts (24),
washers (25) and nuts (26).
14. Attach the tie plates (23) to the equalization beams using the bolts (24), washers (25)
and nuts (26).
15. Attach the other ends of the tie plates (23) to the support assemblies (22) using the bolts
(27), washers (25) and nuts (26).
16. Fit the chains (16) with shackles (15) to the drilled lugs at the forward end of the side arms
(1 and 2) and to the corresponding drilled lugs on the top of the support assemblies (22).
17. When the chains (16) have been adjusted to their required length, cut appropriate lengths
of spiral wrap (19) to cover as much of the chains (16) as possible.

(4) Maintenance
Numbers in parentheses refer to Figure 21.4, unless otherwise specified.
Every 50 Hours: Lubricate the tailgate stub shafts (5) with lubricant specified in (1)
Recommended Lubricants on page 4-16. Lubricate slowly until excess lubricant is observed.

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Intentionally Left Blank

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 Miscellaneous 22

Table of Content
22 Miscellaneous ...........................................................................................22-1
22.1 Welding ........................................................................................................ 22-2
(1) General Welding Procedure .................................................................... 22-3
(a) Repair of Defects Out With the Vicinity of Alloy Steel Castings........... 22-3
(b) Repair of Defects in Alloy Steel Castings and in the Welds Joining
Steel Castings..................................................................................... 22-3
22.2 Service Tools................................................................................................ 22-4
22.3 Standard Bolt and Nut Torque Specifications............................................... 22-5
(1) Self-Locking Fasteners............................................................................ 22-8
(2) Minimum Prevailing Torque - Removal.................................................... 22-9
22.4 Storage....................................................................................................... 22-10
(1) Temporary Storage ................................................................................ 22-10
(2) Under Six Months Extended Storage ................................................... 22-11
(3) Over Six Months Extended Storage ...................................................... 22-12
(4) Removal from Extended Storage .......................................................... 22-12
22.5 Disposal ..................................................................................................... 22-14

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22 Miscellaneous

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

NOTICE
• Always fasten the welding machines ground cable to the piece/frame being welded if
possible.
• The current from the welding rod always follows the path of least resistance. If, for example,
the ground clamp is attached to the rear frame when welding is performed on the front
frame, the current must pass a frame connection to return to the welding machine. 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 cause welding blotches on
the coupling surfaces and increase the wear rate of these components.
• Electric arc welding is recommended for all welded frame repairs. Since the nature and
extent of damage to the frame cannot be predetermined, no definite repair procedure
can be established. As a general rule however, if parts are twisted, bent or pulled apart,
or a frame is bent or out of alignment, no welding should be done until the parts are
straightened or realigned.
• Successfully welded repairs will depend to a great extent upon the use of the proper
equipment, materials and the ability of the welder. The Customer Support Department can
be consulted regarding the feasibility of welding repairs.

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 Miscellaneous 22

(1) General Welding Procedure

(a) Repair of Defects Out With the Vicinity of Alloy Steel Castings
The following general procedure should be used for the repair of defects out with the vicinity of
alloy steel castings.

PROCEDURE
1. Completely ARC-AIR gouge or grind out the crack until sound metal is reached. If ARC-AIR
method is employed, pre-heat area to 100 °C (212 °F), measure 3 - 4" either side of repair
prior to gouging. On completion of gouging grind to remove thin carbon layer.
2. Apply dye-penetrant check to ensure crack has been completely removed.
3. Pre-heat area to 100 °C (212 °F), measured 3 - 4" either side of repair. Avoid local
overheating.
4. Weld completely using E-7016 electrodes. Care must be taken to ensure electrodes are
protected from moisture pick-ups at all times.
5. Allow repair weld to cool slowly.
6. Grind and blend repair to original contour. Paint heat damaged areas.

(b) Repair of Defects in Alloy Steel Castings and in the Welds Joining Steel Castings
The following general procedure should be used for the repair of defects in alloy steel castings
and in the welds joining steel castings.

PROCEDURE
1. Completely ARC-AIR gouge or grind out the crack until sound metal is reached. If ARC-AIR
method is employed, pre-heat area to 200 °C (392 °F), measure 3 - 4" either side of repair
prior to gouging. On completion of gouging grind to remove thin carbon layer.
2. Apply dye-penetrant check to ensure crack has been completely removed.
3. Pre-heat area to 200 °C (392 °F), measured 3 - 4" either side of repair. Avoid local
overheating.
4. Weld completely using E-7016 electrodes. Care must be taken to ensure electrodes are
protected from moisture pick-ups at all times.
5. On completion of welding, post-heat repair area to 400 °C (752 °F), measure 3 - 4" either
side of repair.
6. If welding has to be interrupted for any reason, e.g. overnight, post-heat immediately as
in Step 5.

Maintenance Manual Revision 1.0 15-Sep-2017

TA400 Tier2 Page 22-3
22 Miscellaneous

22.2 Service Tools

The Service Tools section is currently being reviewed, and will be published at the next
planned revision.

15-Sep-2017 Revision 1.0 Maintenance Manual

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 Miscellaneous 22

22.3 Standard Bolt and Nut Torque Specifications

� WARNING
• Some fasteners are important attaching parts which could affect the performance of vital
components and systems, and/or, could result in major repair expense. Fasteners should
be replaced with parts of the same part number, or with equivalent parts, if replacement
becomes necessary. Do not use replacement parts of lesser quality or substitute design.
The torque values shown in the following tables should be used in all cases, unless
otherwise specified elsewhere in this manual, in order to avoid possible personal injury
or property damage.

NOTICE
• Where materials other than GM Standards are used, refer to Table 22.2.

The following torque specification tables are based on GM Standard Materials for bolts, nuts,
studs and self locking fasteners based on SAE bolt steel classifications, or, prevailing torque
specifications for self-locking fasteners.
To prevent the threaded bolts and nuts used on this equipment from being overstressed during
assembly, and to establish a uniform value to which these fasteners can be safely tightened, the
following torque tables have been compiled.
The torque values listed in the tables have been established over a period of years and
cover all conditions of assembly. The maximum torque values for standard bolts and nuts are
based on 75% of the specified minimum proof strength of the bolt steel in order to provide a
safety factor to compensate for the variation in the accuracy of torque wrenches, skill of the
assembler, and variance in fractional conditions. All torque values are for lubricated threads.
The term 'lubricated' includes the application of thread lubricants, cadmium plating or the
use of hardened washers.
To provide a quick method for determining the GM material classification of a particular standard
bolt or nut, compare the bolt head markings to those in the appropriate tables, then locate the
maximum torque value for that bolt size in the column under that marking.
Table 22.1 - Recommended Maximum Torques (Imperial) ±10%

12 Point Cap
SAE Symbol SAE Symbol SAE Symbol SAE Symbol Screws
Size GM 260-M GM 280-M GM 290-M GM 300-M
Steel (SAE Steel (SAE Steel (SAE Steel (SAE
GR 2) GR 5) GR 7) GR 8)
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
0.25 - 20 5 4 8 6 11 8 12 9 14 10
0.25 - 28 7 5 10 7 12 9 14 10 15 11
0.31 - 18 11 8 18 13 22 16 24 18 27 20
0.31 - 24 12 9 19 14 24 18 27 20 30 22
0.38 - 16 20 15 31 23 38 28 43 32 49 36
0.38 - 24 23 17 34 25 43 32 49 36 56 41
0.44 - 14 33 24 47 35 59 43 68 50 75 55
0.44 - 20 37 27 54 40 68 50 79 58 87 64

Maintenance Manual Revision 1.0 15-Sep-2017

TA400 Tier2 Page 22-5
22 Miscellaneous

12 Point Cap
SAE Symbol SAE Symbol SAE Symbol SAE Symbol Screws
Size GM 260-M GM 280-M GM 290-M GM 300-M
Steel (SAE Steel (SAE Steel (SAE Steel (SAE
GR 2) GR 5) GR 7) GR 8)
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
0.50 - 13 50 37 75 55 94 69 106 78 119 88
0.50 - 20 56 41 88 65 106 78 122 90 134 99
0.56 - 12 75 55 108 80 136 100 156 115 171 126
0.56 - 18 81 60 122 90 149 110 176 130 191 141
0.62 - 11 102 75 149 110 190 140 217 160 237 175
0.62 - 18 115 85 169 125 210 155 244 180 270 199
0.75 - 10 176 130 271 200 332 245 380 280 420 310
0.75 - 16 203 150 298 220 366 270 420 310 472 348
0.88 - 9 169 125 434 320 536 395 610 450 679 501
0.88 - 14 190 140 488 360 590 435 678 500 751 554
1.00 - 8 258 190 651 480 800 590 915 675 1021 753
1.00 - 12 285 210 719 530 881 650 1003 740 1119 825
1.00 - 14 285 210 732 540 902 665 1030 760 1148 847
1.12 - 7 366 270 800 590 1132 835 1302 960 1447 1067
1.12 - 12 407 300 902 665 1274 940 1451 1075 1624 1198
1.25 - 7 515 380 1132 835 1600 1180 1830 1350 2043 1507
1.25 - 12 569 420 1254 925 1776 1310 2034 1500 2267 1672
1.38 - 6 664 490 1478 1090 2095 1545 2400 1770 2676 1974
1.38 - 12 759 560 1688 1245 2393 1765 2739 2020 3056 2254
1.50 - 6 881 650 1966 1450 2786 2055 3186 2350 3556 2623
1.50 - 8 936 690 2088 1540 2962 2185 3390 2500 3781 2789
1.50 - 12 990 730 2217 1635 3145 2320 3593 2650 4010 2958
1.75 - 5 - - - - 4393 3240 5016 3700 5604 4133
1.75 - 12 - - - - 5091 3755 5830 4300 6497 4792
1.88 - 8 - - - - 6006 4430 6874 5070 7664 5653
1.88 - 12 - - - - 6304 4650 7213 5320 8048 5936
2.00 - 4.5 - - - - 6623 4885 7565 5580 8448 6231
2.00 - 8 - - - - 7342 5415 8406 6200 9367 6909
2.00 - 12 - - - - 7687 5670 8786 6480 9811 7236
2.25 - 4.5 - - - - 9701 7155 11090 8180 12377 9129
2.25 - 8 - - - - 10629 7840 12148 8960 13566 10006
2.25 - 12 - - - - 11050 8150 12636 9320 14102 10401
2.50 - 12 - - - - 15280 11270 17463 12880 19500 14383

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 Miscellaneous 22

Table 22.2 - Material Conversion Table

SAE Bolt Head
Types of Steel Rockwell Hardness Applicable Torque
Symbols
Plain Low Carbon
(for example SAE Rockwell "B" 85-100 GM 260-M
1018 or 1020)
Plain Medium Carbon
(for example SAE Rockwell "C" 19-30 GM 280-M
1035, 1038 and 1045)
Medium Carbon Alloy
(for example SAE Rockwell "C" 28-34 GM 290-M
4140, 8642 and 5157)
Medium Carbon Alloy
(for example SAE Rockwell "C" 32-38 GM 300-M
4140, 8642 and 5147)

Table 22.3 - Recommended Maximum Torques (Metric) ±10%

Class 8.8 Class 9.8 Class 10.9 Class 12.9
Size
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
M1.6 - 0.35 - - 0.2 0.15 - - 0.2 0.15
M1.6 - 0.20 - - 0.25 0.2 - - 0.4 0.3
M2.0 - 0.40 - - 0.25 0.2 - - 0.45 0.3
M2.0 - 0.25 - - 0.45 0.3 - - 0.45 0.3
M2.0 - 0.45 - - 0.25 0.2 - - 0.45 0.3
M2.5 - 0.35 - - 1 0.75 - - 1 0.75
M3.0 - 0.50 - - 1 0.75 - - 2 1.5
M3.0 - 0.35 - - 1 0.75 - - 2 1.5
M3.5 - 0.60 - - 2 1.5 - - 3 2
M4.0 - 0.70 - - 3 2 - - 4 3
M4.0 - 0.35 - - 3 2 - - 5 3
M5.0 - 0.80 - - 5 4 - - 8 6
M5.0 - 0.50 - - 6 4 - - 9 6
M6.0 - 1.00 - - 9 6 - - 13 10
M6.3 - 1.00 - - 10 8 13 10 16 11
M6.0 - 0.75 - - 10 7 12 9 14 10
M8.0 - 1.25 - - 21 15 27 20 32 23
M8.0 - 1.00 - - 23 17 29 21 34 25
M10.0 - - - 42 31 54 39 63 46
1.50
M10.0 - - - 45 32 57 41 67 48
1.25
M12.0 - - - 74 53 94 68 110 80
1.75
M12.0 - - - 81 58 103 74 121 87
1.25
M14.0 - - - 118 85 151 109 176 127
2.00

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TA400 Tier2 Page 22-7
22 Miscellaneous

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
M14.0 - - - 128 92 163 118 190 137
1.50
M16.0 - - -
169 122 234 169 274 197
2.00
M16.0 - - -
181 130 250 180 292 211
1.50
M18.0 - - -
234 169 323 234 378 273
2.50
M18.0 - - -
263 190 363 262 425 307
1.50
M20.0 - - -
330 239 457 330 531 386
2.50
M20.0 - - -
367 265 507 366 593 423
1.50
M22.0 - - -
451 325 623 450 728 526
2.50
M22.0 - - -
495 357 684 494 800 577
1.50
M24.0 - - -
571 412 790 570 923 667
3.00
M24.0 - - -
623 450 861 622 1007 727
2.00
M27.0 - - -
837 605 1158 836 1354 977
3.00
M27.0 - - -
903 652 1250 902 1461 1055
2.00
M30.0 - - -
1135 820 1570 1134 1835 1325
3.00
M30.0 - - -
1258 908 1740 1256 2034 1468
2.00
M30.0 - - -
1300 939 1799 1299 2102 1516
1.50
M36.0 - - -
1985 1433 2745 1982 3208 2317
4.00
M36.0 - - -
2102 1517 2907 2099 3398 2453
3.00

(1) Self-Locking Fasteners

Self-locking fasteners develop a measured gripping action or torque and provide a renewed
locking action after being removed and reinstalled to their original mating part. The self-locking
fasteners used on this equipment meet specifications necessary to allow the fasteners to be
reused up to five times. Whenever a self-locking fastener is removed, the head of the fastener
should be deeply scribed or otherwise marked to record the number of times the fastener has
been used. Do not use a self-locking fastener more than five times.
The following table shows the minimum torque specifications allowed to remove self-locking
fasteners after the initial break-away torque has been achieved. Any self locking fastener
that can be removed with less than the prevailing torque value shown in the table should be
discarded, even if the fastener has not yet been reused five times.

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 Miscellaneous 22

(2) Minimum Prevailing Torque - Removal

Table 22.4 - Minimum Prevailing Torque - Removal
Size Lock Screws Lock-nuts
SAE Grade 5 and 8, SAE Grade 5 SAE Grade 8
and ASTM A-574
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

Maintenance Manual Revision 1.0 15-Sep-2017

TA400 Tier2 Page 22-9
22 Miscellaneous

22.4 Storage
The storage of machines for short periods of time or during the off-season is an important item if
major damage to components is to be avoided. Failure to take the necessary steps to protect
the various assemblies while the machine is being stored can result in an expensive overhaul
job and delay in returning the machine to work.
(1) Temporary Storage

NOTICE
• If the machine is delivered from the Terex Trucks facility with a wax coating to protect the
paint-work, do not remove it until the machine is removed from storage.
• Do not apply oil or grease to brake discs.

When storing a machine for a period of 30 days or less, the following precautions must be taken:

PROCEDURE
1. INSPECTION AND REPAIR - Thoroughly inspect and test the machine and make any
necessary repairs or adjustments which may be necessary to prepare the machine for
service. This will enable you to put the machine back into use immediately at the end of
the storage period.
2. LUBRICATION - Lubricate the machine completely according to the instructions given in
“Lubrication System" of the Maintenance Manual.
3. COOLING SYSTEM - Verify that the cooling system is adequately protected for the climatic
conditions expected at the storage location. Adjust if necessary.
4. PARKING - After thoroughly cleaning the entire machine, park it on a hard, dry, level
surface that is free from grease and oil. The oil and grease would cause tire deterioration.
Apply the parking brake.
5. FUEL TANK - Fill the fuel tank to prevent moisture condensation within the tank. Coat
filler neck and cap threads with oil.
6. FUEL STOP COCK (Option) - Select the fuel stop cock to the ‘CLOSED’ position.
7. HYDRAULIC TANKS - Coat filler neck and cap threads with oil. Fill the tank to operating
level if necessary.
8. AIR RESERVOIRS - Open all drain cocks at bottom of air tanks.
9. BATTERIES - Where moderate temperatures are expected, the batteries may be left in
the machine. Up to 30 days, the batteries may require a boost at the end of the storage
period. Preferably place the batteries in the shop where they can be inspected, brought up
to full charge and placed on a trickle charge to keep them at full charge. In very cold or hot
climates, store the batteries where they will be protected from temperature extremes. Coat
the battery terminals and cable ends with acid resistant petroleum jelly.
10. TIRES - Remove all grease and oil. Inflate all tires to correct pressure. During storage,
check inflation pressure approximately once every two weeks.
11. TRACKS - Check recoil cylinder pressure and track adjustment. Remove all oil and grease
(rubber tracks).
12. EXHAUSTS - Cover exhaust stack openings with plastic or waterproof paper and secure
with adhesive tape.
13. AIR INTAKES - Cover openings with plastic or waterproof paper and secure with adhesive
tape.

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 Miscellaneous 22

14. SUSPENSION RIDE CYLINDERS - Release the pressure in the cylinders to retract them
for minimum piston rod exposure. Coat the remaining exposed piston rod surface with
a suitable oil or grease.
15. HYDRAULIC CONTROL VALVES - Where possible position hydraulic controls for minimum
exposure of valve spools (spool inside valve body). Coat the remaining exposed spool
surface with a suitable oil or grease.
16. HYDRAULIC CYLINDERS - Where possible retract cylinders for minimum rod exposure.
Coat the remaining exposed piston rod surface with a suitable oil or grease.
17. AIR CYLINDERS - Coat the exposed piston rod surface with a suitable oil or grease.
18. CONTROL CABLES & LINKAGE - All exposed linkage, clevis ends, ball joints etc., which
are not protected during "lubrication" must be protected by a suitable oil or grease.
19. OPEN PORTS & HOSE ENDS - Plug or seal with adhesive tape all open ports.
20. MACHINED SURFACES - Coat any exposed machined bores and surfaces with a suitable
rust preventative.
21. HINGES - Apply oil to all the hinges.
22. SEAT SLIDE ADJUSTERS - Coat with grease.
23. SEATS, ARM RESTS & CUSHIONS - When the machine is not equipped with a cab, cover
these items with plastic or waterproof barrier paper, and secure with adhesive tape. Provide
an opening in the underside of the protective materials to prevent condensation build up.
24. CABS - All windows, doors and vents closed.
25. HOODS, HOODSIDES, COVERS, PANELS, ETC - Installed.
26. SECURITY PANELS AND SECURITY LOCKS - Installed and locked.

(2) Under Six Months Extended Storage

When storing a machine for periods of longer than 30 days, but less than six months, the
following procedure must be followed, in addition to the procedure described above:

PROCEDURE
1. ENGINE - Consult the relevant Engine Manual/ Dealer for storage procedure for periods
longer than 30 days.
2. TRANSMISSION - Consult the relevant Transmission Manual/Dealer for storage procedure
for periods longer than 30 days.
3. BATTERIES - Remove the batteries from the machine and store in shop. Protect batteries
from temperature extremes. Coat the terminals and cable ends with acid resistant
petroleum jelly.
4. VENTS AND BREATHERS - Remove all vents and breathers and plug all the openings with
pipe plugs or seal with adhesive waterproof tape.
5. BELTS - Release tension on all the belts.
6. TIRES - When the extended storage is anticipated, the machines must be blocked up so
weight does not rest on the tires, and inflation pressure reduced to 1 bar (15 lbf/in²). Storage
of such machines must be under cover if possible; otherwise tires must be protected from
the elements by an opaque waterproof covering.
If it is not possible to block up the machines, inflation pressure in the tires must be increased
to 25% above the rated pressure for the actual load on the tire in storage condition.

Maintenance Manual Revision 1.0 15-Sep-2017

TA400 Tier2 Page 22-11
22 Miscellaneous

The storage area surface must be firm, reasonably level, well drained and free of all oil,
fuel or grease. Put 8-19 mm (0.25-0.75 in) of clean gravel under each tire if the area is not
paved. Storage must not be permitted on blacktop or oil stabilized surfaces.
Except in very cold weather, stored machines must be moved occasionally, at least once
every six months, so the same section of the tire is not always under strain from deflection.
Inflation in the tires must be adjusted to the recommended service pressure before shipping
or putting a stored machine into service.
7. RUST PREVENTION - Remove all evidence of rust from the machine and repaint.

(3) Over Six Months Extended Storage

NOTICE
• These steps are in addition to those given previously under 'Extended Storage - Under Six
Months'.
• These steps must be repeated for every Six Month period the machine is in storage.

When a machine is to be stored for a period over SIX MONTHS, the following procedure must
be followed:

PROCEDURE
1. WHEEL BEARINGS - Remove, clean, inspect and repack all wheel bearings.
2. Wash the machine and re-touch any damaged paint finish to avoid rusting.

(4) Removal from Extended Storage

NOTICE
• Field rework must always be implemented in accordance with the appropriate instructions
in the Maintenance Manuals.

The following procedure must be followed when a machine is removed from storage.

PROCEDURE
1. FUEL TANK - Drain off any condensation. Remove covers from openings and re-install
breather.
2. FUEL STOP COCK (Option) - Select the fuel stop cock to the ‘OPEN’ position.
3. HYDRAULIC TANKS - Remove covers from openings and re-install breathers. Fill tank to
operating level if necessary.
4. AIR RESERVOIRS - Close all drain cocks.
5. BATTERIES - Check batteries are fully charged and re-install.
6. TIRES - Inflate to the recommended pressure.
7. TRACKS - Check recoil cylinder pressure and track adjustment.
8. EXHAUSTS - emove temporary storage covers from exhaust stack openings.
9. AIR INTAKES - Remove temporary storage covers from air intake openings.

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 Miscellaneous 22

10. SUSPENSION RIDE CYLINDERS - Remove protective coating from piston rod surface.
Charge with Nitrogen.
11. HYDRAULIC CYLINDERS - Remove protective coating from piston rod surface.
12. VENTS AND BREATHERS - Remove seals and plugs from all breather openings, then
install all breathers and vents.
13. BELTS - Adjust tension on all belts.
14. ENGINES - Consult the relevant Maintenance Manual/Dealer for instructions on removing
an engine from storage.
15. TRANSMISSION - Consult the relevant Maintenance Manual/Dealer for instructions on
removing a transmission from storage.
16. PAINT - Check machine for rust. Remove all rust spots and repaint rusted areas.
17. DECALS - Check condition of decals and replace if necessary.
18. LUBRICATION - Completely lubricate the machine according to the instructions in the
"Lubrication System" section of the relevant Maintenance Manual.
19. GENERAL - Check for fuel, hydraulic oil, coolant and air leaks. Replace all leaking seals.

Maintenance Manual Revision 1.0 15-Sep-2017

TA400 Tier2 Page 22-13
22 Miscellaneous

22.5 Disposal
At the end of its life, the machine must be disassembled by a competent person using safe
working practices, wearing the appropriate Personal Protective equipment and working in
accordance with local regulations.
The appropriate lifting equipment, chocks, and stands must be used to maintain a stable
machine as components are removed and the machines center of mass changes. Fluids
must be drained off into suitable containers and if possible recycled otherwise disposed of an
environmentally friendly in accordance with local regulations.
Care must be taken when dealing with flammable liquids and the machine parts that contained
those liquids. Any process that could ignite flammable materials must not be used on
components that contain flammable liquids in them or have residual flammable liquids on them.
If cutting/welding equipment is used, fire extinguishers must be readily available.
When possible recyclable materials must be separated out and processed in accordance with
local regulations using an authorized agent.

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Page 22-14 TA400 Tier2
 Electrical Schematic Diagrams A

Appendix A Electrical Schematic Diagrams

The following pages (sheets 1 to 34), contain the electrical wiring schematic diagrams.
The following pages (sheets 35 to 38), contain the electrical component designations.

Maintenance Manual Revision 1.0 15-Sep-2017

TA400 Tier2 Page A-1
A Electrical Schematic Diagrams

Intentionally Left Blank

15-Sep-2017 Revision 1.0 Maintenance Manual

Page A-2 TA400 Tier2
 1 2 3 4 5 6 7 8 9 10 11 12

-X1
A A

1
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+6.4 80A
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1
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-F93.X

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1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

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1 Spare 1 Spare 1 Spare 1 1 1 1 1 1 1 1 1
15A 7.5A 25A 3A 2A 2A 15A 15A 20A 20A 5A 5A
C 15A ATO Blade Fuse DIN 72581 7.5A ATO Blade Fuse DIN 72581 25A ATO Blade Fuse DIN 72581 3A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 20A ATO Blade Fuse DIN 72581 20A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 C
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2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

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2/2

2/2

2/2
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F18 2A SPARE
F24 7.5A Terminal 30

F20 15A Reserve Cabin Terminal 30

F22 3A to K18.X1.10 VBBs

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Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-XP2
2
For this document and the object represented in that we reserve all rights according to DIN 34.

F25 2A to SUB-D programming conctr

F23 15A to K18.X1.1 VBBR

F21 20A to B3.6 30EMS

F17 20A to B3.1 30EMS

Spare

Spare
F19 15A to K18.X1.19 VBBO
F25 2A to SUB-D programming connector
D D
12/12 F26 15A Reserve Cabin Terminal 30

9/12 F26 15A Reserve Cabin Terminal 30

11/12 F26 15A Reserve Cabin Terminal 30

-X20

-X20

-X20

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10/12

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6/12

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7/12

8/12

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-F2:2 +6.4 https://one.terex.

+6.4
-XP4

-XP4

-XP4

-XP4

-XP4

-XP4

-XP4

-XP4

-XP4

-XP4
-XP4
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
1

11
10
2

4
3

9
6

7
G G
-F10.X

-F12.X

-F14.X

-F11.X

-F13.X

-F15.X

-F16.X
-F7.X

-F5.X

-F6.X

-F9.X

-F8.X
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2
1 Emergency operation 1 1 1 1 1 1 1 1 1 1 1
2A 7.5A 2A 10A 3A 7.5A 5A 15A 15A 5A 30A 15A
2A ATO Blade Fuse DIN 72581 7.5A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 10A ATO Blade Fuse DIN 72581 3A ATO Blade Fuse DIN 72581 7.5A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 30A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581
+6.4 15369505 +6.4 15247613 +6.4 15369505 +6.4 15247612 +6.4 15247615 +6.4 15247613 +6.4 15247614 +6.4 15247611 +6.4 15247611 +6.4 15247614 +6.4 15247753 +6.4 15247611
-F7 5350661270 -F10 5050650265 -F12 5350661270 -F14 5050650264 -F5 5050650307 -F6 5050650265 -F9 -F11 -F13 -F15 5050650301 -F16 5050650277 -F8 5050650271
2 2 2 2 2 2 2 5050650301 2 5050650271 2 5050650271 2 2 2
https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex.
H H
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2
-F7.X

-F10.X

-F12.X

-F14.X

-F5.X

-F6.X

-F9.X

-F11.X

-F13.X

-F15.X

-F16.X

-F8.X
F16 30A to K13 and K14

F8 15 A to K19.X.10/70 TCU
F7 2A Key switch Emergency operation

F10 7.5A Hazard

F6 7.5A Terminal 30

F13 15A work socket 24V

F12 2A to Telematic connector

F14 10A Air seat compressor

F11 15A to T1 24V/12V convertor

/5.F7
+6.4-K14.X:5

F16 30A to K13 and K14

-X21
I I

2/12
-X21

-X21

-X21
12/12
8/12

7/12
-X21

-X21

-X21

-X21

-X21

-X21

-X21

FIRST USED: TA400 T2

10/12

11/12
6/12

4/12
3/12

5/12

1/12

NEXT ASSY.: 0PL46960

SIM. TO: 15397390
e Date Name Description:
Assignment

d Reverted camera cables back 114378 C. Heyes 08/11/2016

Designed 01/12/2015 J.CRAIG
c Diode R15 Added, S3 Conx Changed 114168 F.Blackwood 09/08/2016 TA400 T2 Location +3.1
b CAMERA CABLE CHANGED 114215 C.HEYES 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 2
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 I
E
B
A

H
D

F
C

G
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
https://one.terex.
5050650519
15369504

15379147

+1
-P1

GND
1A ATO Blade Fuse DIN 72581

1A

https://one.terex.
2

+
1
-X6 -X6 1.00 mm² +1.1 -W20 RD -X10 -X10 1.00 mm² +1.1 -W19 RD

-
2/2 1/2 LED + 2/2 1/2 LED Supply

+1
1

1
-F2

-Xs3

welding splice
Ultrasonic
1.00 mm² +1.1 -W16 WH 1.00 mm² +1.1 -W15 WH
Relay (INIT)_Activation Relay (INIT)_Activation

-Xs2

welding splice
Ultrasonic
1.00 mm² +1.1 -W13 BN
Relay (85) -VE Supply (GND)

-S1
+1.1

Relay (INIT)_Activation
2

2
1.00 mm² +1.1 -W14 WH
welding splice
Ultrasonic
-Xs1
-S1.X -S1.X 1.00 mm² +1.1 -W9 RD 1.00 mm² +1.1 -W23 RD

2
1
2/4 1/4 Relay (30) +VE Supply Relay (30) +VE Supply

Relay (30) +VE Supply

LED -
Relay (85) -VE Supply (GND)
4
3

1.00 mm² +1.1 -W21 BN

1.00 mm² +1.1 -W12 BN

1.00 mm² +1.1 -W10 RD

15375905
Relay (30) +VE Supply

07-2-2-10 921
Master Switch

https://one.terex.

-KA1.X30
-KA2.X85
-KA2.XINIT

1.00 mm² +1.1 -W22 RD

30
-KA1.X85 85
85
-KA2.X30 30

-KA1.XINIT INIT
INIT

relay
relay
3

3
+1
-KA1
Relay (85) -VE Supply (GND)
Double Pole Single Throw Toggle switch

Bi-stable power
Bi-stable power

1.00 mm² +1.1 -W11 BN

15379082
-KA2
+1

15379083
31-311-12-i-919
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31-311-12-i-920

https://one.terex.
Bi-stable power relay 300A

-F3
+1

88
88

88a
88a

Bi-stable power relay 300A

-KA1.X88 -X9 -X9 1.00 mm² +1.1 -W17 RD
1

2/2 1/2 Relay +VE Supply

10A

15247612
2 5050650264
-KA2.X88

-KA1.X88
-KA2.X88

-KA1.X88a
-KA1.X88a
-KA2.X88a

https://one.terex.
4

4
Battery
Battery

15226158
15226158
15226158
15226158

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https://one.terex.

Battery 12V 165Ah

Battery 12V 165Ah
-C2

-C1
+1
+1

+1
-X1.A 120.00 mm² +1 -W6 BK +1 +1 +1 +1
10A ATO Blade Fuse DIN 72581

Chassis GND

12V
12V

1 120.0 mm² +1 -W1 BK -C1.X- -C1.X+ 120.0 mm² +1 -W2 BK -C2.X- -C2.X+ 120.0 mm² +1 -W3 BK

+1 -X1
-
-

Master Relay KA1 GND to Battery C1 negative pole Battery pole connection Master Relay KA2 to Battery C2 positive pole

+
+

1 1 1 1

M10:1
-XGND1.a 2.50 mm² -W2 BN
2 GND
K18.X1.18 to K2.X1
+6/14.D2
-XGND1.a 2.50 mm² -W1 BN +6-S3.X:50
1 GND
120.00 mm²

M8:1
-A1
5

5
+4 -XGND1
Master Relay KA2 to fuse box

K18.X1.18 to K2.X1

+6-A1.X20:1
+6/14.C7

-A1.C4001 2.50 mm² -W3 RD -X3 2.50 mm² +6 -W221 RD

30 EMS F17 20A to B3.1 30EMS F17 20A to B3.1 30EMS
+03A/9.C1
1/8 A/21 A/21
+1 -W4 BK

1.0 mm² +6 -W201 YE

Master
-K18
+6

F17 20A to B3.1 30EMS

-A1.C4001

15353798
15353798
31GND
2/8

https://one.terex.
c

-A1.C4001 1.50 mm² BK -W4 -X3 1.50 mm² +6 -W222 BK +6-A1.X24:12

15 EMS +03A/10.E10

Diesel engine 6 cylinder

3/8 F78 10A to B3.3 15EMS B/21 B/21 F78 10A to B3.3 15EMS
+6
-R15

F78 10A to B3.3 15EMS +6

-Xs13
+6

welding splice
Ultrasonic
Diode_GI751

-A1.C4001 2.50 mm² -W5 RD -X3 2.50 mm² +6 -W223 RD +6-A1.X20:4 1.0 mm² +6 -W199 WH 1.5 mm² +6 -W200 YE -K18.XL
30 EMS +03A/9.C2
Q00

F21 20A to B3.6 30EMS F21 20A to B3.6 30EMS K18.X1.18 to K2.X1 IGN RELAY ON
CR0232

4/8 C/21 C/21 18/55

AN
15325548

F21 20A to B3.6 30EMS

KAT
Mains Relay
5050143198

St-X1 18
Main Controller
https://one.terex.

-A1.C4001
31GND
1.0 mm²

5/8 120.00 mm² +1 -W5 BK

OUT_K2_MainRelayTerminal15_ON

Twisted Pair
Twisted Pair

+6-A1.X30:16 Fuse box to starter

-W6:TW1
-W277:TW1#1

-A1.C4001 -X3
Output binary high side

1.0 mm² -W6 YE 1.0 mm² +6 -W277 YE

31GND CANH +6/12.G1
6

6
6/8 CAN2_H D/21 D/21 CAN2_H CAN2_H

-X1
+6-A1.X30:1
K18.X1.18 to K2.X1 1/6
+6
+6 -W226 WH -X41

-A1.C4001 -X3

120R
1.0 mm² -W6 BU 1.0 mm² +6 -W277 BU

M10:1
CANL CAN2_L CAN2_L +6/12.G1
7/8 E/21 E/21 CAN2_L
/70.F3
-F1
+1

-A1.C4001 1.50 mm² -W7 WH -X3 1.00 mm² +6 -W283 WH Engine running (ER)
1/6
1
1

+5

ER Engine running
-F1.+UBat

+3/33.D4
-F1.30

+1
+1

8/8 Engine running (ER) F/21 F/21 Engine running (ER) +6-K18.XL:24
-X41
30

-A1.C4002 -X3 +6-A1.X24:17

+UBat

1.50 mm² -W8 BK 1.50 mm² +6 -W224 BK

15372182

+5
-F1.1

15 SCR
+1

+03A/10.E12
Mega
605 001 017

1/6 F76 10A to C4014 15_SCR G/21 G/21 F76 10A to C4014 15_SCR -F1.1b
F76 10A to C4014 15_SCR
https://one.terex.

1
30

1
/70.G3
-K2
+5

SCRTL+
100A
Fuse distributor, terminal 30

K18.X1.18 to K2.X1

15325654
Bi-stable power relay with energy storage 200A

5522655685
31-211-12-E-906

https://one.terex.
1.5 mm² +5 -W3 WH

85-
storage

SCRTL-
86+

SCANIA
with energy
https://one.terex.
8JS 742 902-001

Bi-stable relay
1

2
7

7
2/4 1/4
SCRFL+
MEGA-high current fuse

d
c
a
b
e
Fuse distributor 3 x Mega-fuse; 1 x Midi fuse

15302906 5350246823

+5 +5 +5

Customer Interface EMS

-F1.2

SCRFL-
+1
Mega

-K2.X88a -K2.X88 50.0 mm² +5 -W1 BK -F1.2b

30

1 1 F1.2 100A to K2.X88 Terminal 15 1

88

Rev. Index Revision

88a

-A1.V2 2.50 mm² -W13 WH -X3 1.5 mm² +6 -W163 WH +6-Xs23.SB:3

100A

Aircon. compessor clutch ON Aircondition clutch ON Aircondition clutch ON +6/26.B6

1/2 M/21 M/21 Aircondition clutch ON
-A1.V2
https://one.terex.
8JS 742 902-001

Aircon. compessor clutch GND

2/2
-F1.3
+5

+5 +5

CAMERA CABLE CHANGED

15302906 5350246823
MEGA-high current fuse

+1 -F1.3.X -F1.3.X 2.50 mm² +5 -W22 RD

Diode R15 Added, S3 Conx Changed

1

-A1.M1 120.00 mm² +1 -W5 BK 2/2 1/2 S32 Hood lift switch
M1 starter
-F1.3a
Mega

Reverted camera cables back

30A

1 Fuse box to starter

RELEASED TO PRODUCTION
3
8

8
Fuel heater ON -A1.XHeat 2.50 mm² -W20 WH -X3 2.50 mm² +6 -W447 WH +6-A1.X22:18
+03A/9.H7
-X4

Fuel Heater ON Fuel Heater ON

30

1/2 T/21 T/21 Fuel Heater ON

2 https://one.terex.

ECN No.
Fuel heater GND -A1.XHeat

113744
114215
114168
114378
5050650277 15247753

2/2

Name
30A ATO Blade Fuse DIN 72581

S32 Hood lift switch

D. Alford

J.CRAIG
CANL
CANH

C. Heyes
15
31
2.50 mm² +5 -W27 RD

C.HEYES
Midi

Diagnostics
50.0 mm²
30

44

-XGND1.a 2.50 mm² -W17 BN

Date
K2.88a to -X42.X2a Terminal 15

5 GND
01/12/2015
09/08/2016
08/11/2016
+5 -W7 BK
+5-S32.X:2
9

9
-XGND1.a 2.50 mm² -W14 BN
+3/34.C2

3 GND
S32 Hood lift switch

+5 50.0 mm² +5 -W8 BK

Date

-XGND1.b 1.50 mm² +5 -W4 BN F1.1 100A to -X42.X1a Terminal 30

1 GND
M8:2
3
1
+5
-X42.X1a1

-X42.X2a 3

+4 -XGND1

Name
+6

+4
Designed 01/12/2015 J.CRAIG
-X42

Approved 01/12/2015 G.McNEIL

15359837

-XGND.a
603002065
X2
X1

23/06/2016 Checked 01/12/2015 J.BROWNLIE

1 +6.5
https://one.terex.
Energy distribution

M8:1

-X42.X1b2 25.00 mm² +6.5 -W3 BK

2 2

+4 -XGND

F1.1 100A to X1/X2 Terminal 30

10

10
GND
+6.5
+6.5

Type

+5
-X42.X2b
-X42.X1b

-XGND5.a
M.-Nr.: T2

50.00 mm² +6.5 -W1 BK 25.00 mm² +6.5 -W2 BK

1 K2.88a to X6 Terminal 15 F1.1 100A to X1/X2 Terminal 30
M8:1
1
+6.5
-X6.a

TA400 G10
+5 -XGND5
1/1

-A6
-X6
-X5

+6.5
+3.1
+3.1

+3.1
90719
90719

+6.4

-XGND2.a 25.00 mm² +6.5 -W4 BN

+03A/9.B1

-X1 +6.5
11

15400612
11

1 GND F1.1 100A to X1/X2 Terminal 30 1/1 -X1.a

Origin Project
M8:1

90719 1
+6.5 -XGND2

Description:
1/1 K2.88a to X6 Terminal 15

+3.1
TA400 GEN9 T2

+3.1 -X2 +6.5

F1.1 100A to X1/X2 Terminal 30 1/1 -X2.a
GND

+6.5 -X7
-X7.a 1/1 GND 90719 1
1 90719
+6-XGND5:M8:6 (f)

15400615

+3.1
-X3
Drawing number

Spare 1/1
SIM. TO:

90719
12

12
FIRST USED:
+03A/9.I1 NEXT ASSY.:

+3.1
No.

-X4
Assignment

1/1
TA400 T2

Sheet 1
Location +2

90719
15397390
0PL46960

34 Sh.
I
E
B
A

H
D

F
C

G
 1 2 3 4 5 6 7 8 9 10 11 12

-X6
A A

1
+6.4
-XP6
1

-F3:1 +6.4

Master fuse Terminal 15

+6.4 80A
-F3 8JS 742 901-041
5050650489
B MIDI-high current fuse B
https://one.terex.
-F3:2 +6.4

+6.4
K2.88a to X3/X4 Terminal 15

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7
-XP7

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

11
1

10
+6.4-F63.X:1

4
3

9
6

7
/4.C1
F3 Terminal 15
-F30.X

-F52.X

-F56.X

-F53.X

-F50.X

-F27.X

-F58.X

-F35.X

-F41.X

-F28.X

-F40.X
C C
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2
1 1 1 1 1 1 1 1 1 1 1
3A 1A 1A 5A 7.5A 3A 3A 1A 2A 15A 15A
3A ATO Blade Fuse DIN 72581 1A ATO Blade Fuse DIN 72581 1A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 7.5A ATO Blade Fuse DIN 72581 3A ATO Blade Fuse DIN 72581 3A ATO Blade Fuse DIN 72581 1A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581
+6.4 15247615 +6.4 15369504 +6.4 15369504 +6.4 15247614 +6.4 15247613 +6.4 15247615 +6.4 15247615 +6.4 15369504 +6.4 15369505 +6.4 15247611 +6.4 15247611
-F30 5050650307 -F52 5050650519 -F56 5050650519 -F53 5050650301 -F50 5050650265 -F27 5050650307 -F58 5050650307 -F35 5050650519 -F41 5350661270 -F28 5050650271 -F40 5050650271
2 2 2 2 2 2 2 2 2 2 2
https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex.
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2
-F30.X

-F52.X

-F56.X

-F53.X

-F50.X

-F27.X

-F58.X

-F35.X

-F41.X

-F28.X

-F40.X
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
For this document and the object represented in that we reserve all rights according to DIN 34.

F35 1A T15 to P51E

F50 7.5A to K20.XK.2 Dashboard

F27 3A sensors front frame

F41 2A to S4

F28 15A to K18.X2.10 VBB4

F40 15A to K18.X2.32 VBB3

F30 3A to Rockerswitches

11/21 F53 5A to M1 and M4 wiper motors

F58 3A Sensors Drop box

F52 1A to K3 Terminal 15 12V

F56 1A B18 Speed sensor

D D
-X22

-X22

-X22

-X22

-X22

-X22

-X22

-X23

-X23

-X23

-X23
17/21

10/21

19/21

15/21

17/18

2/18
8/21

5/21

9/18

7/18
E E

F F
-F4:1 +6.4
Master fuse Terminal 15
+6.4 80A
-F4 8JS 742 901-041
5050650489
MIDI-high current fuse
-F4:2 +6.4 https://one.terex.
+6.4
-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8
-XP8
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
1

11
10
+6.4-F92.X:1
2

4
3

9
6

7
G /4.G1 G
F4 Terminal 15
-F76.X

-F79.X

-F66.X

-F69.X

-F72.X

-F75.X

-F77.X

-F65.X

-F64.X

-F71.X

-F74.X
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2
1 1 1 1 Heated mirror 1 1 1 1 1 1 1
10A 15A 15A 15A 10A 10A 10A Spare 5A 10A 10A 15A
10A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 10A ATO Blade Fuse DIN 72581 10A ATO Blade Fuse DIN 72581 10A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 10A ATO Blade Fuse DIN 72581 10A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581
+6.4 15247612 +6.4 15247611 +6.4 15247611 +6.4 15247611 +6.4 15247612 +6.4 15247612 +6.4 15247612 +6.4 15247614 +6.4 15247612 +6.4 15247612 +6.4 15247611
-F76 5050650264 -F79 5050650271 -F66 5050650271 -F69 5050650271 -F72 5050650264 -F75 5050650264 -F77 5050650264 -F65 5050650301 -F64 5050650264 -F71 5050650264 -F74 5050650271
2 2 2 2 2 2 2 2 2 2 2
https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex.
H H
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2
-F76.X

-F79.X

-F66.X

-F69.X

-F72.X

-F75.X

-F77.X

-F65.X

-F64.X

-F71.X

-F74.X
F66 15A to K18.X2.19 VBB1
F76 10A to C4014 15_SCR

F74 20A 24V TO HVAC

F79 15A to K18.X2.1 VBB2

F72 10A to K19 X63

F75 10A Terminal 15

F77 10A Spare

F65 5A Brake Pedal Activated

F71 10A
F69 15A to S16 Heated mirror
-X24

-X24

-X24

-X24

-X24

-X24

-X24

-X24

-X24

-X24

-X24
I I
17/18

18/18

13/18

14/18

15/18

10/18

11/18
2/18
7/18

3/18
1/18

FIRST USED: TA400 T2

NEXT ASSY.: 0PL46960
SIM. TO: 15397390
e Date Name Description:
Assignment

d Reverted camera cables back 114378 C. Heyes 08/11/2016

Designed 01/12/2015 J.CRAIG
c Diode R15 Added, S3 Conx Changed 114168 F.Blackwood 09/08/2016 TA400 T2 Location +3.1
b CAMERA CABLE CHANGED 114215 C.HEYES 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 3
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 1 2 3 4 5 6 7 8 9 10 11 12

A A

B B
-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7

-XP7
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
21
20

22

23
12

13

14

15

16

17

18

19
+6.4-XP7:1 +6.4-F63.X:1
/3.C12 /5.C1
F3 Terminal 15 F3 Terminal 15
-F37.X

-F34.X

-F38.X

-F31.X

-F39.X

-F36.X

-F33.X

-F29.X

-F42.X

-F60.X

-F55.X

-F49.X
C C
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2
1 1 1 1 1 1 1 1 1 1 1 1
5A 5A 2A 15A 15A 5A 15A 5A 5A 7.5A 5A 5A
5A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 7.5A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581 5A ATO Blade Fuse DIN 72581
+6.4 15247614 +6.4 15247614 +6.4 15369505 +6.4 15247611 +6.4 15247611 +6.4 15247614 +6.4 15247611 +6.4 15247614 +6.4 15247614 +6.4 15247613 +6.4 15247614 +6.4 15247614
-F37 -F34 -F38 -F31 -F39 5050650271 -F36 5050650301 -F33 5050650271 -F29 5050650301 -F42 5050650301 -F60 5050650265 -F55 5050650301 -F49 5050650301
2 5050650301 2 5050650301 2 5350661270 2 5050650271 2 2 2 2 2 2 2 2
https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex.
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2
-F37.X

-F34.X

-F38.X

-F31.X

-F39.X

-F36.X

-F33.X

-F29.X

-F42.X

-F60.X

-F55.X

-F49.X
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
For this document and the object represented in that we reserve all rights according to DIN 34.

+6.4 +6.4 +6.4 +6.4

F49 5A to OMNIA switch

F39 15A Terminal 15

F36 5A Terminal 15

F60 7.5A Terminal 15

F31 5A TO HVAC Actuators

F55 5A Cabin switches

F38 2A Sensors trailer

D -XP9 -XP10 -XP11 -XP12

D
1 1 1 1

14/18 F29 5A to Oil sensors

5/18 F37 5A Camera system

F37 5A

F34 5A Sensors Hydraulic Block

F34 5A Sensors Hydraulic Block

F29 5A

F42 5A

F42 5A
-X23

-X23

-X23

-X23

-X23

-X23

-X23

-X23

-X23

-X23

-X23

-X22

-X22

-X22
10/18

18/18

11/18

13/18

16/21
6/18

4/18

2/21

4/21
3/18

8/18

1/18
E E
-X23

-X23
15/18

12/18

F F
-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8

-XP8
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
21
20

22

23
12

13

14

15

16

17

18

19
+6.4-XP8:1 +6.4-F92.X:1
G /3.G12 /5.G1 G
F4 Terminal 15 F4 Terminal 15
-F78.X

-F68.X

-F67.X

-F70.X

-F73.X

-F91.X

-F84.X

-F87.X

-F86.X

-F88.X

-F90.X

-F83.X
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2
1 1 1 1 1 1 1 1 1 1 1 1
10A 30A 3A 15A 15A 15A 2A 20A 20A 1A 2A 15A
10A ATO Blade Fuse DIN 72581 30A ATO Blade Fuse DIN 72581 3A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 20A ATO Blade Fuse DIN 72581 20A ATO Blade Fuse DIN 72581 1A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581
+6.4 15247612 +6.4 15247753 +6.4 15247615 +6.4 15247611 +6.4 15247611 +6.4 15247611 +6.4 15369505 +6.4 15247610 +6.4 15247610 +6.4 15369504 +6.4 15369505 +6.4 15247611
-F78 5050650264 -F68 5050650277 -F67 5050650307 -F70 5050650271 -F73 5050650271 -F91 5050650271 -F84 5350661270 -F87 5050650266 -F86 5050650266 -F88 5050650519 -F90 5350661270 -F83 5050650271
2 2 2 2 2 2 2 2 2 2 2 2
https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex.
H H
+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4

+6.4
2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2

2/2
-F78.X

-F68.X

-F67.X

-F70.X

-F73.X

-F91.X

-F84.X

-F87.X

-F86.X

-F88.X

-F90.X

-F83.X
+6.4
-XP17 +6.4 +6.4
1
F78 10A to B3.3 15EMS

F70 15

F73 15A

F91 15A

F84 2A

F88 1A

F90 1A

F83 15A
F67 3A B5 Fuel level sensor

-XP18 -XP19
+6.4 1 1
-XP17
2
F68 30A

8/18 F86 20A M7 Brake oil cooler

9/18 F86 20A M7 Brake oil cooler

F87 20A

F87 20A
F68 30A

F68 30A

I I
-X24

-X24

-X24

-X24

-X24

-X24

-X24

-X25

-X25

-X25

-X25

-X25

-X25

-X25

-X25

-X25
12/18

16/18

10/18

12/18

11/18

15/18

17/18
6/18

4/18

6/18
5/18

9/18

8/18

3/18
FIRST USED: TA400 T2
NEXT ASSY.: 0PL46960
SIM. TO: 15397390
e Date Name Description:
Assignment

d Reverted camera cables back 114378 C. Heyes 08/11/2016

Designed 01/12/2015 J.CRAIG
c Diode R15 Added, S3 Conx Changed 114168 F.Blackwood 09/08/2016 TA400 T2 Location +3.1
b CAMERA CABLE CHANGED 114215 C.HEYES 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 4
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 1 2 3 4 5 6 7 8 9 10 11 12

-XP7

-XP7

-XP7
+6.4

+6.4

+6.4

31
29

30
+6.4-F63.X:1
/6.A1
F3 Terminal 15

-F59.X

-F45.X

-F62.X
A A

+6.4

+6.4

+6.4
1/2

1/2

1/2
1 1 1
10A 20A 15A
10A ATO Blade Fuse DIN 72581 20A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581
+6.4 15247612 +6.4 15247610 +6.4 15247611
-F59 5050650264 -F45 5050650266 -F62 5050650271
2 2 2
https://one.terex. https://one.terex. https://one.terex.

+6.4

+6.4

+6.4
2/2

2/2

2/2
-F59.X

-F45.X

-F62.X https://one.terex.
ATO fuse shunt
-K10.X

-K10.X

5050650870
-K9.X

-K9.X
B B

02400094P
86/5

30/5

86/4

30/4
86 30 86 30
Mini relay NO switch Power relay NO switch

-X50 1
+6.4

3
-X50a
+6.4

+6.4
0 332 209 204 VF7-11H11-S05
-K10 15247616 -K9 5821662032

+6.4
-XP7

-XP7

-XP7

-XP7

-XP7
+6.4

+6.4

+6.4

+6.4

+6.4

PCB holder ATO jumper 2 position

https://one.terex.
ICS-92049+ICS-95212
85 87 87a https://one.terex. 85 87 https://one.terex.
24

25

26

27

28
+6.4-XP7:1

85/5

87/5

85/4

87/4
-K10.X

-K10.X

-K9.X

-K9.X
/4.C12 +6.4
F3 Terminal 15
-XP15
+6.4 1
-XP13
-F32.X

-F51.X

-F57.X

-F54.X

-F48.X
C 1 +6.4 C
+6.4

+6.4

+6.4

+6.4

+6.4
-X31:5
/6.C3
1/2

1/2

1/2

1/2

1/2

-K12.X

-K12.X
2
-XP14

+6.4
-XP13
GND
1 1 1 1 1 1

86/4

30/4
10A 1A 2A 7.5A 2A
10A ATO Blade Fuse DIN 72581 1A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 7.5A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 30
+6.4 +6.4 +6.4 +6.4 +6.4 86

-F47.X

-F46.X
15247612 15369504 15369505 15247613 15369505
-F32 5050650264 -F51 5050650519 -F57 5350661270 -F54 5050650265 -F48 5350661270 Power relay NO switch

+6.4

+6.4
2 2 2 2 2 +6.4 VF7-11H11-S05
https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex.

1/2

1/2
-K12 5821662032
+6.4

+6.4

+6.4

+6.4

+6.4
2/2

2/2

2/2

2/2

2/2
-F32.X

-F51.X

-F57.X

-F54.X

-F48.X
Relay Not Placed

GND
K10.86

K10.87

Q30_K9 Fuel Heater

1 1
20A 10A 85 87 https://one.terex.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

85/4

87/4
-K12.X

-K12.X
20A ATO Blade Fuse DIN 72581 10A ATO Blade Fuse DIN 72581
+6.4 +6.4
For this document and the object represented in that we reserve all rights according to DIN 34.

15247610 15247612
-F47 5050650266 -F46 5050650264
F32 10A

F51 1A

F57 2A

F54 7.5A
2 2

-XP16
D https://one.terex. https://one.terex. D

+6.4
+6.4

+6.4
2/2

2/2
-F47.X

-F46.X

1
Fuel Heater ON
-X22

-X22

-X22

-X22

-X22

-X26

-X22

-X26
20/21
14/21

13/21

12/21

2/21
1/21

7/21

3/21

F46 10A
-X7
1

-X22

-X22

-X26

-X22
21/21
18/21

11/21

3/21
E E

F16 30A to K13 and K14

+6.4-F16.X:2
/2.I10
-F92.X
+6.4

1/2

F16 30A to K13 and K14

1
F 2A +6.4 F
2A ATO Blade Fuse DIN 72581

-XP20
+6.4 -XP20

+6.4
15369505
-F92 1
2 5350661270

2
+6.4 https://one.terex.

2/2
-F92.X

-K14.X

-K14.X

-K14.X

-K13.X

-K13.X
86/4

30/4
4/5

2/5
5/5
-XP8

-XP8

-XP8

-XP8

-XP8
+6.4

+6.4

+6.4

+6.4

+6.4

https://one.terex. 4 5 2 86 30
24

25

26

27

28

+6.4-XP8:1
G /4.G12 Relay Not Placed Power relay NO switch G
F4 Terminal 15 5050247341 -K14 +6.4 VF7-11H11-S05
0 332 207 402 +6.4 -K13 5821662032
Micro relay changer NO switch
3 1 85 87 https://one.terex.
-F80.X

-F85.X

-F81.X

-F89.X

-F82.X

3/5

1/5

85/4

87/4
-K14.X

-K14.X

-K13.X

-K13.X
+6.4

+6.4

+6.4

+6.4

+6.4
1/2

1/2

1/2

1/2

1/2

1
-XP21
+6.4
1 1 1 1 1
15A 2A 15A 15A 15A
15A ATO Blade Fuse DIN 72581 2A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581
+6.4 15247611 +6.4 15369505 +6.4 15247611 +6.4 15247611 +6.4 15247611 +6.4-XP13:1 -X31:5
-F80 5050650271 -F85 5350661270 -F81 5050650271 -F89 5050650271 -F82 5050650271 /6.C9 /6.H4

7
+6.4
-XP13

+6.4
-XP13
2 2 2 2 2 GND GND
https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex.
H H
+6.4

+6.4

+6.4

+6.4

+6.4
2/2

2/2

2/2

2/2

2/2
-F80.X

-F85.X

-F81.X

-F89.X

-F82.X

F92 2A over K14 Terminal 15 ON

Q13_E_BRAKE_FAN_PROV

K13.X.37 BRAKE_FAN_PROV

F16 20A
F80 15A

F85 2A

F81 15A

F89 15A

F82 15A
-X25

-X25

-X25

-X25

-X25

-X25

-X25

-X25

-X25
18/18

16/18

14/18

13/18
4/18

2/18
5/18

7/18
1/18

I I
FIRST USED: TA400 T2
NEXT ASSY.: 0PL46960
SIM. TO: 15397390
e Date Name Description:
Assignment

d Reverted camera cables back 114378 C. Heyes 08/11/2016

Designed 01/12/2015 J.CRAIG
c Diode R15 Added, S3 Conx Changed 114168 F.Blackwood 09/08/2016 TA400 T2 Location +3.1
b CAMERA CABLE CHANGED 114215 C.HEYES 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 5
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 1 2 3 4 5 6 7 8 9 10 11 12

-XP7

-XP7

-XP7
+6.4

+6.4

+6.4
32

33

34
+6.4-XP7:1
/5.A12
F3 Terminal 15

-F61.X

-F44.X

-F43.X

-F63.X
A A

+6.4

+6.4

+6.4

+6.4
1/2

1/2

1/2

1/2
1 1 1 1
15A 15A 15A 7.5A
15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 15A ATO Blade Fuse DIN 72581 7.5A ATO Blade Fuse DIN 72581
+6.4 15247611 +6.4 15247611 +6.4 15247611 +6.4 15247613
-F61 5050650271 -F44 5050650271 -F43 5050650271 -F63 5050650265
2 2 2 2
https://one.terex. https://one.terex. https://one.terex. https://one.terex.

+6.4

+6.4

+6.4

+6.4
2/2

2/2

2/2

2/2
-F61.X

-F44.X

-F43.X

-F63.X
F61 15A

F44 15A

F43 15A

F63 7.5A
B B
-K11.X

-K11.X

-K7.X

-K7.X

-K6.X

-K6.X

-K8.X

-K8.X
86/4

30/4

86/4

30/4

86/4

30/4

3/5
1/5
86 30 86 30 86 30 1 3

Front work light ON

Power relay NO switch Power relay NO switch Power relay NO switch Micro relay changer NO switch
+6.4 VF7-11H11-S05 +6.4 VF7-11H11-S05 +6.4 VF7-11H11-S05 +6.4 0 332 207 402
-K8
Key switch Emergency operation to K11.X.86

-K11 5821662032 -K7 5821662032 -K6 5821662032 15386559

5050247341
85 87 https://one.terex. 85 87 https://one.terex. 85 87 https://one.terex. 2 5 4 https://one.terex.
85/4

87/4

85/4

87/4

85/4

87/4

2/5

5/5
-K11.X

-K11.X

-K7.X

-K7.X

-K6.X

-K6.X

-K8.X

-K8.X
C C

+6.4-XP13:1 -X31:5
/5.C10 /5.H7

5
+6.4
-XP13

+6.4
-XP13

+6.4
-XP13
GND GND
K11.87 emergency operation
GND
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

Rear work light ON

E14/E15 Reat work light ON

E11/E12 Front work light ON

Electrical Horn ON

P1+P2 Electrical Horn ON

For this document and the object represented in that we reserve all rights according to DIN 34.

D D
-X22

-X22

-X26

-X27

-X26

-X27

-X26

-X27
21/21
15/21
6/21

6/21
9/21

8/21

9/21

1/21
E E
9/21

19/21
-X26

-X27

-X28

-X28

-X28

-X28

-X29

-X29

-X29

-X29

-X29

-X29
5/9

3/9

7/9

9/9

6/15

13/15

12/15

9/15

3/15

1/15
+6.4
-X52 1 ATO fuse shunt
+6.4 02400094P
F -X52a 5050650870 F
PCB holder ATO jumper 2 position
M1 front wiper speed 1

KX22.3 to K15X.3

K5 to M1 front wiper speed 2

K5 to K22.X6 front wiper speed 2

F52 1A to K3 Terminal 15 12V

T1 +12V
ICS-92049+ICS-95212 2 https://one.terex.

Wiper motor rear ON

M4 Wiper motor rear ON

GND
F65 5A Brake Pedal Activated

S27 Brake pedal activated

https://one.terex.
K17.X.1

+6.4-X59:3 (3)
/7.C1
1
+6.4
-XP22

K11.87 emergency operation

-K17.X

-K17.X

-K15.X

-K15.X

-K16.X

-K16.X

-K3.X

-K3.X

-K5.X

-K5.X

-K4.X

-K4.X
G G

86/5

30/5
3/5

3/5

3/5

3/5

3/5
1/5

1/5

1/5

1/5

1/5
1 3 1 3 1 3 1 3 1 3 86 30
Micro relay changer NO switch Micro relay changer NO switch Micro relay changer NO switch Micro relay changer NO switch Micro relay changer NO switch Mini relay NO switch
+6.4 0 332 207 402 +6.4 0 332 207 402 +6.4 0 332 207 402 +6.4 0 332 207 402 +6.4 0 332 207 402 +6.4 0 332 209 204
-K17 15386559 -K15 15386559 -K16 15386559 -K3 15386559 -K5 15386559 -K4 15247616
5050247341 5050247341 5050247341 5050247341 5050247341
2 5 4 https://one.terex. 2 5 4 https://one.terex. 2 5 4 https://one.terex. 2 5 4 https://one.terex. 2 5 4 https://one.terex. 85 87 87a https://one.terex.
2/5

5/5

2/5

5/5

4/5

2/5

5/5

4/5

2/5

5/5

4/5

2/5

5/5

4/5

85/5

87/5

87a/5
-K17.X

-K17.X

-K15.X

-K15.X

-K15.X

-K16.X

-K16.X

-K16.X

-K3.X

-K3.X

-K3.X

-K5.X

-K5.X

-K5.X

-K4.X

-K4.X

-K4.X
H H

GND

GND

GND

K4 Park Brake Sol GND

12V Terminal 15

K3.X.4

K5.X.5
F53 5A to M1 and M4 wiper motors
+6.4-XP13:1 -X31:5
/5.H9 /7.H4
8

9
+6.4
-XP13

+6.4
-XP13

+6.4
-XP13
10

GND GND
M1.X.31b to K15.X.4
F53 5A to M1 and M4 wiper motors
S27 Brake pedal activated

F53 5A to M1 and M4 wiper motors

M4.X.31b Wiper motor rear

-X29

-X29

-X29

-X29

-X29

-X29

-X29

-X29

-X29
10/15

11/15

15/15

14/15

2/15

4/15
8/15

7/15

5/15
I I
-X27

-X28

-X28

-X28

-X28
16/21

6/9

4/9

2/9
8/9

FIRST USED: TA400 T2

NEXT ASSY.: 0PL46960
SIM. TO: 15397390
e Date Name Description:
Assignment

d
Reverted camera cables back 114378 C. Heyes 08/11/2016
Designed 01/12/2015 J.CRAIG
c
Diode R15 Added, S3 Conx Changed 114168 F.Blackwood 09/08/2016 TA400 T2 Location +3.1
b
CAMERA CABLE CHANGED 114215 C.HEYES 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a
RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 6
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 1 2 3 4 5 6 7 8 9 10 11 12

A A

19/21

14/21

18/21

12/21

17/21

21/21

15/21
-X26

-X26

-X26

-X26

-X26

-X26

-X26
Low range selection

High range selection

Low Idle Load sense pressure

System hydraulics unloader valve

Body raise
Difflock dropbox
+6.4 Engage mid axle difflock +6.4 +6.4 +6.4 +6.4 +6.4 +6.4
-X66 1 ATO fuse shunt -X55 1 ATO fuse shunt -X57 1 ATO fuse shunt -X53 1 ATO fuse shunt -X65 1 ATO fuse shunt -X58 1 ATO fuse shunt -X54 1 ATO fuse shunt
B +6.4 02400094P +6.4 02400094P +6.4 02400094P +6.4 02400094P +6.4 02400094P +6.4 02400094P +6.4 02400094P B
-X66a 5050650870 -X55a 5050650870 -X57a 5050650870 -X53a 5050650870 -X65a 5050650870 -X58a 5050650870 -X54a 5050650870
PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position
ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex.

https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex.

3 3 3 3 3 3 3

C C
+6.4-K11.X:87 +6.4-X59:3 (3)
/6.G5 /8.D1
2

8
6

7
+6.4
-XP22

+6.4
-XP22

+6.4
-XP22

+6.4
-XP22

+6.4
-XP22

+6.4
-XP22

+6.4
-XP22
K11.87 emergency operation K11.87 emergency operation

Q4 Low range selection

Q5 High range selection

Q2 Low Idle Load sense pressure

Q6 System hydraulics unloader valve

Q8 Body raise
Q3 Difflock dropbox
Q29 Engage mid axle difflock
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
For this document and the object represented in that we reserve all rights according to DIN 34.

D D
-X27

-X27

-X27

-X27

-X27

-X27

-X27
10/21

12/21

14/21

11/21
6/21

5/21

3/21
E E

F25 2A to SUB-D programming connector

+6.4-XP3:1
/2.E6
13/21

7/21

20/21

21/21

6/21

9/21

12/21
-X30

-X30

-X30

-X30

-X30

-X30

-X30

-X33
5/6
F F
+6.4
-X51 1 1W Ω 120 +6.4

R5 AN
ATO fuse shunt RC2512FK-071K2 -R2
+6.4 02400094P
-X51a 5050650870
PCB holder ATO jumper 2 position https://one.terex.
CAN2_H

CR0232 RxD

CR0232 TxD
CAN2_L

CR0232 Test
ICS-92049+ICS-95212 2 https://one.terex. AN Diode
+6.4 8EWS08SPbF
+6.4 -R5
https://one.terex. KAT
-XP26

-XP26
+6.4

https://one.terex.
3 2
1

R5 KAT
G +6.4 G
-XP25

+6.4 120 Ω 1W
-XP25
+6.4

-R1 RC2512FK-071K2
2
1

-P1.X
+6.4

10/2
https://one.terex.
-XP13

-XP13

-XP13

10
CAN2_H

CAN2_L

+6.4

+6.4

+6.4

Glass socket lamp 28V

11

12

13

+6.4-XP13:1 +6.4
+6.4 /6.H7 596 710
GND
-P1 5050650222
-XP24

-XP24
+6.4

9 https://one.terex.
1
3

+6.4

9/2
-P1.X
+6.4 CAN2_L
2
+6.4
-XP24

-XP23

-XP23
+6.4

H +6.4 +6.4 120 Ω 1W H

1

F25 2A to SUB-D programming connector

3

-R3 RC2512FK-071K2 120 Ω 1W

CAN2_H -XP27 +6.4
2
+6.4
-XP23

-R4 RC2512FK-071K2
1

CR0232 RxD

CR0232 TxD

GND
https://one.terex.
https://one.terex.
CAN2_H

CAN2_H

CAN2_H

R2 120OHM H

R2 120OHM H

CAN3_H
GND

GND

GND
CAN2_L

CAN2_L

CAN2_L

R2 120OHM L

R2 120OHM L

CAN3_L

CAN4_H
P1.X.9

CAN4_L
P1.X.9

-X32

-X32

-X32

-X32
6/6

4/6

2/6
-X30

-X30

-X30

-X30

-X30

-X30

-X30

-X30

-X30

-X30

-X30

-X30

-X30

-X33

-X32

1/6
11/21

10/21

19/21

16/21

14/21

18/21

17/21

15/21
4/21

2/21

1/21

3/21

5/21

-X31

-X31

-X31

-X31

-X31

4/6

5/6
I I
2/9

6/9
3/9

5/9

9/9
FIRST USED: TA400 T2
NEXT ASSY.: 0PL46960
SIM. TO: 15397390
e Date Name Description:
Assignment

d Reverted camera cables back 114378 C. Heyes 08/11/2016

Designed 01/12/2015 J.CRAIG
c Diode R15 Added, S3 Conx Changed 114168 F.Blackwood 09/08/2016 TA400 T2 Location +3.1
b CAMERA CABLE CHANGED 114215 C.HEYES 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 7
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 1 2 3 4 5 6 7 8 9 10 11 12

OCDB Triple motor ON 10/21

A A

13/21
System hydraulics float valve

2/21

7/21

16/21

13/21

20/21
-X26

-X27

-X26

-X27

-X26

-X27

-X26

-X33
3/6
https://one.terex.

https://one.terex.

https://one.terex.
ATO fuse shunt

ATO fuse shunt

ATO fuse shunt

5050650870

5050650870

5050650870
02400094P

02400094P

02400094P
Park brake

Body lower
-X63 1

-X62 1

-X64 1
2

3
-X63a

-X62a

-X64a
+6.4

+6.4

+6.4
+6.4

+6.4

+6.4
System hydraulics float valve
PCB holder ATO jumper 2 position

PCB holder ATO jumper 2 position

PCB holder ATO jumper 2 position

https://one.terex.

https://one.terex.

https://one.terex.
ICS-92049+ICS-95212

ICS-92049+ICS-95212

ICS-92049+ICS-95212
B B

+6.4 +6.4 +6.4 +6.4 +6.4

-X67 1 ATO fuse shunt -X56 1 ATO fuse shunt -X68 1 ATO fuse shunt -X59 1 ATO fuse shunt -X61 1 ATO fuse shunt
+6.4 02400094P +6.4 02400094P +6.4 02400094P +6.4 02400094P +6.4 02400094P
-X67a 5050650870 -X56a 5050650870 -X68a 5050650870 -X59a 5050650870 -X61a 5050650870
PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position PCB holder ATO jumper 2 position
ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex. ICS-92049+ICS-95212 2 https://one.terex.

C https://one.terex. https://one.terex. https://one.terex. https://one.terex. https://one.terex. C

Q28 OCDB Triple motor ON

Q17 Park brake

Q10 SytemHydraulics Float

Q9 Body lower
3 3 3 3 3

+6.4-K11.X:87
/7.C11

11
9
+6.4
-XP22

+6.4
-XP22
10

+6.4
-XP22
K11.87 emergency operation
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
For this document and the object represented in that we reserve all rights according to DIN 34.

D D
-X27

-X27

-X27

-X27

-X27
20/21
17/21

18/21

4/21
8/21

E E

4/21
-X26
F F

https://one.terex.
ATO fuse shunt

5050650870
02400094P
G G

-X60 1

3
-X60a
+6.4
+6.4

PCB holder ATO jumper 2 position

https://one.terex.
ICS-92049+ICS-95212
H H

-X27
1/21

I I
FIRST USED: TA400 T2
NEXT ASSY.: 0PL46960
SIM. TO: 15397390
e Date Name Description:
Assignment

d Reverted camera cables back 114378 C. Heyes 08/11/2016

Designed 01/12/2015 J.CRAIG
c Diode R15 Added, S3 Conx Changed 114168 F.Blackwood 09/08/2016 TA400 T2 Location +3.1
b CAMERA CABLE CHANGED 114215 C.HEYES 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 8
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 I
E
B
A

H
D

F
C

G
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-A6
-A6

/9.B1
/9.G1

/10.B1
+2/1.F11

+6.4
+6.4

GND
+2/1.I11
+3.1

+6.5-XGND2:M8:1 (a)
-X22 F57 2A
1/21
1

1
+6 +3.1
F17 20A to B3.1 30EMS 2.50 mm² +6 -W221 RD -A1.X20 -X20
+6 +6 +3.1 +2/1.F5 F17 20A to B3.1 30EMS

+6
-X6.63a 1.5 mm² +6 -W399 BK -A1.X22 -X22 +6-X3:A F17 20A to B3.1 30EMS 1/12 1/1
F60 7.5A Terminal 15
F60 7.5A Terminal 15 2/21 2/21

-X6 63
+6 +3.1
+6-X6.49b:1 -A1.X20 -X20
+3.1 1.50 mm² +6 -W196 RD F20 15A Reserve Cabin Terminal 30
/31.B1 F20 15A Reserve Cabin Terminal 30 2/12
-X22 K12.87 F20 15A Reserve Cabin Terminal 30 2/12
3/21

+3.1
+3.1 -X20 F18 2A SPARE
-X22 3/12
F55 5A Cabin switches
4/21
2

2
+6 +3.1
F21 20A to B3.6 30EMS 2.50 mm² +6 -W223 RD -A1.X20 -X20
+6 +3.1 +2/1.F6 F21 20A to B3.6 30EMS
+6-X16:c -A1.X22 -X22 F21 20A to B3.6 30EMS 4/12 4/12
1.00 mm² +6 -W329 BK F58 3A Sensors Drop box +6-X3:C
+4.4/30.A7 F58 3A Sensors Drop box 5/21
F58 3A Sensors Drop box 5/21
+6 +3.1
F19 15A to K18.X1.19 VBBO 2.50 mm² +6 -W230 RD -A1.X20 -X20 F19 15A to K18.X1.19 VBBO
+6/14.A7 F19 15A to K18.X1.19 VBBO 5/12
+6-K18.XL:19 5/12

+6 +3.1
F22 3A to K18.X1.10 VBBs 1.0 mm² +6 -W227 RD -A1.X20 -X20
+3.1 F22 3A to K18.X1.10 VBBs
+6/14.A6 F22 3A to K18.X1.10 VBBs 6/12
-X22 F54 7.5A +6-X6.2a:1 6/12
7/21
3

3
+6 +3.1
F25 2A to SUB-D programming conctr 0.50 mm² +6 -W92 RD -A1.X20 -X20
+6 +3.1 F25 2A to SUB-D programming conctr
+6-X6.92a:1 +6/21.B9 F25 2A to SUB-D programming conctr 7/12
1.0 mm² +6 -W415 BK -A1.X22 -X22 F56 1A B18 Speed sensor +6-Xs25.SB:3 7/12
+4.4/30.B6 F56 1A B18 Speed sensor 8/21
F56 1A B18 Speed sensor 8/21
+6 +3.1
F23 15A to K18.X1.1 VBBR 2.50 mm² +6 -W229 RD -A1.X20 -X20
+6 +6 +3.1 +6/14.A7 F23 15A to K18.X1.1 VBBR
-XGND5.c 1.00 mm² +6 -W377 BN -A1.X22 -X22 +6-K18.XL:1 F23 15A to K18.X1.1 VBBR 8/12 8/12
GND
1 GND 9/21 9/21

M8:6
+6 +3.1
+6-X6.50b:1 -A1.X20 -X20
1.00 mm² +6 -W388 RD

+6 -XGND5
+6 +3.1 F24 7.5A Terminal 30
+6-A1.X29:6 /31.B2 F24 7.5A Terminal 30 10/12
0.75 mm² +6 -W321 WH -A1.X22 -X22 F52 1A to K3 Terminal 15 12V F24 7.5A Terminal 30 10/12
+6/12.C6 F52 1A to K3 Terminal 15 12V 10/21
F52 1A to K3 Terminal 15 12V 10/21
4

4
+6 +6 +3.1
+6 -X6.54a 1.5 mm² +6 -W390 RD -A1.X20 -X20 F26 15A Reserve Cabin Terminal 30
+3.1
+6-Xs30.SB:3 -A1.X22 -X22 F26 15A Reserve Cabin Terminal 30 9/12 9/12
1.00 mm² +6 -W311 BK
+6 54

F53 5A to M1 and M4 wiper motors

+3/24.E1 F53 5A to M1 and M4 wiper motors 11/21
F53 5A to M1 and M4 wiper motors 11/21
+6 +6 +3.1
-X6.57a 1.5 mm² +6 -W391 RD -A1.X20 -X20 F26 15A Reserve Cabin Terminal 30
+3.1
-X22 F26 15A Reserve Cabin Terminal 30 11/12 11/12
+6 57

K10.87
12/21

+6 +6 +3.1
+6

+3.1 -X6.60a 1.5 mm² +6 -W392 RD -A1.X20 -X20 F26 15A Reserve Cabin Terminal 30
-X22 F26 15A Reserve Cabin Terminal 30 12/12 12/12
-X6 +6 -XJ19 1 -X6 +6 -XJ19 2 -X6 60

F51 1A
13/21
+3.1
5

5
-X21 F6 7.5A Terminal 30
1/12
+3.1 +6
+6

-X22 +6-S21.X:13 -X6.6b

F32 10A 1.0 mm² +6 -W69 RD
14/21 +6/21.B2 F8 15 A to K19.X.10/70 TCU
F8 15 A to K19.X.10/70 TCU

+6 +3.1
2.50 mm²

+6-X16:r -A1.X22 -X22

1.00 mm² +6 -W324 BK F27 3A sensors front frame +6 +6 +6 +3.1
+3/29.A6
+6

F27 3A sensors front frame F27 3A sensors front frame 15/21 15/21 +6-Xs31.SB:1 -X6.3b -X6.3a -A1.X21 -X21
2.5 mm² +6 -W271 RD 2.50 mm² +6 -W278 RD F8 15 A to K19.X.10/70 TCU
+6/16.D2
-X6 6 +6 -XJ13 1 -X6 3

F8 15 A to K19.X.10/70 TCU F8 15 A to K19.X.10/70 TCU F8 15 A to K19.X.10/70 TCU 2/12 2/12

+6 +3.1
+6-Xs22.SB:3 -A1.X22 -X22
1.00 mm² +6 -W191 BK F49 5A to OMNIA switch +6 +3.1
+6/17.A6 F49 5A to OMNIA switch 16/21 +6-Xs33.SB:3
F49 5A to OMNIA switch 16/21 1.00 mm² +6 -W378 RD -A1.X21 -X21 F7 2A Key switch Emergency operation
/9.B11
6

6
F7 2A Key switch Emergency operation F7 2A Key switch Emergency operation 3/12 3/12

+6 +3.1
+6-Xs19.SB:3 -A1.X22 -X22
1.00 mm² +6 -W129 BK F30 3A to Rockerswitches +6 +3.1
+6/18.B4 F30 3A to Rockerswitches 17/21 +6-X37:13
F30 3A to Rockerswitches 17/21 1.00 mm² +6 -W132 WH -A1.X21 -X21 F9 5A Interior lamp
+3/24.A10 F9 5A Interior lamp 4/12
F9 5A Interior lamp 4/12
+6 +3.1
+6-X3:T 2.50 mm² +6 -W447 WH -A1.X22 -X22 Fuel Heater ON +3.1
+2/1.F8 Fuel Heater ON 18/21
Fuel Heater ON 18/21 -X21
5/12

+6 +3.1
+6-K20.XK:02 -A1.X22 -X22
1.00 mm² +6 -W8 BK F50 7.5A to K20.XK.2 Dashboard +6 +3.1
+6/17.A5 F50 7.5A to K20.XK.2 Dashboard 19/21 +6-S6.X:3
F50 7.5A to K20.XK.2 Dashboard 19/21 1.50 mm² +6 -W115 RD -A1.X21 -X21 F10 7.5A Hazard
+6/18.A2
7

7
F10 7.5A Hazard F10 7.5A Hazard 6/12 6/12

d
c
a
b
e
+3.1
-X22 +3.1
20/21 -X21
7/12

Rev. Index Revision

+3.1
-X22 F46 10A +6 +3.1
21/21 +6-T1.+24V:1 -A1.X21
2.5 mm² +6 -W148 RD -X21 F11 15A to T1 24V/12V convertor
+6/26.B3 F11 15A to T1 24V/12V convertor 8/12
F11 15A to T1 24V/12V convertor 8/12
+6 +3.1

Diode R15 Added, S3 Conx Changed

-A1.X22 -X22 Key switch Emergency operation to K11.X.86

CAMERA CABLE CHANGED

Reverted camera cables back
6/21 6/21

RELEASED TO PRODUCTION
8

8
ECN No.
113744
114215
114168
114378
+6 +6 +6 +3.1
+6

+6-W506.X1:2 0.34 mm² +6 -W506.W1 2_WH -X6.53b -X6.53a 1.0 mm² +6 -W389 RD -A1.X21 -X21 F12 2A to Telematic connector
+6/13.F2 F12 2A to Telematic connector F12 2A to Telematic connector 10/12
F12 2A to Telematic connector 10/12
-X6 53

Name
D. Alford

J.CRAIG
C. Heyes

C.HEYES
+6 +3.1
+6-X37:14 1.50 mm² +6 -W131 RD -A1.X21 -X21
+3/24.A9 F14 10A Air seat compressor
F14 10A Air seat compressor F14 10A Air seat compressor 11/12 11/12

Date
+6 +3.1
01/12/2015
09/08/2016
08/11/2016

+6-X1.X+:1 -A1.X21 -X21

2.50 mm² +6 -W136 RD F13 15A work socket 24V
9

+3/25.A4
9
F13 15A work socket 24V F13 15A work socket 24V 12/12 12/12
Date
Name
Designed 01/12/2015 J.CRAIG

Approved 01/12/2015 G.McNEIL

23/06/2016 Checked 01/12/2015 J.BROWNLIE
10

10
Type
M.-Nr.: T2
+6/14.G9

TA400 G10
-S25
+6

Master
-K18
+6

+6 +6
-Xs33

welding splice
Ultrasonic

1.00 mm² +6 -W381 WH -S25.X2 -S25.X1 1.00 mm² +6 -W379 RD 1.00 mm² +6 -W378 RD +6-A1.X21:3
Key switch Emergency operation to K11.X.86 F7 2A Key switch Emergency operation F7 2A Key switch Emergency operation /9.D6
1/1 1/1
3

F7 2A Key switch Emergency operation

+6 +6 +6
Ex-X2
11

15400612
11

-K18.XR 1.00 mm² +6 -W382 WH -S25.X4 -S25.X3 1.00 mm² +6 -W380 RD

Origin Project
I15_E

Key switch Emergency operation ON F7 2A Key switch Emergency operation

3

CR0232

38/55 1/1 1/1

15325548
5050143198
38

Main Controller

https://one.terex.
Emergency operation

Description:
038773
15400822

IN_S25_EmergencyOperation_ON

Input binary high side

TA400 GEN9 T2
GND
4 CONTACT NO x 2

/10.I1
Key switch Q25S1 ( IP65 )

+6-XGND5:M8:3 (c)
2 Positions Momentary

15400615
Drawing number
SIM. TO:
12

12
FIRST USED:
NEXT ASSY.:

No.
Sheet
Assignment
TA400 T2

9
15397390
0PL46960

Location +03A

34 Sh.
I
E
B
A

H
D

F
C

G
 I
E
B
A

H
D

F
C

G
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-A6
-A6
/9.G1
+3.1

/10.B1
/10.G1

+6.4
+6.4

+6/11.B1
-X23 F42 5A
1/18

+3.1
1

-X25

1
F80 15A +6 +3.1
1/18 +6-K18.XR:32 -A1.X23 -X23
2.50 mm² +6 -W238 BK F40 15A to K18.X2.32 VBB3
+6/14.A8 F40 15A to K18.X2.32 VBB3 2/18
F40 15A to K18.X2.32 VBB3 2/18

+3.1
-X25 F82 15A +6 +6 +3.1

+6
2/18 -X6.59a 2.5 mm² +6 -W396 BK -A1.X23 -X23 F39 15A Terminal 15
F39 15A Terminal 15 3/18 3/18

-X6 59
+3.1
-X25 F83 15A +3.1
3/18 -X23 F42 5A
4/18

+3.1
2

-X25

2
F81 15A +6 +6 +3.1
4/18 -X37 1.00 mm² +6 -W435 BK -A1.X23 -X23 F37 5A Camera system
11/15 F37 5A Camera system 5/18 5/18

+3.1
-X25 F85 2A +3.1
5/18 -X23 F37 5A
6/18

+3.1
-X25 F84 2A +6 +3.1
6/18 -A1.X23 -X23 F41 2A to S4
F41 2A to S4 F41 2A to S4 7/18 7/18

+3.1
3

-X25

3
F16 20A +6 +6 +3.1
+6

7/18 -X6.61a 1.0 mm² +6 -W397 BK -A1.X23 -X23 F36 5A Terminal 15

F36 5A Terminal 15 8/18 8/18
-X6 61

+6 +3.1
+6-Xs36.SB:1 -A1.X25 -X25
1.50 mm² +6 -W436 BK F86 20A M7 Brake oil cooler +6 +3.1
/31.A4 F86 20A M7 Brake oil cooler 8/18 F35 1A T15 to P51E
F86 20A M7 Brake oil cooler 8/18 1.00 mm² +6 -W236 RD -A1.X23 -X23 F35 1A T15 to P51E
+6/14.A8 F35 1A T15 to P51E 9/18
+6-K18.XR:51 9/18
+6 +3.1
+6-Xs36.SB:3 -A1.X25 -X25
1.50 mm² +6 -W437 BK F86 20A M7 Brake oil cooler +6 +3.1
/31.A5 F86 20A M7 Brake oil cooler 9/18 +6-X16:x
F86 20A M7 Brake oil cooler 9/18 1.00 mm² +6 -W340 BK -A1.X23 -X23 F38 2A Sensors trailer
+3/23.A7 F38 2A Sensors trailer 10/18
F38 2A Sensors trailer 10/18

+3.1
4

4
-X25 F91 15A +3.1
10/18 -X23
11/18

+3.1
-X25 F87 20A +3.1
11/18 -X23 F34 5A Sensors Hydraulic Block
12/18

+3.1
-X25 F87 20A +3.1
12/18 -X23 F29 5A
13/18

+6 +3.1
5

+6-X6.104a:1

5
2.5 mm² +6 -W440 WH -A1.X25 -X25 K13.X.37 BRAKE_FAN_PROV +6 +3.1
+3/33.B2 K13.X.37 BRAKE_FAN_PROV 13/18 +6-Xs35.SB:3
K13.X.37 BRAKE_FAN_PROV 13/18 1.00 mm² +6 -W393 RD -A1.X23 -X23 F29 5A to Oil sensors
/31.A8 F29 5A to Oil sensors 14/18
F29 5A to Oil sensors 14/18
+6 +3.1
+6-X6.103b:1 1.00 mm² +6 -W439 WH -A1.X25 -X25 Q13_E_BRAKE_FAN_PROV +6 +3.1
+3/33.E1 Q13_E_BRAKE_FAN_PROV 14/18 +6-X16:u
Q13_E_BRAKE_FAN_PROV 14/18 1.00 mm² +6 -W413 BK -A1.X23 -X23 F34 5A Sensors Hydraulic Block
+3/29.A7 F34 5A Sensors Hydraulic Block 15/18
F34 5A Sensors Hydraulic Block 15/18

+3.1
-X25 F88 1A +6 +3.1
15/18 F28 15A to K18.X2.10 VBB4 2.50 mm² +6 -W237 BK -A1.X23 -X23 F28 15A to K18.X2.10 VBB4
+6/14.A8 F28 15A to K18.X2.10 VBB4 17/18
+6-K18.XR:10 17/18

+3.1
6

6
-X25 F92 2A over K14 Terminal 15 ON +6 +3.1
16/18 +6-X6.51b:1 -A1.X23 -X23
1.5 mm² +6 -W198 BK F31 5A TO HVAC Actuators
/31.B2 F31 5A TO HVAC Actuators 18/18
F31 5A TO HVAC Actuators 18/18

+3.1
-X25 F90 1A
17/18
+6 +3.1
+6-K18.XR:19 2.50 mm² +6 -W240 BK -A1.X24 -X24 F66 15A to K18.X2.19 VBB1
+6/14.A9 F66 15A to K18.X2.19 VBB1 1/18
F66 15A to K18.X2.19 VBB1 1/18
+3.1
-X25 F89 15A
18/18
+6 +3.1
+6-A1.X27:19 -A1.X24 -X24
1.00 mm² +6 -W197 BK F65 5A Brake Pedal Activated
+6/11.H7 F65 5A Brake Pedal Activated 2/18
F65 5A Brake Pedal Activated 2/18
7

7
d
c
a
b
e
+3.1
-X24
3/18

Rev. Index Revision

+3.1
-X24 F68 30A
4/18

+3.1

Diode R15 Added, S3 Conx Changed

-X24 F68 30A

CAMERA CABLE CHANGED

Reverted camera cables back
5/18

RELEASED TO PRODUCTION
8

8
+3.1

ECN No.
-X24

113744
114215
114168
114378
F68 30A
6/18

Name
+6 +3.1

D. Alford

J.CRAIG
+6-S16.X:2
C. Heyes
-A1.X24 -X24

C.HEYES
2.50 mm² +6 -W80 BK F69 15A to S16 Heated mirror
+6.1/20.A3 F69 15A to S16 Heated mirror 7/18
F69 15A to S16 Heated mirror 7/18

Date
+3.1
-X24 F70 15
01/12/2015
09/08/2016
08/11/2016

8/18
9

+6 +3.1
+6-X3:H -A1.X24 -X24
1.00 mm² +6 -W328 BK F67 3A B5 Fuel level sensor
Date

+3/23.A10 F67 3A B5 Fuel level sensor 9/18

F67 3A B5 Fuel level sensor 9/18

+3.1
-X24 F71 10A
Name

10/18
Designed 01/12/2015 J.CRAIG

Approved 01/12/2015 G.McNEIL

23/06/2016 Checked 01/12/2015 J.BROWNLIE

+6 +3.1
+6-Xs46.SB:11 2.5 mm² +6 -W164 BK -A1.X24 -X24
+6/26.B5 F74 20A 24V TO HVAC
F74 20A 24V TO HVAC F74 20A 24V TO HVAC 11/18 11/18
10

10

+6
Type

+3.1
+6-X3:B -A1.X24 -X24
1.50 mm² +6 -W222 BK F78 10A to B3.3 15EMS
+2/1.F5 F78 10A to B3.3 15EMS 12/18
12/18
M.-Nr.: T2

F78 10A to B3.3 15EMS

+6 +3.1
-Xs27

welding splice
Ultrasonic

+6-K19.X:63 -A1.X24 -X24

TA400 G10

1.50 mm² +6 -W281 BK 1.50 mm² +6 -W280 BK F72 10A to K19 X63
+6/16.D2 F72 10A to K19 X63 F72 10A to K19 X63 13/18
F72 10A to K19 X63 13/18

+6-S21.X:12
1.00 mm² +6 -W70 BK +6 +3.1
+6/21.B2 F72 10A to K19 X63
+6 F72 10A to K19 X63 -A1.X24 -X24 F75 10A Terminal 15
+6

-X6.56a 1.5 mm² +6 -W394 BK 14/18 14/18

11

15400612
11

F75 10A Terminal 15

Origin Project

+6 +6 +3.1
+6

-X6.58a 1.5 mm² +6 -W395 BK -A1.X24 -X24 F77 10A Spare

Description:

F77 10A Spare 15/18 15/18

-X6 56 -X6 58

TA400 GEN9 T2
GND

+3.1
+6/11.I1

-X24 F73 15A

16/18
+6-XGND5:M8:3 (c)

15400615

+6 +3.1
+6-X3:G
Drawing number

1.50 mm² +6 -W224 BK -A1.X24 -X24 F76 10A to C4014 15_SCR

+2/1.F7
SIM. TO:

F76 10A to C4014 15_SCR F76 10A to C4014 15_SCR 17/18 17/18
12

12
FIRST USED:
NEXT ASSY.:

+6 +3.1
+6-K18.XR:1
No.

2.50 mm² +6 -W239 BK -A1.X24 -X24 F79 15A to K18.X2.1 VBB2

Sheet

+6/14.A8 F79 15A to K18.X2.1 VBB2 18/18

Assignment

F79 15A to K18.X2.1 VBB2 18/18

TA400 T2

10
15397390
0PL46960

Location +03A

34 Sh.
I
E
B
A

H
D

F
C

G
 I
E
B
A

H
D

F
C

G
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-A6
-A6

/12.B1
/11.B1
/11.G1

+6.4
+6.4
+03A/10.G1

GND
-XGND5:M8:6 (f)
+03A/10.I11
1

1
+3.1 +3.1
-X27 -K18.XL:6 1.00 mm² -W319 WH -A1.X26 -X26
X27.1 Electrical Horn ON
1/21
+3/24.C8 Electrical Horn ON 1/21
Electrical Horn ON 1/21

+3.1 +3.1
-X27 X27.2 1.00 mm² -W408 WH -A1.X26 -X26 Q30_K9 Fuel Heater
2/21 +3/33.C3 Q30_K9 Fuel Heater 2/21
-K18.XR:48 2/21
Q30_K9 Fuel Heater

+3.1 +3.1
-X15:t 1.00 mm² -W368 WH -A1.X27 -X27 -X26
+3/28.C2 Q8 Body raise K10.86
Q8 Body raise Q8 Body raise 3/21 3/21 3/21
2

2
+3.1 +3.1
-X27 X27.4 -X26 X26.4
4/21 4/21

+3.1 +3.1
-X15:n -A1.X27 -X27 -X26
1.00 mm² -W362 WH Q4 Low range selection
+3/27.C8 Q4 Low range selection 5/21 5/21
Q4 Low range selection 5/21

+3.1 +3.1
-X15:l -A1.X27 -X27 -K18.XL:7 -A1.X26 -X26
1.00 mm² -W358 WH Q2 Low Idle Load sense pressure 1.00 mm² -W318 WH Front work light ON
+3/27.C4 Q2 Low Idle Load sense pressure 6/21 +3/25.C8 Front work light ON 6/21
Q2 Low Idle Load sense pressure 6/21 Front work light ON 6/21
3

3
+3.1 +3.1
-X27 X27.7 -X26
7/21 7/21

+3.1 +3.1
-X15:A -A1.X27 -X27 -K18.XR:45 -A1.X26 -X26
1.00 mm² -W374 WH Q28 OCDB Triple motor ON 1.00 mm² -W344 WH Rear work light ON
+3/29.E3 Q28 OCDB Triple motor ON 8/21
+3/25.C10 Rear work light ON 8/21
Q28 OCDB Triple motor ON 8/21 Rear work light ON 8/21

-A1.X27:16
+3.1 1.0 mm² -W487 WH +3.1
-X6.45a:1 /11.H6 S27 Brake pedal activated
2.50 mm² -W345 WH -A1.X27 -X27 E14/E15 Reat work light ON S27 Brake pedal activated -A1.X26 -X26 S27 Brake pedal activated
+3/25.A8 E14/E15 Reat work light ON 9/21 9/21
E14/E15 Reat work light ON 9/21 9/21
S27 Brake pedal activated S27 Brake pedal activated
4

4
+3.1 +3.1
-X15:k -A1.X27 -X27 -K18.XR:29 -A1.X26 -X26
1.00 mm² -W356 WH Q29 Engage mid axle difflock 1.00 mm² -W373 WH OCDB Triple motor ON
+3/27.D1 Q29 Engage mid axle difflock 10/21
+3/29.C3 OCDB Triple motor ON 10/21
Q29 Engage mid axle difflock 10/21 OCDB Triple motor ON 10/21

+3.1 +3.1
-X15:r -A1.X27 -X27 -X26
1.00 mm² -W366 WH Q6 System hydraulics unloader valve K12.85
+3/27.C5 Q6 System hydraulics unloader valve 11/21 11/21
Q6 System hydraulics unloader valve 11/21

+3.1 +3.1
-X15:m -A1.X27 -X27 -K18.XR:13 -A1.X26 -X26
1.00 mm² -W360 WH Q3 Difflock dropbox 1.00 mm² -W361 WH Low range selection
+3/27.C11 Q3 Difflock dropbox 12/21 +3/27.C8 Low range selection 12/21
Q3 Difflock dropbox 12/21 Low range selection 12/21
5

5
+3.1 +3.1
-X27 -K18.XR:27 1.00 mm² -W371 WH -A1.X26 -X26
X27.13 +3/28.C4 System hydraulics float valve
13/21 System hydraulics float valve System hydraulics float valve 13/21 13/21

+3.1 +3.1
-X15:p -A1.X27 -X27 -K18.XL:9 -A1.X26 -X26
1.00 mm² -W364 WH Q5 High range selection 1.00 mm² -W357 WH Low Idle Load sense pressure
+3/27.C10 Q5 High range selection 14/21 +3/27.C4 Low Idle Load sense pressure 14/21
Q5 High range selection 14/21 Low Idle Load sense pressure 14/21

+3.1 +3.1
-X6.43a:1 2.50 mm² -W317 WH -A1.X27 -X27 -K18.XR:8 1.00 mm² -W367 WH -A1.X26 -X26
E11/E12 Front work light ON Body raise
+3/25.A6 E11/E12 Front work light ON 15/21
+3/28.C1 Body raise 15/21
E11/E12 Front work light ON 15/21 Body raise 15/21
6

6
-A1.X26:9 1.0 mm² -W487 WH
/11.D4 +3.1 +3.1
S27 Brake pedal activated S27 Brake pedal activated -A1.X27 -X27 -K18.XR:42 1.00 mm² -W375 WH -A1.X26 -X26
S27 Brake pedal activated Park brake
-A1.X29:3 16/21 +3/28.C5 Park brake 16/21
1.0 mm² -W488 WH 16/21 Park brake 16/21
/12.C5 S27 Brake pedal activated
S27 Brake pedal activated
+3.1 +3.1
-X15:v -A1.X27 -X27 -K18.XR:12 -A1.X26 -X26
1.00 mm² -W372 WH Q10 SytemHydraulics Float 1.00 mm² -W363 WH High range selection
+3/28.C4 Q10 SytemHydraulics Float 17/21
+3/27.C9 High range selection 17/21
Q10 SytemHydraulics Float 17/21 High range selection 17/21

+3.1 +3.1
-X15:u -A1.X27 -X27 -K18.XR:14 -A1.X26 -X26
1.00 mm² -W370 WH Q9 Body lower 1.00 mm² -W359 WH Difflock dropbox
+3/28.C3 Q9 Body lower 18/21
+3/27.C11 Difflock dropbox 18/21
Q9 Body lower 18/21 Difflock dropbox 18/21
7

7
+3.1 +3.1
F65 5A Brake Pedal Activated -K18.XL:8

d
c
a
b
-A1.X27 -A1.X26

e
1.00 mm² -W197 BK -X27 F65 5A Brake Pedal Activated 1.00 mm² -W355 WH -X26 Engage mid axle difflock
+03A/10.C7 F65 5A Brake Pedal Activated 19/21
+3/27.C1 Engage mid axle difflock 19/21
-A1.X24:2 19/21 Engage mid axle difflock 19/21

Rev. Index Revision

+3.1 +3.1
-X15:N -A1.X27 -X27 -K18.XR:9 -A1.X26 -X26
1.00 mm² -W376 WH Q17 Park brake 1.00 mm² -W369 WH Body lower
+3/28.C6 Q17 Park brake 20/21 +3/28.C3 Body lower 20/21
Q17 Park brake 20/21 Body lower 20/21

+3.1 +3.1
-X15:j 1.50 mm² -W314 WH -A1.X27 -X27 -K18.XR:11 1.00 mm² -W365 WH -A1.X26 -X26
+3/24.A7 P1+P2 Electrical Horn ON +3/27.C5 System hydraulics unloader valve

Diode R15 Added, S3 Conx Changed

P1+P2 Electrical Horn ON P1+P2 Electrical Horn ON 21/21 21/21 System hydraulics unloader valve 21/21 21/21
System hydraulics unloader valve

CAMERA CABLE CHANGED

Reverted camera cables back

RELEASED TO PRODUCTION
8

8
ECN No.
113744
114215
114168
114378

Name
D. Alford

J.CRAIG
C. Heyes

C.HEYES

Date
01/12/2015
09/08/2016
08/11/2016
9

9
-XGND5.d 2.5 mm² -W402 BN
1 GND
M8:3

Date

-XGND5.d 2.5 mm² -W401 BN

-XGND5

2 GND

-XGND5.d 2.5 mm² -W400 BN

Name

3 GND
Designed 01/12/2015 J.CRAIG

Approved 01/12/2015 G.McNEIL

23/06/2016 Checked 01/12/2015 J.BROWNLIE

-X6.64a -X6.65a -X6.66a

10

10
-X6 64
-X6 65
-X6 66

Type
GND
GND
GND

M.-Nr.: T2
-XJ20 1
-XJ21 1
-XJ22 1

TA400 G10
-X6 67
-X6 68
-X6 69

GND
GND
GND

-XJ20 2
-XJ21 2
-XJ22 2
11

15400612
11
Origin Project
-X6 70
-X6 72

-X6 71

Description:
TA400 GEN9 T2
GND
GND
GND

GND
-XJ20 3
-XJ21 3
-XJ22 3

/12.I1

15400615
Drawing number
GND
GND
GND

-XGND5:M8:4 (d) SIM. TO:

12

-X6 73 -XJ20 4
-X6 74 -XJ21 4
-X6 75 -XJ22 4

12
FIRST USED:
NEXT ASSY.:

No.
Sheet
Assignment
-X6 76
-X6 77
-X6 78

TA400 T2

Location +6
11
15397390
0PL46960

34 Sh.
I
E
B
A

H
D

F
C

G
 I
E
B
A

H
D

F
C

G
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-A6
/12.F1
/11.G1

+6.4

GND
-XGND5:M8:3 (c)
-A6

/11.I11
/13.B1
/12.B1

+6.4
+3.1
-X3:E

Twisted Pair
-W277:TW1#0
-A1.X30
1

-X30

1
1.0 mm² -W277 BU CAN2_L +3.1
+2/1.E6 CAN2_L 1/21 -X37:3
CAN2_L 1/21 1.00 mm² -W174 WH -A1.X28 -X28 M4.X.31b Wiper motor rear
+3/25.A3 M4.X.31b Wiper motor rear 2/9
M4.X.31b Wiper motor rear 2/9

+3.1
-X3:D -A1.X30 -X30
1.0 mm² -W277 YE CAN2_H +3.1
+2/1.E6 CAN2_H 16/21 -K22.X:3
CAN2_H 16/21 1.00 mm² -W127 WH -A1.X28 -X28 KX22.3 to K15X.3
+3/24.A4 KX22.3 to K15X.3 3/9
KX22.3 to K15X.3 3/9

+3.1
-X30 GND +3.1
3/21 -M1.X:2 1.00 mm² -W126 WH -A1.X28 -X28
+3/24.A5 M1.X.31b to K15.X.4
M1.X.31b to K15.X.4 M1.X.31b to K15.X.4 4/9 4/9

+3.1
-Xs3.SB:3

Twisted Pair
-W67:TW1#1
-A1.X30
2

-X30

2
1.0 mm² -W67 BU CAN2_L +3.1
/21.B2 CAN2_L 4/21 -K18.XL:13
CAN2_L 4/21 1.00 mm² -W312 WH -A1.X28 -X28 M1 front wiper speed 1
+3/24.C2 M1 front wiper speed 1 5/9
M1 front wiper speed 1 5/9

+3.1
-Xs2.SB:3 1.0 mm² -W67 YE -A1.X30 -X30
/21.B2 CAN2_H +3.1
CAN2_H CAN2_H 19/21 19/21 -Xs30.SB:2 1.00 mm² -W310 BK -A1.X28 -X28 F53 5A to M1 and M4 wiper motors
+3/24.E2 F53 5A to M1 and M4 wiper motors 6/9
F53 5A to M1 and M4 wiper motors 6/9

+3.1
-Xs28.SB:3 0.75 mm² -W293 WH -A1.X30 -X30 CR0232 RxD +3.1
/14.H1 CR0232 RxD 6/21 -K18.XR:47
CR0232 RxD 6/21 -A1.X28 -X28 Wiper motor rear ON
+3/25.D1 7/9
Wiper motor rear ON 7/9

+3.1

Twisted Pair
-K18.XL:28

-W241:TW1#1
-A1.X30
3

-X30

3
1.0 mm² -W241 BU CAN2_L +3.1
/14.F1 CAN2_L 7/21 -Xs30.SB:5
CAN2_L 7/21 1.00 mm² -W315 BK -A1.X28 -X28 F53 5A to M1 and M4 wiper motors
+3/24.E2 F53 5A to M1 and M4 wiper motors 8/9
F53 5A to M1 and M4 wiper motors 8/9

+3.1
-K18.XL:46 1.0 mm² -W241 YE -A1.X30 -X30 CAN2_H +3.1
/14.F1 CAN2_H 13/21 -X37:1
CAN2_H 13/21 1.00 mm² -W135 WH -A1.X28 -X28 M4 Wiper motor rear ON
+3/25.B2 M4 Wiper motor rear ON 9/9
M4 Wiper motor rear ON 9/9

+3.1
-Xs29.SB:3 0.75 mm² -W294 WH -A1.X30 -X30
/14.H1 CR0232 TxD
CR0232 TxD CR0232 TxD 9/21 9/21

+3.1
+3.1 1.00 mm² -W483 BN -A1.X29 -X29 GND
4

-K19.X:8

Twisted Pair

4
GND 1/15

-W242:TW1#1
1.0 mm² -W242 BU -A1.X30 -X30 CAN2_L 1/15
/16.C7 CAN2_L 10/21
CAN2_L 10/21

+3.1
-X16:E -A1.X29 -X29
+3.1 1.00 mm² +4 -W105 WH K4 Park Brake Sol GND
-K19.X:28 +3/28.C7 K4 Park Brake Sol GND 2/15
1.0 mm² -W242 YE -A1.X30 -X30 CAN2_H K4 Park Brake Sol GND 2/15
/16.C7 CAN2_H 11/21
CAN2_H 11/21

+3.1
-A1.X27:16 1.0 mm² -W488 WH -A1.X29 -X29
+3.1 S27 Brake pedal activated
-Xs32.SB:3
/11.I6 S27 Brake pedal activated 3/15
0.75 mm² -W295 WH -A1.X30 -X30 CR0232 Test S27 Brake pedal activated 3/15
/14.E1 CR0232 Test 12/21
CR0232 Test 12/21

+3.1
-X29
5

5
4/15
+3.1
-X30 GND
2/21
+3.1
+3.1 1.50 mm² -W299 BN -A1.X29 -X29 GND
-X30 GND 5/15 5/15
R2 120OHM L
14/21

+3.1
-A1.X22:10 0.75 mm² -W321 WH -A1.X29 -X29
+3.1 F52 1A to K3 Terminal 15 12V
+03A/9.H4 F52 1A to K3 Terminal 15 12V 6/15
-X30 R2 120OHM H F52 1A to K3 Terminal 15 12V 6/15
15/21

+3.1
+3.1 -X29 K3.X.4
6

6
-X30 7/15
GND
5/21

+3.1
+3.1 0.75 mm² -W322 BN -A1.X29 -X29 GND
-X30 GND 8/15 8/15
R2 120OHM L
17/21

+3.1
-K22.X:1 -A1.X29 -X29
+3.1 1.00 mm² -W443 WH K5 to K22.X6 front wiper speed 2
+3/24.A4 K5 to K22.X6 front wiper speed 2 9/15
-X30 R2 120OHM H K5 to K22.X6 front wiper speed 2 9/15
18/21

+3.1
+3.1 1.50 mm² -W320 BK -A1.X29 -X29 12V Terminal 15
7

7
-X30 12V Terminal 15 10/15 10/15
R2 120OHM L
20/21

d
c
a
b
e
+3.1
+3.1 1.00 mm² -W442 BN -A1.X29 -X29 GND
-X30 GND 11/15 11/15

Rev. Index Revision

R2 120OHM H
21/21

+3.1
-K18.XL:12 1.00 mm² -W128 WH -A1.X29 -X29
+3/24.C1 K5 to M1 front wiper speed 2
K5 to M1 front wiper speed 2 K5 to M1 front wiper speed 2 12/15 12/15

Diode R15 Added, S3 Conx Changed

+3.1

CAMERA CABLE CHANGED

Reverted camera cables back
-Xs15.SB:3 -A1.X29 -X29

RELEASED TO PRODUCTION
1.5 mm² -W154 RD T1 +12V
/26.B1
8

8
-XGND5.c 1.50 mm² -W299 BN T1 +12V T1 +12V 13/15 13/15
2 GND

ECN No.
113744
114215
114168
114378
+3.1
-X29 K5.X.5
-XGND5.c 0.75 mm² -W322 BN 14/15

Name
4 GND

D. Alford

J.CRAIG
C. Heyes

C.HEYES
+3.1
-A3.A:4 1.5 mm² -W157 BK -X6.44b -X6.44a -Xs30.SB:1 1.00 mm² -W441 BK -A1.X29 -X29
/26.B2 +3/24.E1 F53 5A to M1 and M4 wiper motors
12V Terminal 15 12V Terminal 15 F53 5A to M1 and M4 wiper motors F53 5A to M1 and M4 wiper motors 15/15 15/15

Date
-X6 44 2.50 mm²

01/12/2015
09/08/2016
08/11/2016
9

9
Date
-XJ12 1 -X6
47

-XGND5.c 1.00 mm² -W442 BN

Name

8 GND
Designed 01/12/2015 J.CRAIG

Approved 01/12/2015 G.McNEIL

23/06/2016 Checked 01/12/2015 J.BROWNLIE
10

10
Type
M.-Nr.: T2
TA400 G10
11

15400612
11
Origin Project
Description:
TA400 GEN9 T2
GND
/13.I1
-XGND5:M8:4 (d)

15400615
Drawing number
SIM. TO:
12

12
FIRST USED:
NEXT ASSY.:

No.
Sheet
Assignment
TA400 T2

Location +6
12
15397390
0PL46960

34 Sh.
I
E
B
A

H
D

F
C

G
 I
E
B
A

H
D

F
C

G
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-A6
/12.F1

+6.4

GND
-XGND5:M8:3 (c)
/12.I11
1

1
-Xs10

welding splice
Ultrasonic
-X30.a
+3.1
1.00 mm² -W114 BN 0.34 mm² -W506.W1 1_BN -X31
11 GND GND 1/9
DTS 09 S PFF 2
-W506.X1

-K23
+3.1

-T2
-X31

0.35 mm²
1/5 2/9 CR0232 RxD

X3 1
X1 1
GSM
X1 1

GND
-X36 0.35 mm² -W463 BN DTS 09 S PFF 2

GND
F12 2A to Telematic connector

antenna
3_BU/5 GND 0.34 mm² -W506.W1 2_WH 2/5

VDC
+03A/9.E8

GPS

X3 2
X2 2
X2 2
-X36 +3.1

-W113 BN
-X6.53b:1 F12 2A to Telematic connector -X31
1_BN/5 3/5 3/9 CR0232 TxD

X3 3
F25 2A to SUB-D prog. connector DTS 09 S PFF 2

EC2116
-X36
2

2
0.35 mm² -W462 WH

M12 connector
/21.G9

5050143284
2-WH/5 F25 2A to SUB-D prog. connector -Xs25.SB:8 4/5

X3 4
-X36
+3.1

CAN4
-X31
4_BK/5 5/5 4/9

CR3114

0.35 mm²
TELEMATIC

X3 5
CAN_H CAN_L
-X36 DTS 09 S PFF 2

GSM/GPS combined antenna

CR3114
5_GY/5
+3.1

CAN4_H
-X31

0.35 mm²
-W111 BK
5/9 GND

radio modem CR3114

DTS 09 S PFF 2

CAN4_L
+3.1

CAN4_L

CAN4_H
-X31
6/9 F25 2A to SUB-D programming connector

0.34 mm² -W506.W1 5_GY

0.34 mm² -W506.W1 4_BK

-W112 GY -Xs12

welding splice
welding splice

Ultrasonic
Ultrasonic
-Xs11
DTS 09 S PFF 2
3

3
-R14
+3.1
-X31
7/9
TELEMATICS

DTS 09 S PFF 2

120 Ω 1 W

5399000852
+3.1
-X31

Resistor 120 Ohm 1W

8/9
1.0 mm² -W110 YE -X6.31b -X6.31a DTS 09 S PFF 2
CAN4_H
+3.1
-X31
9/9 CR0232 Test

-X6 31 2.50 mm²

4

4
1.0 mm² -W110 BU DTS 09 S PFF 2
CAN4_L

CAN4_H
-XJ5 1

-W110:TW1
Twisted Pair
+3.1

Twisted Pair
Twisted Pair

-K18.XL:44

-W297:TW1#0
-W296:TW1

1.0 mm² -W297 YE -X6.28b -X6.28a 1.0 mm² -W296 YE -A1.X32 -X32 CAN4_H
/14.G1 CAN4_H CAN4_H 1/6
1/6
-X6 28

CAN4_H

+3.1
-K18.XL:26 1.0 mm² -W297 BU -X6.24b -X6.24a 1.0 mm² -W296 BU -A1.X32 -X32
/14.G1 CAN4_L
CAN4_L CAN4_L CAN4_L 2/6 2/6
-X6 24
CAN4_L
5

5
+3.1
-X32
2.50 mm²-XJ4 1 -X6

-X6.27b -X6.27a 3/6

-X6

-X6.25b
27
25

+3.1
-X32 P1.X.9
5/6
CAN3_L

+3.1
2.50 mm² -XJ3 1 -X6

Twisted Pair
Twisted Pair

-K18.XL:27
-W289:TW1#1
-W288:TW1

1.0 mm² -W289 BU -X6.22b -X6.22a 1.0 mm² -W288 BU -A1.X32 -X32 CAN3_L
/14.G1 CAN3_L CAN3_L 4/6
CAN3_L 4/6
22
6

6
+3.1
-K18.XL:45 1.0 mm² -W289 YE -X6.23b -X6.23a 1.0 mm² -W288 YE -A1.X32 -X32 CAN3_H
/14.G1 CAN3_H CAN3_H 6/6
CAN3_H 6/6
-X6 23 2.50 mm²

-Xs6.SB:3
1.0 mm² -W88 BU
/17.A7 CAN3_L
CAN3_L
CAN3_H
-XJ2 1 -X6

-Xs5.SB:3 -X6.26b
1.0 mm² -W88 YE
/17.A7 CAN3_H
CAN3_H
26
7

Twisted Pair

7
-W88:TW1#0

d
c
a
b
e
+3.1
-X33 X33.3
3/6

Rev. Index Revision

+3.1
-X33 P1.X.9
4/6

Diode R15 Added, S3 Conx Changed

+3.1

CAMERA CABLE CHANGED

Reverted camera cables back
-X33

RELEASED TO PRODUCTION
R5 AN
8

8
5/6

ECN No.
113744
114215
114168
114378

Name
D. Alford

J.CRAIG
C. Heyes

C.HEYES +3.1
-X34 Spare
Date 4/6
01/12/2015
09/08/2016
08/11/2016
9

+3.1
-X34 Spare
Date

6/6
Name
-X6 33 2.50 mm²

Designed 01/12/2015 J.CRAIG

Approved 01/12/2015 G.McNEIL

23/06/2016 Checked 01/12/2015 J.BROWNLIE
CAN1_H

-R2
-XJ7 1 -X6
Twisted Pair

-K18.XL:47
-W298:TW1#0

-X6.30a
10

10

1.0 mm² -W298 YE

CAN1_H /14.F1
30

CAN1_H
Type
M.-Nr.: T2
120 Ω 1 W

5399000852
Resistor 120 Ohm 1W

-X6.29a -K18.XL:29
TA400 G10

1.0 mm² -W298 BU

CAN1_L /14.F1
CAN1_L
-X6 29 2.50 mm²
11

15400612
CAN1_L

11
Origin Project
-R10
-XJ6 1 -X6

Description:
32

TA400 GEN9 T2
GND
120 Ω 1 W

5399000852

/14.I1
Resistor 120 Ohm 1W

15400615
Drawing number
-XGND5:M8:4 (d) SIM. TO:
12

12
FIRST USED:
NEXT ASSY.:

No.
Sheet
Assignment
TA400 T2

Location +6
13
15397390
0PL46960

34 Sh.
I
E
B
A

H
D

F
C

G
 1 2 3 4 5 6 7 8 9 10 11 12

F19 15A to K18.X1.19 VBBO

-A1.X20:6

F66 15A to K18.X2.19 VBB1

F28 15A to K18.X2.10 VBB4

F40 15A to K18.X2.32 VBB3

F23 15A to K18.X1.1 VBBR

F79 15A to K18.X2.1 VBB2

1.0 mm² -W227 RD
+03A/9.C3 F22 3A to K18.X1.10 VBBs

+03A/10.E12
F22 3A to K18.X1.10 VBBs

+03A/10.C3

+03A/10.C6

+03A/10.C1

+03A/10.C7
F35 1A T15 to P51E
+03A/9.C3

+03A/9.C2
-X6.2a

-A1.X23:17

-A1.X24:18
A A

-A1.X24:1
-A1.X20:8

-A1.X20:5

-A1.X23:9

-A1.X23:2
-X6 5 2.5 mm² -XJ14 1 -X6 2

S3 Ignition ON
F22 3A to K18.X1.10 VBBs

/18.D1
-X6.79a:1
-X6.5b

-X6.2b -W228 RD
F22 3A to K18.X1.10 VBBs

-W229 RD

-W230 RD

-W236 RD

-W237 BK

-W238 BK

-W239 BK

-W240 BK
F66 15A to K18.X2.19 VBB1
F23 15A to K18.X1.1 VBBR

F35 1A T15 to P51E

F28 15A to K18.X2.10 VBB4

F40 15A to K18.X2.32 VBB3

F79 15A to K18.X2.1 VBB2

F19 15A to K18.X1.19 VBBO
1.0 mm²
-W120 YE

Main Controller
S3 Ignition ON

-K18
CR0232 St Mobile Controller CR0232

2.50 mm²

2.50 mm²

1.00 mm²

2.50 mm²

2.50 mm²

2.50 mm²

2.50 mm²
CR0232
-W220 RD

/15.H1
B 15325548 B
F22 3A to K18.X1.10 VBBs

5050143198
1.0 mm²

https://one.terex.
c -K18.XL -K18.XL
32 VBB15 terminal 15 VBBS 10
CR0232 Ex
1.0 mm²

supply sensors/module -K18 Main Controller

32/55 10/55 Mobile Controller CR0232
-S3.X

-S3.X

+3/23.H10
c -K18.XL CR0232
50/5
15/5

supply via relay VBBR 1 15325548

-S3 1/55 -K18.XR 5050143198
19 VBB 1
-K18.XL

-W121 WH
15 50 19/55
-W201 YE

Ignition lock supply outputs VBBO 19 https://one.terex.

0 I Outputs
K18.X1.18 to K2.X1

CR0232_VBB15_ON
Ignition lock 19/55 -K18.XR
1 VBB 2
34552 relay 1/55 PWM, B H, (2/4 A) Q00_E
15326122 Inputs Outputs 18 +3/24.A6
-K18.XR OUT_M2_WashPump_Front_ON
5050650876 32 VBB 3
1.0 mm²

1.0 mm²

30 https://one.terex. I00 A, B L/H , FRQ PWM, B H, (2/4 A) Q00 32/55 PWM, B H/L, (2/4 A), H Q01_E
C /15.I1 55 18 +2/1.A5 17 /16.C3 C
c IN_S4_EngineStartStopButton_PRESSED OUT_K2_MainRelayTerminal15_ON -K18.XR OUT_K19_AuxiliaryHold
30/5
-S3.X

10 VBB 4
I01 A, B L/H , FRQ PWM, B H/L, (2/4 A), H Q01 10/55 PWM, B H, (2/4 A) Q02_E
/31.I5 36 17 +3/22.A2 16 +3/22.A7
IN_M7_BrakeOilCooler_Fault OUT_E5_ParkingLights_ON OUT_E6_HighBeam_RIGHT_ON
I02 A, B L/H , FRQ PWM, B H, (2/4 A) Q02 -K18.XR 1 PWM, B H/L, (2/4 A), H Q03_E
/31.I8 54 16 +3/22.A4 51 VBB Rel 15 /16.C2
IN_B28_HydraulicOilLevel_is_HIGH OUT_E5_LowBeam_Left_ON 51/55 OUT_K19_AuxiliaryRangeInhibit
I03 A, B L/H , FRQ PWM, B H/L, (2/4 A), H Q03 3 PWM, B H, (2 A) Q04_E
/31.H9 35 15 +3/22.A1 14 +3/27.A10
IN_B29_HydraulicOilTemp_SENSOR OUT_E5_Indicators_LEFT_ON OUT_Q3_DropBoxDifflock_engage
I04 A, B L/H , FRQ PWM, B H, (2 A) Q04 PWM, B H, (2 A) Q05_E
+3/29.I6 53 14 +3/22.A6 13 +3/27.A8
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

+2/1.B5
K18.X1.18 to K2.X1

-X6.83a:1
/18.G2
CR0232_VBB15_ON
-Xs13.SB:3

IN_B3_HydraulicOilFilter_RESTRICTED OUT_E7_BrakeLights_ON OUT_Q4_DropBox_LowRange_select

For this document and the object represented in that we reserve all rights according to DIN 34.

I05 A, B L/H , FRQ PWM, B H, (2 A) Q05 2 PWM, B H, (2 A) Q06_E

/26.C9 34 13 +3/24.A2 12 +3/27.A9
IN_B2_ThrottlePedal_DEACTIVATED OUT_K15_FrontWiper_Speed_1_ON OUT_Q5_DropBox_HighRange_select
D I06 A, B L/H , FRQ PWM, B H, (2 A) Q06 4 PWM, B H, (2 A) Q07_E
D
+3/28.H7 52 12 +3/24.A1 11 +3/27.A4
IN_06_ParkBrakeSw OUT_K5_FrontWiper_Speed_2_ON OUT_Q6_HydraulicsUnloaderValve_ON
I07 A, B L/H , FRQ PWM, B H, (2 A) Q07 Inputs
+3/33.I10 33 11 +3/22.A11
IN_07_Reserve OUT_E8_Indicators_RIGHT_ON I00_E A, B L/H , FRQ PWM, B H, (2/4 A) Q08_E
relay +3/23.I10 55 2 +3/27.A2
IN_B5_FuelLevel_SENSOR OUT_Q27_ExhaustBrake_ON
I08 A, B L/H , FRQ PWM, B H, (2/4 A) Q08 I01_E A, B L/H , FRQ PWM, B H/L, (2/4 A), H Q09_E
+3/33.I4 24 2 +3/22.A5 +4.4/30.I1 36 3 /16.C1
IN_A1_Engine_RUNNING OUT_E5_HighBeam_Left_ON IN_B6_DropBox_primary_HighTemp OUT_K19_RetarderRequest
I09 A, B L/H , FRQ PWM, B H/L, (2/4 A), H Q09 I02_E A, B L/H , FRQ PWM, B H, (2/4 A) Q10_E
/18.H1 41 3 +3/23.A2 +4.4/30.I7 54 4 /15.B5
IN_S3_Ignition_ON OUT_P8_FlashingReverseLamp_ON IN_B7_DropBox_secondary_HighTemp OUT_S24_Hold_BodyLever_in_LowerPos_ON
I10 A, B L/H , FRQ PWM, B H, (2/4 A) Q10 I03_E A, B L/H , FRQ PWM, B H/L, (2/4 A), H Q11_E
/18.H2 23 4 +3/22.A9 +4.4/30.I3 35 5 +3/23.A1
IN_S6_HazardIndicators_ON OUT_E6_LowBeam_Right_ON IN_B12_DropBoxOilPressure_SENSOR OUT_E9_FogLamp_Rear_ON
E E
I11 A, B L/H , FRQ PWM, B H/L, (2/4 A), H Q11 I04_E A, B L/H , FRQ PWM, B H, (2 A) Q12_E
/31.I7 40 5 +3/23.A3 +4.4/30.I8 53 6 /31.A5
IN_B30_BrakePressure_LOW OUT_E20_ReverseLamp_ON IN_B9_DropBox_is_in_HighRange OUT_M7_BrakeOilCoolerFan_PWM
-A1.X30:12 I12 A, B L/H , FRQ PWM, B H, (2 A) Q12 I05_E A, B L/H , FRQ PWM, B H, (2 A) Q13_E
0.75 mm² -W295 WH
/12.G5 CR0232 Test /26.B9 22 6 +3/24.A8 +4.4/30.I10 34 7 +3/27.A6
CR0232 Test IN_B2_ThrottlePedal_POSITION OUT_K8_Horn_ON IN_B10_DropBox_is_in_LowRange OUT_Q11_EngineFanSpeed_PWM
I13 A, B L/H , FRQ PWM, B H, (2 A) Q13 I06_E A, B L/H , FRQ PWM, B H, (2 A) Q14_E
-X34:9
/26.C11 39 7 +3/25.A7 +3/29.I10 52 8 +3/28.A1
0.50 mm² -W100 WH -Xs32 0.75 mm² -W292 WH IN_B2_TrottlePedal_ACTIVATED OUT_E11_WorkLights_Front_ON IN_B13_TrailerBrakeAccuPressure_HIGH OUT_Q08_Body_Raise_PWM
/21.B10 CR0232 Test CR0232 Test
CR0232 Test Ultrasonic I14 A, B L/H , FRQ PWM, B H, (2 A) Q14 I07_E A, B L/H , FRQ PWM, B H, (2 A) Q15_E
-X6.30a:1 welding splice +3/23.I11 21 8 +3/27.A1 +3/29.I8 33 9 +3/28.A2
1.0 mm² -W298 YE IN_B4_AirCleaner_RESTRICTED OUT_Q29_MidAxleDifflock_engage IN_B8_TractorBrakeAccuPressure_HIGH OUT_Q09_Body_Lower_PWM
/13.D10 CAN1_H
CAN1_H I15 A, B L/H , FRQ PWM, B H, (2 A) Q15
-X6.29a:1
+3/29.I7 38 9 +3/27.A3
1.0 mm² -W298 BU IN_B11_ParkBrake_LOCKED OUT_Q2_LowIdle_LoadSensePressure_reduce I08_E A, B L/H , FRQ B H, (2 A) Q16_E
/13.D11 CAN1_L +3/29.I11 24 25 /31.A6
-W298:TW1#1
Twisted Pair

CAN1_L IN_B14_SteeringSystemPressure_HIGH OUT_M7_BrakeOilCoolerFan_ECO_ON

F F
-W241:TW1#0

-K18.XL I09_E B H, (2 A) Q17_E

Twisted Pair

A, B L/H , FRQ
50 TEST +3/23.I6 41 26 +3/33.B1
50/55 IN_B15_Body_is_UP OUT_K14_BrakeFan_PROV
-A1.X30:13 -K18.XL 10 - 32 V I10_E A, B L/H , FRQ B H, (2 A) Q18_E
1.0 mm² -W241 YE
/12.G3 CAN2_H 47 CAN1 H -Xs21.SB:3
+3/23.I8 23 27 +3/28.A4
CAN2_H 47/55 -K18.XL 1.00 mm² -W165 WH IN_B31_MidAxle_is_disconnected OUT_Q10_Hydraulics_Float_ON
-A1.X30:7
29 CAN1 L VREF OUT (5/10V, 400 mA) 51 VREF OUT 5V /26.B8
1.0 mm² -W241 BU 29/55 51/55 VREF OUT 5V I11_E A, B L/H , FRQ B H, (2 A) Q19_E
/12.G3 CAN2_L 46 CAN2 H (J1939) /31.H11 40 28 +3/29.A1
CAN2_L 46/55 5 / 10 V IN_B34_HydraulicBrakeOilTemp OUT_Q12_EngineFan_isolation
-X6.23b:1
28 CAN2 L (J1939)
1.0 mm² -W289 YE 28/55 I12_E A, B L/H , FRQ B H, (2 A) Q20_E
/13.F6 CAN3_H 45 CAN3 H /15.C7 22 29 +3/29.A2
CAN3_H 45/55 IN_S24_BodyRaiseLowerLever_POSITION OUT_Q28_OCDB_TripleMotor_ON
-X6.22b:1
27 CAN3 L -K18.XL
1.0 mm² -W289 BU 27/55 GND 20 I13_E A, B L/H , FRQ B H, (2 A) Q21_E
/13.F6 CAN3_L 44 CAN4 H 20/55 +4.4/30.F6 39 30 +3/28.A10
-W289:TW1#0
Twisted Pair

CAN3_L 44/55 IN_B18_VehicleSpeed_Sensor OUT_Q15_BodyTailGate_open

26 CAN4 L -K18.XL
26/55 Output GND 37 I14_E A, B L/H , FRQ B H, (2 A) Q22_E
G 37/55 +4.4/30.I11 21 31 +3/28.A11 G
Output GND 42 IN_B19_DropBoxDifflock_OilPressure_Low OUT_Q16_BodyTailGate_closed
-X6.28b:1
25 RxD 42/55
1.0 mm² -W297 YE 25/55 I15_E A, B L/H , FRQ B H, (2 A) Q23_E
/13.F4 CAN4_H 43 TxD A = analogue +03A/9.H11 38 50 +3/25.A3
CAN4_H 43/55 IN_S25_EmergencyOperation_ON OUT_M5_WashPump_Rear_ON
-X6.24b:1 BH = binary high side
1.0 mm² -W297 BU 30 USB P
/13.F5 CAN4_L BL = binary low side
-W297:TW1#1

Q24_E
Twisted Pair

CAN4_L 30/55 B H, (2 A)
48 USB N FRQ = frequency/pulse inputs 42 +3/28.A5
48/55 OUT_Q17_ParkBrake_unlock
-A1.X30:6
31 USB 5V H = H-Bridge function
0.75 mm² -W293 WH 31/55 B H, (2 A) Q25_E
/12.G3 CR0232 RxD 49 USB GND PWM = puls width modulation -K18.XR 43 +3/29.A3
CR0232 RxD 49/55 20 GND OUT_Q18_DropBoxParkBrake_interlock
20/55
-X34:2 -Xs28 B H, (2 A) Q26_E
0.50 mm² -W94 WH 0.75 mm² -W291 WH -K18.XR
/21.B9 CR0232 RxD CR0232 RxD 44 +3/24.C10
CR0232 RxD Ultrasonic 37 Output GND OUT_P6 _WarningBuzzer_ON
welding splice 37/55
-A1.X30:9 B H, (2 A) Q27_E
H /12.G4
0.75 mm² -W294 WH
45 +3/25.A9 H
CR0232 TxD -XGND_Contlr OUT_E14_WorkLights_Rear_ON

-W235 BN
CR0232 TxD

GND
-X34:3 -Xs29 *8 B H, (2 A) Q28_E
-W231 BN

-W232 BN

-W233 BN

-W234 BN

-W496 BN
0.50 mm² -W95 WH 0.75 mm² -W290 WH 46
/21.B9 CR0232 TxD CR0232 TxD A = analogue +3/25.A11
GND

GND

GND

GND

GND
CR0232 TxD Ultrasonic OUT_P7_RotatingBeacon_ON
welding splice BH = binary high side
B H, (2 A) Q29_E
47 +3/25.A1

2.50 mm²
-X34:4 BL = binary low side
0.50 mm² -W97 WH OUT_K16_RearWiper_ON
2.50 mm²

2.50 mm²

2.50 mm²

2.50 mm²

2.50 mm²
/21.B9 CR0232 USB P FRQ = frequency/pulse inputs
CR0232 USB P B H, (2 A) Q30_E
-X34:1 H = H-Bridge function 48 +3/33.B3
0.50 mm² -W96 WH OUT_K9_FuelHeater_ENABLE
/21.B9 CR0232 USB N PWM = puls width modulation
CR0232 USB N B H, (2 A) Q31_E
-X34:7 VBBn = supply of the outputs via relays 1/3 and 2/4 49 +3/23.A4
OUT_Q31_Reverse_Alarm_ON
-XGND5.e
0.50 mm² -W98 WH
-XGND5.b

/21.B10 CR0232 USB 5V

CR0232 USB 5V
-XGND5.b

-XGND5.b

-XGND5.e

-XGND5.e
-X34:8
I 0.50 mm² -W99 WH I
/21.B10 CR0232 USB GND
1

CR0232 USB GND

FIRST USED: TA400 T2
2

2
3

3
-XGND5:M8:3 (c) M8:4 M8:5 GND NEXT ASSY.: 0PL46960
/13.I11
GND -XGND5 -XGND5 SIM. TO: 15397390
e Date Name Description:
Assignment

d Reverted camera cables back 114378 C. Heyes 08/11/2016

Designed 01/12/2015 J.CRAIG
c Diode R15 Added, S3 Conx Changed 114168 D. Alford 09/08/2016 TA400 GEN9 T2 Location +6
b CAMERA CABLE CHANGED 114215 C.HEYES 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 14
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 1 2 3 4 5 6 7 8 9 10 11 12

https://one.terex.
A Body raise - lower joystick
A
5050143198
Main Controller
15325548
CR0232
Output binary high side

-K18 OUT_S24_Hold_BodyLever_in_LowerPos_ON

F30 3A to Rockerswitches

S27 Brake pedal activated

/14.E12 Master
Q10_E

VREF OUT 5V
Ex-X2 4
F41 2A to S4

-K18.XR
4/55
B B

S27 Brake pedal activated

-K18.XR
22/55
-X6.110a
C C
Ex-X2 22
F30 3A to Rockerswitches -X6 110 I12_E

-W188 WH

-W189 WH
-K18 IN_S24_BodyRaiseLowerLever_POSITION

S24 Body joystick switch output

VREF OUT 5V

S24 Body joystick analog output

-X6.110b
/14.G9
F41 2A to S4

Master
Input binary high side

1.0 mm²

1.0 mm²
CR0232
https://one.terex. 5050143198
15325548
Main Controller
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

KAT Body raise - lower joystick

-R16
For this document and the object represented in that we reserve all rights according to DIN 34.

Diode_GI750
Diode_GI750 AN https://one.terex.
-S4.X

D D
1/2

-X6.111b
button Start/Stop
270007004
-S4 15326123

-S24.X1

-S24.X2

-S24.X2
5350249986 -X6 111
-S27.X

1/1
-WA2.B32..X2
+4
1
https://one.terex.
2/2
-S4.X

A/3

2/2

2/4

3/4
-X6.111a
A 2 1 1
Brake pedal

Analogue 5V

Proximity relay
Controller
From IFM
Switch NC contact

From Body
E Brake Pedal Brake pedal position switch Joystick for body raise/low E
Br.status supply

output
Position Switch 15503750
-S27 LSL 20011369
Brake pedal
-W171 WH

15314454
https://one.terex.
K18.X1.55 to S4

Lights/

-S24

-WA2.B32..X1 +4 -WA2.B32..W1 1
relays
Brake

https://one.terex.

Analogue 5V

Camera Cable
/70.C6 Body Raise/ Lower
Joystick
1.0 mm²

B C

GND

GND
C/3
B/3
-S27.X

-S27.X

-S24.X1 2 3

-S24.X2
1/2

1/4
-W490 WH

F F
S27 Brake pedal activated
-W183 WH

+4

1/1
S27 Brake pedal deactivated

-W489 WH
S27 Brake pedal activated
1.0 mm²

+7.1
-WA2.B32..X1
1/1
1.0 mm²

1.0 mm²

-Xs40
Ultrasonic
welding splice

G G

+7.1 -WA2.B32..W1 1
Camera Cable
-W182 WH

-W186 BN

-W187 BN
GND

GND
S27 Brake pedal activated
1.0 mm²

1.0 mm²

1.0 mm²

-WA2.B32..X2
-K20.XK
-K18.XL

-K20.XJ

H H
55/55

26/26

10/26

1/1
St-X1 55 XJ 26 XK 10
I00
+6.1 +6.1
-K18 IN_S4_EngineStartStopButton_PRESSED -K20 IN_S27_BrakePedal_DEACTIVATED -K20 IN_S27_BrakePedal_ACTIVATED
/14.C3 Master /17.H1 Master /17.E4 Master
Input binary high side Input binary high side Input binary high side
CR0232 Cobo Dashboard 15325370 Cobo Dashboard 15325370
15325548 15325370 15325370
5050143198 Dashboard Display Dashboard Display
-X30.c

Main Controller Brake pedal Brake pedal

I Engine Start Stop I
1

-X30.c

https://one.terex. https://one.terex. https://one.terex.

FIRST USED: TA400 T2
2

M8:3 GND NEXT ASSY.: 0PL46960

GND -X30 SIM. TO: 15397390
e Date Name Description:
Assignment

d Reverted camera cables back 114378 C. Heyes 08/11/2016

Designed 08/11/2016 J.CRAIG
c Diode R15 Added, S3 Conx Changed 114168 D. Alford 09/08/2016 TA400 T2 Location +6
b CAMERA CABLES CHANGED 114215 C. Heyes 23/06/2016 Checked 01/12/2015 J.BROWNLIE Type TA400 G10 Origin Project Drawing number
a RELEASED TO PRODUCTION 113744 J.CRAIG 01/12/2015 Sheet 15
Rev. Index Revision ECN No. Name Date Approved 01/12/2015 G.McNEIL M.-Nr.: T2 15400612 15400615 No. 34 Sh.
1 2 3 4 5 6 7 8 9 10 11 12
 1 2 3 4 5 6 7 8 9 10 11 12

A A

TCU K19.X.12 Sensor supply

TCU K19.X.58 Analog return
/21.H11
-S22.X:A

-X6.14a
/21.B11
Transmission

-S22.X:C
-X6 11-XJ15 1 -X6 14 Allison Transmission
5050143198 5050143198 5050143198 29545538 Allison Transmission
2.50 mm²
TCU TCU Range Inhibit +4.1 https://one.terex.

-X6.11b

-X6.14b
7 -A2
B Main Controller Main Controller Main Controller CAN 1 +4.1 /70.F4 B
15325548 15325548 15325548 + 28 -K19.X +4.1
-K19 CAN 2.0B -A2.X
CR0232 CR0232 CR0232 /70.F2 - 8 28/80 1.0 mm² -W267 WH -X11 -X11 1.00 mm² +4.1 -W4 WH 5

TRANSMISSION COMPANION HARNESS ALLISON PT No 295478

J1939 TCU K19.X.12 Sensor supply TCU K19.X.12 Sensor supply 112 Trans oil level sender B38

-W72 WH
Output binary low side Output binary high side Output binary high side DATA CAN 1 49 8/80 a/35 a/35 +4.1 5/37

TCU K19.X.12 Sensor supply

LINK SHIELD 48 1.0 mm² -W268 WH -X11 -X11 1.00 mm² +4.1 -W5 WH 22
OUT_K19_RetarderRequest OUT_K19_AuxiliaryRangeInhibit OUT_K19_AuxiliaryHold TCU K19.X.58 Analog return TCU K19.X.58 Analog return 158 Harness Splice (Sensor return)
-K18 -K18 -K18 29 +4.1 b/35 b/35 22/37

-W242:TW1#0
/14.E12 Master /14.C12 Master /14.C12 Master
-X11 -X11

Twisted Pair
65 26 1.00 mm² +4.1 -W6 WH 21
Q09_E Q03_E Q01_E 175 Trans oil retarder temp sender B32

1.00 mm²
CAN 2 TCU K19.X.75 oil retarder temp sender
5 + 6 +4.1 c/35 c/35 21/37
Ex-X2 3 Ex-X2 15 Ex-X2 17 24
CAN 2.0B
27 -A1.X30:11 -X11 -X11 32
J1939 - 1.0 mm² -W242 YE
/12.G4 1.00 mm² +4.1 -W7 WH
116 Trans oil level sender B38
64 67 CAN2_H d/35 d/35 TCU K19.X.16 Oil level sender 32/37
CAN2_H +4.1
-K18.XR

-K18.XR

-K18.XR
3/55

15/55

17/55
DATA CAN 2
50