Terex TA30 Articulated Dumptruck Maintenance Manual

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TA30
Articulated Dumptruck
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MAIN LIBRARY INDEX
TECHNICAL PUBLICATIONS DEPARTMENT

TEREX EQUIPMENT LIMITED
MOTHERWELL, SCOTLAND ML1 5RY
REF. NO. SM 799
SM 1936 Rev 1 11-00

Service
The information contained within this
Alert must not be made available to
third parties not authorised to receive it.
Information
Alert
DATE: April 1994 B168
MODEL: General
SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS
PURPOSE:
To advise potentially hazardous condition.
DETAIL:
It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces a
highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315 C.
The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.
We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.
b. If this is affirmed - Do Not Touch
c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.
d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by washing
thoroughly with Limewater (Calcium Hydroxide solution).
f. Any cloths, residue and gloves used MUST be safely discarded after use.
Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.
TEREX SERVICE DEPARTMENT

TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046
TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752
NOTICE DE SCURIT IMPORTANTE
Un entretien et des rparations adquats sont importants pour la scurit, un fonctionnement fiable de tous les vhicules
moteur. Les procdures dentretien recommandes et dcrites dans cette publication sont des mthodes effectives
permettant lexcution doprations dentretien. Certaines de ces oprations dentretien ncessitent lutilisation doutils
conus tout particulirement cette fin. Les outils spciaux doivent tre utiliss lorsquils sont recommands.
Il est important de remarquer que cette publication comprend diffrents AVERTISSEMENTS et NOTES qui doivent tre lus
avec prcaution afin de minimiser le risque de blessures du personnel ou de mise en pratique de mthodes de service
inadquat risquant dendommager le vhicule ou de le rendre peu sr. Il est galement important de comprendre que ces
AVERTISSEMENTS et NOTES ne sont pas exhaustifs. Il nest pas possible de connatre, dvaluer et de faire part au
personnel de TOUTES les mthodes imaginables en fonction desquelles lentretien peut tre effectuer ou de tous les
risques possibles en rsultant. Par consquent, une valuation aussi large na pas t prise en considration. Donc,
quiconque utilise une procdure dentretien ou un outil qui nest pas recommand doit tout dabord sassurer que ni sa
scurit et ni la scurit du vhicule ne sera remise en cause par la mthode dentretien quil/elle slectionne.
Deux types den-tte sont utilises dans ce manuel pour attirer votre attention.
1. AVERTISSEMENT - Ce symbole est utilis lorsquune procdure de fonctionnement, pratique, etc., qui, si elle nest pas
observe correctement, risque dentraner des blessures corporelles voire la mort. Recherche ce symbole pour indiquer les
prcautions de scurit importantes. Il signifie - ATTENTION! SOYEZ PRUDENT! VOTRE SECURITE EST EN JEU!
2. Note - Ce symbole est utilis lorsquune procdure de fonctionnemnet, mthode, etc., qui, si elle nest pas observe strictement,
risque dentraner des dommages ou une destruction de lquipement.
AVERTISSEMENT
Nutilisez jamais des pices qui sont altres, modifies ou affaiblies lors du fonctionnement. Ceci peut srieusement
remettre en cause lintgrit de la machine et provoquer des dommages de lquipement ou de graves blessures
corporelles.
SMF 222 Rev 1 9-93

TABLE OF CONTENTS
Section No. Description SM No.

000 GENERAL INFORMATION
0000 Technical Data - TA30 1937 Rev 1
100 CHASSIS
0010 Frames 1960
0020 Articulation and Oscillation Pivot - Pre May 2000 Production 1975
0020 Articulation and Oscillation Pivot - From May 2000 Production 1988 Rev 1
0040 Hood and Mounting 1984 Rev 1
0070 Fenders and Mounting 1963
110 ENGINE
0030 Engine and Mounting 1964
0040 Kysor DST Fan 1974
0050 Air Cleaner 1958
120 TRANSMISSION
0010 Transmission and Mounting 1965
130 DRIVELINES
0010 Front and Rear Drivelines 1534 Rev 1
140 FRONT AXLE GROUP
0020 Axle Group (Hub) (Refer to Section 160-0030) -
0040 Wheel Rim and Tyre (Refer to Section 160-0050) -
0060 Differential Drive Head (Refer to Section 160-0020) -
150 CENTRE AXLE
0020 Differential Drive Head 1971
160 REAR AXLE GROUP
0020 Differential Drive Head 1969
0030 Axle Group (Hub) 1968
0050 Wheel Rim and Tyre 1970
165 BRAKE PARTS
0010 Brake Parts - Rear 1962
0020 Brake Parts - Front 1961
170 PARKING BRAKE
0010 Parking Brake and Mounting 1967
180 SUSPENSION SYSTEM
0020 Front Suspension 1979
0021 Air Spring 1480
0022 Levelling Valve 1481
0040 Rear Suspension 1978
190 ELECTRICAL SYSTEM
0000 Circuit Diagrams 1946 Rev 1
0270 Switches and Sensors 1959 Rev 1
200 FUEL SYSTEM
0040 Fuel Tank, Lines and Mounting 1942
SM 1935 Rev 1 11-00 1

TABLE OF CONTENTS
Section No. Description SM No.

210 COOLING SYSTEM
0000 Cooling System 1983
0040 Radiator, Header Tank and Mounting 1987
0060 Transmission Oil Cooler 1977
0100 Hydraulic Oil Cooler 1976
220 STEERING SYSTEM
0000 Steering System Schematic 1943
0050 Steering Pump (Refer to Section 230-0050) -
0090 Steering Valve 1986 Rev 1
0105 Priority Valve 1947
0120 Steering Cylinder 1955
0140 Emergency Valve 1944
230 BODY SYSTEM
0000 Body System Schematic 1949 Rev 1
0040 Hydraulic Tank 1950
0050 Main Hydraulic Pump 1951
0060 Body Control Valve 1952
0081 Body Control Joystick 1953 Rev 1
0121 Pilot Supply Valve 1954
0130 Body Cylinder 1956
250 BRAKING SYSTEM
0000 Air Braking System Schematic 1948
0000 Hydraulic Braking System Schematic 1982
0070 Treadle Valve 1939
0170 Air Tanks and Mounting 1941
0190 Park Emergency Control Valve 1940
0200 Air Drier 1985 Rev 1
0260 Pressure Converter 1508
0270 Air Breather 1509
0280 Relay Emergency Valve 1945
0290 Pressure Protection Valve (4 way) 1938
260 OPERATORS COMPARTMENT
0010 Cab and Mounting 1957
0090 Driver Seat and Mounting 1981
0130 Air Conditioning 1966
270 BODY
0010 Body and Mounting 1980
300 MISCELLANEOUS
0020 Lubrication System 1972
0070 Service Tools 1973
0080 Axle Bolt and Nut Torque Specifications 1521
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239
* * * *
2 SM 1935 Rev 1 11-00
GENERAL INFORMATION - Technical Data
Section 000-0000
SM - 2476
2 615
Max. 1 435 (8-7)
Body (4-8) 2 815
Depth (9-3)
45
Vehicle Clearance
Turning Diameter
65 5 885
17.6 m (58-0) (19-4)
4 840
(15-10)
4 390
(14-5)
3 405
(11-2)
3 310
(10-10) 2 860
(9-4)
3 190
(10-6) 1 835
(6-0)
505
(1-8) 25
1 580 660
(5-2) (2-2)
2 400 1 260 2 820 1 720 1 245
2 200 (9-3)
(7-3) (7-10) (4-2) (5-8) (4-1)
2 820 9 445
(9-3) (31-0)
30/65 R 25 tyres increase width over tyres to 3 000 mm (9-10) Dimensions in mm (ft-in)
Fig. 1 - Machine Dimensions
ENGINE overspeed. Blocked filter indicator and filter bypass system

Make/Model ..................................... Cummins MTA11-C300 provide valve block with additional protection from unfiltered
Type .......... Four cycle, low emission, direct injection diesel, oil.
water-cooled, turbocharged and aftercooled.
Gross power at 2 100 rev/min ....... 224 kW (300 hp, 304 PS) Pressures:
Net power at 2 100 rev/min ........... 214 kW (287 hp, 291 PS) Main .......................................... 16 + 2 bar (232 + 30 lbf/in)
Lockup (Wk) .............................. 14 1 bar (190 15 lbf/in)
Note: Gross power rated to SAE J1995 Jun 90. Engine Converter 'IN' ............... 7.6 bar (110 lbf/in2) at 2 300 rev/min
emission meets USA EPA/CARB MOH 40 CFR 89 and Converter 'OUT' ............. 4.8 bar (70 lbf/in2) at 2 300 rev/min
EU NRMM (non-road mobile machinery) directive. Converter Relief Valve ............................ 8.5 bar (123 lbf/in2)
Retarder .................................................... 5.5 bar (80 lbf/in2)
Maximum Torque ... 1 376 Nm (1 015 lbf ft) at 1 300 rev/min
Temperatures:
Number of cylinders/configuration ........................... 6, in line
Normal ...................................... 80 - 110 C (176 - 230 F)
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in)
Maximum ..................................................... 120 C (248 F)
Total Displacement ................................. 10.8 litres (660 in)
Air cleaner ..................................... Dry type, double element Stall Speed .............................................. 1 655 50 rev/min
Starting ...................................................................... Electric
Maximum Speed (No load) ............................. 2 450 rev/min Ratios:
Maximum Speed (Full load) ............................ 2 100 rev/min Torque Converter ........................................................ 1.84:1
Idle Speed ................................................... 675/750 rev/min Transmission .................................................... Refer to table
Safe Operating Angle ................................... 43/94% Grade
Forward
TRANSMISSION Gear 1 2 3 4 5 6
Make/Model .................................. ZF 6WG 260 II Automatic Ratio 5.35 3.45 2.21 1.42 0.97 0.62
with manual override. The transmission assembly consists km/h 5.0 8.0 12.5 19.5 29.0 45.0
of a torque converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. Automatic mile/h 3.0 5.0 8.0 12.0 18.0 28.0
shifting throughout the range, with kickdown feature. Lockup Reverse
action in all forward gears. A torque proportioning output Gear 1 2 3
differential transmits drive permanently to front and rear
axles. This differential may be locked by the driver for use in Ratio 5.35 2.21 0.97
difficult traction conditions. Standard integral hydraulic km/h 5.0 12.5 29.0
retarder which is automatically operated should the engine mile/h 3.0 8.0 18.0
SM 1937 Rev 1 11-00 1

General Information - Technical Data
Section 000-0000
AXLES WHEELS AND TYRES
Three axles in permanent all-wheel drive with differential Wheels: ............ 5-piece earthmover rims with 12 stud fixing
coupling between each axle to prevent driveline wind-up. Size:
Heavy duty axles with fully-floating axle shafts and outboard Standard ....................... 25 x 19.50 in for 23.5 R25** tyres
planetary reduction gearing. Optional ...................... 25 x 22.00 in for 30/65 R25** tyres
Tyres:
Automatic limited slip differentials in each axle. Centre axle Standard ........................................................... 23.5 R25**
incorporates a through-drive differential to transmit drive to Optional .......................................................... 30/65 R25**
the rear axle. Locking of this differential is actuated
simultaneously with the transmission output differential lock. Inflation Pressures (Bridgestone):
Front Rear
Ratios: 23.5 R25** 4.0 bar (58 lbf/in) 4.8 bar (69 lbf/in)
Differential ............................................................... 3.44:1 30/65 R25** 4.3 bar (62 lbf/in) 4.3 bar (62 lbf/in)
Planetary ................................................................. 6.35:1
Total Reduction ..................................................... 21.85:1 Note: Tyre pressures should be regarded as nominal only.
It is recommended that for tyres both listed and unlisted, the
user should consult the tyre manufacturer and evaluate all
SUSPENSION job conditions in order to make the proper selection.
Front: Axle is carried on the leading arms of a sub-frame
pivoting on the main frame. Suspension is by flexible air HYDRAULIC SYSTEM
bellows with four heavy duty hydraulic dampers.
Steering and Body Hoist
The steering and body hoist systems are supplied with oil
Axle Vertical Travel ..................................... 127 mm (5 in)
from a common tank by the main hydraulic pump. Gear
pump driven from power takeoff on transmission. System
Rear: Each axle is coupled to the frame by three rubber-
components are protected by full flow filtration on the return
bushed links with lateral restraint by transverse link.
line.
Pivoting inter-axle balance beams equalise load on each
axle. Suspension movement is cushioned by rubber/metal
Pump:
laminated compression units between each axle and
Type .............................................................................. Gear
underside of balance beam ends.
Capacity at 2 300 rev/min ........... 4.49 litre/s (71 US gal/min)
Axle Vertical Travel ............................. 130 mm (5.12 in)
Axle Oscillation .......................................................... 12 Steering System
Hydrostatic power steering by two single-stage, double-
acting, cushioned steering cylinders. Emergency steering
BRAKES pressure is provided by a ground driven pump mounted on
Air assisted hydraulic dry disc on each wheel with two the rear of the transmission. An audible alarm and warning
heavy-duty callipers per disc at the front and a single light indicates should the emergency system activate.
heavy-duty calliper per disc at the rear. Independent circuits Conforms to ISO 5010, SAE J53.
for front and rear brake systems. Overstroke actuates
warning light. Brake system meets ISO 3450, SAE J1473. System Pressure ................................. 241 bar (3 500 lbf/in)
Steering Angle to either side ............................................ 45
Air System Pressure ............................... 7.6 bar (110 lbf/in) Lock to Lock Turns, steering wheel .................................... 4
Total Air Reservoir Capacity ................... 55 litres (3 356 in) Vehicle Clearance Circle (SAE) ....................... 17.6 m (58 ft)
Hydraulic Brake Fluid Capacity ...... 2.64 litres (0.68 US gal)
Body Hoist System
Parking: Spring-applied, air-released disc on rear
Two single-stage, double-acting hoist rams, cushioned at
driveline.
both ends of stroke. Electro servo assisted hoist control.
Emergency: Emergency brake control actuates the
System Pressure ................................. 221 bar (3 200 lbf/in)
service brakes. Automatic application of
Control Valve ........................... Pilot Operated, Open Centre
service brakes should pressure fall in the
Body Raise Time (loaded) .......................................... 12 sec
brake air system.
Body Lower Time (power down) ................................ 7.5 sec
Retardation: Hydraulic retarder integral with transmission.
2 SM 1937 Rev 1 11-00

General Information - Technical Data
Section 000-0000
ELECTRICAL SYSTEM TYPICAL NOISE LEVELS
Type .............................................. 24 volt, Negative Ground Operator Ear (ISO 6394) ............................................ 79 dbA
Battery ......................................... Two, 12 Volt, 143 Ah each
Accessories ................................................................ 24 Volt *Exterior Sound Rating (SAE J88 JUN 86) ............. TBA dbA
Alternator .................................................................. 70 Amp *- The above result is for the mode giving the highest
exterior sound level when measured and operated as per
the prescribed procedures of the standard. Results shown
BODY are for the vehicle in base configuration.
Of all welded construction, fabricated from high hardness
(min. 360 BHN) 1 000 MPa (145 000 lbf/in) yield strength Note: Noise Level Exposure to the operator and bystander
steel. 25 tail chute angle provides good load retention personnel may be higher depending upon proximity to
without tailgate. buildings, rock piles, machinery, etc.. The actual job site
Noise Level Exposure must be measured and applicable
Plate Thicknesses: regulations complied with in respect to Employee Hearing
Floor and Tailchute ................................... 15 mm (0.59 in) Protection.
Sides ......................................................... 12 mm (0.47 in)
Front ........................................................... 8 mm (0.31 in)
Vehicle Weights
Volume:
Standard Vehicle kg lb
Struck (SAE) .......................................... 13.0 m (17.0 yd)
Heaped 2:1 (SAE) ................................. 16.0 m (21.0 yd) Net Distribution
Front Axle 10 585 23 335
SERVICE CAPACITIES Centre Axle 5 000 11 025
Rear Axle 4 970 10 955
Fuel tank ............................................. 330 litres (87 US gal)
Hydraulic System Vehicle, Net 20 555 45 315
(steering & body) .......................... 200 litres (52.8 US gal) Payload 27 000 59 525
Engine Crankcase ............................. 40 litres (10.5 US gal) Gross Distribution
Cooling System .................................. 59 litres (15.6 US gal)
Transmission & filters (dry fill) ............ 52 litres (13.8 US gal) Front Axle 14 450 31 860
Transmission & filters (wet fill) ............. 26 litres (6.9 US gal) Bogie Axle, leading 16 545 36 470
Differentials - Front & Rear (each) ....... 11 litres (2.9 US gal) Bogie Axle, rear 16 560 36 510
Differential - Centre .............................. 14 litres (3.7 US gal) Vehicle, Gross 47 555 104 840
Planetaries (each) ............................... 3.5 litres (0.9 US gal) Bare Chassis 16 025 35 330
Service Brakes ..................................... 3 litres (0.79 US gal)
Body 4 000 8 820
Air Conditioning Compressor ...... 0.125 litres (0.033 US gal)
Body Hoists (Pair) 530 1 170
* * * *
SM 1937 Rev 1 11-00 3

CHASSIS - Frames
Section 100-0010
SM - 2475
Fig. 1 - General Arrangement of Frame Assemblies
DESCRIPTION frame, secures the coupling in position. Wear on the

The chassis consists of two separate frame thrust faces of the bushes is compensated by
assemblies which provide the articulation of the unit. tightening this thrust nut.
The front and rear frames are constructed of all
welded high-grade steel fabrications with rectangular
box section beams forming main, side and cross INSPECTION AND MAINTENANCE
members. The frames are coupled to provide 45
articulation to each side as well as oscillation. Inspection
Inspect the frames and attached parts at intervals not
The front frame is fabricated to form a rigid structure exceeding 250 hours for cracked or broken welds and
which carries the cab, power train and suspension bending of the frame. Any defects found should be
system. repaired before they progress into major failures.
The rear frame is fabricated to form a rigid structure

which carries the body, body hydraulics, suspension Straightening
and rear drive axles. Hydraulic straightening or aligning equipment should
be used to straighten bent or twisted frames whenever
Oscillation between the front and rear frames is possible. However, if heat must be applied, never heat
provided by a large diameter cylindrical coupling the metal beyond a dull, cherry red colour, as too
carried on nylon bushes located in the rear frame. much heat will weaken the metal. When it is necessary
Longitudinal shocks are absorbed by the thrust faces to heat the metal, apply heat uniformly over the area to
of the nylon bushes. A large thrust nut, which is be straightened and protect the heated surface from
threaded to the end of the coupling and locked to the sudden cooling. Frame parts that cannot be
straightened should be renewed.
SM 1960 4-00 1
Chassis - Frames
Section 100-0010
Welding clamp is attached to the rear frame when welding is

Electric arc welding is recommended for all welded performed on the front frame, the current must pass a
frame repairs. Since the nature and extent of damage frame connection to return to the welding machine.
to the frame cannot be predetermined, no definite Since the pivot coupling offers the least resistance but
repair procedure can be established. As a general rule not a sound electrical connection, small electric arcs
however, if parts are twisted, bent or pulled apart or a may be set up across the moving parts which may
frame is bent or out of alignment, no welding should be cause welding blotches on their wearing surfaces and
done until the parts are straightened or realigned. increase the wear rate of these components.
Successfully welded repairs will depend to a great

extent upon the use of the proper equipment, materials Reinforcement
and the ability of the welder. The Service Department Frame reinforcement can be made with channel or
can be consulted regarding the feasibility of, welding angle or flat structural stock. Whenever possible, the
repairs. reinforcement should extend well beyond the bent,
broken or cracked area. The reinforcement stock
thickness should not exceed that of the frame stock
WARNING and the material should be of the same tensile
Welding and flame cutting cadmium plated strength.
metals produce odourless fumes which are
toxic. Recommended industrial hygiene
practice for protection of the welding operator Painting
from the cadmium fumes and metallic oxides A check of the condition of the paint should be made
requires enclosure ventilation specifically approximately twice a year and chassis repainted if
designed for the welding process. A necessary.
respiratory protective device such as the
M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
will provide protection against cadmium, WARNING
fumes and metallic oxides. The 'Gasfoe' Welding, burning, heating or dressing surfaces
respirator has been approved by the U.S. previously painted using polyurethane paint
Bureau of Mines: Approval number 23B-10, produces fumes which are toxic. Surfaces
and is designed to protect against gases, must be prepared using paint stripper prior to
vapours, and/or metal fumes. area being reworked. Recommended Industrial
Hygiene and Safety Rules should be followed
Note: Disconnect the battery and alternator cables for protection of the welding operator from the
before performing any welding on the frames. Failure fumes.
to do so may seriously damage the machines
electrical equipment. Always fasten the welding To keep rust and corrosion to a minimum, periodic
machines ground cable to the piece/frame being painting of abrasions and other exposed metal areas
welded if possible. on the frames is highly recommended.
Note: The current from the welding rod always follows If painting of a frame is required, thoroughly clean the
the path of least resistance. If, for example, the ground areas to be painted. Apply a primer coat of red oxide
and then a finish coat of polyurethane enamel.
* * * *
2 SM 1960 4-00
CHASSIS - Articulation and Oscillation Pivot
Section 100-0020
SM - 2483
13 51 35
44
45 14 34
36 52 41
14 36
4 43 14
5 41
1 25
6 26
7,8,9
22 23
24 2 20
10
22 14
16
11 33 46 32
14
47
55 14 40 31
17 39
29 30
12 19
2,3,50 18 29
54
53 38
58 15
57
56 19 37
6
30 LUBRICATION POINT
28 18 38
25 27 14
21
26 20 48
59
42
49
48 49
1 - Pivot 17 - Retainer
2 - Coupling 18 - 'O' Ring
3 - Pipe 19 - Spacer 33 - Bolt
4 - 'O' Ring 20 - Bolt 34 - Thrust Nut 47 - Washer
5 - Retainer 21 - Retainer 35 - Lockplate 48 - Lube Line
6 - Bearing 22 - Nipple 36 - Bolt 49 - Connector
*7 - Shim 23 - Elbow 37 - Shaft 50 - Lube Fitting
*8 - Shim 24 - Lube Fitting 38 - Bush 51 - Nut
*9 - Shim 25 - Locknut 39 - Washer 52 - Spacer
10 - 'O' Ring 26 - Washer 40 - Seal 53 - Bolt
11 - Retainer 27 - Front Yoke 41 - 'V' Ring 54 - Hardened Washer
12 - Seal 28 - Housing 42 - Adaptor 55 - Pin
13 - Bolt 29 - Seal 43 - Bush 56 - Bolt
14 - Lockwasher 30 - Bearing 44 - Pin 57 - Lockwasher
15 - Lube Fitting 31 - Housing 45 - Washer 58 - Bracket
16 - Brake Yoke 32 - Pin 46 - Bolt 59 - Lube Fitting
* Lower bearing shims not shown
Fig. 1 - Articulation and Oscillation Pivot
DESCRIPTION AND OPERATION

The articulation and oscillation pivot allows the front Articulation bearings, oscillation bushes, pivot
and rear frames to rotate horizontally (articulation) and driveshaft bearings and associated parts can be
tilt laterally (oscillation) with respect to each other. It is removed, inspected and replaced or renewed by
also the main load bearing coupling between the two following the procedures outlined in this section.
frames. The pivot assembly houses the driveshaft
connecting the drive between the front and rear
frames.
SM 1975 4-00 1
Chassis - Articulation and Oscillation Pivot
Section 100-0020
PIVOT DRIVESHAFT BEARINGS yoke (27). Remove yoke (27) from shaft (37).
Removal 6. Remove bolts (1, Fig. 3), lockwashers (2, Fig. 3),
Numbers in parentheses refer to Fig. 1, unless nuts (3, Fig. 3) and protective guard (4, Fig. 3), if fitted,
otherwise specified. from beneath rear of pivot housing.
Note: It is not necessary to separate the frames in

order to remove the pivot driveshaft assembly. WARNING
Tensioned spring on adjuster.
WARNING 7. Slacken adjuster (14, Fig. 3) until brake pads

To prevent personal injury and property (13, Fig. 3) are sufficiently clear of parking brake disc
damage, make sure blocking or lifting (5, Fig. 3) to permit removal of calliper (7, Fig. 3).
equipment is properly secured and of adequate
capacity to do the job safely. 8. Note positions of front and rear wedge plates
(8 & 9, Fig. 3) to aid in 'Installation'. Remove bolts
1. Position the vehicle in a level work area, apply the (6, Fig. 3), washers (11, Fig. 3), nuts (12, Fig. 3), front
parking brake and switch off the engine. and rear wedge plates (8 & 9, Fig. 3) and left hand
torque plate (10, Fig. 3).
2. Block all road wheels and place the battery master
switch in the 'Off' position. 9. Move and secure calliper (7, Fig. 3) clear of parking
brake disc (5, Fig. 3).
3. Open drain cocks on air tanks to drain air pressure
from the tanks. Close air tank drain cocks when air Note: Take extra care when handling drivelines since
has exhausted from the air tanks. any deformity on a rotating mass creates vibration and
excessive wear during any operation.
Note: Take extra care when handling drivelines as any
deformity on a rotating mass creates vibration and 10. Match mark brake yoke (16) and mating surface of
excessive wear during any operation. pivot - centre axle driveline (Fig. 2) to aid in
'Installation'. Remove bolts, lockwashers and caps and
4. Match mark yokes and mating surfaces of remove driveline from the machine.
transmission - pivot driveline (Fig. 2) to aid in
'Installation'. Remove bolts, lockwashers and caps and 11. Remove bolts (57) and lockwashers (14) from rear
remove driveline from the machine. housing (31).
Note: Take care to avoid damaging pipe (3) when Note: Take extra care when handling driveshafts as
performing Step 5. any deformity on a rotating mass creates vibration and
5. Remove locknut (25) and washers (26) from front
SM - 002
Transmission - Pivot Pivot - Centre Axle
Fig. 2 - Drivelines
2 SM 1975 4-00
Section 100-0020
SM - 003
1 - Bolt 9 - Rear Wedge Plate

2 - Lockwasher 10 - LH Torque Plate
3 - Nut 11 - Washer
4 - Guard 12 - Locknut
5 - Disc 13 - Brake Pad
6 - Bolt 14 - Adjuster
7 - Calliper 15 - Bolts
8 - Front Wedge Plate 16 - Washers
Fig. 3 - Parking Brake Assembly
12. Withdraw pivot driveshaft assembly from pivot by (58) securing pipe (3) to pivot (1) assembly.
pulling rearwards on brake yoke/disc assembly and
place in suitable location for further work. Note: Take care to avoid damaging pipe (3) when
performing Steps 17 through 18.
13. Remove front locknut (25) then position front yoke
(27) fully on to front of shaft (37) and suitably restrain 17. Remove bolts (20) and lockwashers (14) from front
to resist rotation. Remove rear locknut (25), washers housing (28).
(26) and rear yoke brake/disc assembly (16). Tag front
and rear ends of shaft (37) and install locknuts (25) on 18. Tag and remove front housing (28). Note position
the shaft to protect the threads. of seal (12) in front housing (28) to aid in 'Installation'.
Remove and discard seal (12).
14. Tag and remove housing (31). Note position of
seal (40) to aid in 'Installation'. Remove and discard
seal (40). WARNING
When necessary to drive out components, use
15. Remove washer (39), rear bearing (30) and spacer a soft drift to avoid injury and damage from
(19) from rear of shaft (37). flying chips.
16. Remove bolt (56), lockwasher (57) and bracket 19. Using a suitable puller/drift, remove bearing (30).
SM 1975 4-00 3
Section 100-0020
20. Remove spacer (19). Note position of seals (29) in SM - 004
pivot (1) housing to aid in 'Installation'. Remove and
discard seals (29).
Inspection
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
1. Clean parts with a suitable solvent and let dry. DO

NOT spin bearings with compressed air. Place
bearings on clean surface, cover with lint free cloth
and allow to dry. 1 - Shaft 2 - Bushes 3 - Shoulder
2. Check pivot driveshaft bearings (30) for wear or Fig. 4 - Shaft and Bushes
damage, replace if required.
and new bushes (38) and allow to dry. Refer to Fig. 4.
3. Inspect bushes (38) for wear. Replace if badly
scored. 4. Apply LOCTITE Fugeteile 35 to shaft (37) mating
faces and install new bushes (38), with the recesses in
bushes (38) against shoulder on driveshaft (37). Make
Installation sure that bushes (38) are fully home against the
Numbers in parentheses refer to Fig. 1, unless shoulders. Refer to Fig. 4.
5. Allow 15 minutes for retaining compound to cure to
Note: Tighten all fasteners without special torques handling strength.
specified, to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE 6. Degrease front bearing (30) housing in pivot (1) with
SPECIFICATIONS. a suitable solvent and allow to dry.
Note: If bushes (38) are to be renewed, then proceed Note: Do not use retaining compound on the housing
with Steps 1 thru 5, if the bushes (38) are satisfactory, for the rear pivot shaft bearing.
proceed from Step 6.
Note: Front bearing (30) of shaft (37) is secured with
retaining compound as well as normal hardware.
WARNINGS Cleaning the bearing housing ensures a good bond.
To prevent personal injury and property THE REAR BEARING IS SECURED BY NORMAL
damage, make sure blocking or lifting HARDWARE ONLY.
capacity to do the job safely. 7. Apply coat of grease to new seals (29) and install
seals in pivot housing. Make sure seal lips are facing
When necessary to drive out outwards as shown on Fig. 5.
components, use a soft drift to avoid injury
and damage from flying chips. 8. Make sure that pivot shaft bearing (30) is
pre-packed with grease then position spacer (19),
1. Apply suitable heat to bushes (38) to break bond of bearing (30) and washer (39) on rear of shaft (37).
retaining compound. Remove locknuts (25) from their
protective position on shaft (37), then remove bushes 9. Apply bead of grease to fill inner rim of new seal (40)
(38) with a suitable drift. and position new seal in rear housing (31). Refer to
Fig. 6. Fill lube fitting (24) assembly on rear housing with
2. Allow shaft (37) to cool. Thoroughly clean shaft (37) grease and make sure that nipple (22) does not protrude
and new bushes (38) with a suitable solvent. Wash into grease slot in rear face of housing (31).
mating faces of shaft (37) and new bushes (38) with
chlorethane and allow to dry. Note: Take extra care when handling driveshafts as
any deformity on a rotating mass creates vibration and
3. Apply LOCTITE primer to mating faces of shaft (37) excessive wear during any operation.
4 SM 1975 4-00
Section 100-0020
SM - 005 SM - 006
SEAL
SEAL
HOUSING
Fig. 5 - Pivot Housing Inner Seals Fig. 6 - Typical Outer Seal Installation
10. Assemble rear housing (31) and brake yoke/disc 18. Make sure mating surfaces of housing (28) are still
assembly (16) onto rear of shaft (37). Secure with clean then apply coating of retaining compound to
locknut (25) and both washers (26) but only fingertight mating surfaces of bearing (30) and housing (28).
at this stage. Install bearing (30) on to front of shaft (37).
11. Insert shaft (37) assembly fully into pivot (1) from 19. Pack housing (28) of with grease from 1/3 to 1/2 of
the rear. Take care not to dislodge internal seals (29). capacity.
12. Partially withdraw shaft (37) assembly to enable 20. Install front housing (28), front yoke (27), both
housing of rear pivot driveline bearing (30) to be filled washers (26) and locknut (25).
with grease from 1/3 to 1/2 of capacity.
Note: Take care to avoid damaging the pipe (3) when
13. Reposition shaft (37) assembly fully in pivot (1). performing Steps 21 through 22.
14. Align housing (31) with lube fitting (24) uppermost 21. Lock brake yoke/disc (16) assembly with a suitable
and secure with lockwashers (14) and bolts (20). tool and install locknut (25) on front yoke (27). Torque
Torque tighten bolts (20) to 106 Nm (78 lbf ft). tighten locknut (25) to 678 Nm (500 lbf ft).
15. Apply a bead of grease to fill inner rim of new seal 22. Lock front yoke (27) and torque tighten locknut
(12) and position seal in front housing (28). Refer to (25) on brake yoke assembly to 678 Nm (500 lbf ft).
Fig. 6. Fill pipe (3), through lube fitting (50), with
grease. Make sure that pipe (3) does not protrude into 23. Align front housing (28) with pipe (3) uppermost
grease slot in rear face of housing (28). and secure in place with bolts (20) and lockwashers
(14). Torque tighten bolts (20) to 106 Nm (78 lbf ft).
16. Install spacer (19) onto front of shaft (37).
24. Install bracket (58), and secure with lockwasher
17. Pre-pack bearing (30) with grease taking care not (57) and bolt (56).
to place any grease on outer curved surface. Clean
this surface with a suitable solvent where necessary 25. Check that no end float exists by pulling and
and allow to dry. pushing on the brake yoke/disc assembly.
Note: Make sure that Steps 18 through 22 are Note: Take extra care when handling drivelines as
performed within the hardening time of the retaining chips, dents, burrs or deformity on any rotating mass
compound in use. creates vibration and excessive wear during any
operation. (Steps 26 & 28).
SM 1975 4-00 5
Section 100-0020
26. Connect pivot - centre axle driveline (Fig. 2) to has exhausted from the air tanks.
brake yoke/disc assembly as noted on 'Removal'.
Install caps and secure with lockwashers and bolts. 4. Position levelling jack under centre front portion of
the front frame. Raise jack and block frame to remain
27. Position parking brake calliper (7, Fig. 3) in level after removal of the articulation pins. Check that
position and install left hand torque plate (10, Fig. 3), front wheels are still effectively blocked.
front and rear wedge plates (8 & 9, Fig. 3) and secure
in place with bolts (6, Fig. 3), washers (11, Fig. 3) and Note: Make sure that front frame is correctly
locknuts (12, Fig. 3). supported and prevented from tilting on the axle, or
damage to coupling etc. could result.
28. Install transmission - pivot driveline (Fig. 2) with
caps, lockwashers and bolts as noted on 'Removal'. 5. Disconnect steering cylinders by removing bolts
(36), lockwashers (14), washers (45) and pins (44)
29. Position guard (4, Fig. 3), if fitted, and secure to from attachment points on pivot (1) housing. Move
frame using bolts (1, Fig. 3), lockwashers (2, Fig. 3) steering cylinders clear of pivot (1) housing and
and nuts (3, Fig. 3). secure.
30. Place the battery master switch in the on position, Note: Take extra care when handling drivelines as
start the engine and allow air pressure in the tanks to chips, dents, burrs or deformity on any rotating mass
build up to correct operating pressure. creates vibration and excessive wear during any
operation.
31. Adjust parking brake as shown in Section 170-0010,
PARKING BRAKE AND MOUNTING. 6. Match mark yokes and mating surfaces of
32. Remove all blocking from the road wheels. 'Installation'. Remove bolts, lockwashers and caps and
remove driveline from the machine.
ARTICULATION BEARINGS 7. Remove bolt (53) and hardened washer (54)

securing pin (55) to pivot (1) housing. Remove nut (51)
Removal and withdraw pin (55), tapping pin downwards to ease
Numbers in parentheses refer to Fig. 1, unless removal. Take care not to damage the threads on pin
otherwise specified. (55).
Note: The lengths of the electrical, hydraulic and air Note: It may be necessary to adjust the frame levelling
connections between the two frames are designed to jack to relieve binding between pin (55) and pin bores
permit articulation. As a result, the frames can be during removal.
separated sufficiently to permit removal of the
articulation bearings without disconnecting these 8. Remove bolt (46), lockwasher (14) and washer (47)
connections. securing pin (32) to pivot (1) housing.
9. Remove pin (32), tapping pin upwards to ease

WARNING removal. Take care not to damage the threads on pin
To prevent personal injury and property (32).
damage, make sure blocking or lifting
equipment is properly secured and of adequate Note: It may be necessary to adjust the frame levelling
capacity to do the job safely. jack to relieve binding between pin (32) and pin bores
during removal.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. 10. Attach suitable lifting equipment to the rear frame
and take up slack.
switch in the 'Off' position. Note: Only separate the frames sufficiently to permit
removal of the articulation bearings or damage to
3. Open drain cocks on air tanks to drain air pressure electrical, hydraulic and air connections could result.
from the tanks. Close air tank drain cocks when air
11. Remove blocking from the rear frame and wheels
6 SM 1975 4-00
Section 100-0020
and use lifting equipment to pull the rear frame away SM - 007
from the front frame. After moving, block the rear
frame and wheels securely.
12. Mark all bearing retainers (5, 11, 17 & 21) to aid in
'Installation'.
Note: Retainers (5, 11, 17 & 21) are not

interchangeable.
13. Remove bolts (13), lockwashers (14), retainers

(5, 11, 17 & 21) and upper and lower shims (7, 8 & 9).
14. Remove and discard 'O' rings (4, 10 & 18).

Remove spacer (52) noting orientation to aid in
1 - Upper Retainer 6 - Bolts
'Installation'.
2 - Lower Retainer 7 - Washers
3 - Upper 'O' Ring 8 - Cups
15. Remove and tag all bearings (6) to aid in 4 - Lower 'O' Ring 9 - Cones
'Installation', where appropriate. 5 - Shims 10 - Lugs
Fig. 7 - Section Through Articulation Bearing

Note: Never interchange cups or cones between
bearings.
that bearing cones are back to back and position
retainer (11), for top articulation bearing, and retainer
Inspection (21), for bottom articulation bearing on underside of
Numbers in parentheses refer to Fig. 1. bearing housing. Make sure that bearings are pre-
packed with grease including end faces and faces on
1. Clean parts with a suitable solvent and let dry. DO bearing cups.
bearings on clean surface, cover with lint free cloth 2. Install top retainer (5), for top articulation bearing,
and allow to dry. and retainer (21), for bottom articulation bearing.
2. Check articulation bearings (6) and pins (32 & 55) 3. Lubricate bolts (13 for top and 33 for bottom) and
for wear or damage. Renew if required. install along with washers (14). Torque tighten bolts
(13 & 33) to 27 Nm (20 lbf ft).
Installation 4. Use feeler gauges to measure end float and record
Numbers in parentheses refer to Fig. 1, unless value. Refer to Fig. 8.
Note: End float is equal to the sum of the clearances
between both retainers and the lug.
WARNING
To prevent personal injury and property 5. Select shims to total value of -0.07 to +0.02 mm
damage, make sure blocking or lifting (-0.003 to +0.001 in) of that recorded at Step 4.
capacity to do the job safely. SM - 008
Note: Two bearings are installed on EACH articulation

point. Each bearing comprises a cup and a cone and
are installed into the articulation point with the cones
'back to back'. Refer to Fig. 7.

bearings.
1. Insert both bearing cups and cones into housing so Fig. 8 - Measuring End Float
SM 1975 4-00 7
Section 100-0020
6. Remove bolts (13 & 33), lubricate and coat with 19. Place the battery master switch in the on position,
anti-seize compound then install shims (7, 8 & 9) start the engine and allow air pressure in the tanks to
beneath appropriate upper retainer (5 for upper build up to correct operating pressure.
articulation bearing, 17 for lower articulation bearing).
20. Lower and remove jack and all blocking
7. Re-install bolts (13 & 33) and washers (14) and equipment.
torque tighten to 106 Nm (78 lbf ft).
8. Install spacer (52) in upper bearing as noted on OSCILLATION BUSHES

removal. Install upper 'O' ring (4) and lower 'O' ring
(10) for top bearing (6). Removal
Note: The lower bearing is NOT fitted with a spacer. otherwise specified.
9. Install 'O' rings (18) for lower bearing (6).

WARNING
10. Attach suitable lifting equipment to the rear frame To prevent personal injury and property
and take up slack. damage, make sure blocking or lifting
11. Remove blocking from rear frame and wheels. capacity to do the job safely.
Move rear frame with lifting equipment to align the
articulation pin bores. Block the rear frame and wheels 1. Position the vehicle in a level work area, apply the
to remain level and stationary. parking brake and switch off the engine.
12. Clean articulation pins (32 & 55) with suitable 2. Block all road wheels and place the battery master
solvent, allow to dry then coat them with anti-seize switch in the 'Off' position.
compound including threads on upper pin (55).
13. Insert articulation pin (32). from the tanks. Close air tank drain cocks when air
has exhausted from the air tanks.
Note: It may be necessary to adjust the levelling jack
beneath front frame to permit entry of articulation pin 4. Remove hydraulic oil tank remote drain plug and
(32). Pin (32) may be tapped in to place taking care drain hydraulic oil into a suitable container. Re-install
that it is not misaligned and does not cause damage to drain plug in hydraulic tank remote drain fitting.
the pin, bearings or pivot housing lugs.
5. Tag all air and hydraulic lines between front and
14. Secure pin (32) with washer (47), lockwasher (14) rear frames to aid in 'Installation. Disconnect all air and
and bolt (36). hydraulic lines. Cap line fittings and plug lines to
prevent ingress of dirt.
15. Insert upper articulation pin (55).
6. Disconnect electrical wiring and any other
16. Install nut (51) on pin (55). Torque tighten nut (51) attachments that would be damaged on separation of
to 1 424 Nm (1 050 lbf ft). front and rear frames.
Note: Take extra care when handling drivelines as 7. Position levelling jack under centre front portion of
chips, dents, burrs or deformity on any rotating mass the front frame. Raise the jack and block the front
creates vibration and excessive wear during any frame, front and rear, so it will remain level after
operation. separation. Check that both front wheels are still
securely blocked.
17. Install transmission - centre driveline (Fig. 2) with
caps, lockwashers and bolts as noted on 'Removal'. Note: Make sure that the front frame is correctly
supported and prevented from tilting on the axle or
18. Position steering cylinders in place on pivot (1) and damage to coupling etc. could result.
install pins (44). Secure pins (44) with bolts (36),
washers (45) and lockwashers (14).
8 SM 1975 4-00
Section 100-0020
Note: Take extra care when handling drivelines as assembly to avoid damage to end threads.
chips, dents, burrs or deformity on any rotating mass
creates vibration and excessive wear during any 18. Replace thrust nut (34) on pivot (1) to protect
operation. threads.
8. Remove bolts (1, Fig. 3), lockwashers (2, Fig. 3), 19. Note position of front 'V' ring (41) to aid in
nuts (3, Fig. 3) and protective guard (4, Fig. 3), if fitted, 'Installation'. Remove and discard 'V' ring (41).
from beneath rear of pivot housing.
20. Inspect oscillation bushes (43) as described in
'Inspection'. If bushes are to be renewed, proceed with
WARNING Step 20.
21. Remove oscillation bush/es (43) with hammer and
9. Slacken adjuster (14, Fig. 3) until brake pads chisel.
(13, Fig. 3) are sufficiently clear of parking brake disc
(5, Fig. 3) to permit removal of calliper (7, Fig. 3). Note: The suggested method is to make an axial cut
along the bush then to lever the bush in order to
10. Note positions of front and rear wedge plates collapse it upon itself.
(6, Fig. 3), washers (11, Fig. 3), nuts (12, Fig. 3), front
and rear wedge plates (8 & 9, Fig. 3) and left hand Inspection
torque plate (10, Fig. 3). Numbers in parentheses refer to Fig. 1.
11. Move and secure calliper (7, Fig. 3) clear of 1. Clean oscillation bushes (43) with a suitable solvent
parking brake disc (5, Fig. 3). and allow to dry.
Note: Take extra care when handling drivelines since 2. Inspect oscillation bushes (43) for wear, scoring,
any deformity on a rotating mass creates vibration and erosion and 'out of round'. Pay particular attention to
excessive wear during any operation. the thrust faces of the bushes which should also be
inspected for cracking/splitting. Renew if required.
12. Match mark brake yoke (16) and mating surface of
pivot - centre axle driveline (Fig. 2) to aid in
'Installation'. Remove bolts, lockwashers and caps and Installation
remove driveline from the machine. Numbers in parentheses refer to Fig. 1, unless
13. Mark disc (5, Fig. 3) assembly to aid in 'Installation'
then remove bolts (15, Fig. 3) washers (16, Fig. 3) and Note: Tighten all fasteners without special torques
disc (5, Fig. 3). specified, to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
14. Remove bolts (36), lockwashers (14) and TORQUE SPECIFICATIONS.
lockplate (35).
15. Using special tool, which can be fabricated as WARNING

shown in Fig. 11, remove thrust nut (34) from pivot (1). To prevent personal injury and property
Note position of rear 'V' ring (41) to aid in 'Installation'. damage, make sure blocking or lifting
Remove and discard 'V' ring (41). equipment is properly secured and of adequate
capacity to do the job safely.
16. Attach suitable lifting equipment to the front of the
rear frame and take up slack. 1. Wipe bush housing clean using suitable solvent and
allow to dry.
17. Remove all blocking from rear frame and wheels
and using suitable lifting equipment draw the rear 2. Apply LOCQUIC primer to housing and allow to dry
frame from pivot (1) assembly. When clear, block the for 10 minutes. Apply LOCTITE RC-35 to housing.
rear frame and wheels.
3. Align new bushes to housing with grease holes aligned
Note: Use care when separating rear frame and pivot vertically and identification 'PAINT DOT' at Top Dead
SM 1975 4-00 9
Section 100-0020
Centre. Refer to Fig. 9. Drift bushes into housing using lockwashers (14). Torque tighten bolts (36) to 75 Nm
hammer with soft packing for protection. (55 lbf ft).
4. Using special tool, which can be fabricated as 10. Grease oscillation bushes (43) through lube fittings
shown in Fig. 11, remove thrust nut (34) from pivot (1). (59) until excess lubrication is seen.
Clean grease from pivot exterior using a suitable
solvent where necessary and allow to dry. 11. Check that no end float exists at oscillation bushes by
pushing and pulling on brake yoke assembly.
Note: Use care on inserting the pivot housing
assembly or damage to the thread could occur. 12. Position brake disc (5, Fig. 3) onto brake yoke (16)
as noted at 'Removal'. Secure in place with bolts (15,
5. Install new pre-greased front 'V' ring (41). Refer to Fig. 3) and washers (16, Fig. 3).
Fig. 10. Apply liberal coat of grease to external surface
of pivot (1) and mating faces of bushes (43). Note: Take extra care when handling drivelines as
6. Attach suitable lifting equipment to the front of the SM - 011
rear frame and take up slack.

PAINT DOT
and use lifting equipment to line-up and draw the rear
frame onto pivot (1) assembly.
8. Install new pre-greased rear 'V' ring (41). Refer to

Fig. 10. Using special tool, as shown in Fig. 11, install
and tighten thrust nut (34) until there is no end float/
clearance at thrust face of either bush (43). Slacken
thrust nut (34) until pin of lockplate (35) can be
inserted in first available hole in thrust nut (34).
Fig. 9 - Installing Oscillation Bushes
9. Secure lockplate (35) with bolts (36) and
SM - 010
FRONT 'V' RING REAR 'V' RING
OSCILLATION
BUSH PAINT
LUBE HOLE LUBE HOLE
DOT
PAINT
DOT
THRUST NUT
Fig. 10 - Pivot Housing 'V' Ring Installation
10 SM 1975 4-00
Section 100-0020
chips, dents, burrs or deformity on any rotating mass 5. Remove bolts and lockwashers securing lockplate
creates vibration and excessive wear during any at the thrust nut and remove the lockplate.
operation.
6. Using special tool, which can be manufactured as
13. Connect pivot - centre axle driveline (Fig. 2) at shown in Fig. 11, tighten thrust nut until there is no end
brake yoke using bolts, lockwashers and caps as float/clearance at thrust face of either bush. Slacken
noted at 'Removal'. thrust nut until pin of the lockplate can be inserted in
the first available hole in the thrust nut.
14. Position parking brake calliper (7, Fig. 3) in
position and install left hand torque plate (10, Fig. 3), 7. Secure lockplate with bolts and lockwashers.
front and rear wedge plates (8 & 9, Fig. 3) and secure Torque tighten bolts to 75 Nm (55 lbf ft).
in place with bolts (6, Fig. 3), washers (11, Fig. 3) and
locknuts (12, Fig. 3). 8. Lower jack and remove all blocking from the front
wheels.
15. Position guard (4, Fig. 3), if fitted, and secure to
frame using bolts (1, Fig. 3), lockwashers (2, Fig. 3)
and nuts (3, Fig. 3). MAINTENANCE
The end float/clearance at the thrust face of the
16. Remove all protective plugs and connect all air and oscillation bushes should be checked every 250 hours.
hydraulic lines and other attachments disconnected in Any clearance found must be removed by adjustment
preparation for separation of front and rear frames. of the thrust nut, as described under 'Thrust Nut
Adjustment'.
17. Fill hydraulic oil tank with hydraulic oil, as specified
in Section 300-0020, LUBRICATION SYSTEM. Note: A practical method of establishing the effective
adjustment of the thrust nut is to use movement of the
18. Place the battery master switch in the on position, machines body in the raised position. Move the body
start the engine and allow air pressure in the tanks to from fully raised to almost fully raised while watching
build up to correct operating pressure. Check air and the effect of this action on the frame and pivot
hydraulic lines for leaks. Tighten line fittings as arrangement. Any slackness between the thrust nut
required. and thrust faces will be clearly visible movement of the
frame.
19. Adjust parking brake as shown in Section
170-0010, PARKING BRAKE AND MOUNTING. Very little other maintenance of the articulation and
oscillation pivot is required other than to stress the
20. Remove all blocking from the road wheels. importance of correct lubrication of the assembly.
Lubricate the oscillation bushes, articulation bearings/

THRUST NUT ADJUSTMENT pins and the pivot driveshaft bearings in accordance
1. Position the vehicle in a level work area, apply the with Section 300-0020, LUBRICATION SYSTEM but
parking brake and switch off the engine. note the following precautions:-
2. Block all road wheels and place the battery master Note: The oscillation bushes are lubricated every 10
switch in the 'Off' position. to 15 hours.
3. Open drain cocks on air tanks to drain air pressure Note: DO NOT exceed the lubrication schedule for the
from the tanks. Close air tank drain cocks when air pivot driveshaft bearings i.e. 4 shots of a hand grease
has exhausted from the air tanks. gun every 250 hours.
4. Position levelling jack under centre front portion of

the front frame and raise the jack to ensure both SPECIAL TOOL
frames are parallel. The special tool required for removal and installation of
the thrust nut, can be manufactured, as shown in
Fig. 11.
SM 1975 4-00 11
Section 100-0020
SM - 844
Dimensions in mm (in)
Fig. 11 - Fabrication Details of Thrust Nut Removal and Installation Tool
SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 13 Bolt 106 78
1 20 Bolt 106 78
1 25 Nut 678 500
1 33 Bolt 106 78
1 36 Bolt 75 55
1 51 Nut 1 425 1 050
12 SM 1975 4-00
Section 100-0020
ARTICULATION AND OSCILLATION felt throughout the frame.

PIVOT DIAGNOSIS
Noise and vibration caused by the pivot driveshaft Noise from the articulation and oscillation points must
assembly appear only at certain speeds and generally be investigated.
come and go as these speeds are approached and
passed. When the driveshaft assembly noise becomes An 'Articulation and Oscillation Pivot Diagnosis' table is
excessive, it takes the form of a vibration which can be shown below.
ARTICULATION AND OSCILLATION PIVOT DIAGNOSIS

CONDITION REASON REMEDY
Noise (Pivot Driveshaft) Insufficient lubricant Check seals.
Install proper grade of lubricant.
Out of balance driveshaft assembly Check alignment.
Vibration (Pivot Driveshaft) Backlash due to worn bearings, Renew worn parts.
housings, yokes and trunnions
Yoke not in line Renew driveshaft assembly or
assemble correctly.
Driveshaft out of balance Renew driveshaft assembly.
Noise (Articulation/Oscillation Excessive run out or distorted yokes Dismantle and correct, or renew,
Points) damaged part.
Loose nut on yoke Check splines, if worn. Renew shaft.
Torque tighten nut to value in 'Special
Torque Specifications' in this section.
Insufficient lubricant Lubricate. Investigate/revise lubrication
schedules. Refer to Section 300-0020,
LUBRICATION SYSTEM. Check seals
for lubricant loss/contamination. Renew
as necessary.
Worn bearings/bushes Inspect/renew as necessary.
* * * *
SM 1975 4-00 13
CHASSIS - Articulation and Oscillation Pivot
Section 100-0020
SM - 2495
13 51 35
44 34
45
14 36 52 41
61 36
14 4 1 14
5 43
62
60 41 25
6 26
7,8,9
22 23
24 2
10 22 20
14
32 16
11 46
33
14
47 31
14
55 39 40
17 30
29 19
18 29
54 12
53 2,3,50 38 LUBRICATION POINT

57 58 15
19 37
56
30 6
38 48
28 18
59
25 27 14 21 42
26 20
49
48 49
1 - Pivot 17 - Retainer 33 - Bolt

2 - Coupling 18 - 'O' Ring 34 - Thrust Nut
3 - Pipe 19 - Spacer 35 - Lockplate 49 - Connector
4 - 'O' Ring 20 - Bolt 36 - Bolt 50 - Lube Fitting
5 - Retainer 21 - Retainer 37 - Shaft 51 - Nut
6 - Bearing 22 - Nipple 38 - Bush 52 - Spacer
*7 - Shim 23 - Elbow 39 - Washer 53 - Bolt
*8 - Shim 24 - Lube Fitting 40 - Seal 54 - Hardened Washer
*9 - Shim 25 - Locknut 41 - 'V' Ring 55 - Pin
10 - 'O' Ring 26 - Washer 42 - Adaptor 56 - Bolt
11 - Retainer 27 - Front Yoke 43 - Bush 57 - Lockwasher
12 - Seal 28 - Housing 44 - Pin 58 - Bracket
13 - Bolt 29 - Seal 45 - Washer 59 - Lube Fitting
14 - Lockwasher 30 - Bearing 46 - Bolt 60 - Guard
15 - Lube Fitting 31 - Housing 47 - Washer 61 - Bolt
16 - Brake Yoke 32 - Pin 48 - Lube Line 62 - Lockwasher
* Lower bearing shims not shown
Fig. 1 - Articulation and Oscillation Pivot
DESCRIPTION AND OPERATION

The articulation and oscillation pivot allows the front Articulation bearings, oscillation bushes, pivot
and rear frames to rotate horizontally (articulation) and driveshaft bearings and associated parts can be
tilt laterally (oscillation) with respect to each other. It is removed, inspected and replaced or renewed by
also the main load bearing coupling between the two following the procedures outlined in this section.
frames. The pivot assembly houses the driveshaft
connecting the drive between the front and rear
frames.
SM 1988 Rev 1 11-00 1

Section 100-0020
PIVOT DRIVESHAFT BEARINGS yoke (27). Remove yoke (27) from shaft (37).
Removal 6. Remove bolts (1, Fig. 3), lockwashers (2, Fig. 3),
Numbers in parentheses refer to Fig. 1, unless nuts (3, Fig. 3) and protective guard (4, Fig. 3), if fitted,
otherwise specified. from beneath rear of pivot housing.
Note: It is not necessary to separate the frames in

order to remove the pivot driveshaft assembly. WARNING
WARNING 7. Slacken adjuster (14, Fig. 3) until brake pads

To prevent personal injury and property (13, Fig. 3) are sufficiently clear of parking brake disc
damage, make sure blocking or lifting (5, Fig. 3) to permit removal of calliper (7, Fig. 3).
capacity to do the job safely. 8. Note positions of front and rear wedge plates
1. Position the vehicle in a level work area, apply the (6, Fig. 3), washers (11, Fig. 3), nuts (12, Fig. 3), front
parking brake and switch off the engine. and rear wedge plates (8 & 9, Fig. 3) and left hand
torque plate (10, Fig. 3).
switch in the 'Off' position. 9. Move and secure calliper (7, Fig. 3) clear of parking
from the tanks. Close air tank drain cocks when air Note: Take extra care when handling drivelines since
has exhausted from the air tanks. any deformity on a rotating mass creates vibration and
Note: Take extra care when handling drivelines as any
deformity on a rotating mass creates vibration and 10. Match mark brake yoke (16) and mating surface of
excessive wear during any operation. pivot - centre axle driveline (Fig. 2) to aid in
'Installation'. Remove bolts, lockwashers and caps and
4. Match mark yokes and mating surfaces of remove driveline from the machine.
'Installation'. Remove bolts, lockwashers and caps and 11. Remove bolts (57) and lockwashers (14) from rear
remove driveline from the machine. housing (31).
Note: Take care to avoid damaging pipe (3) when Note: Take extra care when handling driveshafts as
performing Step 5. any deformity on a rotating mass creates vibration and
5. Remove locknut (25) and washers (26) from front
SM - 002
Transmission - Pivot Pivot - Centre Axle
Fig. 2 - Drivelines
2 SM 1988 Rev 1 11-00

Section 100-0020
SM - 003
1 - Bolt 9 - Rear Wedge Plate

2 - Lockwasher 10 - LH Torque Plate
3 - Nut 11 - Washer
4 - Guard 12 - Locknut
5 - Disc 13 - Brake Pad
6 - Bolt 14 - Adjuster
7 - Calliper 15 - Bolts
8 - Front Wedge Plate 16 - Washers
Fig. 3 - Parking Brake Assembly
12. Withdraw pivot driveshaft assembly from pivot by (58) securing pipe (3) to pivot (1) assembly.
pulling rearwards on brake yoke/disc assembly and
place in suitable location for further work. Note: Take care to avoid damaging pipe (3) when
performing Steps 17 through 18.
13. Remove front locknut (25) then position front yoke
(27) fully on to front of shaft (37) and suitably restrain 17. Remove bolts (20) and lockwashers (14) from front
to resist rotation. Remove rear locknut (25), washers housing (28).
(26) and rear yoke brake/disc assembly (16). Tag front
and rear ends of shaft (37) and install locknuts (25) on 18. Tag and remove front housing (28). Note position
the shaft to protect the threads. of seal (12) in front housing (28) to aid in 'Installation'.
Remove and discard seal (12).
14. Tag and remove housing (31). Note position of
seal (40) to aid in 'Installation'. Remove and discard
seal (40). WARNING
When necessary to drive out components, use
15. Remove washer (39), rear bearing (30) and spacer a soft drift to avoid injury and damage from
(19) from rear of shaft (37). flying chips.
16. Remove bolt (56), lockwasher (57) and bracket 19. Using a suitable puller/drift, remove bearing (30).
SM 1988 Rev 1 11-00 3

Section 100-0020
20. Remove spacer (19). Note position of seals (29) in SM - 004
pivot (1) housing to aid in 'Installation'. Remove and
discard seals (29).
Inspection
1. Clean parts with a suitable solvent and let dry. DO

bearings on clean surface, cover with lint free cloth
and allow to dry. 1 - Shaft 2 - Bushes 3 - Shoulder
2. Check pivot driveshaft bearings (30) for wear or Fig. 4 - Shaft and Bushes
damage, replace if required.
and new bushes (38) and allow to dry. Refer to Fig. 4.
3. Inspect bushes (38) for wear. Replace if badly
scored. 4. Apply LOCTITE 638 to shaft (37) mating faces and
install new bushes (38), with the recesses in bushes
(38) against shoulder on driveshaft (37). Make sure
Installation that bushes (38) are fully home against the shoulders.
Numbers in parentheses refer to Fig. 1, unless Refer to Fig. 4.
5. Allow 15 minutes for retaining compound to cure to
Note: Tighten all fasteners without special torques handling strength.
300-0080, STANDARD BOLT AND NUT TORQUE 6. Degrease front bearing (30) housing in pivot (1) with
SPECIFICATIONS. a suitable solvent and allow to dry.
Note: If bushes (38) are to be renewed, then proceed Note: Do not use retaining compound on the housing
with Steps 1 thru 5, if the bushes (38) are satisfactory, for the rear pivot shaft bearing.
proceed from Step 6.
Note: Front bearing (30) of shaft (37) is secured with
retaining compound as well as normal hardware.
WARNINGS Cleaning the bearing housing ensures a good bond.
To prevent personal injury and property THE REAR BEARING IS SECURED BY NORMAL
damage, make sure blocking or lifting HARDWARE ONLY.
capacity to do the job safely. 7. Apply coat of grease to new seals (29) and install
seals in pivot housing. Make sure seal lips are facing
When necessary to drive out outwards as shown on Fig. 5.
components, use a soft drift to avoid injury
and damage from flying chips. 8. Make sure that pivot shaft bearing (30) is
pre-packed with grease then position spacer (19),
1. Apply suitable heat to bushes (38) to break bond of bearing (30) and washer (39) on rear of shaft (37).
retaining compound. Remove locknuts (25) from their
protective position on shaft (37), then remove bushes 9. Apply bead of grease to fill inner rim of new seal (40)
(38) with a suitable drift. and position new seal in rear housing (31). Refer to
Fig. 6. Fill lube fitting (24) assembly on rear housing with
2. Allow shaft (37) to cool. Thoroughly clean shaft (37) grease and make sure that nipple (22) does not protrude
and new bushes (38) with a suitable solvent. Wash into grease slot in rear face of housing (31).
mating faces of shaft (37) and new bushes (38) with
chlorethane and allow to dry. Note: Take extra care when handling driveshafts as
any deformity on a rotating mass creates vibration and
3. Apply LOCTITE primer to mating faces of shaft (37) excessive wear during any operation.
4 SM 1988 Rev 1 11-00

Section 100-0020
SM - 005 SM - 006
SEAL
SEAL
HOUSING
Fig. 5 - Pivot Housing Inner Seals Fig. 6 - Typical Outer Seal Installation
10. Assemble rear housing (31) and brake yoke/disc 18. Make sure mating surfaces of housing (28) are still
assembly (16) onto rear of shaft (37). Secure with clean then apply coating of retaining compound to
locknut (25) and both washers (26) but only fingertight mating surfaces of bearing (30) and housing (28).
at this stage. Install bearing (30) on to front of shaft (37).
11. Insert shaft (37) assembly fully into pivot (1) from 19. Pack housing (28) of with grease from 1/3 to 1/2 of
the rear. Take care not to dislodge internal seals (29). capacity.
12. Partially withdraw shaft (37) assembly to enable 20. Install front housing (28), front yoke (27), both
housing of rear pivot driveline bearing (30) to be filled washers (26) and locknut (25).
with grease from 1/3 to 1/2 of capacity.
Note: Take care to avoid damaging the pipe (3) when
13. Reposition shaft (37) assembly fully in pivot (1). performing Steps 21 through 22.
14. Align housing (31) with lube fitting (24) uppermost 21. Lock brake yoke/disc (16) assembly with a suitable
and secure with lockwashers (14) and bolts (20). tool and install locknut (25) on front yoke (27). Torque
Torque tighten bolts (20) to 106 Nm (78 lbf ft). tighten locknut (25) to 678 Nm (500 lbf ft).
15. Apply a bead of grease to fill inner rim of new seal 22. Lock front yoke (27) and torque tighten locknut
(12) and position seal in front housing (28). Refer to (25) on brake yoke assembly to 678 Nm (500 lbf ft).
Fig. 6. Fill pipe (3), through lube fitting (50), with
grease. Make sure that pipe (3) does not protrude into 23. Align front housing (28) with pipe (3) uppermost
grease slot in rear face of housing (28). and secure in place with bolts (20) and lockwashers
(14). Torque tighten bolts (20) to 106 Nm (78 lbf ft).
16. Install spacer (19) onto front of shaft (37).
24. Install bracket (58), and secure with lockwasher
17. Pre-pack bearing (30) with grease taking care not (57) and bolt (56).
to place any grease on outer curved surface. Clean
this surface with a suitable solvent where necessary 25. Check that no end float exists by pulling and
and allow to dry. pushing on the brake yoke/disc assembly.
Note: Make sure that Steps 18 through 22 are Note: Take extra care when handling drivelines as
performed within the hardening time of the retaining chips, dents, burrs or deformity on any rotating mass
compound in use. creates vibration and excessive wear during any
operation. (Steps 26 & 28).
SM 1988 Rev 1 11-00 5

Section 100-0020
26. Connect pivot - centre axle driveline (Fig. 2) to has exhausted from the air tanks.
brake yoke/disc assembly as noted on 'Removal'.
Install caps and secure with lockwashers and bolts. 4. Position levelling jack under centre front portion of
the front frame. Raise jack and block frame to remain
27. Position parking brake calliper (7, Fig. 3) in level after removal of the articulation pins. Check that
position and install left hand torque plate (10, Fig. 3), front wheels are still effectively blocked.
front and rear wedge plates (8 & 9, Fig. 3) and secure
in place with bolts (6, Fig. 3), washers (11, Fig. 3) and Note: Make sure that front frame is correctly
locknuts (12, Fig. 3). supported and prevented from tilting on the axle, or
damage to coupling etc. could result.
28. Install transmission - pivot driveline (Fig. 2) with
caps, lockwashers and bolts as noted on 'Removal'. 5. Disconnect steering cylinders by removing bolts
(36), lockwashers (14), washers (45) and pins (44)
29. Position guard (4, Fig. 3), if fitted, and secure to from attachment points on pivot (1) housing. Move
frame using bolts (1, Fig. 3), lockwashers (2, Fig. 3) steering cylinders clear of pivot (1) housing and
and nuts (3, Fig. 3). secure.
30. Place the battery master switch in the on position, Note: Take extra care when handling drivelines as
start the engine and allow air pressure in the tanks to chips, dents, burrs or deformity on any rotating mass
build up to correct operating pressure. creates vibration and excessive wear during any
operation.
31. Adjust parking brake as shown in Section 170-0010,
PARKING BRAKE AND MOUNTING. 6. Match mark yokes and mating surfaces of
32. Remove all blocking from the road wheels. 'Installation'. Remove bolts, lockwashers and caps and
remove driveline from the machine.
ARTICULATION BEARINGS 7. Remove bolt (53) and hardened washer (54)

securing pin (55) to pivot (1) housing. Remove nut (51)
Removal and withdraw pin (55), tapping pin downwards to ease
Numbers in parentheses refer to Fig. 1, unless removal. Take care not to damage the threads on pin
otherwise specified. (55).
Note: The lengths of the electrical, hydraulic and air Note: It may be necessary to adjust the frame levelling
connections between the two frames are designed to jack to relieve binding between pin (55) and pin bores
permit articulation. As a result, the frames can be during removal.
separated sufficiently to permit removal of the
articulation bearings without disconnecting these 8. Remove bolt (46), lockwasher (14) and washer (47)
connections. securing pin (32) to pivot (1) housing.
9. Remove pin (32), tapping pin upwards to ease

WARNING removal. Take care not to damage the threads on pin
To prevent personal injury and property (32).
equipment is properly secured and of adequate Note: It may be necessary to adjust the frame levelling
capacity to do the job safely. jack to relieve binding between pin (32) and pin bores
during removal.
parking brake and switch off the engine. 10. Attach suitable lifting equipment to the rear frame
and take up slack.
switch in the 'Off' position. Note: Only separate the frames sufficiently to permit
removal of the articulation bearings or damage to
3. Open drain cocks on air tanks to drain air pressure electrical, hydraulic and air connections could result.
from the tanks. Close air tank drain cocks when air
11. Remove blocking from the rear frame and wheels
6 SM 1988 Rev 1 11-00

Section 100-0020
and use lifting equipment to pull the rear frame away SM - 007
from the front frame. After moving, block the rear
frame and wheels securely.
12. Mark all bearing retainers (5, 11, 17 & 21) to aid in
'Installation'.
Note: Retainers (5, 11, 17 & 21) are not

interchangeable.
13. Remove bolts (13), lockwashers (14), retainers

(5, 11, 17 & 21) and upper and lower shims (7, 8 & 9).
14. Remove and discard 'O' rings (4, 10 & 18).

Remove spacer (52) noting orientation to aid in
1 - Upper Retainer 6 - Bolts
'Installation'.
2 - Lower Retainer 7 - Washers
3 - Upper 'O' Ring 8 - Cups
15. Remove and tag all bearings (6) to aid in 4 - Lower 'O' Ring 9 - Cones
'Installation', where appropriate. 5 - Shims 10 - Lugs
Fig. 7 - Section Through Articulation Bearing

bearings.
that bearing cones are back to back and position
retainer (11), for top articulation bearing, and retainer
Inspection (21), for bottom articulation bearing on underside of
Numbers in parentheses refer to Fig. 1. bearing housing. Make sure that bearings are pre-
packed with grease including end faces and faces on
1. Clean parts with a suitable solvent and let dry. DO bearing cups.
bearings on clean surface, cover with lint free cloth 2. Install top retainer (5), for top articulation bearing,
and allow to dry. and retainer (21), for bottom articulation bearing.
2. Check articulation bearings (6) and pins (32 & 55) 3. Lubricate bolts (13 for top and 33 for bottom) and
for wear or damage. Renew if required. install along with washers (14). Torque tighten bolts
(13 & 33) to 27 Nm (20 lbf ft).
Installation 4. Use feeler gauges to measure end float and record
Numbers in parentheses refer to Fig. 1, unless value. Refer to Fig. 8.
Note: End float is equal to the sum of the clearances
between both retainers and the lug.
WARNING
To prevent personal injury and property 5. Select shims to total value of -0.07 to +0.02 mm
damage, make sure blocking or lifting (-0.003 to +0.001 in) of that recorded at Step 4.
capacity to do the job safely. SM - 008
Note: Two bearings are installed on EACH articulation

point. Each bearing comprises a cup and a cone and
are installed into the articulation point with the cones
'back to back'. Refer to Fig. 7.

bearings.
1. Insert both bearing cups and cones into housing so Fig. 8 - Measuring End Float
SM 1988 Rev 1 11-00 7

Section 100-0020
6. Remove bolts (13 & 33), lubricate and coat with 19. Place the battery master switch in the on position,
anti-seize compound then install shims (7, 8 & 9) start the engine and allow air pressure in the tanks to
beneath appropriate upper retainer (5 for upper build up to correct operating pressure.
articulation bearing, 17 for lower articulation bearing).
20. Lower and remove jack and all blocking
7. Re-install bolts (13 & 33) and washers (14) and equipment.
torque tighten to 106 Nm (78 lbf ft).
8. Install spacer (52) in upper bearing as noted on OSCILLATION BUSHES

removal. Install upper 'O' ring (4) and lower 'O' ring
(10) for top bearing (6). Removal
Note: The lower bearing is NOT fitted with a spacer. otherwise specified.
9. Install 'O' rings (18) for lower bearing (6).

WARNING
10. Attach suitable lifting equipment to the rear frame To prevent personal injury and property
and take up slack. damage, make sure blocking or lifting
11. Remove blocking from rear frame and wheels. capacity to do the job safely.
Move rear frame with lifting equipment to align the
articulation pin bores. Block the rear frame and wheels 1. Position the vehicle in a level work area, apply the
to remain level and stationary. parking brake and switch off the engine.
12. Clean articulation pins (32 & 55) with suitable 2. Block all road wheels and place the battery master
solvent, allow to dry then coat them with anti-seize switch in the 'Off' position.
compound including threads on upper pin (55).
13. Insert articulation pin (32). from the tanks. Close air tank drain cocks when air
has exhausted from the air tanks.
Note: It may be necessary to adjust the levelling jack
beneath front frame to permit entry of articulation pin 4. Remove hydraulic oil tank remote drain plug and
(32). Pin (32) may be tapped in to place taking care drain hydraulic oil into a suitable container. Re-install
that it is not misaligned and does not cause damage to drain plug in hydraulic tank remote drain fitting.
the pin, bearings or pivot housing lugs.
5. Tag all air and hydraulic lines between front and
14. Secure pin (32) with washer (47), lockwasher (14) rear frames to aid in 'Installation. Disconnect all air and
and bolt (36). hydraulic lines. Cap line fittings and plug lines to
prevent ingress of dirt.
15. Insert upper articulation pin (55).
6. Disconnect electrical wiring and any other
16. Install nut (51) on pin (55). Torque tighten nut (51) attachments that would be damaged on separation of
to 1 424 Nm (1 050 lbf ft). front and rear frames.
Note: Take extra care when handling drivelines as 7. Position levelling jack under centre front portion of
chips, dents, burrs or deformity on any rotating mass the front frame. Raise the jack and block the front
creates vibration and excessive wear during any frame, front and rear, so it will remain level after
operation. separation. Check that both front wheels are still
securely blocked.
17. Install transmission - centre driveline (Fig. 2) with
caps, lockwashers and bolts as noted on 'Removal'. Note: Make sure that the front frame is correctly
supported and prevented from tilting on the axle or
18. Position steering cylinders in place on pivot (1) and damage to coupling etc. could result.
install pins (44). Secure pins (44) with bolts (36),
washers (45) and lockwashers (14).
8 SM 1988 Rev 1 11-00

Section 100-0020
Note: Take extra care when handling drivelines as assembly to avoid damage to end threads.
chips, dents, burrs or deformity on any rotating mass
creates vibration and excessive wear during any 18. Replace thrust nut (34) on pivot (1) to protect
operation. threads.
8. Remove bolts (1, Fig. 3), lockwashers (2, Fig. 3), 19. Note position of front 'V' ring (41) to aid in
nuts (3, Fig. 3) and protective guard (4, Fig. 3), if fitted, 'Installation'. Remove and discard 'V' ring (41).
from beneath rear of pivot housing.
20. Inspect oscillation bushes (43) as described in
'Inspection'. If bushes are to be renewed, proceed with
WARNING Step 21.
21. Remove oscillation bush/es (43) with hammer and
9. Slacken adjuster (14, Fig. 3) until brake pads chisel.
(13, Fig. 3) are sufficiently clear of parking brake disc
(5, Fig. 3) to permit removal of calliper (7, Fig. 3). Note: The suggested method is to make an axial cut
along the bush then to lever the bush in order to
10. Note positions of front and rear wedge plates collapse it upon itself.
(6, Fig. 3), washers (11, Fig. 3), nuts (12, Fig. 3), front
and rear wedge plates (8 & 9, Fig. 3) and left hand Inspection
torque plate (10, Fig. 3). Numbers in parentheses refer to Fig. 1.
11. Move and secure calliper (7, Fig. 3) clear of 1. Clean oscillation bushes (43) with a suitable solvent
parking brake disc (5, Fig. 3). and allow to dry.
Note: Take extra care when handling drivelines since 2. Inspect oscillation bushes (43) for wear, scoring,
any deformity on a rotating mass creates vibration and erosion and 'out of round'. Pay particular attention to
excessive wear during any operation. the thrust faces of the bushes which should also be
inspected for cracking/splitting. Renew if required.
12. Match mark brake yoke (16) and mating surface of
pivot - centre axle driveline (Fig. 2) to aid in
'Installation'. Remove bolts, lockwashers and caps and Installation
remove driveline from the machine. Numbers in parentheses refer to Fig. 1, unless
13. Mark disc (5, Fig. 3) assembly to aid in 'Installation'
then remove bolts (15, Fig. 3) washers (16, Fig. 3) and Note: Tighten all fasteners without special torques
disc (5, Fig. 3). specified, to standard torques listed in
14. Remove bolts (36), lockwashers (14) and TORQUE SPECIFICATIONS.
lockplate (35).
15. Using special tool, which can be fabricated as WARNING

shown in Fig. 11, remove thrust nut (34) from pivot (1). To prevent personal injury and property
Note position of rear 'V' ring (41) to aid in 'Installation'. damage, make sure blocking or lifting
Remove and discard 'V' ring (41). equipment is properly secured and of adequate
capacity to do the job safely.
16. Attach suitable lifting equipment to the front of the
rear frame and take up slack. 1. Wipe bush housing clean using suitable solvent and
allow to dry.
and using suitable lifting equipment draw the rear 2. Apply LOCQUIC primer to housing and allow to dry
frame from pivot (1) assembly. When clear, block the for 10 minutes. Apply LOCTITE RC-35 to housing.
rear frame and wheels.
3. Align new bushes to housing with grease holes aligned
Note: Use care when separating rear frame and pivot vertically and identification 'PAINT DOT' at Top Dead
SM 1988 Rev 1 11-00 9

Section 100-0020
Centre. Refer to Fig. 9. Drift bushes into housing using lockwashers (14). Torque tighten bolts (36) to 75 Nm
hammer with soft packing for protection. (55 lbf ft).
4. Using special tool, which can be fabricated as 10. Grease oscillation bushes (43) through lube fittings
shown in Fig. 11, remove thrust nut (34) from pivot (1). (59) until excess lubrication is seen.
Clean grease from pivot exterior using a suitable
solvent where necessary and allow to dry. 11. Check that no end float exists at oscillation bushes by
pushing and pulling on brake yoke assembly.
Note: Use care on inserting the pivot housing
assembly or damage to the thread could occur. 12. Position brake disc (5, Fig. 3) onto brake yoke (16)
as noted at 'Removal'. Secure in place with bolts (15,
5. Install new pre-greased front 'V' ring (41). Refer to Fig. 3) and washers (16, Fig. 3).
Fig. 10. Apply liberal coat of grease to external surface
of pivot (1) and mating faces of bushes (43). Note: Take extra care when handling drivelines as
6. Attach suitable lifting equipment to the front of the SM - 011
rear frame and take up slack.

PAINT DOT
and use lifting equipment to line-up and draw the rear
frame onto pivot (1) assembly.
8. Install new pre-greased rear 'V' ring (41). Refer to

Fig. 10. Using special tool, as shown in Fig. 11, install
and tighten thrust nut (34) until there is no end float/
clearance at thrust face of either bush (43). Slacken
thrust nut (34) until pin of lockplate (35) can be
inserted in first available hole in thrust nut (34).
Fig. 9 - Installing Oscillation Bushes
9. Secure lockplate (35) with bolts (36) and
SM - 010
FRONT 'V' RING REAR 'V' RING
OSCILLATION
BUSH PAINT
LUBE HOLE LUBE HOLE
DOT
PAINT
DOT
THRUST NUT
Fig. 10 - Pivot Housing 'V' Ring Installation
10 SM 1988 Rev 1 11-00

Section 100-0020
chips, dents, burrs or deformity on any rotating mass 5. Remove bolts and lockwashers securing lockplate
creates vibration and excessive wear during any at the thrust nut and remove the lockplate.
operation.
6. Using special tool, which can be manufactured as
13. Connect pivot - centre axle driveline (Fig. 2) at shown in Fig. 11, tighten thrust nut until there is no end
brake yoke using bolts, lockwashers and caps as float/clearance at thrust face of either bush. Slacken
noted at 'Removal'. thrust nut until pin of the lockplate can be inserted in
the first available hole in the thrust nut.
14. Position parking brake calliper (7, Fig. 3) in
position and install left hand torque plate (10, Fig. 3), 7. Secure lockplate with bolts and lockwashers.
front and rear wedge plates (8 & 9, Fig. 3) and secure Torque tighten bolts to 75 Nm (55 lbf ft).
in place with bolts (6, Fig. 3), washers (11, Fig. 3) and
locknuts (12, Fig. 3). 8. Lower jack and remove all blocking from the front
wheels.
15. Position guard (4, Fig. 3), if fitted, and secure to
frame using bolts (1, Fig. 3), lockwashers (2, Fig. 3)
and nuts (3, Fig. 3). MAINTENANCE
The end float/clearance at the thrust face of the
16. Remove all protective plugs and connect all air and oscillation bushes should be checked every 250 hours.
hydraulic lines and other attachments disconnected in Any clearance found must be removed by adjustment
preparation for separation of front and rear frames. of the thrust nut, as described under 'Thrust Nut
Adjustment'.
17. Fill hydraulic oil tank with hydraulic oil, as specified
in Section 300-0020, LUBRICATION SYSTEM. Note: A practical method of establishing the effective
adjustment of the thrust nut is to use movement of the
18. Place the battery master switch in the on position, machines body in the raised position. Move the body
start the engine and allow air pressure in the tanks to from fully raised to almost fully raised while watching
build up to correct operating pressure. Check air and the effect of this action on the frame and pivot
hydraulic lines for leaks. Tighten line fittings as arrangement. Any slackness between the thrust nut
required. and thrust faces will be clearly visible movement of the
frame.
19. Adjust parking brake as shown in Section
170-0010, PARKING BRAKE AND MOUNTING. Very little other maintenance of the articulation and
oscillation pivot is required other than to stress the
20. Remove all blocking from the road wheels. importance of correct lubrication of the assembly.
Lubricate the oscillation bushes, articulation bearings/

THRUST NUT ADJUSTMENT pins and the pivot driveshaft bearings in accordance
1. Position the vehicle in a level work area, apply the with Section 300-0020, LUBRICATION SYSTEM but
parking brake and switch off the engine. note the following precautions:-
2. Block all road wheels and place the battery master Note: The oscillation bushes are lubricated every 10
switch in the 'Off' position. to 15 hours.
3. Open drain cocks on air tanks to drain air pressure Note: DO NOT exceed the lubrication schedule for the
from the tanks. Close air tank drain cocks when air pivot driveshaft bearings i.e. 4 shots of a hand grease
has exhausted from the air tanks. gun every 250 hours.
4. Position levelling jack under centre front portion of

the front frame and raise the jack to ensure both SPECIAL TOOL
frames are parallel. The special tool required for removal and installation of
the thrust nut, can be manufactured, as shown in
Fig. 11.
SM 1988 Rev 1 11-00 11

Section 100-0020
SM - 844
Fig. 11 - Fabrication Details of Thrust Nut Removal and Installation Tool

TORQUE
1 13 Bolt 106 78
1 20 Bolt 106 78
1 25 Nut 678 500
1 33 Bolt 106 78
1 36 Bolt 75 55
1 51 Nut 1 425 1 050
12 SM 1988 Rev 1 11-00

Section 100-0020
ARTICULATION AND OSCILLATION felt throughout the frame.

PIVOT DIAGNOSIS
Noise and vibration caused by the pivot driveshaft Noise from the articulation and oscillation points must
assembly appear only at certain speeds and generally be investigated.
come and go as these speeds are approached and
passed. When the driveshaft assembly noise becomes An 'Articulation and Oscillation Pivot Diagnosis' table is
excessive, it takes the form of a vibration which can be shown below.
ARTICULATION AND OSCILLATION PIVOT DIAGNOSIS

Noise (Pivot Driveshaft) Insufficient lubricant Check seals.
Install proper grade of lubricant.
Out of balance driveshaft assembly Check alignment.
Vibration (Pivot Driveshaft) Backlash due to worn bearings, Renew worn parts.
housings, yokes and trunnions
Yoke not in line Renew driveshaft assembly or
assemble correctly.
Driveshaft out of balance Renew driveshaft assembly.
Noise (Articulation/Oscillation Excessive run out or distorted yokes Dismantle and correct, or renew,
Points) damaged part.
Loose nut on yoke Check splines, if worn. Renew shaft.
Torque tighten nut to value in 'Special
Torque Specifications' in this section.
Insufficient lubricant Lubricate. Investigate/revise lubrication
schedules. Refer to Section 300-0020,
LUBRICATION SYSTEM. Check seals
for lubricant loss/contamination. Renew
as necessary.
Worn bearings/bushes Inspect/renew as necessary.
* * * *
SM 1988 Rev 1 11-00 13

CHASSIS - Hood and Mounting
Section 100-0040
SM - 2492
30 29 34 33
39 62 63
21 22 40
11
64
20 28 6 41 12
26 32 18 42
13
31
25 9 14
23
27 61 15
26
24 25 23
1
16
17 35 10
8 5 3 36
7
4 37
2 37
36
38
16
19
57 53 54
52
55 54 44
53
56 59 60 45
45
55 58 19 46
51 47 48
50 49 56 43
1 - Hood 17 - Handle - LH 33 - Washer 49 - Bolt

2 - Grille 18 - Handle - RH 34 - Locknut 50 - Lockwasher
3 - Grille Subframe 19 - Hood Prop 35 - Bolt 51 - Locknut
4 - Bolt 20 - Bolt 36 - Hardened Washer 52 - Torsion Bar
5 - Washer 21 - Washer 37 - Washer 53 - Washer
6 - Blanking Cover 22 - Locknut 38 - Locknut 54 - Split Pin
7 - Bolt 23 - Washer 39 - Bolt 55 - Plate
8 - Lockwasher 24 - Spring 40 - Washer 56 - Hinge
9 - Ball Joint 25 - Plate 41 - Hardened Washer 57 - Bolt
10 - Cable Assembly 26 - Spacer 42 - Locknut 58 - Bracket
11 - Goalpost Support Assembly 27 - Cam Plate 43 - Plate 59 - Bolt
12 - Bolt 28 - Cam Plate 44 - Bolt 60 - Washer
13 - Hood Stop 29 - Cotter Pin 45 - Locknut 61 - Plate
14 - Spring 30 - Split Pin 46 - Bolt 62 - Bolt
15 - Locknut 31 - Bracket 47 - Washer 63 - Washer
16 - Handle - Front 32 - Bolt 48 - Locknut 64 - Locknut
Fig 1 - Hood and Mounting
HOOD 2. Block all road wheels and place the battery master
switch in the 'Off' position.
Removal
Numbers in parentheses refer to Fig. 1. 3. Remove bolts (7) and lockwashers (8) securing
grille (2) to grille subframe (3). Secure grille (2) clear of
hood (1).
WARNING
To prevent personal injury and property 4. Pull cable assembly (10), handle inside cab, to
damage, be sure blocking materials and lifting release hood catch and lift up hood (1). Secure hood
equipment are properly secured and of (1) in raised position using suitable lifting equipment.
adequate capacity to do the job safely.
5. Carefully remove split pins (54) and slide washers
1. Position the machine on a level surface, apply the (53) from torsion bars (52). Remove torsion bars (52)
parking brake and switch off the engine. from mounting brackets.
SM 1984 Rev 1 11-00 1

Chassis - Hood and Mounting
Section 100-0040
Note: Exercise caution as torsion bars (52) may GOALPOST SUPPORT ASSEMBLY
spring when released from mounting brackets.
Removal
6. Remove bolts (49), lockwashers (50) and locknuts Numbers in parentheses refer to Fig. 1.
(51) securing hinges (56) to frame and lift hood (1)
assembly from the machine.
WARNING
7. If required, remove bolts (4) and lockwashers (5) To prevent personal injury and property
securing grille subframe (3) to hood (1). Secure grille damage, be sure blocking materials and lifting
subframe (3) clear of hood (1). equipment are properly secured and of
8. If required, remove mounting hardware securing
handles (16, 17 & 18) to hood (1). Secure handles (16, 1. Position the machine on a level surface, apply the
17 & 18) clear of hood (1). parking brake and switch off the engine.
Installation 2. Block all road wheels and place the battery master
Numbers in parentheses refer to Fig. 1. switch in the off position.
Note: Tighten all fasteners to torques listed in 3. Pull cable assembly (10), handle inside cab, to
Section 300-0080, STANDARD BOLT AND NUT release hood catch and lift up hood (1).
TORQUE SPECIFICATIONS.
4. Remove mounting hardware securing purge tank to
mounting bracket on the right hand side of goalpost
WARNING support (11) assembly. Secure purge tank clear of
To prevent personal injury and property goalpost support (11) assembly.
damage, be sure blocking materials and lifting
equipment are properly secured and of 5. Remove mounting hardware securing brake
adequate capacity to do the job safely. reservoir to mounting bracket on the left hand side of
goalpost support (11) assembly. Secure brake
1. If removed, secure handles (16, 17 & 18) to hood reservoir clear of goalpost support (11) assembly.
(1) using mounting hardware as removed at
'Removal'. 6. With a suitable container available to catch leakage,
remove drain plug from radiator header tank and drain
2. If removed, secure grille subframe (3) to hood (1) coolant. Apply Loctite 225 to drain plug and reinstall in
with bolts (4) and lockwashers (5). header tank.
3. Using suitable lifting equipment, lift and position 7. Ensure all cooling lines connected to header tank
hood (1) on the machine and align holes in hinges (56) are identified for ease of installation and with suitable
with mounting holes on frame. Secure hood (1) using containers available to catch leakage, disconnect
bolts (49), lockwashers (50) and locknuts (51). cooling lines. Fit blanking caps to all open lines.
4. Carefully install torsion bars (52) to mounting 8. Note routing of all hoses and harnesses attached to
brackets and secure in place with washers (53) and goalpost support (11) assembly and disconnect.
split pins (54).
9. Disconnect ball joint (9) from cam assembly (27)
Note: Exercise caution as torsion bars (52) may and secure cable clear of lock mechanism.
spring from mounting brackets.
10. Check to make certain that all necessary line and
5. Remove lifting equipment and lower hood (1) to cable disconnections have been made, before lifting
match with goalpost support assembly (11). goalpost support (11) assembly.
6. Install grille (2) to hood (1) and secure using bolts 11. Attach suitable lifting equipment to goalpost
(7) and lockwashers (8). support (11) assembly. Remove bolts (35), hardened
washers (36), washers (37) and locknuts (38) securing
7. Remove wheel blocks.
2 SM 1984 Rev 1 11-00

Chassis - Hood and Mounting
Section 100-0040
goalpost support (11) assembly to its mounting. Lift 6. Install purge tank to mounting bracket on the right
goalpost support (11) assembly from the machine. hand side of goalpost support (11) assembly and
secure using mounting hardware as removed during
12. If required, remove locknuts (15), bolts (12), hood 'Removal'.
stops (13) and springs (14) from goalpost support (11)
assembly. 7. Install brake reservoir to mounting bracket on the
left hand side of goalpost support (11) assembly and
13. If required, remove mounting hardware securing secure using mounting hardware as removed during
blanking cover (6) to right hand fender. Remove 'Removal'.
blanking cover (6) from the machine.
8. Remove blanking caps from all cooling lines and
connect cooling lines to radiator header tank as tagged
Installation at 'Removal'.
Numbers in parentheses refer to Fig. 1.
9. Secure all hoses and harnesses to goalpost support
Note: Tighten all fasteners to torques listed in (11) assembly following routing as noted at 'Removal'.
TORQUE SPECIFICATIONS. 10. Fill radiator header tank with coolant as specified
in Section 210-0000, COOLING SYSTEM.
WARNING 11. Lubricate hood catch mechanism. Use grease as

To prevent personal injury and property specified in Section 300-0020, LUBRICATION
damage, be sure blocking materials and lifting SYSTEM.
equipment are properly secured and of
adequate capacity to do the job safely. 12. Lower hood assembly and check for correct
alignment between hood (1) and goalpost support (11)
1. If removed, secure blanking cover (6) to right hand assembly and for operation of hood catch mechanism.
fender with mounting hardware as removed at
'Removal'. 13. Remove wheel blocks.
2. If removed, secure hood stops (13) and springs (14)

to goalpost support (11) assembly with bolts (12) and MAINTENANCE
locknuts (15). Periodically check bolts (49), lockwashers (50) and
locknuts (51) and tighten when necessary.
3. Using suitable lifting equipment, lift and position
goalpost support (11) assembly on the machine. Periodically check condition of lock mechanism and
Secure goalpost support (11) assembly to its mounting adjust and lubricate when necessary.
with bolts (35), hardened washers (36), washers (37)
and locknuts (38).
SPECIAL TOOLS
4. Remove lifting equipment. There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
5. Connect ball joint (9) to cam assembly (27) and SERVICE TOOLS, for part numbers of general service
secure cable assembly using clips removed during tools and adhesives required. These tools and
'Removal'. adhesives are available from your dealer.
* * * *
SM 1984 Rev 1 11-00 3

CHASSIS - Fenders and Mounting
Section 100-0070
SM - 2478
12 24 16,37
22 23 19
MTG. ON
11 7 HYD. TANK
25 36
20
26 17
4 18
21
6 22
23
1
5
9
27 8
34
6
2
13 28
10
14
33 6
32
3 15,35
28
15 29 29
35 30 31
1 - LH Fender
2 - Support Bracket 11 - Grab Handle 20 - Spillguard 29 - Bolt
3 - Contour Plate 12 - Grip 21 - Bolt 30 - Lockwasher
4 - Side Panel 13 - Cover Plate 22 - Washer 31 - Nut
5 - Cover Plate 14 - Plate 23 - Locknut 32 - Bolt
6 - Step Assembly 15 - Mudflap - LH 24 - Support Plate 33 - Lockwasher
7 - RH Fender 16 - Bolt 25 - Bolt 34 - Nut
8 - Support 17 - Chain Assembly 26 - Bolt 35 - Mudflap - RH
9 - Spacer 18 - Strap 27 - Nut 36 - Plate
10 - Counter Plate 19 - Wire Tensioner 28 - Stiffener 37 - Lockwasher
Fig. 1 - Fenders and Mounting
REMOVAL/INSTALLATION MAINTENANCE
Periodically check mounting bolts and nuts and
tighten when necessary.
WARNING
To prevent personal injury and property A check of the condition of the paint should be made
damage, be sure blocking materials and lifting approximately twice a year. If painting is required,
equipment are properly secured and of thoroughly clean the areas to be painted. Apply a
adequate capacity to do the job safely. primer coat of red oxide and then a finish coat of
polyurethane enamel.
The fenders and associated parts are secured by
normal hardware. Before loosening any fasteners, To keep rust and corrosion to a minimum, periodic
secure the items with suitable lifting equipment. Care painting of abrasions and other exposed metal areas
should be exercised at all times to ensure no damage is highly recommended.
to equipment or personnel.
* * * *
SM 1963 4-00 1
ENGINE - Engine and Mounting
Section 110-0030
SM - 2479
ENGINE - LHS
39
1
21 23 6
19
32 31
28
22 24 34
23
29
33
30
20 23
2
25 26 27 3
15 RAD. WATER PIPE
14 17 16
11 11
10
5 4
35
9
18 9
37 7 10
17
13 8 38 12
13
36
1 - Engine 11 - Bolt 21 - Bolt 31 - Bolt

2 - Fan Belt 12 - Bolt 22 - Bolt 32 - Washer
3 - Alternator Belt 13 - Locknut 23 - Lockwasher 33 - Drive Clutch Fan
4 - Lube Oil Filter 14 - Bolt 24 - Plate Friction 34 - Hose
5 - Coolant Filter 15 - Lockwasher 25 - Flexible Element 35 - Valve Sensor
6 - Fuel Filter 16 - Bolt 26 - Radial Bearing 36 - Bolt
7 - Front Mounting Bracket 17 - Lockwasher 27 - Axial Bearing 37 - Locknut
8 - Rear Mounting Bracket 18 - Bracket 28 - Flange 38 - P-Clip
9 - Rubber Mount 19 - Cover 29 - Hub Flanged 39 - Radiator Support
10 - Snubbing Washer 20 - Bolt 30 - Fan Bracket
Fig. 1 - Engine and Mounting
DESCRIPTION and two rear mounting brackets (8) which are bolted to
Numbers in parentheses refer to Fig. 1. the engine and attached to the tractor frame through
rubber mounts (9). Rubber mounts (9) provide
For engine make, model and specification, refer to sufficient flexibility to absorb varying engine vibration
Section 000-0000, GENERAL INFORMATION. For and torsional loads.
engine servicing and repair data refer to the engine
manufacturers service manual. Lube oil filter (4) and coolant filter (5) are mounted on
the right hand side of engine (1) and fuel filter (6) is
The engine is supported by front mounting bracket (7) mounted on the left hand side.
SM 1964 4-00 1
Engine - Engine and Mounting
Section 110-0030
REMOVAL 7. With suitable containers in position, open drain

Numbers in parentheses refer to Fig. 1. cocks and drain coolant from the radiator and engine.
Close all drain cocks securely after draining.
WARNINGS 8. Identify cooling and heater lines for ease of

To prevent personal injury and property installation and, with suitable containers in position to
damage, be sure wheel blocks, blocking catch spillage, disconnect lines from engine (1) and
materials and lifting equipment are properly remove the radiator assembly. Refer to Section
secured and of adequate capacity to do the job 210-0040, RADIATOR AND MOUNTING.
safely.
9. Disconnect exhaust piping from the engine
High electrical current. Disconnect turbocharger at the silencer.
battery ground cable at battery before
removing engine attachments. High electrical 10. Disconnect compressor air outlet tube and secure
current can cause sparks and personal injury clear of engine.
from burns.
11. Disconnect accelerator cable at engine (1).
Note: Tag all lines, cables and linkages disconnected
during removal to aid in installation. 12. Identify and disconnect cables at starter motor and
alternator.
parking brake and switch off the engine. 13. Identify and disconnect electrical cables from the
oil pressure sender switch, engine temperature switch,
2. Block all road wheels, place the steering lock bar in fuel shut off solenoid and proximity switches on engine
the 'Locked' position and the battery master switch in (1).
the 'Off' position. Disconnect battery cables from
terminal posts (ground cable first). 14. Identify fuel lines for ease of installation and, with a
suitable container in position, disconnect fuel lines
3. Pull on handle to release hood catch and lift up the from engine (1). Cap open line ends and fittings to
hood. prevent entry of dirt.
4. Remove engine hood assembly and goalpost 15. Disconnect clips securing items to the engine that
support assembly. Refer to Section 110-0030, HOOD cannot be removed with the engine.
AND MOUNTING.
16. Disconnect driveline between transmission and
5. Place a suitable container under the engine drain engine (1) and secure clear of the engine. Refer to
port, remove drain plug and drain oil. After draining, Section 130-0010, FRONT & REAR DRIVELINES.
reinstall drain plug and tighten securely.
Note: If anti-spill drain plug is fitted, remove cap from WARNING

connection, install drain tube connection and drain oil Heavy assembly. To prevent personal injury
into a suitable container. and property damage, be sure lifting device is
properly secured and of adequate capacity to
do the job safely.
WARNING
Air Conditioners contain harmful gas. 17. Attach suitable lifting equipment to lifting brackets
Refrigerant will rapidly freeze all objects with on engine (1) and raise lifting equipment to take up the
which it comes into contact. It can cause slack.
serious damage to the eyes and skin. Refer to
Section 260-0130, AIR CONDITIONING before 18. Remove locknuts (13), snubbing washers (10) and
disconnecting any air conditioner lines. bolts (11) securing front and rear mounting brackets (7
& 8) to the rubber mounts/support brackets and rubber
6. Evacuate the air conditioning system and mounts/crossmember.
disconnect the lines at the compressor. Refer to
Section 260-0130, AIR CONDITIONING.
2 SM 1964 4-00
Section 110-0030
19. Check to make certain that all necessary line and INSPECTION
cable disconnections have been made, before lifting Numbers in parentheses refer to Fig. 1.
engine (1).
1. Inspect rubber mounts (9) for damage and replace if
20. Carefully lift engine (1) up and forwards clear of required.
the frame and remove to a suitable work area. Mount
engine (1) securely on a work stand. 2. Check mounting brackets (7 & 8), engine support
brackets and crossmember on the frame for cracks
and damage. Repair or replace as necessary.
DISASSEMBLY
Numbers in parentheses refer to Fig. 1. 3. Inspect engine coupling (24 thru 29) for damage
and repair or replace if required.
1. Remove bolts (12 & 16) and lockwashers (17)
securing front mounting bracket (7) to engine (1).
Remove front mounting bracket (7). ASSEMBLY
2. Remove bolts (14) and lockwashers (15) securing
rear mounting brackets (8) to engine (1). Remove rear 1. Remove covers from engine ports and install new
mounting brackets (8). lube oil filter (4), coolant filter (5) and fuel filter (6) on
engine (1), as described under 'Maintenance'.
3. Remove air cleaner tubes and piping from turbocharger.
2. Install front mounting bracket (7) on engine (1) and
4. Remove exhaust piping from turbocharger. secure with bolts (12 & 16) and lockwashers (17).
Tighten bolts (12) to a torque of 60 Nm (44 lbf ft).
5. If fitted, remove mounting hardware securing drive Tighten bolts (16) to a torque of 45 Nm (33 lbf ft).
clutch fan (33) to fan (30). Remove drive clutch fan
(33). Remove bolts (31) and washers (32) securing fan 3. Install both rear mounting brackets (8) on engine (1)
(30) on engine (1). Remove fan (30). and secure with bolts (14) and lockwashers (15).
6. Remove bolts (20 & 21) and lockwashers (23)
securing cover (19) to flywheel housing. Remove 4. Install air cleaner tubes and piping and connect to
cover (19). turbocharger.
7. Remove bolts (22) and lockwashers (23) securing 5. Install exhaust piping and connect to turbocharger.
engine coupling (24 thru 29) to flywheel. Remove
engine coupling (24 thru 29). 6. Install radiator support bracket (39) to engine (1)
and secure using mounting hardware as removed at
8. Remove mounting hardware securing radiator Disassembly.
support bracket (39) to engine (1). Remove radiator
support bracket (39). 7. Install engine coupling (24 thru 29) on engine flywheel
and secure with bolts (22) and lockwashers (23). Tighten
9. Remove and discard lube oil filter (4), coolant bolts (22) to a torque of 31 Nm (23 lbf ft).
filter (5) and fuel filter (6) from engine (1), as described
under 'Maintenance'. Cover engine ports to prevent 8. Install cover (19) on engine flywheel housing and
entry of dirt. secure with bolts (20 & 21) and lockwashers (23).
Tighten bolts (20 & 21) to a torque of 31 Nm (23 lbf ft).
10. Refer to engine manufacturers SERVICE
MANUAL if engine service or repair is required. 9. Install fan (30) on engine and secure with bolts (31) and
washers (32). Tighten bolts (31) to a torque of 31 Nm
(23 lbf ft). If applicable, install drive clutch fan (33) to fan
(30) using hardware removed during disassembly.
SM 1964 4-00 3
Section 110-0030
INSTALLATION proximity switches on engine (1), as identified at

Numbers in parentheses refer to Fig. 1. removal.
Note: Tighten all fasteners without special torques 9. Connect accelerator cable to engine (1).
specified to standard torques listed in section
300-0080, STANDARD BOLT AND NUT TORQUE 10. Connect compressor air outlet tube to engine (1).
SPECIFICATIONS.
11. Connect air conditioning lines at the compressor
as identified at removal. On completion of engine (1)
WARNING installation, the air conditioning system will require to
Heavy assembly. To prevent personal injury be charged. Refer to Section 260-0130, AIR
and property damage, be sure wheel blocks, CONDITIONING.
blocking materials and lifting equipment are
properly secured and of adequate capacity to 12. Connect exhaust piping to the turbocharger at the
do the job safely. silencer.
1. Lubricate rubber mounts (9) with water or a suitable 13. Install radiator assembly on the tractor frame and
rubber lubricant. Insert rubber mounts (9) into the connect cooling and heater lines to radiator assembly
frame crossmember from above and support brackets and engine (1). Refer to Section 210-0040,
from below. Use a driver of the same diameter as the RADIATOR AND MOUNTING.
internal metal sleeve in rubber mount (9) to drive the
mounts fully home. Install opposite half of rubber 14. Secure any clips to the engine which were
mounts (9) over protruding diameter of rubber mounts removed to facilitate engine removal.
previously installed.
15. Connect air tube to the air cleaner and secure with
2. Attach suitable lifting equipment to engine (1) lifting mounting hardware removed during removal.
brackets and carefully position engine (1) in the frame.
16. Connect cables to battery terminal posts (ground
3. Install bolts (11) through front mounting bracket (7), cable last).
rubber mounts (9) and the frame crossmember. Install
snubbing washers (10) and locknuts (13) on bolts (11). 17. Ensure all lines, harnesses and cables are
Tighten locknuts (13) to a torque of 298 Nm secured with clips and clamps as removed during
(220 lbf ft). removal. Ensure no lines are chaffing on sharp edges
or resting against areas where heat will be evident.
4. Install a snubbing washer (10) onto each rear
mounting bolt (11) and install bolts through rear 18. Ensure all coolant drain cocks on engine (1) and
mounting brackets (8), rubber mounts (9) and frame the radiator assembly are securely closed and shut off
support brackets. Install locknuts (13) on bolts (11) cock at coolant filter (5) housing is open. Fill the
and tighten locknuts (13) to a torque of 298 Nm cooling system with coolant specified in Section
(220 lbf ft). 300-0020, LUBRICATION SYSTEM. Check the
coolant level as described in Section 210-0000,
5. Connect driveline between transmission and engine COOLING SYSTEM.
and secure with mounting hardware removed during
removal. Refer to Section 130-0010, FRONT & REAR 19. Fill engine (1) with lube oil specified in Section
DRIVELINES. 300-0020, LUBRICATION SYSTEM. Check oil level as
described under 'Maintenance'.
6. Remove blanking caps and connect fuel lines to
engine (1) ports, as identified at removal. 20. Place the battery master switch in the 'On' position,
start the engine and bring the engine oil to operating
7. Connect electrical cables to the alternator and temperature. Check all lines and fittings for leaks and
starter motor, as identified at removal. tighten as required.
8. Connect cables to the oil pressure sender switch, 21. Using suitable lifting equipment, install hood assembly
engine temperature switch, fuel shut off solenoid and and goalpost support assembly on the vehicle. Refer to
Section 110-0030, HOOD AND MOUNTING.
4 SM 1964 4-00
Section 110-0030
22. Ensure parking brake is applied, disconnect
steering lock bar and secure in the 'Stowed' position.
WARNING
Remove wheel blocks from all road wheels.
Personal injury can result from a fan blade
failure. Never pull or pry on the fan as this can
MAINTENANCE damage the blades and lead to fan failure.
Drive Belts - Visually inspect all drive belts daily.
Replace belts that are cracked or frayed and adjust
Note: Carry out the following maintenance procedures
belts that have a glazed or shiny surface which
in conjunction with additional procedures listed in
indicates belt slippage. Correctly installed and
Section 300-0020, LUBRICATION SYSTEM.
tensioned belts will show even pulley and belt wear.
WARNING Every 250 Hours

Do not use the rocker cover as a step. The
Fuel Filter (6) - Clean the area around the fuel filter
material is plastic and will not withstand
head and replace the fuel filter.
weight of any consequence.
Position the vehicle on a level work area, apply the
Every 10 Hours (Daily) parking brake and switch off the engine. Using a strap
type filter wrench, remove fuel filter (6) and discard the
General - Visually check the engine for leaks, loose or
thread adaptor sealing ring. Clean the gasket surface
damaged parts, worn or damaged belts or any change
of the filter head.
in engine appearance. Listen for any unusual engine
noise which can indicate that a service is required.
Install the new thread adaptor sealing ring (supplied
with new filter) and apply a film of clean engine oil to
Oil Level Check - Position the vehicle on a level work
lubricate the filter seal. Fill the new filter with clean fuel
area, apply the parking brake, shut off the engine and
specified in Section 300-0020, LUBRICATION
wait at least five minutes (to allow oil to drain to the oil
SYSTEM.
pan) before checking the oil level. The oil level should
be between the low (L) and high (H) marks on the
Install new fuel filter (6) on the filter head and tighten
dipstick. Add oil if low. Refer to Section 300-0020,
by hand until the gasket contacts the filter head
LUBRICATION SYSTEM for oil specification.
surface. Tighten fuel filter (6) per filter manufacturer's
instructions.
Note: Never operate the engine with oil level below
the low (L) or above the high (H) mark on the dipstick.
Note: Mechanical tightening of the filter is not
recommended and may result in seal and/or cartridge
Fuel Filter/Water Separator (6) - Drain the water and
damage. Tighten filter by hand only.
sediment from the separator daily. Position the vehicle
on a level work area, apply the parking brake, shut off
Engine Oil and Lube Oil Filter (4) - Replace the
the engine and, with a suitable container below the
lubricating oil and oil filters.
drain valve to catch spillage, open the drain valve by
hand. Turn the valve anticlockwise approximately
1.5 - 2 turns until draining occurs. Drain the filter sump
WARNING
until clear fuel is visible. Turn the valve clockwise to
Avoid direct contact of hot oil with your skin.
close the drain valve.
Hot oil can cause serious personal injury.
Note: Do not overtighten the drain valve as
Operate the engine until the water temperature
overtightening can damage the threads.
reaches 60 C (140 F). Position the vehicle on a level
work area, apply the parking brake and switch off the
Cooling Fan (30) - Visually inspect the fan for cracks,
engine. Position a suitable container under the engine
loose rivets, and bent or loose blades. Check the fan
oil drain plug and drain the oil immediately to make
to make sure that mounting bolts (31) are secure.
sure all the oil and suspended contaminants are
Tighten bolts as required. Replace any fan that is
removed from the engine.
damaged.
SM 1964 4-00 5
Section 110-0030
Clean the area around the lube oil filter head and, Coolant Filter (5) - Check the DCA4 concentration
using strap type filter wrench, remove lube oil filter (4). and replace the coolant filter at every oil and filter
Discard lube oil filter (4) if it is not required for a failure change interval. Refer to Section 210-0000, COOLING
analysis. Clean the gasket sealing surface of the filter SYSTEM.
head.
Crankcase Breather - Check and clean the
Note: The 'O' ring can stick on the filter head. Make crankcase breather hose. Remove the breather hose
sure the 'O' ring is removed and discarded. and check internally for obstructions or sludge buildup.
Clean or replace breather hose as necessary, to
Note: Fill the filter with clean lubricating oil prior to prevent excess crankcase pressure buildup.
installation. The lack of lubrication during the delay
until the filter is pumped full of oil is harmful to the Drive Belts - Check belt tension and adjust if
engine. necessary, as described under 'Drive Belt Adjustment'.
Apply a light film of clean lubricating oil to the gasket Air Intake System - Inspect the air intake piping for
surface of the new filter and install the filter on the filter cracked hoses, loose clamps, or punctures which can
head as specified by the filter manufacturer. The damage the engine. Tighten or replace parts as
tightening instructions are normally printed on the necessary to make sure the air intake system does not
outside of the filter. leak.
Note: Mechanical tightening of the filter is not

recommended and may result in seal and/or cartridge DRIVE BELT ADJUSTMENT
damage. Tighten filter by hand only. Note: Position the vehicle in a level work area, apply
the parking brake and switch off the engine. Block all
Check and clean the engine oil drain plug threads and road wheels and place the battery master switch in the
the seal surface. Install and tighten the drain plug to a 'Off' position.
torque of 90 Nm (65 lbf ft). Fill the engine with clean
lubricating oil specified in Section 300-0020, Measure the belt tension in the centre span of the
LUBRICATION SYSTEM. The oil level should be pulleys using a belt tension gauge. The belt tension
between the low (L) and high (H) marks on the should be within the following limits:
dipstick.
Fan Belt Tension
Note: Before starting the engine, follow the steps Belt Tension 'New' - 890 N (200 lbf)
below to make sure the engine receives correct Belt Tension 'Used' - 360 to 710 N (80 to 160 lbf)
lubrication. Lack of lubrication will damage the engine.
Alternator Belt Tension
a. Disconnect the electrical wire from the fuel pump Belt Tension 'New' - 670 N (150 lbf)
solenoid valve. Belt Tension 'Used' - 270 to 530 N (60 to 120 lbf)
b. Switch on the ignition and rotate the crankshaft Note: A belt is considered 'Used' if it has been in
using the starter motor, until oil pressure appears on service for 10 minutes or longer. If the used belt
the pressure gauge or the warning light goes out. tension is less than the minimum value, tighten the belt
to the maximum value.
c. Connect the electrical wire to the fuel pump solenoid
valve. An alternative method (deflection method) can be
used to check the belt tension by applying 110 N (25 lbf)
Start the engine and operate at idle speed to inspect force on the belt between the pulleys. If the deflection
for leaks at the filter and oil drain plug. Shut off the is more than one belt thickness per foot (305 mm) of
engine, wait approximately five minutes to let the oil pulley centre distance, the belt tension must be
drain back to the sump and check the oil level again. adjusted.
Add oil as necessary to bring the level to the high (H)
mark on the dipstick.
6 SM 1964 4-00
Section 110-0030
Fan Belt Adjustment Alternator Belt Adjustment
Loosen the idler pulley lock nut and adjust the belt to Loosen the adjustment link locking capscrew and turn
the correct tension. Tighten the idler pulley lock nut to the capscrew to adjust belt tension. Tighten the
a torque of 165 - 190 Nm (120 - 140 lbf ft). adjustment link locking capscrew to a torque of 80 Nm
(60 lbf ft).
Note: Do not adjust fan belt tension to full value with
the adjusting screw. Belt tension can increase when
the lock nut is tightened and cause reduced belt and SERVICE TOOLS
bearing life. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required.

TORQUE
1 12 Bolt 60 44
1 13 Locknut 298 220
1 14 Bolt 190 140
1 16 Bolt 45 33
1 20 Bolt 31 23
1 21 Bolt 31 23
1 22 Bolt 31 23
1 31 Bolt 31 23
- - Engine Drain Plug 90 65
- - Fan Idler Pulley Lock Nut 165 - 190 120 - 140
- - Alternator Adjustment Link Capscrew 80 60
* * * *
SM 1964 4-00 7
ENGINE AND MOUNTING - Kysor DST Fan
Section 110-0040
SM - 1903
2,3
1
5
8
6 RAD. WATER PIPE
SOLENOID
SUPPLY
1 - Bolt 5 - DST Fan Drive

2 - Lockwasher 6 - Solenoid
3 - Nut 7 - Sensor Control Valve
4 - Fan 8 - Nylon Tube
Fig. 1 - Typical Layout View of Kysor DST Fan and Clutch
DESCRIPTION AND OPERATION fan drive (5) to give the engine cooling fan (4) idle
Numbers in parentheses refer to Fig. 1. speed. At a pre-determined coolant temperature, the
outlet pressure from the sensor control valve (7)
The single sensing direct temperature sensing (DST) increases giving an increased fan speed. Any further
fan drive system comprises of two main components. rises in coolant temperature results in increased fan
A coolant sensor control valve (7) and a fully speed. The fan speed increases proportionally with the
modulating viscous fan drive (5) driving the engine increase in coolant temperature over a 5 C range,
cooling fan (4). until the fan is fully engaged.
Air pressure is fed from the supply into the inlet When the coolant temperature drops, so the fan speed
connection of the sensor control valve (7). When the reduces proportionally until the idle speed is reached.
temperature is below a pre-determined value, the
sensor control valve (7) supplies idle pressure to the The DST fan drive (5) has a failsafe feature, ie. if the
DST fan drive (5). This idle pressure controls the DST air pressure to the fan drops to zero, the fan will be
automatically engaged.
SM 1974 4-00 1
Engine and Mounting - Kysor DST Fan
Section 110-0040
REMOVAL and nuts (3). Torque tighten nuts (3) to 27 Nm

Numbers in parentheses refer to Fig. 1. (20 lbf ft).
2. Using suitable lifting equipment, position fan (4)

WARNING assembly on the machine and secure to engine with
To prevent personal injury and property bolts (1). Torque tighten bolts (1) to 47 Nm (35 lbf ft).
equipment is properly secured and of adequate Note: Ensure there is even clearance, all the way
capacity to do the job safely. round, between fan (4) and the fan shroud.
1. Position the vehicle in a level work area, apply the 3. Connect nylon tube (8) to DST fan drive (5) braided
parking brake and switch off the engine. tube.
2. Block all road wheels and place the battery master 4. Install fan guards to the fan shroud and secure with
switch in the 'Off' position. mounting hardware, as removed at 'Removal'.
3. If required, remove mounting hardware securing 5. If removed, position the hood assembly on the
hood assembly to the machine and, using suitable machine using a suitable lifting device. Secure hood
lifting equipment, remove hood assembly. assembly on the machine with mounting hardware, as
removed at 'Removal'.
4. Remove mounting hardware securing fan guards to
the fan shroud. Remove fan guards from the machine. 6. Start the engine and check for correct operation of
the fan. Refer to 'Testing' procedures contained in this
5. Disconnect nylon tube (8) from DST fan drive (5) section.
braided tube.
6. Support fan (4) assembly with suitable lifting
equipment and remove bolts (1) securing fan (4)
assembly to the engine. Remove fan (4) assembly TESTING
from the machine.
Static Test
7. Remove nuts (3) and lockwashers (2) securing DST Note: This test will only determine if the fan drive has
fan drive (5) to fan (4) mounting surface of housing. seized or is very close to seizure.
Remove DST fan drive (5) from housing.
With the engine stopped, the fan should turn smoothly
with resistance (viscous) without scraping, scratching
INSTALLATION or grating noise.
Note: Rotation without resistance indicates a fault.
Note: Tighten all fasteners without special torques
300-0080, STANDARD BOLT AND NUT TORQUE Basic Dynamic Test - Cut In/Cut Out
SPECIFICATIONS. Note: This test is carried out with the machine static
and secured at rest.
WARNING After the machine has stood for approximately 30

To prevent personal injury and property minutes with the engine stopped, start the engine and
damage, make sure blocking or lifting increase engine speed to 2 100 rev/min.
capacity to do the job safely. Initially the fan noise should be loud (cut in), but before
a further minute has elapsed, the fan noise should
1. Install DST fan drive (5) on fan (4) mounting surface significantly reduce (cut out).
of housing and secure in place with lockwashers (2)
2 SM 1974 4-00
Engine and Mounting - Kysor DST Fan
Section 110-0040
Basic Dynamic Test - Fan Drive Operation MAINTENANCE

Note: This test is carried out with the machine static
and secured at rest. Every 10 Hours/Daily
Check the fan for debris or damage. Clean or replace
1. Place a cardboard, or alternative material, sheet as required.
over the radiator front with an approximate 100 mm
(4 in) diameter hole in the sheet, in line with the centre Note: This Kysor DST fan is a non-serviceable
of the fan drive. component. However, the following instructions must
be strictly adhered to:
2. Start the engine and increase engine speed to
2 100 rev/min. 1. DO NOT clean around fan drive with steam or high
pressure jet.
3. Fan noise should initially be loud and reduce
significantly before 1 minute has elapsed. 2. DO NOT tamper with modulation control
mechanism for ANY reason.
4. Maintain engine speed at 2 100 rev/min. Fan drive
should 'cut in' (engage) before coolant temperature 3. DO NOT add any fluids or lubricants to the drive.
gauge indicates excessive coolant temperature.
4. DO NOT restrict fan rotation during engine
5. Return engine speed to idle, quickly remove the operation for ANY reason.
sheet in front of the radiator and bring engine speed
back up to 2 100 rev/min. Fan speed should 'cut out' 5. DO NOT operate a machine with a damaged fan
(disengage) within 1 minute. assembly. Replace a damaged fan as soon as the
fault is noted.
Failsafe Check 6. DO NOT disassemble ANY fan assembly or

Note: This test is carried out with the machine static associated parts that are still within the warranty
and secured at rest. Hood should be raised and coverage period.
secured.
7. IMMEDIATELY investigate and correct ANY
1. Start the engine and increase engine speed to operator complaint involving drive or cooling system
2 100 rev/min. performance.
2. Maintain engine speed at 2 100 rev/min and

disconnect nylon tubing from the fan drive braided
tube. Fan should automatically engage to full flow
speed.

TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
1 1 Bolt 47 35
1 3 Nut 27 20
* * * *
SM 1974 4-00 3
ENGINE - Air Cleaner
Section 110-0050
SM - 1532
3
6
1 - Air Cleaner Body

2 - Primary Element
3 - Safety Element
4 - Cover Assembly
5 - Latch
6 - Vacuator Valve
Fig. 1 - Exploded View of Typical Air Cleaner
DESCRIPTION AND OPERATION A mechanical air restriction gauge (16, Fig. 2) is

Numbers in parentheses refer to Fig. 1. mounted on the air cleaner body and shows when the
system air flow is being restricted. A red band
The dual dry element air cleaner is remote mounted gradually rises in the gauge window as air restriction
horizontally on the right hand fender of the machine. increases. The red band is locked when maximum
The air cleaner prolongs engine life by removing grit, allowable restriction is reached. When the red band
dust and water from the air as it enters the engine. Grit locks at the top of the gauge window, primary filter
and dust, combined with engine oil, forms a highly element (2) should be serviced. Air restriction gauge
abrasive compound which can destroy the engine in a (16, Fig. 2) should be reset by pushing the button on
comparatively short period of time. the gauge, holding it for several seconds and then
releasing it.
A rubber vacuator valve (6) attached to end cover (1)
in a downward position, ejects grit, dust and water While air restriction gauge (16, Fig. 2) indicates the
while the engine is running. Vacuator valve (6) need for servicing, it does not give as precise a
minimizes the need for daily servicing. Even though measurement as a water manometer or vacuum
vacuator valve (6) is normally under a slight vacuum gauge. Refer to 'Measuring Air Restriction'.
when the engine is running, pulsing of the vacuum
opens and closes the rubber valve, expelling dust and Secondary (safety) element (3) is installed in air
water as they collect. When the engine is stopped, cleaner body (1) inside of primary element (2). This
vacuator valve (6) opens and expels any accumulated element increases the reliability of the air cleaners
grit, dust or water.
SM 1958 4-00 1
Engine - Air Cleaner
Section 110-0050
SM - 2472
16
14
10 13
17 11
1
12
15
9
7
8
S.W.E.
TO
2 TURBO
3
5 5
4
4
2
13 - 'U' Bolt
1 - Air Cleaner Assembly 5 - Lockwasher 9 - Band Clamp 14 - Bracket
2 - Bracket 6 - Plug 10 - Cap 15 - Bolt
3 - Bolt 7 - Hose 11 - Clamp 16 - Air Restriction Gauge
4 - Nut 8 - Band Clamp 12 - Air Intake Tube 17 - Clamp
Fig. 2 - Exploded View of Typical Air Cleaner Mounting
protection of the engine from airborne dirt. It protects 3. Pull on handle to release hood catch and lift up the
the engine from dirt admitted by a damaged primary hood.
element (2), or dirt that might be dropped into air
cleaner assembly while changing primary element (2). 4. Slacken clamps (8 & 9) and slide hose (7) clear of
the air cleaner assembly.
AIR CLEANER 5. Using suitable lifting equipment, support the air

cleaner assembly and remove bolts (3) and nuts (4).
Removal Remove air cleaner assembly from brackets (2).
6. Blank off air cleaner outlet and hose (7) end with
1. Position the vehicle in a level work area, apply the tape or cardboard to prevent entry of dirt.
parking brake and switch off the engine.
7. If required, remove bolts (3), nuts (4) and
2. Block all road wheels, place the steering lock bar in lockwashers (5) securing brackets (2) to the right hand
the 'Locked' position and the battery master switch in fender. Remove brackets (2).
the 'Off' position.
2 SM 1958 4-00
Section 110-0050
Disassembly MAINTENANCE
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless
otherwise specified. otherwise specified.
Note: Air cleaner body (1) should be thoroughly

cleaned twice a year. Do not apply heat in any form to WARNING
air cleaner body (1). Always shutdown the engine before servicing
air cleaner.
1. Release latches (5) on cover assembly (4) and
remove cover assembly from air cleaner body (1). Check air restriction gauge (16, Fig. 2) daily. The air
cleaner elements should be serviced only when the
2. Remove primary element (2) and safety element (3) maximum allowable restriction has been reached, as
from air cleaner body (1). indicated by air cleaner restriction gauge (16, Fig. 2).
The elements should not be serviced on the basis of
3. Open clamps (17, Fig. 2) and remove from air visual observation as this would lead to over service.
cleaner body (1). Open clamp (11, Fig. 2) on cap When restriction readings finally indicate a change,
assembly (10, Fig. 2) and remove cap assembly from remove primary element (2) carefully and clean/
air cleaner body (1). replace as required. Refer to 'Primary Element'.
4. Blank off air cleaner body (1) outlets with tape or Never attempt to clean safety element (3). Change
cardboard. Reach inside body with a compressed air safety element (3) after every third primary element (2)
nozzle or brush and remove dust from the body. service.
5. Remove all loose dust from air cleaner body (1) and Make sure vacuator valve (6) is not damaged or
remove tape or cardboard from body outlets. plugged and that the joint with cover assembly (4) is
not broken. If vacuator valve (6) is lost or damaged,
Note: Assembly and installation of the air cleaner replace it to maintain pre-cleaner efficiency and normal
assembly is the reverse of disassembly and removal. filter element service life.
Check condition of clamps (8 & 9, Fig. 2), hump hose

Assembly/Installation (7, Fig. 2) and elbow (12, Fig. 2). Tighten/replace as
Numbers in parentheses refer to Fig. 2, unless necessary.
Note: Tighten all fasteners to standard torques listed Primary Element

in Section 300-0080, STANDARD BOLT AND NUT Numbers in parentheses refer to Fig. 1.
Although a paper primary element (2) is used, it is
Assembly and installation of the air cleaner assembly possible to clean it so that it can be reused. The
is the reverse of disassembly and removal. Reset air number of times one element can be reused depends
restriction gauge (16). on the type of dirt on the element and the care
exercised in cleaning.
Following installation, but before starting the engine,
the following system checks should be carried out: The life of a properly cleaned element will be
approximately as long as that of a new element for the
a. Check air intake tube (12) for defects and that first one or two cleanings. After that, the life of the
clamps (8 & 9) (and those supplied with the engine) element will gradually decrease with each cleaning;
are securely tightened to ensure that there are no however, it should perform satisfactorily through
leaks in the system. approximately six cleanings, providing it does not rupture.
b. Check that air cleaner mounting brackets (2) are Visually determine the condition of primary element (2)
secure and that air cleaner is mounted securely. and choose either the compressed air or washing
method.
1. Release latches (5) on cover assembly (4) and
SM 1958 4-00 3
Section 110-0050
remove cover assembly from air cleaner body (1). Inspection of element on the outside will disclose any
holes where concentrated light shines through. Even
2. Remove primary element (2) from air cleaner body (1). the smallest hole will pass dust to the engine and may
result in costly engine repairs.
3. Using a damp cloth and a suitable solvent, wipe out
all excess dust from air cleaner body (1) and allow to 9. Install primary element (2) in air cleaner body (1).
dry.
10. Install cover assembly (4) on air cleaner body (1)
4. If the major contaminant on primary element (2) is and secure with latches (5).
light dust, direct a jet of compressed air, not exceeding
6.9 bar (100 lbf/in2), against the pleats of the element.
The air jet should be directed in the opposite direction Secondary Element
of normal operating air flow. Move the air jet up and Numbers in parentheses refer to Fig. 1.
down the pleats, holding the air nozzle 25 mm (1.0 in)
away from the pleats, to prevent rupturing the element Since safety element (3) is protected from
with either the nozzle or air jet. contamination by primary element (2), it needs no
periodic cleaning and should be replaced only after
5. In cases where the dust cake on primary element every third primary element (2) service.
(2) contains oil or carbon, air will not clean effectively.
Using manufacturers recommended solution and 1. With primary element (2) removed from air cleaner
warm water, not exceeding 48 C (120 F), soak body (1), remove safety element (3).
primary element (2) for fifteen minutes. Element
should be gently agitated to assist cleaning process. 2. Remove any dust dislodged into air cleaner body (1)
outlet and, using a damp cloth and a suitable solvent,
Note: It is possible to modify an old agitator type wipe out all excess dust from air cleaner body (1) and
washing machine for primary element (2) cleaning. Do allow to dry.
not soak or agitate primary element (2) in the solution
for more than fifteen minutes. Prolonged exposure 3. Install new safety element (3) followed by primary
softens vertical seams in the element. element (2) in air cleaner body (1)
6. Rinse washed element thoroughly with a low 4. Install cover assembly (4) on air cleaner body (1)
pressure stream of water, not exceeding 0.7 bar and secure with latches (5).
(10 lbf/in2), opposite from the normal air flow, until
rinse water runs clear.
Recommendations
7. Air dry primary element (2) thoroughly before Numbers in parentheses refer to Fig. 2.
returning it to service. Drying is a slow process which
may be hastened by exposing element to slowly 1. Under no condition should the vehicle be operated
circulating heated air. Heated air temperature should without both filter elements in each air cleaner
not exceed 46o C (115o F). Drying time can be reduced assembly.
to about three hours with heated air. DO NOT use a
light bulb for drying. DO NOT use compressed air on a 2. It is very important that hump hose (7) and air intake
wet element. tube (12) from the air cleaner assembly to the engine
be airtight or the purpose of the air cleaner will be
Note: Replace paper elements after six cleanings or completely defeated. All clamps (8 & 9) (and those
two years in service, whichever comes first. Mark each supplied with the engine) should be checked
cleaned element to show total cleanings to date. frequently and tightened to prevent leaks.
8. After primary element (2) is thoroughly dried, 3. Keep new or cleaned filter elements on hand for
inspect for damage or ruptures, especially close to the replacement to prevent unnecessary downtime of the
end caps. To detect paper ruptures, place a bright light vehicle.
bulb inside the element and rotate element slowly.
4 SM 1958 4-00
Section 110-0050
MEASURING AIR RESTRICTION c. With the manometer held vertically and the engine
Numbers in parentheses refer to Fig. 2. drawing maximum air, the difference in height of the
water columns in the two legs is measured as the air
As a dry air cleaner element becomes loaded with cleaner restriction.
dust, the vacuum on the engine side of the air cleaner
(air cleaner outlet) increases. This vacuum is generally d. If the restriction exceeds the levels indicated, engine
measured as 'restriction in mm (inches) of water'. performance will be affected. Primary filter element
should be cleaned or replaced.
The recommended maximum allowable intake
restrictions at rated speed and load are as follows: Vacuum Gauge
a. Remove air restriction gauge (16) from port in air
a. 380 mm-H2O (15 in-H2O) with clean filter elements. cleaner assembly.
b. 635 mm-H2O (25 in-H2O) with dirty filter elements.
b. Connect the hose from the vacuum gauge to
While the air restriction gauge sends a signal to port and, with the engine drawing maximum air, take a
indicate the need for servicing, it does not give as note of the reading on the gauge.
precise a measurement as a water manometer or
vacuum gauge. c. If the restriction exceeds the levels indicated, engine
performance will be affected. Primary filter element
Water Manometer should be cleaned or replaced.
a. Remove air restriction gauge (16) from port in air
cleaner assembly.
SERVICE TOOLS
b. Hold water manometer vertically and fill both legs Refer to Section 300-0070, SERVICE TOOLS for part
approximately half full of water. Connect one of the numbers of service tools referenced in this section and
upper ends to port by means of a flexible hose. general service tools required. These tools are
available from your dealer.
* * * *
SM 1958 4-00 5
TRANSMISSION - Transmission and Mounting
Section 120-0010
SM - 2011
25 26,27
28,29
16 22
21
26 18
30
20
17
19
12 6
1
25
11
6
15
3
2
7 LH
13 RH
3
4 24
8
5
14 23
5
9
10
15 - Dipstick Tube 23 - Screw

1 - Front Bracket Assembly 8 - Isolation Mount 16 - Bracket 24 - Gasket
2 - Isolation Mount 9 - Lockwasher 17 - Clamp 25 - Dipstick
3 - Snubbing Washer 10 - Bolt 18 - Bolt 26 - Latch Assembly
4 - Washer 11 - Lockwasher 19 - Washer 27 - Clamp
5 - Locknut 12 - Bolt 20 - Locknut 28 - Bolt
6 - Bolt 13 - RH Bracket 21 - Bolt 29 - Locknut
7 - LH Bracket 14 - Hardened Washer 22 - Lockwasher 30 - Padlock
Fig. 1 - Exploded View of Transmission and Mounting
DESCRIPTION The transmission assembly consists of a torque

Numbers in parentheses refer to Fig. 1. converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. A
For transmission make, model and specification, refer wear-resistant hydraulic retarder is integral of the
to Section 000-0000, GENERAL INFORMATION. For transmission.
transmission servicing and repair data refer to
transmission manufacturers service manual. Two engine dependent power takeoffs at the rear of
the transmission provide the drive for the steering
The transmission is supported by front bracket pump and the hydraulic pump for the body hoist
assembly (1), LH bracket (7) and RH bracket (13) system.
which are bolted to the transmission and attached to
front frame mounting brackets through isolation Mounted off front bracket assembly (1) are the
mounts (2 & 8). Isolation mounts (2 & 8) provide retarder solenoid, differential lock solenoid and
sufficient flexibility to absorb varying transmission pressure reducing valve.
vibration and torsional loads.
SM 1965 4-00 1
Transmission - Transmission and Mounting
Section 120-0010
SM - 1829
K2 KR KV K4 K3
4
K1
Y
9 2
10
VIEWED FROM THE REAR
1 DETAIL Y
6
1 - Retarder Oil Temperature Sender

2 - Main Control Valve
8 3 - Difflock Warning Light Switch
4 - Lockup Solenoid
7 5 - Engine Speed Sensor
6 - Output Speed Sensor
7 - Central Gear Train Sensor
8 - Turbine Speed Sensor
9 - Oil Temperature Sender (Gauge)
10 - Breather
3 KV, KR, K1 to K4 - Supply ports to

Multi-disc Clutches
Fig. 2 - Location of Transmission Switches, Sensors and Solenoids
SWITCHES AND SENSORS The transmission oil temperature is monitored by

Numbers in parentheses refer to Fig. 2, unless temperature sensors in the main control valve, which
otherwise specified. sends a signal to illuminate the transmission STOP
warning light. The light will illuminate to indicate any of
Transmission Oil Temperature the following conditions:
Oil temperature sender (9) sends a signal to indicate
transmission oil temperature on the transmission oil High retarder temperature
temperature gauge. The gauge should read in the High transmission sump temperature
green zone during normal operation and may read in Engine overspeed
the yellow zone during retarder operation. If the needle
remains in the red zone for extended periods, the If the light illuminates during normal operation, a fault
machine should be brought to a stop, transmission code will also register on the display unit (See EST-37
shifted to neutral and engine speed increased to Trouble Shooting tables). Bring the machine to a stop
1 200 - 1 500 rev/min. Under this condition, oil and investigate the cause.
temperature should drop to normal values in about
2 - 3 minutes. If oil temperature does not drop, the
cause should be investigated.
2 SM 1965 4-00
Section 120-0010
SM - 1826
VALVE BLOCK
COVER
Y3 Y4
Y2 Y5 6
Y1 Y6
2 1
HOUSING
SYSTEM PRESSURE FROM
CONTROL UNIT BREATHER
1 - Main Pressure Valve 16+2 bar 5 - Follow-on Slide

2 - Pressure Reduction Valve 9 bar 6 - Proportional Valve (P1 to P6)
3 - Lockup Solenoid 7 - Vibration Damper
4 - Lockup Reduction & Shift Valve 8 - Harness Connection Y1 to Y6 - Pressure Regulators
Fig. 3 - Sectional View of Typical Control Unit with Lockup Clutch (Wk)
Lockup Clutch (Wk) The transmission is equipped with six multi-disc

The transmission lockup clutch is automatically clutches. These clutches are controlled via the six
engaged. Engine speed is picked up by turbine speed proportional valves (6, Fig. 3). Each proportional valve
sensor (8) which sends a signal to energise lockup (6, Fig. 3) is composed of a pressure regulator (Y1 to
solenoid (3, Fig. 3) when turbine speed reaches a Y6, Fig.3), follow-on slide (5, Fig. 3) and vibration
predetermined level. Energising lockup solenoid damper (7, Fig. 3).
(3, Fig. 3) will move lockup valve (4, Fig. 3) across,
allowing oil to flow through the valve to engage lockup. The control pressure of 9 bar for the actuation of the
follow-on slides (5, Fig. 3) is created by the pressure
reduction valve (2, Fig. 3). The pressure oil (16+2 bar)
Gear Selection is directed via the follow-on slide (5, Fig. 3) to the
The transmission can be engaged and disengaged respective clutch.
under load by means of hydraulically controlled multi-
disc clutches. All gears run in antifriction bearings and Due to the direct proportional control with separate
are constantly meshed. The gears, bearings and pressure modulation for each clutch, the pressures to
clutches are lubricated with cooled oil. the clutches, which are taking place in the gear
change, are controlled. In this way, a hydraulic
SM 1965 4-00 3
Section 120-0010
intersection of the clutches to be engaged and differential lock is released. On activation of the
disengaged becomes possible. This creates fast differential lock switch, the transmission differential
shiftings without traction force interruption. lock solenoid is energised and air pressure is
exhausted at the transmission differential lock and
applied at the centre axle differential lock. In this
Speedometer Sensor condition, the differential locks are engaged.
Speedometer sensor, within the ECU, sends a signal
to the speedometer, via the speedometer frequency Note: The differential locks can be preselected when
divider, to indicate travel speed in kilometres per hour the machine is moving however, they will only engage
and miles per hour. on the move when the vehicle speed is below 5 km/hr.
Note: Before driving in soft or slippery conditions, stop

Differential Locks and engage the differential locks. Spinning wheels can
Note: The transmission differential lock requires air result in damage to the transmission and axle
pressure to hold it 'Off', whereas, the centre axle differentials.
differential lock requires pressure to hold it 'On'.
Note: Disengage differential locks when driving on
When the engine is started, air pressure is applied to firm ground.
the transmission differential lock to ensure the
4 SM 1965 4-00
DRAWING
2nd POWER TAKE-OFF

HORIZONTAL
SCHEDULE OF MEASURING POINTS

CONVERTER
CLICK HERE FOR
Measurements to be carried out with oil at normal operating 14

RETARDER WK
temperature of 80 C and operating at full speed. KV K1
SM 1965 4-00
MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE: 1st POWER TAKE-OFF
51 = Before the Convertor - Opening Pressure 8.5 bar

52 = Behind the Convertor - Opening Pressure 5 bar INPUT
53 = Clutch forward 16+2 bar KV
55 = Clutch reverse 16+2 bar KR KR K2
56 = Clutch 16+2 bar K1 PUMP
57 = Clutch 16+2 bar K2
58 = Clutch 16+2 bar K3
6 31
60 = Clutch 16+2 bar K4 K4 K3
63 = Temperature 100 C behind the retarder (short time 150 C)
65 = System pressure 16+2
66 = Temperature 100 C behind the converter (short time 120 C)
67 = WK-Control pressure 131 bar 39
OUTPUT OUTPUT
58
56 ENGAGEMENT AND DISENGAGEMENT DIFFERENTIAL
53
DIFFERENTIAL LOCK
60 D C
INDUCTIVE TRANSMITTERS AND SPEED SENSORS
E B 6 = Inductive Transmitter n Turbine
55 14 = Inductive Transmitter n Engine
F A
31 = Speed Sensor n Output and Speedometer
G
39 = Inductive Transmitter n Central Gear Train
J H K
57
66 PRESS REG. UNDER VOLTAGE

51
52 SPEED Y1 Y2 Y3 Y4 Y5 Y6
F1
F2
F3
Fig. 4 - Typical Schedule of Measuring Points and Gear Pattern

F4
F5
F6
63 R1
67 65 R2
R3
N
CLUTCH KR K4 K1 K3 KV K2
POS. VALVE F E D C B A
POINTS 55 60 56 58 53 57
SM - 1824
Section 120-0010
5
6
KR K4 K1 K3 KV K2
SM - 1822
F 55 E 60 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D
Section 120-0010
Y1 NFS Y2 NFS Y3 NFS Y4 NFS Y5 NFS Y6 NFS
RV-9
TEMP
No. Denomination of the Position Port

K 65
NOT SCOPE OF SUPPLY ZF
15 To the heat exchanger
WK-M HDV
AIR RESERVOIR 8 bar 16 From the heat exchanger
WK-V 28 To the ZF-filter
29 From the ZF-filter
SCOPE OF SUPPLY ZF 32 Behind the Convertor to heat exchanger
PRESSURE REDUCTION VALVE 33 Before the Convertor to heat exchanger
5.5 bar 34 From heat exchanger to lubrication into Transmission
CONVERTER
67 WK 51 Before the Convertor - Opening Pressure 8.5 bar H
51 52 Behind the Convertor - Opening Pressure 5 bar
53 Clutch forward 16+2 bar KV B
55 Clutch reverse 16+2 bar KR F
H 56 Clutch 16+2 bar K1 D
TO THE RETARDER VALVE WSV 57 Clutch 16+2 bar K2 A
5.5 bar 66 52 58 Clutch 16+2 bar K3 C

60 Clutch 16+2 bar K4 E
29 63 Temp. 100 C behind the retarder (short time 150 C)
WGV 65 System pressure 16+2 K
66 Temp. 100 C behind the converter (short time 120 C)
BYPASS VALVE 67 WK-Control pressure 131 bar
ZF-FINE FILTER
32
WT (SCOPE OF SUPPLY CUSTOMER) 28
16 15
WITH RETARDER
RT-V
LEGEND:
FILLING POSITON IN THE CABIN TRANSMISSION PUMP = MAIN PRESSURE
63 = CONTROLLED MAIN PRESSURE
= PILOT PRESSURE
= CONVERTER INLET PRESSURE
WITHOUT RETARDER = CONVERTER EXIT PRESSURE
Fig. 5 - Oil Circulation Diagram for Typical Transmission with Lockup Clutch and Retarder
= LUBRICATION
= RETURN TO SUMP
COARSE FILTER
LUBRICATION
33 34
RT OIL SUMP
SM 1965 4-00
DRAWING
HORIZONTAL
CLICK HERE FOR
Section 120-0010
OPERATION
VTS-3 Shift Controller - Operation: The shift
EST-37 Automatic Shift Control controller has 3 positions the lever can rest in,
The EST-37 transmission is equipped with an Forward, Neutral and Reverse. Within each of these
electronic control unit (ECU) which continually positions, the gear can be changed by pushing the
monitors the transmission and shift system electrical lever to the right (+) to upshift or to the left (-) to
components and warns the operator when a problem downshift. In the Neutral position, this can be used to
develops. It also takes action to prevent damage to the preselect the starting gear (the default being 2nd
transmission, and provides the serviceman with gear).
diagnostic capabilities so that problems can be
corrected quickly and easily. The shift controller has a 'Function' button on the top
of the lever which is used to switch between automatic
When a fault occurs, a two digit error code will be and manual modes. Press the function button from
displayed on the LCD display on the dash panel. The 'NEUTRAL' and move the lever forward to select
error code is also recorded in the transmission ECU, automatic mode, when driving normal upshifting and
and can be accessed by the serviceman by plugging downshifting will occur. If required, a gear can be held
in a data reader to extract information relating to the in manual mode by pressing the function button once,
fault. The error code recorded in the ECU memory will to resume full automatic mode the function button
remain until it is erased by a technician. should be pressed again. Manual gears can also be
selected by pushing the lever to the left for lower gears
If a major fault is detected, it is the operators or to the right for higher gears, again by pressing the
responsibility to shut down the machine as soon as it function button once automatic mode will be resumed.
is safe to do so. The machine should not be restarted
until the fault has been diagnosed and corrected. Note: The transmission will only allow gearshifting
when the predetermined values have been reached.
Refer to 'EST-37 Trouble Shooting' table for a list of
fault codes and checks. Note: There is no shift inhibitor in the gear shift
control, therefore, no resistance would be felt while
The EST-37 transmission control has been designed moving through the gear ranges.
to provide the driver with maximum operational
flexibility by allowing the choice of automatic or manual The gear lever housing sends a signal to the electronic
gear selection to optimize vehicle performance under control unit, which in turn will only allow the engine to
all operating conditions. be started when the gear lever is in the 'NEUTRAL'
position. The gear shift lever must always be placed in
The transmission provides six forward gears, three 'NEUTRAL' and the parking brake applied when
reverse gears and a neutral position. The gear starting the engine, or whenever the machine is left
positions are indicated on the LCD display located on unattended.
the dash panel. The transmission will only operate in
the gear selected by the operator in the manual range, When shifting from 'NEUTRAL' to start from a
or, when the lever is in the automatic range, shifts will standstill, or to reverse direction, decelerate the engine
occur automatically between 1st and 6th gear, to idle speed before selecting the proper gear. When
depending on operating requirements. The reverse 'REVERSE' is selected, the 'Reverse Alarm' sounds
gears 1st through 3rd are manual mode only. and the 'Reverse Light' illuminates to warn personnel
to the rear of the machine that reverse gear has been
selected.
WARNING During reversing operations it is recommended to
Before any welding is done on a machine reduce engine speed, use only 1st or 2nd gear and
equipped with an EST-37 shift system, disconnect never exceed 10 km/h (6.2 mile/h).
battery earth cable, battery supply cable alternator
earth cables, alternator supply positive cables
and electrical connections at the ECU to avoid
damage to electrical components. Turn off battery
master switch to isolate the batteries before
disconnecting any components.
SM 1965 4-00 7
Section 120-0010
SM - 1828 SM - 2335
IDLE
S
T
O
FULL LOAD/
THROTTLE P
KICK/HOLD
DOWN 1 2 3
1 - Bars show gear ranges and full display (as

shown) indicates driving in automatic mode.
2 - Display shows actual driving direction.
3 - Display shows actual gear in use.
Fig. 6 - Accelerator Load Ranges and Kickdown Position Fig. 7 - Dashboard Display
The electronic control system distinguishes between A dashboard display is provided which indicates gear
the throttle position (or load ranges) depending on the selected and driving direction as follows (See Fig. 7):
governor position (injection pump). On a light throttle
opening, the transmission will give earlier upshifts and Manual Mode - When driving with shift selector in
later downshifts than when operating at full throttle. manual range, the bars only are shown in position 1,
and, driving direction and gear selected are indicated
A kickdown facility (See Fig. 6), which can be used in positions 2 and 3.
when automatic mode is selected, allows for the
possibility of selecting a lower gear by pressing down Automatic Mode - When driving with shift selector in
fully on the throttle pedal and holding. This can be automatic range, a full display of bars and arrows are
used to provide a downshift on demand provided that shown in position 1, and, driving direction and gear
the vehicle speed is within the range allowable. That selected are indicated in positions 2 and 3.
is, the vehicle is not travelling at a speed that would
result in the engine overspeeding in the lower gear. Under certain conditions the transmission may start to
When driving with kickdown, the transmission will give 'hunt' between gears when in automatic mode. The
earlier downshifts and later upshifts. To disengage the transmission changes up and down between two
transmission kickdown, release the throttle pedal and gears at short intervals because there is not sufficient
allow it to return to a light throttle position. power to sustain driving in the higher gear, but is
sufficient for upshifting from the lower gear. By using
When operating in automatic range with the display the shift display, it can be established which gears are
indicating that the transmission has downshifted to 2nd involved and in these circumstances the lower gear
gear, there are two options for providing a further should be selected using the shift control lever.
downshift as conditions indicate. Automatic mode should be reselected at the earliest
opportunity.
1. 1st gear can be manually selected by pushing the
shift lever to the left. During machine operation, watch for wide deviations
from normal readings on the transmission oil
2. Kickdown can be selected from 2nd automatic, temperature gauge. If the gauge shows the oil
when the transmission will downshift to 1st gear, temperature rising above the green zone during
depending upon vehicle speed. normal operation, or above the yellow zone during
retarder operation, the machine must be stopped and
When the kickdown is released the transmission will inspected for external oil leakage. If no leaks are
upshift to 2nd automatic, provided that the forward found, shift to 'NEUTRAL' and operate the engine at
speed has increased sufficiently to allow this to 1 200 - 1 500 rev/min. If the transmission oil
happen, and that the shift lever is in the automatic temperature does not decrease into the green zone
mode. within 2 or 3 minutes, the cause of the overheating
should be corrected before the machine is operated
further.
8 SM 1965 4-00
Section 120-0010
Note: In cold weather, the transmission oil should be
warmed up by running the engine at idle speed with WARNINGS
the gear selector in neutral, since the system will not
Never allow the machine to coast with the
operate satisfactorily if the oil is too cold.
transmission in 'NEUTRAL'.
When temporarily stopped, such as for yielding the When running down a gradient the engine
right-of-way to a loaded machine, the transmission can speed should not be allowed to drop below
be left in gear and the machine held stationary with the 1 200 rev/min, at which point, lockup would
service brakes. disengage preventing retarder operation.
In the event of a loss of electric power to the
When stopped for a more extended period with the
gear shift control, the transmission will
engine left running, shift to 'NEUTRAL' to avoid
automatically shift to 'NEUTRAL'. If this
unnecessary heat buildup, and apply the parking
occurs, stop the machine using the service
brake.
brakes and apply the parking brake. Do not
operate until the fault has been repaired.
Always select 'NEUTRAL' and apply the
WARNING
parking brake before leaving the operators
Always select the correct drive direction and seat.
gear before releasing the parking brake.
The retarder will automatically disengage when
the oil temperature reaches 150 C (302 F),
unless an engine overspeed condition exists.
Display during operation

Symbol Meaning Remarks
1F, 1R Actual gear and direction. Left digit shows
2F, 2R actual gear, right digit shows actual
3F, 3R direction
4F
5F
6F
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing only 6WG:
direction F or R selected while turbine
speed is too high, CAUTION gear will
engage if turbine speed drops
NN not neutral, waiting for neutral after go engage a gear, first move shift
power up or a severe fault selector to neutral position and again
to F or R position
** oil temperature too low, no gear available warm up engine / transmission
*N oil temperature low, only one gear available warm up engine / transmission
1 bar (special symbol) manual mode 1. gear
2 bars manual mode 2. gear
4 bars and 2 arrows automatic mode
bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed
above a certain limit and lockup clutch
not activated
spanner at least one fault active select neutral to get fault code displayed
fault code see faultcode list
SM 1965 4-00 9
Section 120-0010
Display during operation - Continued

WS warning sump temperature changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WR warning retarder temperature changes between actual gear/direction
WT warning torque converter temperature changes between actual gear/direction
WE warning high engine speed changes between actual gear/direction
PN direction F or R selected while parking transmission in neutral until parking
brake engaged brake is released CAUTION: vehicle
starts to move after release of parking
brake
F or R flashing direction F or R selected while turbine
speed is to high, CAUTION gear will
engage if turbine speed drops
EE flashing no communication with display checked wiring from TCU to display
The AEB-Starter is a tool to start the AEB (automatic filling parameter adjustment) of ergopower transmissions
with ease. Connect AEB-Starter to plug X25 located below dash adjacent to TCU.
Display during AEB-Mode

PL AEB - Starter is plugged at the diagnostic
plug
ST AEB-Starter-button is pressed
K1..K4,KV,KR calibrating clutch K1..K4,KV,KR
_ and Kx wait for start, initialization of clutch Kx,
x: 1, 2, 3, 4, V, R
and Kx fast fill time determination of clutch Kx
= and Kx compensating pressure determination of
clutch Kx
OK calibration for all clutches finished Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
after removing AEB-Starter
STOP AEB cancelled (activation stopped) Transmission stays in neutral, you
STOP and Kx AEB stopped, clutch Kx cant be calibrated Transmission stays in neutral, you
Spanner and Kx Kx couldnt be calibrated, AEB finished Transmission stays in neutral, you
E engine speed too low, -> raise engine
speed
E engine speed too high, -> lower engine
speed
T transmission oil temperature too low,
-> heat up transmission
10 SM 1965 4-00
Section 120-0010
Display during AEB-Mode - Continued

T transmission oil temperature too high
-> cool down transmission
FT transmission temperature not in defined Transmission stays in neutral, you
range during calibration have to restart the TCU (ignition off/on)
FB operating mode not NORMAL or Transmission stays in neutral, you
transmission temperature sensor defective have to restart the TCU (ignition off/on)
or storing of Calibrated values to
EEPROM-has failed.
FO Outputspeed_not_zero Transmission stays in neutral, you
FN Shift lever not in Neutral position Transmission stays in neutral, you
FP Parkbrake_not_applied Transmission stays in neutral, you
STOP AEB - Starter was used incorrect or is Transmission stays in neutral, you
defective have to restart the TCU (ignition off/on)
TABLE OF FAULT CODES

Fault MEANING OF CODE TCU reaction Checks Remarks
Code possible reason for fault detection
(hex)
11 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to check cables from TCU to Failure cannot be
TCU detected a wrong signal combination for the neutral shift lever detected in systems
gear range OP-Mode: transmission check signal combinations with DW2/DW3 shift
cable from shift lever to TCU is broken shutdown of shift lever positions for lever
cable is defective and is contacted to battery voltage gear range
or vehicle ground
shift lever is defective
12 LOGICAL ERROR AT DIRECTION SELECT SIGNAL TCU shifts transmission to check cables from TCU to
TCU detected a wrong signal combination for the neutral shift lever
direction OP-Mode: transmission check signal combinations
cable from shift lever to TCU is broken shutdown of shift lever positions
cable is defective and is contacted to battery voltage F-N-R
or vehicle ground
shift lever is defective
23 S.C. TO BATTERY VOLTAGE AT LOAD SENSOR INPUT retarder function is affected check cable from TCU to Availability of retarder
the measured voltage is too high: TCU uses default load sensor depends on default load
cable is defective and is contacted to battery voltage OP-Mode: normal check connectors
load sensor has an internal defect check load sensor sensor
connector pin is contacted to battery voltage check assembly tolerances
of load sensor
24 S.C. TO GROUND OR O.C. AT LOAD SENSOR INPUT retarder function is affected check cable from TCU to Availability of retarder
the measured voltage is too low: TCU uses default load sensor depends on default load
cable is defective and is contacted to vehicle ground OP-Mode: normal check connectors
cable has no connection to TCU check load sensor sensor
load sensor has an internal defect check assembly tolerances
connector pin is contacted to vehicle ground or is of load sensor
broken
25 S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION SUMP no reaction, check cable from TCU to
TEMPERATURE SENSOR INPUT TCU uses default temp. sensor
the measured voltage is too high: OP-Mode: normal check connectors
cable is defective and is contacted to battery voltage check temperature sensor
cable has no connection to TCU
temperature sensor has an internal defect
connector pin is contacted to battery voltage or is
broken
SM 1965 4-00 11
Section 120-0010

(hex)
26 S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE SENSOR no reaction, check cable from TCU to
INPUT TCU uses default temp. sensor
the measured voltage is too low: OP-Mode: normal check connectors
cable is defective and is contacted to vehicle ground check temperature sensor
connector pin is contacted to vehicle ground
27 S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER no reaction, check cable from TCU to
TEMPERATURE SENSOR INPUT TCU uses default temp. sensor
the measured voltage is too high: OP-Mode: normal check connectors
cable is defective and is contacted to battery voltage check temperature sensor
connector pin is contacted to battery voltage or is
broken
28 S.C. TO GROUND AT RETARDER TEMPERATURE SENSOR INPUT no reaction, check cable from TCU to
the measured voltage is too low: TCU uses default temp. sensor
cable is defective and is contacted to vehicle ground OP-Mode: normal check connectors
temperature sensor has an internal defect check temperature sensor
connector pin is contacted to vehicle ground
31 S.C. TO BATTERY VOLTAGE OR O.C. AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage higher than 7.00 V at speed control sensor
input pin check connectors
cable is defective and is contacted to battery voltage check speed sensor
speed sensor has an internal defect
connector pin is contacted to battery voltage or has
no contact
32 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed input control sensor
pin check connectors
cable/connector is defective and is contacted to check speed sensor
vehicle ground
33 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a engine speed over a threshold and the control sensor power up to TCU
next moment the measured speed is zero check connectors
cable / connector is defective and has bad contact check speed sensor
speed sensor has an internal defect check sensor gap
sensor gap has the wrong size
34 S.C. TO BATTERY VOLTAGE OR O.C. AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
input pin if a failure is existing at check connectors
cable is defective and is contacted to battery voltage output speed, check speed sensor
cable has no connection to TCU TCU shifts to neutral
speed sensor has an internal defect OP-Mode: limp home
no contact
35 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed control sensor
input pin if a failure is existing at check connectors
cable / connector is defective and is contacted to output speed, check speed sensor
vehicle ground TCU shifts to neutral
speed sensor has an internal defect OP-Mode: limp home
36 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a turbine speed over a threshold and control sensor power up of TCU
at the next moment the measured speed is zero if a failure is existing at check connectors
cable / connector is defective and has bad contact output speed, check speed sensor
speed sensor has an internal defect TCU shifts to neutral check sensor gap
sensor gap has the wrong size OP-Mode: limp home
12 SM 1965 4-00
Section 120-0010

(hex)
37 S.C. TO BATTERY VOLTAGE OR O.C. AT INTERNAL SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
input pin check connectors
cable is defective and is contacted to battery voltage check speed sensor
no contact
38 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed input control sensor
pin check connectors
cable / connector is defective and is contacted to check speed sensor
vehicle ground
39 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a internal speed over a threshold and at control sensor power up of TCU
the next moment the measured speed is zero check connectors
cable / connector is defective and has bad contact check speed sensor
speed sensor has an internal defect check sensor gap
sensor gap has the wrong size
3A S.C. TO BATTERY VOLTAGE OR O.C. AT OUTPUT SPEED INPUT special mode for gear check cable from TCU to
TCU measures a voltage higher than 12.5 V at speed selection sensor
input pin OP-Mode: substitute clutch check connectors
cable is defective and is contacted to battery voltage control check speed sensor
cable has no connection to TCU if a failure is existing at
speed sensor has an internal defect turbine speed,
connector pin is contacted to battery voltage or has TCU shifts to neutral
no contact OP-Mode: limp home
3B S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear check cable from TCU to
TCU measures a voltage less than 1.00V at speed input selection sensor
pin OP-Mode: substitute clutch check connectors
cable / connector is defective and is contacted to control check speed sensor
vehicle ground if a failure is existing at
turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3C LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear check cable from TCU to This fault is reset after
TCU measures a output speed over a threshold and at selection sensor power up of TCU
the next moment the measured speed is zero OP-Mode: substitute clutch check connectors
cable / connector is defective and has bad contact control check speed sensor
speed sensor has an internal defect if a failure is existing at check sensor gap
sensor gap has the wrong size turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3E OUTPUT SPEED ZERO DOESNT FIT TO OTHER SPEED SIGNALS special mode for gear check sensor signal of This fault is reset after
if transmission is not neutral and the shifting has selection output speed sensor power up of TCU
finished, OP-Mode: substitute clutch check sensor gap of output
TCU measures outputspeed zero and turbine speed or control speed sensor
internal speed not equal to zero. if a failure is existing at check cable from TCU to
speed sensor has an internal defect turbine speed, sensor
sensor gap has the wrong size TCU shifts to neutral
OP-Mode: limp home
56 ENGINE CONF TIMEOUT OP-Mode: substitute clutch check engine controller
Timeout of CAN-message ENGINE CONF from engine control check wire of CAN-Bus
controller check cable to engine
interference on CAN-Bus controller
CAN wire/connector is broken
CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
SM 1965 4-00 13
Section 120-0010

(hex)
57 EEC1 TIMEOUT OP-Mode: substitute clutch check EEC controller
Timeout of CAN-message EEC1 from EEC controller control check wire of CAN-Bus
interference on CAN-Bus check cable to EEC
CAN wire/connector is broken controller
58 EEC3 TIMEOUT OP-Mode: substitute clutch check EEC controller
Timeout of CAN-message EEC3 from EEC controller control check wire of CAN-Bus
interference on CAN-Bus check cable to EEC
CAN wire/connector is broken controller
65 ENGINGE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for engine torque is defective control check wire of CAN-Bus
engine controller is defective check cable to engine
66 KICKDOWN SIGNAL no reaction check engine controller
CAN signal for kickdown is defective check wire of CAN-Bus
69 REFERENCE ENGINE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for reference of engine torque is defective control check wire of CAN-Bus
6A ACTUAL ENGINE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for actual engine torque is defective control check wire of CAN-Bus
6B NOM FRICTION TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for nominal friction torque is defective control check wire of CAN-Bus
6E EEC2 TIMEOUT no reaction check EEC controller
Timeout of CAN-message EEC2 from EEC controller TCU uses default signal check wire of CAN-Bus
interference on CAN-Bus accelerator pedal in idle check cable to EEC
CAN wire/connector is broken position controller
CAN wire/connector is defective and has contact to OP-Mode: normal
6F ACCELERATOR LOW IDLE SWITCH SIGNAL no reaction check EEC controller if this signal is not
CAN signal for manual downshift is defective TCU uses default signal check wire of CAN-Bus transmitted via CAN,
EEC controller is defective accelerator pedal in idle check cable to EEC TCU uses default
interference on CAN-Bus position controller signal
OP-Mode: normal
71 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 TCU shifts to neutral check cable from TCU to 1)
see figure 8
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K1 valve is too high. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending TCU to gearbox
battery voltage TCU shifts to neutral check regulator resistance 1)
cable / connector is defective and has contact to OP-Mode: TCU shutdown check internal wire
another regulator output of the TCU harness of the gearbox
regulator has an internal defect
72 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral check cable from TCU to 1)
see figure 8
limit, the voltage at K1 valve is too low. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
vehicle ground TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
14 SM 1965 4-00
Section 120-0010

(hex)
73 O.C. AT CLUTCHK1 TCU shifts to neutral check cable from TCU to 1)
see figure 8
limit. if failure at another check connectors from
cable / connector is defective and has no contact to clutch is pending gearbox to TCU
TCU TCU shifts to neutral check regulator resistance 1)
see figure 8
see figure 8
see figure 8
see figure 8
see figure 8
see figure 8
see figure 8
SM 1965 4-00 15
Section 120-0010

(hex)
see figure 8
83 O.C. AT CLUTCH K4 TCU shifts to neutral check cable from TCU to 1)
see figure 8
84 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral check cable from TCU to 1)
see figure 8
limit, the voltage at KV valve is too high. if failure at another check connectors from
85 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral check cable from TCU to 1)
see figure 8
limit, the voltage at KV valve is too low. if failure at another check connectors from
86 O.C. AT CLUTCH KV TCU shifts to neutral check cable from TCU to 1)
see figure 8
87 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral check cable from TCU to 1)
see figure 8
limit, the voltage at KR valve is too high. if failure at another check connectors from
88 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral check cable from TCU to 1)
see figure 8
limit, the voltage at KR valve is too low. if failure at another check connectors from
89 O.C. AT CLUTCH KR TCU shifts to neutral check cable from TCU to 1)
see figure 8
16 SM 1965 4-00
Section 120-0010

(hex)
91 S.C. TO GROUND AT RELAY REVERSE WARNING ALARM backup alarm will be on check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that until TCU power down backup alarm device
looks like a s.c. to vehicle ground even if fault vanishes check connectors from
cable is defective and is contacted to vehicle ground (loose connection) backup alarm device to
backup alarm device has an internal defect OP-Mode: normal TCU
connector pin is contacted to vehicle ground check resistance 1) of
backup alarm device
92 S.C. TO BATTERY VOLTAGE AT RELAY REVERSE WARNING ALARM no reaction check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal backup alarm device
looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery voltage backup alarm device to
backup alarm device has an internal defect TCU
connector pin is contacted to battery voltage check resistance 1) of
backup alarm device
93 O.C. AT RELAY REVERSE WARNING ALARM no reaction check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal backup alarm device
looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU backup alarm device to
backup alarm device has an internal defect TCU
connector has no connection to TCU check resistance 1) of
backup alarm device
9A S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH no reaction check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal converter clutch solenoid
looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle ground converter clutch solenoid
converter clutch solenoid has an internal defect to TCU
connector pin is contacted to vehicle ground check resistance 1) of
converter clutch solenoid
9B O.C. AT CONVERTER LOCK UP CLUTCH converter clutch always check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that open, retarder not converter clutch solenoid
looks like a o.c. for this output pin available check connectors from
cable is defective and has no connection to TCU OP-Mode: normal converter clutch solenoid
connector has no connection to TCU check resistance 1) of
9C S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP CLUTCH no reaction check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal converter clutch solenoid
cable is defective and is contacted to battery voltage converter clutch solenoid
connector pin is contacted to battery voltage check resistance 1) of
9D S.C. TO GROUND AT RETARDER no reaction check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal retarder solenoid
cable is defective and is contacted to vehicle ground retarder solenoid to TCU
retarder solenoid has an internal defect check resistance 1) of
connector pin is contacted to vehicle ground retarder solenoid
9E O.C. AT RETARDER no reaction check cable from TCU to 1)
see figure 8
cable is defective and has no connection to TCU retarder solenoid to TCU
connector has no connection to TCU retarder solenoid
9F S.C. TO BATTERY VOLTAGE AT RETARDER SOLENOID no reaction check cable from TCU to 1)
see figure 8
cable is defective and is contacted to battery voltage retarder solenoid to TCU
connector pin is contacted to battery voltage retarder solenoid
SM 1965 4-00 17
Section 120-0010

(hex)
A1 S.C. TO GROUND AT DIFFLOCK SOLENOID no reaction check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal difflock solenoid
cable is defective and is contacted to vehicle ground difflock solenoid to TCU
difflock solenoid has an internal defect check resistance 1) of
connector pin is contacted to vehicle ground difflock solenoid
A2 S.C. TO BATTERY VOLTAGE AT DIFFLOCK SOLENOID no reaction check cable from TCU to 1)
see figure 8
cable is defective and is contacted to battery voltage difflock solenoid to TCU
connector pin is contacted to battery voltage difflock solenoid
A3 O.C. AT DIFFLOCK SOLENOID no reaction check cable from TCU to 1)
see figure 8
cable is defective and has no connection to TCU difflock solenoid to TCU
connector has no connection to TCU difflock solenoid
A4 S.C. TO GROUND AT WARNING SIGNAL OUTPUT no reaction check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal warning device
cable is defective and is contacted to vehicle ground warning device to TCU
warning device has an internal defect check resistance 1) of
connector pin is contacted to vehicle ground warning device
A5 O.C. AT WARNING SIGNAL OUTPUT no reaction check cable from TCU to 1)
see figure 8
cable is defective and has no connection to TCU warning device to TCU
connector has no connection to TCU warning device
A6 S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT no reaction check cable from TCU to 1)
see figure 8
cable is defective and is contacted to battery voltage warning device to TCU
connector pin is contacted to battery voltage warning device
B1 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral check pressure at clutch K1
TCU calculates a differential speed at closed clutch K1. OP-Mode: limp home check main press. in system
If this calculated value is out of range, TCU interprets if failure at another check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
low pressure at clutch K1 TCU shifts to neutral check sensor gap at output
low main pressure OP-Mode: TCU shutdown speed sensor
wrong signal at internal speed sensor check signal at internal
wrong signal at output speed sensor speed sensor
wrong size of the sensor gap check signal at output
clutch is defective speed sensor
replace clutch
replace clutch
18 SM 1965 4-00
Section 120-0010

(hex)
replace clutch
low pressure at clutch K4 TCU shifts to neutral check sensor gap at turbine
wrong signal at turbine speed sensor speed sensor
wrong size of the sensor gap check signal at turbine
replace clutch
B5 SLIPPAGE AT CLUTCH KV TCU shifts to neutral check pressure at clutch KV
TCU calculates a differential speed at closed clutch KV. OP-Mode: limp home check main press. in system
low pressure at clutch KV TCU shifts to neutral check sensor gap at turbine
replace clutch
B6 SLIPPAGE AT CLUTCH KR TCU shifts to neutral check pressure at clutch KR
TCU calculates a differential speed at closed clutch KR. OP-Mode: limp home check main press. in system
low pressure at clutch KR TCU shifts to neutral check sensor gap at turbine
replace clutch
B7 OVERTEMP SUMP no reaction cool down machine
TCU measured a temperature in the oil sump that is OP-Mode: normal check oil level
TCU measured a temperature in the oil sump that is OP-Mode: normal check oil level
over the allowed threshold. check temperature sensor
B8 OVERTEMP RETARDER TCU disables retarder cool down machine
TCU measured a temperature in the retarder oil that is OP-Mode: normal check oil level
over the allowed threshold. check temperature sensor
B9 OVERSPEED ENGINE retarder applies - not used
OP-Mode: normal
BA DIFFERENTIAL PRESSURE OIL FILTER no reaction check oil filter
TCU measured a voltage at differential pressure switch OP-Mode: normal check wiring from TCU to
out of the allowed range. differential pressure switch
oil filter is polluted check differential pressure
cable/connector is broken or cable/connector is switch (measure resistance)
contacted to battery voltage or vehicle ground
differential pressure switch is defective
SM 1965 4-00 19
Section 120-0010

(hex)
BB SLIPPAGE AT CONVERTER LOCKUP CLUTCH check pressure at
TCU calculates a differential speed at closed converter converter lockup clutch
lockup clutch. If this calculated value is out of range, check main pressure in the
TCU interprets this as slipping clutch. system
low pressure at converter lockup clutch check sensor gap at engine
low main pressure speed sensor
wrong signal at engine speed sensor check sensor gap at turbine
wrong size of the sensor gap check signal at engine
check signal at turbine
speed sensor
replace clutch
BD S.C. TO GROUND AT ENGINE BRAKE SOLENOID no reaction check cable from TCU to 1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-mode: normal engine brake solenoid
cable is defective and is contacted to vehicle ground engine brake solenoid
engine brake solenoid has an internal defect to TCU
connector pin is contacted to vehicle ground check the resistance 1) of
engine brake solenoid
BE S.C. TO BATTERY VOLTAGE AT ENGINE BRAKE no reaction check cable from TCU to 1)
see figure 8
cable is defective and is contacted to battery voltage engine brake solenoid
connector pin is contacted to battery voltage check the resistance 1) of
BF O.C. AT ENGINE BRAKE no reaction check cable from TCU to 1)
see figure 8
cable is defective and has no connection to TCU engine brake solenoid
connector has no connection to TCU check the resistance 1) of
D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 check cables and fault codes no. 21
TCU measures more than 6V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
check power supply at
pin AU1 (should be
approx. 5V)
D2 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS see fault codes no. 21 check cables and fault codes no. 21
TCU measures less than 4V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
check power supply at
pin AU1 (should be
approx. 5V)
D3 LOW POWER AT BATTERY shift to neutral check power supply
measured voltage at power supply is lower OP-Mode: TCU shutdown battery
than 18 V check cables from
batteries to TCU
check connectors from
batteries to TCU
D4 HIGH POWER AT BATTERY shift to neutral check power supply
measured voltage at power supply is higher OP-Mode: TCU shutdown battery
than 32.5 V check cables from
batteries to TCU
check connectors from
batteries to TCU
20 SM 1965 4-00
Section 120-0010

(hex)
D5 ERROR AT SWITCH 1 FOR VALVE POWER SUPPLY VPS1 shift to neutral check fuse
TCU switched on VPS1 and measured VPS1 is off or OP-Mode: TCU shutdown check cables from
TCU switched off VPS1 and measured VPS1 is still on gearbox to TCU
cable or connectors are defect and are contacted to check connectors from
battery voltage gearbox to TCU
cable or connectors are defect and are contacted to replace TCU
vehicle ground
permanent power supply KL30 missing
TCU has an internal defect
D6 ERROR AT SWITCH 2 FOR VALVE POWER SUPPLY VPS2 shift to neutral check fuse
TCU switched on VPS2 and measured VPS2 is off or OP-Mode: TCU shutdown check cables from
TCU switched off VPS2 and measured VPS2 is still on gearbox to TCU
cable or connectors are defect and are contacted to check connectors from
battery voltage gearbox to TCU
cable or connectors are defect and are contacted to replace TCU
vehicle ground
permanent power supply KL30 missing
TCU has an internal defect
E3 S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT no reaction check cable from TCU
TCU sends data to the display and measures always a OP-Mode: normal to the display
high voltage level on the connector. check connectors at
cable or connectors are defect and are contacted to the display
battery voltage change display
display has an internal defect
E4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction check cable from TCU
TCU sends data to the display and measures always a OP-Mode: normal to the display
high voltage level on the connector. check connectors at
cable or connectors are defect and are contacted to the display
vehicle ground change display
display has an internal defect
F1 GENERAL EEPROM FAULT no reaction replace TCU often shown
TCU cannot read non volatile memory OP-Mode: normal together with fault
TCU is defective code F2
F3 APPLICATION ERROR transmission stay neutral replace TCU fault occurs only if
something of this application is wrong OP-Mode: TCU shutdown a test engineer did
something wrong in
the application of
the vehicle
F5 CLUTCH FAILURE transmission stay neutral check clutch TCU shows also the
AEB was not able to adjust clutch filling parameters OP-Mode: TCU shutdown affected clutch on
One of the AEB-Values is out of limit the Display
F6 CLUTCH ADJUSTMENT DATA LOST TCU shifts to neutral execute AEB
TCU was not able to read correct clutch adjustment OP-Mode: limp home
parameters
interference during saving data on non volatile
memory
TCU is brand new or from another vehicle
SM 1965 4-00 21
Section 120-0010
8.1 Actuator:
1
2
G
open circuit: R12 R1G R2G

short cut to ground: R12 R; R1G 0, R2G R or R1G R, R2G 0 (for s.c. to ground, G is connected to
vehicle ground)
short cut to battery: R12 R; R1G 0, R2G R or R1G R, R2G 0 (for s.c. to battery, G is connected to
battery voltage)
8.2 Cable: UBat
P (power supply)
TCU
1 2 Actuator / Sensor
C (chassis)
Gnd
open circuit: R12 R1P R1C R2P R2C

short cut to ground: R12 0; R1C R2C 0, R1P R2P
short cut to battery: R12 0, R1C R2C , R1P R2P 0
Fig. 8 - Measuring Resistance at Actuator/Sensors and Cable
REMOVAL 3. Place a suitable container under the transmission

drain port, remove drain plug and drain oil. After
draining, reinstall drain plug and tighten securely.
Note: If anti-spill drain plug is fitted, remove cap from
WARNING connection, install drain tube connection and drain oil
into a suitable container.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 4. Open drain cocks on air tanks and drain all air from
secured and of adequate capacity to do the job the system. Close drain cocks securely after draining.
safely.
5. Remove drain plug from remote drain cock on the
Note: Tag all lines, cables and linkages disconnected hydraulic tank and drain hydraulic oil into a suitable
during removal to aid in installation. container. Close drain cock and reinstall drain plug.
Refer to Section 230-0040, HYDRAULIC TANK.
parking brake and switch off the engine. 6. Disconnect transmission harness at the cab floor
and earth strap between rear LH side of the
transmission and the frame.
2. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in
the 'Off' position. Disconnect battery cables from 7. Remove cab from the machine. Refer to
terminal posts (ground cable first). Section 260-0010, CAB AND MOUNTING.
22 SM 1965 4-00
Section 120-0010
SM - 2480
11
12 13 7
5
8
12 12 6
10 10 1
9
2 14
9
3
15 1
4
14
16
1 - Adaptor 5 - Elbow 9 - Dust Cap 13 - Tee Piece

2 - Hose Assembly 6 - Tube Assembly 10 - Adaptor 14 - Diagnostic Nipple
3 - Hose Assembly 7 - Tube Assembly 11 - Elbow 15 - Oil Filter Head
4 - Elbow 8 - Tube Assembly 12 - Adaptor 16 - Filter Cartridge
Fig. 9 - Transmission Oil Lines
8. Disconnect all drivelines connected to the 13. Disconnect air line from transmission retarder port
transmission and secure clear of the transmission. fitting. Cap line end and fitting to prevent entry of dirt.
Refer to Section 130-0010, FRONT & REAR
DRIVELINES. 14. Identify and tag oil filter hose assemblies
(2 & 3, Fig. 9) to aid in installation. Disconnect hose
9. Identify and tag hydraulic lines at the main hydraulic assemblies (2 & 3, Fig. 9) and cap open ends and
pump to aid in installation. Disconnect hydraulic lines adaptors (1, Fig. 9) and elbow (4, Fig. 9) to prevent
and cap lines and ports to prevent entry of dirt. entry of dirt.
10. Remove main hydraulic pump from transmission 15. Identify and tag diagnostic hose assemblies
PTO. Refer to Section 230-0050, MAIN HYDRAULIC (6, 7 & 8, Fig. 9) to aid in installation. Disconnect tube
PUMP. assemblies (6, 7 & 8, Fig. 9) and cap open ends and
elbow (5, Fig. 9), adaptor (12, Fig. 9) and tee piece
11. Identify and tag oil cooler lines at the transmission (13, Fig. 9) to prevent entry of dirt.
retarder to aid in installation. Disconnect both lines and
cap lines and ports to prevent entry of dirt. Refer to 16. Remove mounting hardware securing body control
Section 210-0060, TRANSMISSION OIL COOLER. valve bracket to the RH frame rail and ease bracket
towards the wheel to allow clearance for transmission
12. Identify and tag air lines connected to retarder removal.
solenoid, differential lock solenoid and pressure
reducing valve mounted on front bracket assembly (1).
SM 1965 4-00 23
Section 120-0010
17. Remove locknut (20), bolt (18), washer (19) and (7) from the transmission. Remove isolation mount (8)
clamp (17) securing dipstick tube (15) assembly to from LH bracket (7) and replace if required.
bracket (16). Remove screws (23), dipstick tube (15)
assembly and gasket (24) from the transmission. 4. Remove bolts (10), lockwashers (9) and RH bracket
(13) from the transmission. Remove isolation mount
18. Disconnect all clips securing lines and cables to (8) from RH bracket (13) and replace if required.
the transmission which are not removed with the
transmission assembly. 5. If required, identify and tag electrical connections to
engine speed sensor, output speed sensor, central
19. Attach suitable lifting equipment to transmission gear train sensor and turbine speed sensor (5, 6, 7 &
lifting eyes and raise lifting equipment to take up the 8, Fig. 2) and remove sensors from the transmission.
slack.
6. If required, identify and tag electrical connections to
20. Remove locknut (5), hardened washer (14), bolt oil temperature sender (gauge) (9, Fig. 2) and retarder
(6) and snubbing washer (3) securing LH bracket (7) oil temperature sender (1, Fig. 2) and remove from the
to frame mounts. top of the transmission.
21. Remove locknut (5), hardened washer (14), bolt 7. Refer to transmission manufacturers service
(6) and snubbing washer (3) securing RH bracket (13) manual if transmission service or repair is required.
to frame mounts.
22. Remove locknuts (5), washers (4), snubbing INSPECTION

washers (3) and bolts (6) securing front bracket Numbers in parentheses refer to Fig. 1.
assembly (1) to frame mounts.
1. Check front bracket assembly (1), LH bracket (7),
23. Check to make certain that all necessary line and RH bracket (13) and frame mounting brackets for
cable disconnections have been made before lifting cracks and damage. Repair or replace as required.
the transmission.
2. Check general condition of transmission assembly
24. Carefully raise the transmission ensuring that no for wear and damage. Check for worn or damaged
lines, cables or components foul during removal. driveline flanges and excessive wear on mounting
When the transmission is clear of the frame assembly, holes.
move to a suitable work area and mount securely on a
work stand. 3. Check condition of all electrical harnesses and
connections and repair/replace as required. Check
25. Remove front isolation mounts (2) from frame condition of all hydraulic lines on the transmission and
mounts and replace if required. replace if damaged.
DISASSEMBLY ASSEMBLY
1. Remove mounting hardware securing retarder Note: Tighten all fasteners without special torques
solenoid, differential lock solenoid and pressure specified to standard torques listed in Section
reducing valve to front bracket assembly (1). Remove 300-0080, STANDARD BOLT AND NUT TORQUE
items from front bracket assembly (1). SPECIFICATIONS.
2. Remove bolts (12), lockwashers (11) and front 1. If removed, install oil temperature sender (gauge)
bracket assembly (1) from the transmission. (9, Fig. 2) and retarder oil temperature sender
(9, Fig. 2) in top of the transmission. Tighten electrical
3. Remove bolts (10), lockwashers (9) and LH bracket connection securely.
24 SM 1965 4-00
Section 120-0010
2. If removed, install engine speed sensor, output 2. Lubricate rear isolation mounts (8) with water or a
speed sensor, central gear train sensor and turbine suitable rubber lubricant and install in brackets
speed sensor (5, 6, 7 & 8, Fig. 2) in the transmission (7 & 13), with spigots to the underside of the brackets.
as shown in Fig. 2. Tighten electrical connections
securely. 3. Attach suitable lifting equipment to transmission
lifting eyes and carefully position the transmission
3. Apply Loctite Activator 'T' and Loctite 638 to bolts assembly in the frame. Take care to avoid snagging
(10). Secure LH bracket (7) and RH bracket (13) to the any lines, harnesses or components attached to the
transmission with bolts (10) and lockwashers (9). transmission.
4. Secure rear mounting brackets (7 & 13) to frame
4. Secure front bracket assembly (1) to the mounts with bolts (6), snubbing washers (3), hardened
transmission with bolts (12) and lockwashers (11). washers (14) and locknuts (5), as shown in Fig. 1.
Tighten bolts (12) to a torque of 225 Nm (166 lbf ft). Tighten bolts (6) to a torque of 265 Nm (195 lbf ft).
5. Secure retarder solenoid, differential lock solenoid 5. Secure front bracket assembly (1) to frame
and pressure reducing valve to front bracket mounts with bolts (6), snubbing washers (3), washers
assembly (1) with mounting hardware removed during (4) and locknuts (5), as shown in Fig. 1. Tighten bolts
disassembly. (6) to a torque of 300 Nm (220 lbf ft).
6. Remove lifting equipment from transmission lifting

INSTALLATION eyes.
otherwise specified. 7. Install new gasket (24) on dipstick tube (15)
assembly and secure assembly to the transmission
Note: Tighten all fasteners without special torques with screws (23). Secure dipstick tube (15) to
specified to standard torques listed in Section bracket (16) with bolt (18), washer (19), clamp (17)
300-0080, STANDARD BOLT AND NUT TORQUE and locknut (20).
SPECIFICATIONS.
8. Secure body control valve mounting bracket to the
Note: Tighten all hydraulic lines fitted with ORFS RH frame rail with mounting hardware removed during
connections, as described in Section 250-0000, removal.
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
where used. 9. Remove blanking cap from tube assembly
(8, Fig. 9) and adaptor (12, Fig. 9) and connect tube
assembly to the adaptor.
WARNING
To prevent personal injury and property 10. Remove blanking cap from tube assembly
damage, be sure wheel blocks, blocking (7, Fig. 9) and tee piece (13, Fig. 9) and connect tube
materials and lifting equipment are properly assembly to the tee piece.
secured and of adequate capacity to do the job
safely. 11. Remove blanking cap from tube assembly
(6, Fig. 9) and elbow (5, Fig. 9) and connect tube
Note: Isolation mounts (2 & 8) are colour coded to aid assembly to the elbow.
in installation. Front isolation mounts (2) are green and
white whereas rear isolation mounts (8) are blue and 12. Remove blanking caps from hose assemblies
white. (2 & 3, Fig. 9), elbow (4, Fig. 9) and adaptors (1, Fig. 9)
and connect hose assemblies to the elbow and adaptors.
1. Lubricate front isolation mounts (2) with water or a
suitable rubber lubricant and install in front frame 13. Remove blanking cap from retarder air line and
mounts, with spigots to the underside of the mounts. retarder port fitting and connect air line to the fitting.
SM 1965 4-00 25
Section 120-0010
14. Remove blanking caps and connect air lines to 27. Check for correct operation of the transmission,
retarder solenoid, differential lock solenoid and shift selector and warning lights.
pressure reducing valve mounted on front bracket
assembly (1), as identified at removal.
MAINTENANCE
15. Remove blanking caps from transmission oil cooler
lines and retarder ports and connect oil cooler lines. Periodic Inspections
Refer to Section 210-0060, TRANSMISSION OIL For easier inspection, the transmission should be kept
COOLER. clean. Make periodic checks for loose mounting bolts
and leaking air and oil lines. Check the condition of
16. Install main hydraulic pump on transmission PTO electrical harnesses and connections regularly.
and secure with mounting hardware removed during
removal. Refer to Section 230-0050, MAIN Transmission breather (10, Fig. 2) should be checked
HYDRAULIC PUMP. on a regular basis, and as frequently as necessary,
depending on operating conditions. A badly corroded
17. Remove blanking caps and connect hydraulic lines or plugged breather restricts proper breathing and
to the main hydraulic pump, as identified at removal. causes a buildup of condensation and subsequent oil
deterioration.
18. Connect all drivelines to the transmission and
secure with mounting hardware removed during
removal. Refer to Section 130-0010, FRONT & REAR Oil Level Check
DRIVELINES.
19. Prior to installing the cab, ensure that all connections WARNING
to the transmission, other than cab connections, are When checking the oil level, be sure that the
connected securely and properly clipped. parking brake is applied and all road wheels
are securely blocked.
20. Install the cab assembly on the front frame. Refer
to Section 260-0010, CAB AND MOUNTING. Check the transmission oil level and add oil if low,
every 10 hours/daily. Use only oil specified in
21. Connect transmission harness at the cab floor and Section 300-0020, LUBRICATION SYSTEM.
earth strap between LH side of the transmission and
the frame. Because the transmission oil cools, lubricates and
transmits hydraulic power it is important that the
22. Fill hydraulic tank with hydraulic oil specified in proper oil level be maintained at all times. If the oil
Section 300-0020, LUBRICATION SYSTEM. Refer to level is too low, the converter and clutches will not
Section 230-0040, HYDRAULIC TANK for fill level and receive an adequate supply of oil. If the oil level is too
procedure. high, the oil will aerate and the transmission will
overheat. It is absolutely necessary that the oil put into
23. Fill transmission with engine oil specified in the transmission is clean.
Section 300-0020, LUBRICATION SYSTEM. Check
the oil level as described under 'Oil Level Check'. Cold Oil Level Check
This check is made only to determine if the
24. Connect battery cables to battery terminal posts transmission contains sufficient oil for safe starting.
(ground cable last). Make sure there is some oil showing on dipstick
(25, Fig. 1).
25. Turn the battery master switch to the 'On' position,
start the engine and make an operational check of all Hot Oil Level Check
lines and electrical connections disconnected during 1. Position the vehicle on a level work area, apply the
removal. Check for leaks and tighten lines and fittings parking brake and block all road wheels securely.
as required.
2. With the transmission in neutral and the engine
26. Ensure parking brake is applied, disconnect running, allow the machine to idle until normal
steering lock bar and secure in the 'Stowed' position. operating temperature of 80 C (176 F) is achieved.
Remove wheel blocks from all road wheels. Transmission oil pressure gauge on the dash should
show a steady reading.
26 SM 1965 4-00
Section 120-0010
3. With parking brake applied, foot on service brake, The internal filter and finger magnet at the lower front
engine idling and transmission operating at normal left hand of the sump should be removed and cleaned
temperature, select each gear position in turn. Allow with mineral spirits at each oil and filter change. Metal
the transmission to remain in each gear for 5 - 10 particles in the oil (except for the minute particles
seconds. normally trapped in the oil filters) indicate damage has
occurred in the transmission. When these particles are
4. Return gear selector to neutral and, with the engine found in the filters, the cause must be established and
idling, check the oil level on dipstick (25, Fig. 1). Oil rectified immediately to prevent damage to the
level should be up to, but not over, the upper mark on transmission.
the dipstick. Add oil if low.
At each oil change, examine the used oil for evidence
of dirt or water. A normal amount of condensation will
Oil and Filter Change emulsify in the oil during transmission operation.
After the first 100 hours of operating a new or rebuilt However, if there is evidence of water or engine
transmission, the transmission oil and filter cartridges coolant in the oil, the cause must be established and
(16, Fig. 8) should be changed. Internal filter and rectified immediately to prevent damage to the
finger magnet at the lower front left hand of the sump transmission.
should be removed and cleaned.
The transmission oil and filter cartridges should be SERVICE TOOLS

changed every 1 000 hours, or sooner, depending on There are no special tools required for the procedures
operating conditions. Clean oil filter head (15, Fig. 9) outlined in this section. Refer to Section 300-0070,
when changing filter cartridges (16, Fig. 9). Also, the SERVICE TOOLS, for part numbers of service tools
oil must be changed whenever there are traces of dirt which should be used in conjunction with procedures
or evidence of high temperature indicated by outlined in the transmission manufacturers service
discoloration or strong odour. manual, and, general service tools required. These
tools are available from your dealer.

TORQUE
1 6, Front Mounts Bolt 300 220
1 6, Rear Mounts Bolt 265 195
1 10 Bolt 410 302
1 12 Bolt 225 166
* * * *
SM 1965 4-00 27
DRIVELINES - Front and Rear Drivelines
Section 130-0010
SM - 2010
11
PART OF
ENGINE FRONT
14 FRAME
13
12
2 2
TRANSMISSION
3 1
10 10
5 7 7
TO
TRAILER
FRONT AXLE
10 4 10 9 8 6
1 - Driveline Assembly 6 - Driveline Assembly

2 - Cross Assembly 7 - Cross Assembly 11 - Bracket
3 - Shaft Seal 8 - Shaft Seal 12 - Bolt
4 - Driveline Assembly 9 - Capscrew 13 - Washer
5 - Cross Assembly 10 - Capscrew 14 - Locknut
Fig. 1 - Front Drivelines and Mounting
DESCRIPTION generated during operation, preventing tension or

Numbers in parentheses refer to Fig. 1, unless compression loads from causing serious damage to
otherwise specified. the components.
The function of the driveline is to transmit rotating Note: Extra care should be taken when handling the
power from one point to another in a smooth and drivelines since chips, dents, burrs or deformity on any
continuous action while allowing a degree of rotating mass creates vibration and excessive wear
movement or misalignment of the components it during any operation.
connects.
There are three driveline assemblies installed between
The drivelines must operate through constantly various components in the tractor frame as follows:
changing relative angles between the components
they are mounted to and must also be capable of Driveline assembly (1) is connected between the
changing length while transmitting torque. engine drive and transmission input drive.
A typical driveline consists of universal joints which Driveline assembly (4) is connected between the front
allow some misalignment and permit the driveline to axle drive flange and transmission final drive.
pivot in any direction, and, a light rigid hollow slip yoke
and splined shaft assembly forming a slip joint. Driveline assembly (6) connects the rear final drive of
the transmission to the articulation and oscillation
The slip joint accommodates length variations pivot.
SM 1534 Rev 1 3-00 1

Drivelines - Front and Rear Drivelines
Section 130-0010
SM - 1441
PARKING BRAKE
CENTRE AXLE
REAR AXLE
6 7 5 6
3 4 2 3
1
1
ARTICULATION AND
OSCILLATION PIVOT
1 - Capscrew
2 - Driveline Assembly 4 - Shaft Seal 6 - Cross Assembly
3 - Cross Assembly 5 - Driveline Assembly 7 - Shaft Seal
Fig. 2 - Rear Drivelines and Mounting
There are two driveline assemblies connecting the

centre and rear axles to the drive supplied from the WARNING
transmission, through the pivot drive arrangement, as To prevent serious injury or death, DO NOT go
follows: under the vehicle when the engine is running.
Rotating shafts can be dangerous. You can
Driveline assembly (2, Fig. 2) is connected between snag clothes, skin, hair, hands, etc..
the pivot drive arrangement and the centre axle.
Driveline assembly (5, Fig. 2) is connected between parking brake and switch off the engine.
the centre axle and the rear axle.
REMOVAL
Numbers in parentheses refer to Fig. 1, unless Note: Access to remove driveline assembly (1) can be
otherwise specified. obtained through the service access plate on the cab
floor.
Note: Extra care should be taken when handling
drivelines since carelessness can result in premature 3. Remove floor mat back and remove mounting
failure of the components. Chips, dents, burrs, or any hardware securing access plate to the cab floor.
other deformity of universal joints will prevent accurate Remove access plate from the cab.
mating. This will cause misalignment which is
accompanied by vibration and excessive wear. 4. Remove bolts (12), washers (13) and locknuts (14)
securing bracket (11) over driveline assembly (1) and
onto the engine crossmember. Remove guard bracket.
WARNING
To prevent personal injury and property 5. Match mark cross assemblies (2) and their mating
damage, be sure wheel blocks, blocking surfaces to ensure correct mating alignment when
materials and lifting equipment are properly installing driveline assembly (1).
safely.
2 SM 1534 Rev 1 3-00

Section 130-0010
6. Support driveline (1) with suitable lifting equipment SM - 088
and remove capscrews (10) securing cross
assemblies (2) to their mating components. Remove APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
driveline assembly (1). If necessary tap driveline
assembly (1) from its mating components with a soft
faced hammer.
STRAIGHT EDGE
Note: Access to driveline assemblies (4 & 6) can be
obtained from underneath the vehicle.
7. Match mark cross assemblies (5 & 7) and their

mating surfaces to ensure correct mating alignment
REMOVE ALL
when installing driveline assemblies (4 & 6).
BURRS AND
PAINT FROM
8. Remove capscrews (10) securing cross assemblies THESE SURFACES
(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.
Fig. 3 - Checking Parallelism
9. Remove capscrews (9) securing cross assemblies
(7) to their mating components and remove driveline
assembly (6). If necessary tap driveline assembly (6) from driveline assembly (1).
from its mating components with a soft faced hammer.
3. Place the shaft end of driveline assembly (1) in a
Note: Access to driveline assemblies (2 & 5, Fig. 2) soft jawed vice.
can be obtained from underneath the vehicle.
4. Remove capscrews (10) and cross assembly (2)
10. Match mark cross assemblies (4 & 6, Fig. 2) and from driveline assembly (1).
their mating surfaces to ensure correct mating
alignment when installing driveline assemblies (2 & 5, 5. Repeat steps 1 to 4 for drivelines (4 & 6) and
Fig. 2). (2 & 5, Fig. 2)
11. Remove capscrews (1, Fig. 2) securing cross

assemblies (4, Fig. 2) to their mating components and INSPECTION
remove driveline assembly (2, Fig. 2). If necessary tap 1. Clean all metal parts in a suitable solvent, and dry
driveline assembly (2, Fig. 2) from its mating all parts with compressed air.
components with a soft faced hammer.
2. Inspect splines of shaft and yoke for nicks, burrs
12. Remove capscrews (1, Fig. 2) securing cross and excessive wear. Replace if wear is excessive or
assemblies (6, Fig. 2) to their mating components and splines are nicked. Burrs may be removed with a fine
remove driveline assembly (5, Fig. 2). If necessary tap file or medium India stone.
driveline assembly (5, Fig. 2) from its mating
components with a soft faced hammer. 3. Check the surfaces of the components that cross
assemblies mate against for parallelism. Refer to Fig. 3.
DISASSEMBLY 4. Check condition of mounting capscrews and replace
if required.
Cross Assembly
ASSEMBLY
1. Place the yoke end of driveline assembly (1) in a
soft jawed vice, clamping on the tube of shaft. Cross Assembly
Note: Do not distort the tube with excessive grip.
1. Place the yoke end of driveline assembly (1) in a
2. Remove capscrews (10) and cross assembly (2) soft jawed vice, clamping on the tube of shaft.
SM 1534 Rev 1 3-00 3

Section 130-0010
Note: Do not distort the tube with excessive grip. 3. Position driveline assembly (4) on the vehicle as
shown in Fig. 1 and align match marks on cross
2. Install cross assembly (2) to yoke end of driveline assemblies (5) with those on its mating surfaces.
assembly (1) and secure with capscrews (10).
4. Apply Loctite 243 to the threads of capscrews (10)
3. Place the shaft end of driveline assembly (1) in a and secure cross assemblies (5) to its mating surfaces
soft jawed vice. with capscrews (10). Tighten capscrews (10) to a
torque of 153 Nm (113 lbf ft).
4. Install cross assembly (2) to shaft end of driveline
assembly (1) and secure with capscrews (10). 5. Position driveline assembly (1) on the vehicle as
shown in Fig. 1 and align match marks on cross
5. Repeat steps 1 to 4 for drivelines (4 & 6) and assemblies (2) with those on its mating surfaces.
(2 & 5, Fig. 2)
6. Apply Loctite 243 to the threads of capscrews (10)
and secure cross assemblies (2) to its mating surfaces
INSTALLATION with capscrews (10). Tighten capscrews (10) to a
Numbers in parentheses refer to Fig. 1, unless torque of 153 Nm (113 lbf ft).
7. Secure bracket (11) over driveline assembly (1) and
Note: Tighten all fasteners without special torques onto engine crossmember with bolts (12), washers
specified to standard torques listed in Section (13) and locknuts (14).
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 8. Secure access plate to cab floor with mounting
hardware removed during removal. Place cab floor
Note: Extra care should be taken when handling mat in position and ensure that all pedals are free to
drivelines since carelessness can result in premature operate.
failure of the components. Chips, dents, burrs, or any
other deformity of wing bearings will prevent accurate 9. Position driveline assembly (2, Fig. 2) on the vehicle
mating. This will cause misalignment which is as shown and align match marks on cross assemblies
accompanied by vibration and excessive wear. (3, Fig. 2) with those on its mating surfaces.
11. Apply Loctite 243 to the threads of capscrews

WARNINGS (1, Fig. 2) and secure cross assemblies (3, Fig. 2) to
To prevent personal injury and property its mating surfaces with capscrews (1, Fig. 2). Tighten
damage, be sure wheel blocks, blocking capscrews (1, Fig. 2) to a torque of 153 Nm
materials and lifting equipment are properly (113 lbf ft).
safely. 12. Position driveline assembly (5, Fig. 2) on the
vehicle as shown and align match marks on cross
To prevent serious injury or death, DO assemblies (6, Fig. 2) with those on its mating
NOT go under the vehicle when the engine is surfaces.
running. Rotating shafts can be dangerous.
You can snag clothes, skin, hair, hands, etc.. 13. Apply Loctite 243 to the threads of capscrews
(1, Fig. 2) and secure cross assemblies (6, Fig. 2) to
1. Position driveline assembly (6) on the vehicle as its mating surfaces with capscrews (1, Fig. 2). Tighten
shown in Fig. 1 and align match marks on cross capscrews (1, Fig. 2) to a torque of 153 Nm
assemblies (7) with those on its mating surfaces. (113 lbf ft).
2. Apply Loctite 243 to the threads of capscrews (9) 14. Place the battery master switch in the 'On'
and secure cross assemblies (7) to its mating surfaces position, ensure the parking brake is applied and start
with capscrews (9). Tighten capscrews (9) to a torque the engine. Remove wheel blocks from all road
of 153 Nm (113 lbf ft). wheels.
4 SM 1534 Rev 1 3-00

Section 130-0010
MAINTENANCE With the pry bar, check the universal joints for play. If
Every 500 hours, check the universal joints for wear loose, replace the universal joints. Check the splines
and replace if required. at the slip joint and replace the yoke if excessively
worn.
Periodic Inspection
Use a small pry bar to check the companion flange
yokes for looseness. If loose, drop one end of the SERVICE TOOLS
driveline and twist the yoke to check the backlash There are no special tools required for the procedures
between the splines and yokes. Replace any yoke that outlined in this section. Refer to Section 300-0070,
does not fit snugly. SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
adhesives are available from your dealer.
DRIVELINE DIAGNOSIS CHART

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

TORQUE
1 9 Capscrew 153 113
1 10 Capscrew 153 113
* * * *
SM 1534 Rev 1 3-00 5

CENTRE AXLE - Differential Drive Head
Section 150-0020
DESCRIPTION and short axle shafts are removed. Refer to

The differential assembly is mounted to the axle Section 160-0030, AXLE GROUP (HUB).
housing. It comprises of two differentials; one for the
normal cross-axle drive function; the other for the thru- 6. Identify the relationship of the front and rear
drive. driveline flanges and differential flanges with punch
marks.
The differential is a spiral bevel ring gear type with an
automatically limited slip element (See Fig. 2). 7. Disconnect the drivelines from the differential
flanges. The drivelines can be removed if it is
The thru-drive differential is lockable by the operator. convenient to do so.
Note: Never engage or disengage the Differential 8. Support the weight of the thru-drive differential and
Lock when moving or when the wheels are spinning. countershaft case assembly with suitable lifting
equipment. Remove bolts (50 & 74) securing
countershaft case (49) to differential housing (73) and
REMOVAL AND INSTALLATION carefully remove countershaft case (49) assembly
Numbers in parentheses refer to Fig. 1. clear of differential housing (73).
9. Support the weight of differential housing (73)

WARNING assembly with suitable lifting equipment. Remove bolts
To prevent personal injury and property (75) securing differential housing (73) to the axle
damage, be sure wheel blocks, blocking housing. Thread in three puller bolts to break the seal
materials and lifting equipment are properly between the differential and axle housing and to
secured and of adequate capacity to do the job partially pull the differential assembly out of the axle
safely. housing. Carefully remove differential housing (73)
assembly clear of axle housing. Remove shim (72).
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure the INSTALLATION
body in the partially raised position. Installation is the reversal of the 'Removal' procedure.
2. Apply the parking brake and switch off the engine. Note: Use sealing compound between the axle
housing and differential housing mounting faces.
the 'Locked' position and the battery master switch in Note: Tighten all fasteners to standard torques listed
the 'Off' position. in Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container. Add gear oil of the type specified in Section 300-0020,
LUBRICATION SYSTEM, through the differential filler/
5. Remove the planetary assemblies and axle shafts level hole until the oil is level with the bottom of the
from the axle housing. Note from which side the long filler/level hole. Fill the planetary assemblies up to the
'Oil Level Check Line'.
SM 1971 4-00 1
Centre Axle - Differential Drive Head
Section 150-0020
SM - 250
Fig. 1 - Exploded View Of Centre Differential
2 SM 1971 4-00
Section 150-0020
LEGEND FOR FIG. 1.

1 - Drive Flange 23 - Shifter Fork Assembly 45 - Bolt 67 - Adjusting Nut
2 - Dust Cover 24 - Thrust Block 46 - Seal Ring 68 - Tapered Bearing
3 - Castle Nut 25 - Tapered Bearing 47 - Spacing Ring 69 - Bolt
4 - Differential Housing 26 - Plug 48 - Spur Gear * 70 - Differential Assembly
5 - Seal Ring 27 - Seal Ring 49 - Countershaft Case 71 - Ring Gear
6 - Shaft Seal 28 - Bolt 50 - Bolt 72 - Shim
7 - Bolt 29 - Bolt 51 - Roll Pin 73 - Differential Housing
8 - Bearing Flange 30 - Lockwasher 52 - Bolt 74 - Bolt
9 - Shim 31 - Plug 53 - Cover 75 - Bolt
10 - Ball Bearing 32 - Filter Element 54 - Nut 76 - Drive Flange Shaft
11 - Shim 33 - Limit Disc 55 - Roller Bearing 77 - Dust Shield
12 - Intermediate Flange 34 - Cover 56 - Spacing Ring 78 - Seal Retainer
13 - Bolt 35 - 'U' Section Ring 57 - Gear 79 - Shaft Seal
14 - Differential Case Half 36 - Piston 58 - Bearing Retaining Bush 80 - Snap Ring
15 - Thrust Washer 37 - Centring Ring 59 - Shim 81 - Ball Bearing
16 - Side Gear 38 - Spring 60 - Roller Bearing 82 - Shim
17 - Thrust Washer 39 - Nut 61 - Pinion Gear 83 - Circlip
18 - Pinion Gear 40 - Bolt 62 - Bearing Cap 84 - Spacing Ring
19 - Spider 41 - Contact Switch 63 - Bolt 85 - Tapered Bearing
20 - Differential Case Half 42 - Seal Ring 64 - Washer 86 - Slotted Nut
21 - Shift Collar 43 - Contact Pin 65 - Lockwire
22 - Differential Side Gear 44 - Shifter Fork Lock Pin 66 - Cotter Pin * - See Fig. 2
SM - 252
5 - Externally Splined Disc

6 - Internally Splined Disc
7 - Thrust Ring
1 - Bolt 8 - Side Gear
2 - Lockwasher 9 - Axle
3 - Cover 10 - Pinion Gear
4 - Thrust Washer 11 - Housing
Fig. 2 - Exploded View of Limited Slip Cross-axle Differential
SM 1971 4-00 3
Section 150-0020
DISASSEMBLY SM - 1109

1. If not done so previously, remove bolts (50 & 74)

which attach countershaft case (49) to differential
housing (73) and lift off the countershaft case
assembly.
2. Remove cotter pins (66) and adjusting nuts (67).

Index mark bearing caps (62) and differential housing
(73). Remove lockwire (65), bolts (63), washers (64)
and bearing caps (62). Remove the outer races of Fig. 3 - Removing Differential Assembly
tapered bearings (68) from differential assembly (70).
Remove differential assembly (70) from the differential SM - 1110
housing as shown in Fig. 3.
3. Index mark cover (3, Fig. 2) and housing (11, Fig. 2).
Remove bolts (1, Fig. 2) and lockwashers (2, Fig. 2)
and lift off cover.
4. Remove thrust washer (4, Fig. 2), two externally

splined discs (5, Fig. 2), two internally splined discs
(6, Fig. 2), thrust ring (7, Fig. 2) and side gear (8, Fig. 2).
5. Remove four pinion gears (10, Fig. 2) and axle

(9, Fig. 2) out of housing (11, Fig. 2). Fig. 4 - Removing Ring Gear Bolts
6. Remove the other side gear (8, Fig. 2), thrust ring SM - 1111
(7, Fig. 2), two internally splined discs (6, Fig. 2), two
externally splined discs (5, Fig. 2) and thrust washer
(4, Fig. 2) from housing (11, Fig. 2).
7. It is not necessary to remove ring gear (71) from

housing (11, Fig. 2) unless ring gear (71) and pinion
gear (61) are being replaced. The ring gear and pinion
gear are only sold as a matched set and cannot be
replaced separately. Remove bolts (69) as shown in
Fig. 4 and press the ring gear off the housing. If
necessary, pull the inner races of tapered bearings
(68) from the cover and housing. Fig. 5 - Removing Contact Switch
8. Screw out contact switch (41) with seal ring (42)

SM - 1112
and remove contact pin (43) from differential housing
(4) bore. Refer to Fig. 5.
9. Remove bolts (29), lockwashers (30) and cover (34)

from differential housing (4). Refer to Fig. 6.
10. Remove castle nut (3), drive flange (1), dust cover
(2) and seal ring (5) from differential case half (14).
11. Remove bolts (7) and bearing flange (8) from

differential housing (4). Shaft seal (6) is removed with
bearing flange (8). Remove shims (9 & 11) from
Fig. 6 - Removing Cover
intermediate flange (12).
4 SM 1971 4-00
Section 150-0020
SM - 1113 12. Press the thru-drive differential case assembly

(13 thru 20) out of intermediate flange (12), as shown
in Fig. 7.
13. With a bearing puller, pull ball bearing (10) off the
bearing journal of differential case half (14).
Fig. 7 - Pressing Differential Assembly

From Intermediate Flange
SM - 1114 14. Index mark differential case halves (14 & 20).
Remove bolts (13) from differential case half (14) and
separate the differential case halves. Remove thrust
washer (15), side gear (16), thrust washers (17),
pinion gears (18) and spider (19). Refer to Fig. 8.
Fig. 8 - Separating Differential
SM - 1115 15. Remove bolts (45) from shifter fork lock pins (44).
Push down on piston (36) and remove shifter fork lock
pins (44) with seal rings (46) from differential housing
(4) as shown in Fig. 9. Remove and discard seal rings
(46).
Fig. 9 - Removing Shifter Fork Lock Pins
SM - 1116 16. Remove shifter fork (23) with thrust blocks (24),
piston (36) with centring ring (37) and spring (38) from
differential housing (4). Also remove shift collar (21).
Refer to Fig. 10.
Fig. 10 - Removing Shifter Fork And Piston
SM 1971 4-00 5
Section 150-0020
17. Unlock slotted nut (86) and remove it from the SM - 1117
threaded end of differential side gear (22) as shown in
Fig. 11. With a soft drift and hammer, drive differential
side gear (22) from countershaft case (49). Remove
inner race of tapered bearing (85). Inner race of
tapered bearing (25) will come out with differential side
gear (22). Remove spacing ring (47). If necessary, pull
the inner race of tapered bearing (25) from differential
side gear (22).
18. Remove inner and outer bolts (28) which fasten

differential housing (4) to countershaft case (49). Refer
to Fig. 12. Remove the differential housing. If Fig. 11 - Removing Slotted Nut
necessary, pull the outer race of tapered bearing (25)
from differential housing (4).
SM - 1118
19. Remove spur gear (48) from countershaft case

(49) as shown in Fig. 13. Pull outer race of tapered
bearing (85) from countershaft case (49) and remove
spacing ring (84).
20. Remove bolts (52) and cover (53) from

countershaft case (49) as shown in Fig. 14.
21. Unlock and remove nut (54) from pinion gear (61)
shaft. With the press set shown in Fig. 15, press pinion
gear (61) out of countershaft case (49). Remove Fig. 12 - Removing Bolts
spacing ring (56) from the shaft end of pinion gear
(61).
SM - 1119
22. Drive roller bearing (55) out of its bore in

countershaft case (49).
23. Press pinion gear (61) out of gear (57) and bearing
retaining bush (58) as shown in Fig. 16. Drive roller
bearing (60) out of the bearing retaining bush and
remove shim (59).
24. Remove circlip (83) and shim (82) from drive

flange shaft (76) and withdraw drive flange shaft from
axle housing. Remove dust shield (77) from end of
drive flange shaft (76). Fig. 13 - Removing Spur Gear
25. Remove seal retainer (78) and pull shaft seal (79)
from axle housing. Remove snap rings (80) and drive
ball bearing (81) from the axle housing.
6 SM 1971 4-00
Section 150-0020
SM - 1120 INSPECTION
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
Fig. 14 - Removing Cover
with a cloth.
SM - 1121 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
Fig. 15 - Pressing Out Pinion Gear surfaces. Repair or replace as necessary.
SM - 1122
Note: If either ring gear or pinion gear is defective,
both gears must be replaced, because they are
serviced only as a matched set. Make sure the ring
gear and pinion gear have the same mating numbers.
6. Check for pitted, scored or worn thrust surfaces of

differential case halves.
Fig. 16 - Pressing Pinion Gear Out Of Gear And Bearing
SM 1971 4-00 7
Section 150-0020
ASSEMBLY SM - 1133
Numbers in parentheses refer to Fig. 1 unless

specified otherwise.

specified to torques listed in Section 300-0080, AXLE
BOLT AND NUT TORQUE SPECIFICATIONS.
Note: During assembly and installation, make sure

that mated, punch marked, or otherwise identified
parts are returned to their original positions, if still
serviceable.
Fig. 17 - Measuring Dimension 'A'
1. Align the index marks on bearing caps (62) and
differential housing (73) and fasten with washers (64) SM - 1134
and bolts (63). Install the special shims and measuring

shaft into the differential bearing bores. Measure the
distance from the middle of the differential bearing
flange face. Refer to Fig. 17. This will be dimension 'A'.
e.g. 164.2 mm (6.40 in).
2. Install bearing retaining bush (58) into countershaft

case (49) until it is seated. Measure dimension 'B' from
the flange face of countershaft case (49) to the bearing
contact face using a straightedge and depth
micrometer as shown in Fig. 18. e.g. 25.75 mm (1.00 in).
Fig. 18 - Measuring Dimension 'B'
3. Measure the width of roller bearing (60) as shown in
Fig. 19. e.g. 37.05 mm (1.50 in). SM - 1135
Example:
Dimension 'A' 164.2 mm (6.40 in)
+ Dimension 'B' 25.75 mm (1.00 in)
= 189.95 mm (7.40 in)
- Bearing width 37.05 mm (1.45 in)
Dimension 'X' = 152.90 mm (5.95 in)
4. Refer to Fig. 20. Read distance dimension etched

on the face of pinion gear (61). e.g. 151.80 mm (5.92 in).
Example: Fig. 19 - Measuring Bearing Width

Dimension 'X' 152.90 mm (5.95 in)
- Pinion Dimension 151.80 mm (5.92 in)
SM - 1136
Shim Size = 1.10 mm (0.03 in)
5. Place the determined size shim (59) in bearing

retaining bush (58), then press or drive roller bearing
151.8
(60) into its bore in the retaining bush.
Fig. 20 - Pinion Gear Dimension
8 SM 1971 4-00
Section 150-0020
SM - 1137 6. Place the assembled bearing retaining bush (58) on

pinion gear (61) as shown in Fig. 21 and install gear
(57) chamfered side down.
7. Press or drive the assembled pinion gear (61) into

its bore in countershaft case (49) until it is completely
seated.
Fig. 21 - Installing Gear And Pinion Gear
SM - 1130 8. Install spacing ring (56) on the end of pinion gear

(61) shaft as shown in Fig. 22. e.g. 23.9 mm (0.93 in).
If parts are not being replaced, then use the same
spacing ring that was removed. Size of the spacing
ring is determined in Step 11.
9. Press roller bearing (55) on pinion gear (61) shaft

and into countershaft case (49).
Fig. 22 - Installing Spacing Ring
SM - 1162 10. Thread nut (54) on pinion gear (61) shaft. Tighten
nut (54) to a torque of 750 Nm (550 lbf ft). Refer to
Fig. 23.
Fig. 23 - Tightening Nut
SM - 1138 11. Install a dial indicator as shown in Fig. 24 and with

pry bars move the pinion up and down to determine
the end play. Write down the measured end play. If for
example there is an end play of 0.2 mm (0.0078 in) the
installed spacing ring (56) of 23.9 mm (0.93 in) must
be replaced by a narrower spacing ring by
0.22 - 0.24 mm (0.0086 - 0.0094 in). To do this repeat
Steps 7 through 10. With the proper thickness spacing
ring installed, bearing (55) pre-load will be 3 Nm
(18 lbf ft).
Fig. 24 - Measuring Pinion Gear End Play
SM 1971 4-00 9
Section 150-0020
12. Place spur gear (48) in countershaft case (49). It SM - 1131
will be necessary to mesh this gear with gear (57)
already installed. Refer to Fig. 25.
Fig. 25 - Installing Spur Gear
13. Install differential housing (4) on countershaft case SM - 1139

(49). Fasten together with bolts (28). Put Loctite 270
on the two outside bolts. Maximum torque of bolts (28)
is 160 Nm (120 lbf ft). Refer to Fig. 26.
Fig. 26 - Installing Differential Housing
14. Press outer race of tapered bearing (25) into SM - 1140

differential housing (4). Press inner race of tapered
bearing (25) on differential side gear (22). Slide
spacing ring (47) on the differential side gear and
insert differential side gear into spur gear (48). Refer to
Fig. 27.
Fig. 27 - Installing Side Gear
15. Place a spacing ring (84) of 22 mm (0.878 in) over SM - 1123

the opposite end of differential side gear (22). Press
outer race of tapered bearing (85) into its bore in
countershaft case (49). Press the inner race of tapered
bearing (85) onto differential side gear (22). Refer to
Fig. 28.
Fig. 28 - Installing Bearing And Spacer
10 SM 1971 4-00
Section 150-0020
SM - 1124 16. Thread slotted nut (86) onto the threaded end of
differential side gear (22). Tighten slotted nut (86) to a
torque of 550 Nm (400 lbf ft). Refer to Fig. 29.
Fig. 29 - Torque Tightening Slotted Nut
SM - 1132 17. Using a dial indicator determine differential side

gear (22) end play. For example, if there is a
measured end play of 0.1 mm (0.0039 in) then spacing
ring (84) thickness must be reduced by 0.1 mm
(0.0039 in). To install a narrower spacing ring (84)
repeat Steps 15 & 16. Lock slotted nut (86) to
differential side gear (22). There must be no bearing
(85) end play or pre-load. Refer to Fig. 30.
Fig. 30 - Measuring Side Gear End Play
SM - 1125 18. Mesh shift collar (21) with differential side gear
(22) splines. Refer to Fig. 31.
Fig. 31 - Installing Shift Collar
SM - 1126 19. Assemble thrust blocks (24) to shifter fork (23) and
install in differential housing (4). Thrust blocks fit into
shift collar (21) groove. Refer to Fig. 32.
Fig. 32 - Installing Shifter Fork
SM 1971 4-00 11
Section 150-0020
20. Place 'U' section ring (35) on piston (36) OD. Slide SM - 1127
centring ring (37) and spring (38) on the piston stem.
Insert the assembled piston into its bore in differential
housing (4). Be sure the piston stem makes contact
with shifter fork (23). Refer to Fig. 33.
Fig. 33 - Installing Piston
21. Place new seal rings (46) on the ends of shifter SM - 1128
fork lock pins (44) and insert them into differential
housing (4) bores. To facilitate assembly, push shifter
piston (36) down slightly. Bolt in place with bolts (45).
Refer to Fig. 34.
Fig. 34 - Installing Shifter Fork Locks
22. If limit disc (33), filter element (32) and plug (31) SM - 1129
were removed from cover (34), reinstall them. Install
the cover on differential housing (4) and fasten with
bolts (29) and lockwashers (30). Tighten bolts (29) to a
torque of 42 Nm (30 lbf ft). Refer to Fig. 35.
Fig. 35 - Installing Cover
23. Place thrust washer (15) in differential case half SM - 1141

(14). Refer to Fig. 36.
Fig. 36 - Insert Thrust Washer
12 SM 1971 4-00
Section 150-0020
SM - 1142 24. Place side gear (16) into differential case half (14).
Refer to Fig. 37.
Fig. 37 - Insert Side Gear
SM - 1143 25. Install pinion gears (18) and thrust washers (17) on
spider (19) arms. Be sure the thrust washer notches
are properly positioned on the pinion gears. Install the
assembled spider in differential case half (14). Refer to
Fig. 38.
Fig. 38 - Installing Spider Assembly
SM - 1144 26. With a dial indicator gauge, check pinion gear (18)
backlash as shown in Fig. 39. Backlash should be
between 0.15 - 0.2 mm (0.00585 - 0.0078 in).
Fig. 39 - Checking Pinion Gear Backlash
SM - 1145 27. Align the index marks and place second differential
case half (20) on top of the assembled differential case
half (14). Bolt the two case halves together with bolts
(13). Tighten bolts (13) to a torque of 120 Nm
(90 lbf ft). Refer to Fig. 40.
Fig. 40 - Bolting Differential Case Together
SM 1971 4-00 13
Section 150-0020
28. Install differential assembly (13 thru 20) into the SM - 1146
bore of differential housing (4) as shown in Fig. 41. Be
sure the teeth on differential case half (20) mesh with
shift collar (21) teeth.
Fig. 41 - Installing Differential Assembly
29. Measure the distance from differential housing (4) SM - 1147

face to differential case half (14) face as shown in
Fig. 42. Record this as dimension 'A'. e.g. 9.0 mm
(0.351 in).
30. With a straightedge and blocks measure SM - 1148

dimension 'B' from intermediate flange (12) face to the
inner race of ball bearing (10) as shown in Fig. 43. e.g.
10.5 mm (0.410 in).
Example:
Dimension 'B' 10.5 mm (0.410 in)

- Dimension 'A' 9.0 mm (0.351 in)
Difference = 1.5 mm (0.059 in)
Because of the backlash, the axial displacement of the

complete differential assembly is 0.2 mm (0.008 in). Fig. 43 - Measuring Dimension 'B'
Difference 1.5 mm (0.059 in) SM - 1149

+ 0.2 mm (0.008 in)
Shim Size = 1.7 mm (0.067 in)
31. Lift the differential assembly (13 thru 20) out of

differential housing (4). Place intermediate flange (12)
on differential case half (14) and press ball bearing
(10) on differential case half (14) as shown in Fig. 44.
Fig. 44 - Pressing Ball Bearing
14 SM 1971 4-00
Section 150-0020
SM - 1150 32. Using a seal driver, install shaft seal (6) in bearing
flange (8) with the seal lip facing down. Refer to Fig.
45.
Fig. 45 - Installing Shaft Seal
SM - 1151 33. Measure the distance ball bearing (10) is above

intermediate flange (12) face as shown in Fig. 46. This
is dimension 'A'. e.g. 5.0 mm (0.195 in).
SM - 1152 34. Measure the distance from bearing flange (8) face
to ball bearing (10) contact face as shown in Fig. 47.
This is dimension 'B'. e.g. 6.5 mm (0.240 in).
Dimension 'B' 6.5 mm (0.240 in)

- Dimension 'A' 5.0 mm (0.195 in)
Required Shim = 1.5 mm (0.045 in)
Place the required shim (9) in bearing flange (8)

recess.
Fig. 47 - Measuring Dimension 'B'
SM - 1153 35. Coat intermediate flange (12) bolt circle with

sealing compound, install the size shim (11)
determined in Steps 29 and 30 and install bearing
flange (8). Bolt the flanges together with bolts (7).
Refer to Fig. 48.
36. Install dust cover (2) and seal ring (5) on the
splined end of drive flange (1). Align the drive flange
splines with the internal splines in differential case half
(14) and install the drive flange into the differential
case assembly. Thread castle nut (3) onto the
threaded end of differential case half (14). Tighten
Fig. 48 - Installing Bearing Flange castle nut (3) to a torque of 1 200 Nm (885 lbf ft).
SM 1971 4-00 15
Section 150-0020
37. If removed, install differential lock nut (39) and bolt SM - 1154
(40). Coat the bolt threads with Loctite 270. Actuate
the differential lock with compressed air while
threading the bolt with lock nut in differential housing
(4) until contact is made. After contact is made, turn
adjusting bolt (40) in approximately 1/3 turn and lock in
position with lock nut (39). Refer to Fig. 49.
Fig. 49 - Adjusting Differential Lock Bolt
38. Install contact pin (43) in differential housing (4). SM - 1111

Place seal ring (42) on contact switch (41) and insert
contact switch in differential housing as shown in Fig. 50.
39. If ring gear (71) was removed from housing

(11, Fig. 2) then assemble them. Align the index marks
and press the ring gear on the housing and bolt them
together with bolts (69). Tighten bolts (69) to a torque
of 210 Nm (160 lbf ft).
40. Press the inner races of tapered bearings (68) on

cover (3, Fig. 2) and housing (11, Fig. 2).
Fig. 50 - Installing Contact Switch
41. Place one thrust washer (4, Fig. 2) with lubrication
slot facing up in housing (11, Fig. 2).
SM - 878
42. Alternately, install an externally splined disc

(5, Fig. 2) and then an internally splined disc
(6, Fig. 2) until all the discs have been installed.
43. Install thrust ring (7, Fig. 2) on top of internally

splined disc (6, Fig. 2). Install the thrust ring with the
open face up.
44. Install one side gear (8, Fig. 2) into thrust ring
(7, Fig. 2) and make sure the side gear splines into the
two internally splined discs (6, Fig. 2). Fig. 51 - Installing Shaft and Pinion Gears
45. Assemble axles (9, Fig. 2) and pinion gears

(10, Fig. 2) together and install on the installed side SM - 879
gear (8, Fig. 2). Refer to Fig. 51
46. Install other side gear (8, Fig. 2) and other thrust
ring (7, Fig. 2) flat side up. Refer to Figs. 52 & 53.
16 SM 1971 4-00
Section 150-0020
SM - 880 47. Alternately, install an internally splined disc

(6, Fig. 2) and then an externally splined disc (5, Fig. 2)
until all the discs have been installed.
Fig. 53 - Installing Thrust Ring
SM - 881 48. Determine the end play between the discs and the
housing as shown in Figs. 54 & 55.
Step 1 - Determine the dimension between the

housing face and internally splined disc (6, Fig. 2). e.g.
The measurement is 6.00 mm (90.236 in).
Step 2 - Determine the dimension between housing

(11, Fig. 2) and cover (3, Fig. 2). For example the
measurement is 5.80 mm (0.228 in).
Step 1 Dimension 6.00 mm (0.236 in)

Fig. 54 - Determining End Play - Step 2 Dimension 5.80 mm (0.228 in)
Difference = 0.20 mm (0.008 in)
SM - 882
The correct end play between the housing cover and
both plate packs should be between 0.20 - 0.80 mm
(0.008 - 0.031 in). The end play should be as close to
0.20 mm (0.008 in) as possible. The end play is
controlled by installing different thicknesses of
internally splined plates. Refer to the parts book for
different thicknesses of plates available.
Fig. 55 - Determining End Play
SM - 883 49. Place thrust washer (4, Fig. 2) on side gear

(8, Fig. 2) as shown in Fig. 56.
Fig. 56 - Installing Thrust Washer
SM 1971 4-00 17
Section 150-0020
50. Place cover (3, Fig. 2) on housing (11, Fig. 2), SM - 884
cover threads of bolts (1, Fig. 2) with Loctite 270 and
fasten cover and housing together as shown in
Fig. 57. Tighten bolts (1, Fig. 2) to a torque of 110 Nm
(82 lbf ft).
Fig. 57 - Fastening Cover and Housing
51. Temporarily install countershaft case (49) SM - 1159

assembly on differential housing (73). Bolt together
with bolts (50 & 74). Refer to Fig. 58.
Fig. 58 - Installing Countershaft Case
52. Place the two outer races of tapered bearings (68) SM - 1160
on the inner races and install the differential assembly
into differential housing (73). Install bearing cap (62),
washers (64) and bolts (63). Tighten bolts (63) to a
torque of 245 Nm (180 lbf ft). Thread in adjusting nuts
(67) and displace the differential to obtain a backlash
of 0.25 - 0.35 mm (0.010 - 0.014 in). Refer to Fig. 59.
Bearing adjusting nuts (67) have two basic functions:

Pre-loading the bearings, and positioning ring gear
(71) to obtain the correct backlash between the ring
gear and the pinion gear.
Fig. 59 - Installing Differential And Bearing Caps
53. To check the backlash between ring gear (71) and
pinion gear (61), mount a dial indicator gauge at a right
SM - 1161
angle on the ring gear outer diameter as shown in
Fig. 60. Rock the ring gear back and forth being
careful not to move the pinion.
Note: Backlash can be adjusted without changing the

bearing pre-load by loosening one bearing adjusting
nut a certain number of notches and tightening the
opposite nut the same number of notches.
54. Tighten adjusting nut (67) opposite ring gear (71) two
notches in order to obtain the bearing pre-load of
3 - 4 Nm (115 - 155 lbf ft), then recheck the backlash.
Fig. 60 - Checking Backlash
18 SM 1971 4-00
Section 150-0020
55. Ring gear runout is measured by mounting a dial SM - 893
indicator gauge on the backside of the ring gear.
Carefully rotate the ring gear and read the dial
indicator gauge. Maximum allowable run out is
0.08 mm (0.003 in).
56. To check ring gear (71) tooth pattern, coat about

twelve ring gear teeth with prussian blue, oiled red
lead or some other easily removed paint 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.
Gear tooth patterns are covered under 'Gleason Gear

Tooth System'.
57. After all adjustments are made and the gear tooth
pattern is correct, lock adjusting nuts (67) with cotter Fig. 61 - Coast Side (Concave)
pins (66). Lock bearing cap bolts (63) in place with
lockwire (65). SM - 894
58. Coat cover (53) bolt flange with sealing compound

and install on countershaft case (49). Fasten the cover to
the countershaft case with bolts (52). Tighten bolts (52)
to a torque of 49 Nm (35 lbf ft).
59. Press ball bearing (81) into bore in the axle

housing and retain with snap rings (80). Install shaft
seal (79) in axle housing and retain with seal
retainer (78).
60. Insert dust shield (77) over drive flange shaft (76)
and insert drive flange shaft through axle housing,
shaft seal (79) and ball bearing (81). Install shim (82)
over drive flange shaft (76) and retain with circlip (83).
Fig. 62 - Drive Side (Convex)

GLEASON GEAR TOOTH SYSTEM
Ideal tooth-contact patterns are shown in Figs. 61 & 62 SM - 895
indicating the pinion distance is correct.
If the patterns obtained are the same as that shown in

Figs. 63 & 64 then decrease the pinion distance. Refer
to Fig. 65.

Figs. 66 & 67 then increase the pinion distance. Refer
to Fig. 68.
Fig. 63 - Coast Side (Concave)
SM 1971 4-00 19
Section 150-0020
SM - 896 SM - 899
Fig. 64 - Drive Side (Convex) Fig. 67 - Drive Side (Convex)
SM - 897 SM - 900
Fig. 65 - Pinion Distance Must Be Decreased Fig. 68 - Pinion Distance Must Be Increased
SM - 898
20 SM 1971 4-00
Section 150-0020
MAINTENANCE SPECIAL TOOLS

Proper lubrication of the differential assembly is The special tools referenced in this section are
essential if the differentials are to deliver the service available from your dealer. Refer to Section 300-0070,
intended. Section 300-0020, LUBRICATION SYSTEM SERVICE TOOLS, for part numbers of general service
gives full information on the proper lubrication intervals tools and sealants required.
and the lubricant which should be used.

TORQUE
1 3 Castle Nut 1 200 885
1 13 Bolt 120 90
1 28 Bolt 160 120
1 29 Bolt 42 30
1 45 Bolt 42 30
1 52 Bolt 49 35
1 54 Nut 750 550
1 63 Bolt 245 180
1 69 Bolt 210 160
1 86 Slotted Nut 550 400
2 1 Bolt 110 82
DIFFERENTIAL DIAGNOSIS
Noises and vibrations originating in the tyres, WARNING
transmission, planetaries and drivelines are easily To prevent personal injury and property
transmitted and may be erroneously attributed to the damage, be sure wheel blocks, blocking
differential. Therefore, all possible sources of noise materials and lifting equipment are properly
should be investigated before the differential is taken secured and of adequate capacity to do the job
apart. safely.
Whenever noises such as a grating or rattle are heard WARNING

coming from the differential, stop the unit immediately. Removing the axle shafts or drivelines will
One tooth from a gear can cause damage to all gears make the parking brake ineffective.
and bearings. When the differential is definitely at fault,
remove the axle shafts and disconnect the driveline
before moving the vehicle.
DIAGNOSIS CHART
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust
SM 1971 4-00 21
Section 150-0020
DIAGNOSIS CHART (CONTINUED)

Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case
* * * *
22 SM 1971 4-00
REAR AXLE GROUP - Differential Drive Head
Section 160-0020
SM - 849
1 - Bearing Adjuster 4 - Drive Flange 7 - Side Gear

2 - Housing 5 - Ring Gear 8 - Differential Case Assembly
3 - Pinion Gear (Drive) 6 - Spider (Pinion) Gear
Fig. 1 - Sectional View of Typical Differential
DESCRIPTION driveline yoke attaches directly to differential

Numbers and letters in parentheses refer to Fig. 1. flange (4) which is splined to the shaft of pinion gear (3).
Fig. 1 illustrates both a standard pinion gear and

spider differential (A) and a limited slip type (B). Limited Slip Assembly
Basically the differential consists of pinion gear (3) and Numbers in parentheses refer to Fig. 2.
ring gear (5). The differential is a spiral bevel ring gear
type with an automatically operating limited slip The limited slip assembly consists of housing (1), thrust
element (B). washers (2), externally splined discs (3), internally splined
discs (4), thrust ring (5), side gears (6), pinion gears (7),
The differential is mounted to the axle housing. The differential axle (8) and cover (9).
SM 1969 4-00 1
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 850
1- Housing
2- Thrust Washers 5 - Thrust Ring 8 - Differential Axle
3- Externally Splined Discs 6 - Side Gears 9 - Cover
4- Internally Splined Discs 7 - Pinion Gears 10 - Bolts
Fig. 2 - Exploded View of Limited Slip Assembly
OPERATION turn creating the same effect, one gear continues to

Numbers in parentheses refer to Fig. 2, unless revolve but pinion gears (7) cease to act rigidly with it.
otherwise specified. Pinion gears (7) now rotate on their own axis,
permitting one drive wheel to rotate at a different
Pinion gear (3, Fig. 1) is mated with ring gear (5, Fig. 1) speed from the other. Since the ratio of the pinion and
which is bolted to differential case assembly (8, Fig. 1). side gear assembly is approximately 2 to 1, the result
is that as one drive wheel slows down, the speed of
When both drive wheels are free to turn under equal the other proportionately increases. This prohibits the
resistance loads, ring gear (5, Fig. 1) and four small application of a torsional load to either axle, which is
pinion (spider) gears (7, Fig. 1) act as one rigid unit, greater than that existing during normal operation.
transmitting torque to both splined side gears (6). Side
gears (6), being splined to the axle shafts, then drive Thus pinion gears (7) serve a dual purpose:
each rear wheel with the same amount of torque at
identical rates of speed. In this instance, pinion gears (7) 1. They allow a differential in speed between the two
do not rotate on their axis, therefore, side gears (6) drive wheels, permitting maximum manoeuvrability.
rotate at the same rev/min as ring gear (5 Fig. 1).
2. They prohibit the application of all torque to one axle
When resistance on one drive wheel exceeds the shaft.
resistance on the other, or when the vehicle makes a
2 SM 1969 4-00
Section 160-0020
REMOVAL 8. Index mark differential housing (14) and the axle

Numbers in parentheses refer to Fig. 3. housing to ensure that differential housing (14) is
installed in the same position.
WARNING 9. Loosen and remove bolts (13) from the differential

To prevent personal injury and property and axle housings. Thread in three puller bolts to break
damage, be sure wheel blocks, blocking the seal between the differential and axle housings and
materials and lifting equipment are properly to partially pull the differential assembly out of the axle
secured and of adequate capacity to do the job housing.
safely.
10. Using suitable lifting equipment, support the weight
1. Before attempting to remove the road wheels, drive of the differential assembly.
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil. Note: When removing the rear differential, weld a loop
to the bottom side of the body above the differential
Note: If the rear differential is being removed, raise the and attach the lifting device.
body and prop it up with the body prop.
11. Pull out the differential assembly until it clears the
2. Apply the parking brake and switch off the engine. axle housing, then carefully lower it to the floor. Slide
the differential assembly out from beneath the vehicle.
the 'Off' position. INSTALLATION
Installation is the reversal of the 'Removal' procedure.
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container. Note: Use sealing compound between the axle
housing and differential housing mounting faces.
5. Remove the planetary assemblies and axle shafts
from the axle housing. If necessary, note from which Note: Tighten all fasteners to standard torques listed in
side the long and short axle shafts are removed. Refer Section 300-0080, AXLE BOLT AND NUT TORQUE
to Section 160-0030, AXLE GROUP (HUB). SPECIFICATIONS.
6. Identify the relationship of the driveline flange and Add gear oil of the type specified in Section 300-0020,
differential pinion flange with punch marks. LUBRICATION SYSTEM, through the differential filler/
level hole until the oil is level with the bottom of the
7. Disconnect the driveline from the differential drive filler/level hole. Fill the planetary assemblies up to the
flange. The driveline can be removed if it is convenient 'Oil Level Check Line'.
to do so.
SM 1969 4-00 3
Section 160-0020
SM - 851
1 - Cotter Pin 10 - Adjusting Nut 19 - Washer

2 - Slotted Nut 11 - Roller Bearing 20 - Bolt 28 - Externally Splined Plate
3 - Washer 12 - Roller Bearing 21 - Lockwire 29 - Internally Splined Plate
4 - Drive Flange 13 - Bolt 22 - Bearing Cap 30 - Side Gear
5 - Bolt 14 - Differential Housing 23 - Bolt 31 - Pinion Gear
6 - Dust Shield 15 - Spacing Washer (shim) 24 - Lock Plate 32 - Axle
7 - Pinion Shaft Seal 16 - Roller Bearing 25 - Bolt 33 - Housing
8 - Bearing 17 - Pinion Gear 26 - Cover 34 - Bolt
9 - Spacing Washer (Shim) 18 - Ring Gear 27 - Thrust Washer 35 - Thrust Ring
Fig. 3 - Exploded View of Front and Rear Differential
4 SM 1969 4-00
Section 160-0020
SM - 852 DISASSEMBLY
Note: The following removal procedure assumes the

complete axle assembly was removed from the
vehicle.
1. Punch mark the mounting position of differential

housing (14) to the axle housing as shown by arrows
in Fig. 4. Remove mounting bolts (13).
Fig. 4 - Removing Mounting Bolts
SM - 853 2. Remove both planetary assemblies and axle shafts

by following the procedure in Section 160-0030, AXLE
GROUP (HUB). Use three puller bolts to pull the
differential assembly away from the axle housing and
then lift it out of the axle housing as shown in Fig. 5.
Fig. 5 - Removing Differential Assembly
SM - 854 3. Remove lockwire (21) from bolts (20 & 23) as

shown by the arrows in Fig. 6.
Fig. 6 - Removing Lockwire
SM - 855 4. Remove bolts (23) and lock plate (24) from bearing
caps (22) as shown in Fig. 7.
Fig. 7 - Removing Lockplates
SM 1969 4-00 5
Section 160-0020
5. Punch mark bearing caps (22) and differential SM - 856
housing (14) as shown in Fig. 8. Loosen adjusting nuts
(10). Remove bolts (20), washers (19) and bearing
caps (22).
Fig. 8 - Removing Bearing Caps
6. Remove both adjusting nuts (10) as shown in Fig. 9. SM - 857
Fig. 9 - Removing Adjusting Nuts
7. Lift the differential assembly out of differential SM - 858

housing (14) with the special tool as shown in Fig. 10.
Fig. 10 - Removing Differential
8. Remove outer races of tapered roller bearings SM - 859

(11 & 12). Pull the inner race of the bearings with a
puller from cover (26) and housing (33) with the puller
shown in Fig. 11.
Fig. 11 - Removing Bearing Inner Race
6 SM 1969 4-00
Section 160-0020
SM - 860 9. Remove bolts (25) from cover (26) as shown in

Fig. 12.
Fig. 12 - Removing Cover Bolts
SM - 861 10. Punch mark cover (26) and housing (33) as shown
by the arrows in Fig. 13, then lift off the cover.
11. Remove thrust washer (27), two externally splined

plates (28), two internally splined plates (29), thrust
ring (35) and side gear (30).
12. Remove four pinion gears (31) and axle (32) out of
housing (33).
13. Remove other side gear (30), thrust ring (35), two
internally splined plates (29), two externally splined
Fig. 13 - Removing Cover plates (28) and thrust washer (27) from housing (33).
SM - 862 14. If necessary, pull the inner race of tapered roller

bearing (11) off housing (33). If ring gear (18) is being
removed from housing (33), punch mark them so they
can be assembled in the same position. Remove
bolts (34) as shown in Fig. 14 and press ring gear (18)
off housing (33).
15. Remove cotter pin (1), slotted nut (2), washer (3)
and drive flange (4) from pinion gear (17).
Fig. 14 - Removing Ring Gear Bolts
SM - 863 16. Remove and discard pinion shaft seal (7) from
differential housing (14) as shown in Fig. 15.
Fig. 15 - Removing Pinion Shaft Seal
SM 1969 4-00 7
Section 160-0020
17. Press pinion gear (17) out of differential housing SM - 864
(14) as shown in Fig. 16. Remove spacing washer (15).
Fig. 16 - Pressing Out Pinion Shaft
18. With the special tool shown in Fig. 17 pull the inner SM - 865
race of the bearing off the pinion drive end.
Fig. 17 - Pulling Inner Race of Bearing
INSPECTION 5. Check for pitted, scored or worn thrust surfaces of

1. Clean all parts with a suitable solvent. Dry all parts, differential case halves.
except bearings, with compressed air or with soft,
clean lint free cloths. DO NOT spin bearings with 6. During assembly and installation, make sure that
compressed air. Place bearings on a clean surface, mated, punch marked or otherwise identified parts are
cover with lint free cloths and allow to dry. returned to their original positions, if still serviceable.
2. Coat cleaned, dried parts immediately with light oil

to prevent corrosion. If parts are not to be assembled ASSEMBLY
immediately, treat them with a good quality rust Numbers in parentheses refer to Fig. 3.
preventive and wrap them with treated paper or
suitable material designed to prevent corrosion. Note: Tighten all fasteners without special torques
specified to standard torques listed in
3. Before installing the differential assembly into the Section 300-0080, AXLE BOLT AND NUT TORQUE
axle housing, clean the inside and outside of the axle SPECIFICATIONS.
housing to remove any debris or dirt.
The first step in the assembly procedure is to
4. Inspect all gears, pinions and splines for cracked or determine the thickness of the spacing washer or shim
broken teeth, excessive wear, and pitted or scored (15). Fig. 18 illustrates the special tools needed to
surfaces. Repair or replace as necessary. determine the shim size.
Dimensions A + B + C = X which is the shim size.
Note: If either ring gear or pinion gear is defective,
both gears must be replaced, because they are
serviced only as a matched set. Make sure the ring
gear and pinion gear have the same mating numbers.
8 SM 1969 4-00
Section 160-0020
SM - 866
1 Measuring Piston 15269936

2 Thrust Washer 15269935
3 Adaptor Pieces 15269937
4 Measuring Shaft 15269934
Fig. 18 - Determining Shim Thickness
SM - 867 1. Using a feeler gauge, determine the gap between

the measuring piston and measuring shaft as shown in
Fig. 19. For example:
Dimension 'A' + 'B' = 191.8 mm (7.551 in)

+ Dimension 'C' = 15.0 mm (0.591 in)
(half the diameter of the measuring shaft).
Dimension 'X' = 206.8 mm (8.142 in)
Fig. 19 - Determining Pinion and Shaft Gap
SM - 868 2. Next, determine the thickness of tapered roller

bearing (16) as shown in Fig. 20. For example:
(Straight edge +
gauge blocks) = 90.0 mm (3.543 in)
- Measured Value = 43.9 mm (1.728 in)
Bearing Thickness = 46.1 mm (1.815 in)
Fig. 20 - Determining Bearing Thickness
SM 1969 4-00 9
Section 160-0020
3. The arrow in Fig. 21 is pointing to a dimension SM - 869
etched on the face of pinion gear (17). For example
159.90 mm (6.295 in).
Dimension 'XI' = 46.10 mm (1.815 in)

(Bearing Thickness)
+ 159.90 mm (6.295 in)
= 206.00 mm (8.110 in)
Example:
Dimension 'X' = 206.80 mm (8.142 in)
- Dimension 'XI' = 206.00 mm (8.110 in)
Shim Thickness = 0.80 mm (0.032 in) Fig. 21 - Dimension on Drive Pinion Face
4. Place shim (15), of the correct thickness as SM - 870

determined in Steps 1, 2 and 3 into differential housing
(14) as shown in Fig. 22.
Fig. 22 - Placing Shim in Housing
5. Using a special driving tool, drive the outer race of SM - 871

tapered roller bearing (16) into differential housing (14)
as shown in Fig. 23.
Fig. 23 - Installing Outer Race of Bearing
6. Turn differential housing (14) over and install outer SM - 872

race of tapered bearing (8) into its bore as shown in
Fig. 24.
Fig. 24 - Installing Outer Race of Bearing
10 SM 1969 4-00
Section 160-0020
SM - 873 7. Heat the inner race of tapered roller bearing (16) to

approximately 90 C (190 F) and install it on the shaft
of pinion gear (17). Be sure it is seated against the
shaft shoulder as shown in Fig. 25.
Fig. 25 - Installing Inner Race of Bearing
SM - 874 8. The following steps are required to determine the

thickness of spacing washer (9). Place the special
measuring ring on the shoulder of pinion gear (17) as
shown by the arrows in Fig. 26.
Fig. 26 - Determining Thickness of Spacer
SM - 875 9. Place the pre-assembled pinion gear (17) on a

suitable spacing tube. Lift up differential housing (14)
and carefully place it over the pinion. Heat the inner
race of bearing (8) to approximately 90 C (190 F)
and install it on the shaft of pinion gear (17). Drive the
inner bearing race until it is seated against the outer
race as shown in Fig. 27.
Fig. 27 - Installing Pinion into Housing
SM - 876 10. If dust shield (6) was removed from drive flange (4),
press it back on the drive flange. Spline drive flange
(4) to pinion (17). Install slotted nut (2) and tighten to a
torque of 600 Nm (443 lbf ft). Check the rolling
resistance as shown in Fig. 28. Rolling resistance
should be 1.1 - 2.3 Nm (0.81 -1.70 lbf ft).
Note: Correct rolling resistance is obtained by

loosening or tightening the slotted nut. Record the
torque figure because it will be required later.
Fig. 28 - Checking Rolling Resistance
SM 1969 4-00 11
Section 160-0020
11. Remove slotted nut (2), pull off drive flange (4) and SM - 877
remove pinion gear (17) from differential housing (14).
Remove and measure the measuring ring with a
micrometer. The thickness of the compressed
measuring ring will be the thickness of spacing washer
(9).
Place spacing washer (9) on the shoulder of the pinion

shaft. Then install the assembled pinion gear into
differential housing (14).
12. Coat the outer diameter of pinion shaft seal (7)

with sealing compound. With the seal lip facing inward Fig. 29 - Installing Shaft Seal
and using the seal driver shown in Fig. 29, drive seal
(7) into differential housing (14).
SM - 878
13. Slide drive flange (4) on the shaft of pinion gear

(17). Place washer (3) on the pinion shaft and thread
on slotted nut (2). Torque slotted nut (2) to the setting
determined in Step 10. Lock slotted nut (2) in place
with cotter pin (1).
14. If ring gear (18) was removed from housing (33),

make sure the ring gear and housing surfaces are
clean and free from grease. Install two line-up studs,
line up index marks and press the ring gear back on.
Install bolts (34) and, with a dial indicator gauge, check Fig. 30 - Installing Shaft and Pinion Gears
ring gear run-out. Maximum allowable run-out is 0.08
mm (0.003 in).
SM - 879
15. Heat inner roller bearing (12) race to 90 C (190 F)

and press it on to the hub of housing (33) until it is
firmly seated.
16. Place one thrust washer (27) with the lubrication

slot facing up.
17. Alternately, install an externally splined plate (28)

and then an internally splined plate (29) until all plates
have been installed.
18. Install thrust ring (35) on top of the internally splined
plate (29). Install thrust ring (35) with open face up.
SM - 880
19. Install one side gear (30) into thrust ring (35).
Make sure the side gear splines into the two internally
splined plates (29).
20. Assemble axles (32) and pinion gears (31)

together and install on the installed side gear (30), as
shown in Fig. 30.
21. Install the other side gear (30) and the other thrust
ring (35), flat side up, as shown in Figs. 31 and 32.
Fig. 32 - Installing Thrust Ring
12 SM 1969 4-00
Section 160-0020
SM - 881 22. Alternately install an internally splined plate (29)

and externally splined plate (28) until all plates are
installed.
23. Determine the end play between the plates and the
housing as shown in Figs. 33 and 34.
Step 1 - Determine the dimension between the

housing face and the internally splined plate (29). For
example - the measurement is 6.00 mm (0.236 in).
Step 2 - Determine the dimension between housing

Fig. 33 - Determining End Play (33) and cover face (26). For example - the
measurement is 5.80 mm (0.228 in).
SM - 882
Step 1 Dimension ........... 6.00 mm (0.236 in)
Step 2 Dimension ........... 5.80 mm (0.228 in)
Difference ....................... 0.20 mm (0.008 in)
The correct end play between the housing cover and

both plate packs should be between 0.20 - 0.80 mm
(0.008 - 0.031 in). The end play should be as close to
0.20 mm (0.008 in) as possible. The end play is
controlled by installing different thicknesses of
internally splined plates. Refer to the parts book for
Fig. 34 - Determining End Play different thicknesses of plates available.
SM - 883 24. Place thrust washer (27) on side gear (30), as

shown in Fig. 35.
25. Heat inner race of roller bearing (11) to

approximately 90 C (190 F) and press it on to the
hub of cover (26) until it is firmly seated against the
cover.
Fig. 35 - Installing Thrust Washer
SM - 884 26. Place cover (26) on housing (33), cover threads of

necked-down bolts (25) with Loctite 270 and fasten
cover and housing together as shown in Fig. 36. Use
only new necked-down bolts. Tighten bolts (25) to a
Fig. 36 - Fastening Cover and Housing
SM 1969 4-00 13
Section 160-0020
27. Place outer races of roller bearings (11 & 12) on SM - 885
both differential ends. Using the special lifting tool
install ring gear (18) assembly into differential
housing (14), as shown in Fig. 37.
Fig. 37 - Installing Ring Gear Assembly
28. Coat the threads of adjusting nuts (10) with SM - 886

Molykote and loosely thread into lower bearing cups,
Fig. 38 - Installing Adjusting Nuts
29. Align the index marks and install bearing caps (22) SM - 887
with washer (19) and bolts (20), as shown in Fig. 39.
Fig. 39 - Installing Bearing Caps
30. Thread both adjusting nuts (10) into bearing caps SM - 888
(22) as shown, until the yoke width is between
340 - 340.30 mm (13.386 - 13.400 in) diagonally
across the bearing cap lock pads, as shown in Fig. 40.
Note: Bearing adjusting nuts (10) have two basic

functions: preloading the bearings and positioning ring
gear (18) to obtain the correct backlash between it and
pinion gear (17).
Fig. 40 - Measuring Yoke Width
14 SM 1969 4-00
Section 160-0020
SM - 889 31. To check the backlash between ring gear (18) and
pinion gear (17), mount a dial indicator gauge at right
angles to the outer diameter of the ring gear tooth flank
as shown in Fig. 41. Rock the ring gear back and forth
being careful not to move the pinion gear. Backlash
should be 0.30 mm (0.012 in).
Note: Backlash can be adjusted without changing the

bearing preload by loosening one bearing adjuster nut
a certain number of notches and tightening the
opposite adjuster nut the same number of notches.
Fig. 41 - Measuring Backlash
SM - 890 32. The ring gear run-out is measured by mounting a

dial indicator gauge on the backside of ring gear (18)
as shown in Fig. 42. Carefully rotate ring gear (18) and
read the dial indicator. Maximum allowable
run-out is 0.08 mm (0.003 in).
Fig. 42 - Measuring Ring Gear Runout
SM - 891 33. To check the tooth pattern of ring gear (18), 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 Fig. 43.
Gear tooth patterns for the Gleason Gear Tooth

system are on the following pages.
Fig. 43 - Checking Contact Pattern
SM - 892 34. After all adjustments and gear patterns are correct,
secure adjusting nut lock plates (24) in place with bolts
(23) and lockwire (21), as shown in Fig. 44.
Fig. 44 - Locking Adjusting Nuts
SM 1969 4-00 15
Section 160-0020
GLEASON GEAR TOOTH SYSTEM SM - 895
Ideal tooth-contact pattern shown in Figs. 45 and 46

indicating the pinion distance is correct.

Figs. 47 and 48 then decrease the pinion distance
(Fig. 49).

Figs. 50 and 51 then increase the pinion distance
(Fig. 52).
SM - 893 SM - 896
Fig. 45 - Coast Side (Concave) Fig. 48 - Drive Side (Convex)
SM - 894 SM - 897
Fig. 46 - Drive Side (Convex) Fig. 49 - Pinion Distance must be Decreased
16 SM 1969 4-00
Section 160-0020
SM - 898
SM - 899
Fig. 51 - Drive Side (Convex)
SM - 900
Fig. 52 - Pinion Distance must be Increased
SM 1969 4-00 17
Section 160-0020
MAINTENANCE should be investigated before the differential is taken

Proper lubrication of the differential assembly is apart.
essential if the differentials are to deliver the service
intended. Section 300-0020, LUBRICATION SYSTEM Whenever noises such as a grating or rattle are heard
gives full information on the proper lubrication intervals coming from the differential, stop the unit immediately.
and the lubricant which should be used. 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
SPECIAL TOOLS before moving the vehicle.
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service WARNINGS
tools and sealants required. To prevent personal injury and property
materials and lifting equipment are properly
DIFFERENTIAL DIAGNOSIS secured and of adequate capacity to do the job
Noises and vibrations originating in the tyres, safely.
transmission, planetaries and drivelines are easily
transmitted and may be erroneously attributed to the Removing the axle shafts or drivelines
differential. Therefore, all possible sources of noise will make the parking brake ineffective.
DIAGNOSIS CHART
Vibration Broken gear teeth Replace damaged gear
Excessive run-out of pinion or flanged case Disassemble, correct or replace faulty
part
Continual noise Bearing worn Replace worn parts
Gears damaged or worn Replace gears
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Loose ring and pinion gear adjustment Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case

TORQUE
3 2 Slotted Nut 600 443
3 20 Bolt 295 218
3 25 Bolt 110 82
* * * *
18 SM 1969 4-00
REAR AXLE GROUP - Axle Group (Hub)
Section 160-0030
SM - 1781
30
10
31 7 8
5 33
32
35
34
13 12
6
9 11
22
28
2,3
1 4
38
21 37
17
15
14
24
23
27 25
29 26
18
36
20 19
16
1 - Hub Carrier 29 - Slotted Nut
2 - Capscrew 11 - Wheel Bolt 20 - Retainer Ring 30 - Axle Housing
3 - Capscrew 12 - Wheel Nut 21 - Thrust Washer 31 - Brake Disc
4 - Washer 13 - Lockwasher 22 - Bolt 32 - Capscrew
5 -Nut 14 - Locking Plate 23 - 'O' Ring 33 - Washer
6 - Roller Bearing 15 - Lock Screw 24 - Plug Screw 34 - Split Pin
7 - Bearing Inner Race 16 - Ring Gear 25 - Driver 35 - Split Pin
8 - Bearing Outer Race 17 - Sun Gear Shaft 26 - Thrust Washer 36 - Shim
9 - Shaft Seal 18 - Planet Carrier 27 - Grooved Pin 37 - 'O' Ring
10 - Hub 19 - Planet Gear 28 - Axle Shaft 38 - Plug
Fig. 1 - Exploded View of Planetary and Wheel
OPERATION meshed with sun gear shaft (17) rotate anticlockwise.

Numbers and letters in parentheses refer to Fig. 1. Ring gear (16) is splined to hub carrier (1) and does
not rotate but causes planet gears (19), which are
Power from the differential is transmitted through a meshed with ring gear (16), to move around it in a
fully floating axle shaft connected to sun gear shaft (17) clockwise direction. As planet carrier (18) is bolted to
by driver (25). As sun gear shaft (17) rotates in a wheel hub (10) the wheel then rotates in a clockwise
clockwise direction, the four planet gears (19) direction.
SM 1968 4-00 1
Rear Axle Group - Axle Group (Hub)
Section 160-0030
REMOVAL AND DISASSEMBLY SM - 1026
Note: On dismantling, clean all parts in paraffin or

other suitable cleaning agent and place on a clean
work surface.
WARNINGS
materials and lifting equipment are properly Fig. 2 - Jacking Planet Carrier Out Of Hub
safely.
SM - 1027

damage, the procedure for removing tyre and
rim assembly described in Section 160-0050,
WHEEL, RIM AND TYRE, must be strictly
followed.
When necessary to drive out components

during disassembly, be sure to use a soft drift
to prevent property damage and personal
injury.
Fig. 3 - Removing Planet Carrier Assembly
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. lowest points. Remove plug screws (24) and
'O' rings (23) and drain oil from hubs.
2. Apply the parking brake and switch off the engine.
9. Index mark planet carrier (18) and hub (10) to aid
3. Block the appropriate road wheels, place the in installation.
steering lock bar in the 'Locked' position and the
battery master switch in the 'Off' position. 10. Remove bolts (22) then prise planet carrier (18)
from hub (10) and place on the floor with planet gears
4. Whilst road wheels are still on the ground, loosen (19) facing upwards. If necessary, use jacking bolts
wheel nuts (12). in tapped holes provided, as shown in Fig. 2.
5. Jack up the axle and support with suitably placed 11. Remove bearing inner race (7) from hub carrier (1).
stands or timbers.
12. Lift out sun gear shaft (17) from planet carrier
6. Support tyre and rim assembly with a suitable sling (18) assembly. Remove retainer rings (20) and pull
and lifting device. Remove wheel nuts (12) and planet gears (19) from planet carrier (18). Remove
remove tyre and rim assembly from the machine. thrust washer (21).
Remove opposite road wheel in the same way.
13. Remove driver (25) from axle shaft (28). Remove
7. Place suitable containers under the differential and thrust washer (26) from grooved pins (27) on hub
both hubs (10). Remove differential drain plug and carrier (1). Pull axle shaft (28) from axle housing
drain oil from the differential. (30).
8. Rotate hubs (10) until plug screws (24) are at their 14. Remove the brake calliper. Refer to Section
165-0010, BRAKE PARTS - REAR.
2 SM 1968 4-00
Section 160-0030
SM - 1028 18. Remove shaft seal (9), roller bearing (6) and
bearing outer race (8) from hub (10) as shown in Fig. 5.
19. If it is necessary to remove hub carrier (1) from

axle housing (30), index mark hub carrier and axle
housing to aid in installation. Support hub carrier (1)
with suitable lifting equipment and remove capscrews
(2 & 3), washers (4), nuts (5) and slot pins (34 & 35).
If necessary, tap hub carrier (1) loose from axle
housing (30).
20. If necessary, drive or press wheel bolts (11) from

Fig. 4 - Removing Slotted Nut
hub (10).
SM - 1029
INSPECTION
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 washers (21 & 26) to make sure they
are free of burrs and are absolutely flat. Replace all
'O' rings.
Fig. 5 - Removing Bearing Outer Race

ASSEMBLY AND INSTALLATION
SM - 1030 Note: Tighten all fasteners without special torques

specified to standard torques listed in Section
300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNING
damage, be sure lifting equipment is properly
safely.
Fig. 6 - Installing Wheel Bolts
1. Cover the mounting flange of axle housing (30)
with Loctite 574 sealing compound and line up the
15. Remove two lock screws (15) and locking plate (14) index mark on hub carrier (1) with the mark on axle
from ring gear (16). Remove slotted nut (29) from hub housing (30). Secure hub carrier (1) to axle housing
carrier (1) with the special tool as shown in Fig. 4. (30) with capscrews (2 & 3), washers (4), nuts (5)
Remove shims (36) from hub carrier (1). and slot pins (34 & 35). Tighten capscrews (2 & 3) to
a torque of 460 Nm (340 lbf ft).
16. Using suitable lifting equipment, remove ring gear
(16), then hub (10) assembly from hub carrier (1). 2. If removed, install new wheel bolts (11) on hub
(10) using the special tool shown in Fig. 6.
17. If necessary, remove capscrews (32), washers
(33) and brake disc (31) from hub (10). 3. Place brake disc (31) on hub (10) and secure with
capscrews (32) and washers (33). Tighten
capscrews (32) to a torque of 295 Nm (220 lbf ft).
SM 1968 4-00 3
Section 160-0030
4. Install roller bearing (6) in inner bore of hub (10). SM - 1031
Coat outer diameter of shaft seal (9) with Loctite 574
sealing compound and, with the seal lip facing down,
press shaft seal (9) into the bore of hub (10) with the
special tool shown in Fig. 7. Turn the hub over and
press bearing outer race (8) into the hub bore.
5. With a suitable lifting device, pick up hub (10)

assembly, then, being careful to prevent damaging
the lip of shaft seal (9), slide hub (10) assembly onto
hub carrier (1). Be sure hub (10) assembly is firmly
seated against the shoulder of hub carrier (1).
Fig. 7 - Installing Shaft Seal
6. Install bearing inner race (7) on the splined end of
hub carrier (1) as shown in Fig. 8. Be sure the inner SM - 1032
race is firmly seated.
7. Slide ring gear (16) over the splines of hub carrier

(1). Be sure it is pushed all the way in.
8. Select shim (36) and install over the splines of hub

carrier (1) so that front edge of ring gear (16) is
protruding by 0.03 - 0.30 mm (0.001 - 0.012 in).
9. Install slotted nut (29) on hub carrier (1) threads

and, using special tool shown in Fig. 9, tighten slotted
nut (29) to a torque of 1 000 Nm (738 lbf ft). Fig. 8 - Installing Bearing Inner Race
Note: During tightening the wheel hub must be

SM - 1033
spinning.
10. Check the rolling resistance of hub (10) by wrapping

a length of string around hub (10) and pulling with a
suitable scale as shown in Fig. 10. The rolling resistance
(T) should be 12 - 18 Nm (9 - 13 lbf ft) for new bearings,
or 6 - 9 Nm (4.5 - 6.5 lbf ft) for run-in bearings.
Formula to calculate F.
F = T/R
Where: Fig. 9 - Tightening Slotted Nut

F = Pull in N (lbf)
T = Rolling resistance Nm (lbf ft)
R = Radius of hub m (ft) SM - 1034
F
Adjust shim (36) thickness to achieve the correct
rolling resistance. If rolling torque not reached, select
a thinner shim (36). If rolling torque is exceeded,
select a thicker shim (36).
11. When rolling resistance is correct, remove slotted

nut (29).
12. Using Loctite 243, coat the threads of hub carrier

(1) and slotted nut (29). Thread slotted nut (29) on
Fig. 10 - Checking Hub Rolling Resistance
4 SM 1968 4-00
Section 160-0030
SM - 1035 15. Carefully slide axle shaft (28) through the bore of
hub carrier (1) until the axle shaft splines into the
differential side gears. Place thrust washer (26) onto
grooved pins (27) on hub carrier (1). Slide driver (25)
onto axle shaft (28).
16. Press planet gear assemblies (19) onto the pins

of planet carrier (18) as shown in Fig. 11. Secure
planet gears by installing retainer rings (20).
17. Position thrust washer (21) into the recess in

planet carrier (18). Before positioning sun gear shaft (17)
Fig. 11 - Installing Planet gear Assemblies it is necessary at this stage to determine the end play
of sun gear shaft (17) before installing the planetary
SM - 1036
assembly into the hub. The required end play should
be 0.3 - 0.5 mm (0.012 - 0.020 in) and can be
achieved by installing different thicknesses of thrust
washer (21).
Note: Thrust washers are available in thicknesses of

6.5 mm (0.256 in), 6.3 mm (0.248 in), 6.0 mm (0.236 in),
5.0 mm (0.197 in), 3.5 mm (0.138 in), 3.3 mm (0.130 in),
3.1 mm (0.122 in), 2.9 mm (0.114 in) and 2.7 mm
(0.106 in).
Determine end play of sun gear shaft (17) as follows:

a. Position the assembled planet carrier (18) as
shown in Fig. 12. Place a straight edge and gauge
SM - 1037
blocks on the carrier mounting surface and measure
the distance between the top of the straight edge and
thrust washer (21). Record this as dimension 'A'.
Example:
Straight edge + gauge blocks = 100.00 mm (3.937 in)
Measured distance = 85.10 mm (3.350 in)
Dimension 'A' = 14.90 mm (0.587 in)
b. Slide sun gear shaft (17) fully into driver (25).

Place gauge blocks and straight edge across the
Fig. 13 - Measuring Dimension 'B' mounting surface of hub (10) and measure the
distance from the outer surface of the end of sun
gear shaft (17) as shown in Fig. 13. Record this as
hub carrier (1) threads and, using the special tool dimension 'B'.
shown in Fig. 9, tighten slotted nut (29) to a torque of
1 000 Nm (738 lbf ft). Example:
Straight edge + gauge block = 100.00 mm (3.937 in)
13. Install locking plate (14) and secure with lock Measured distance = 85.40 mm (3.362 in)
screws (15). Tighten lock screws (15) to a torque of Dimension 'B' = 14.60 mm (0.575 in)
79 Nm (58 lbf ft).
Example:
14. Re-check the rolling resistance of hub (10). The Dimension 'A' = 14.90 mm (0.587 in)
rolling resistance (T) should be 12 - 18 Nm Dimension 'B' = 14.60 mm (0.574 in)
(9 - 13 lbf ft) for new bearings, or 6 - 9 Nm Difference (End play) = 0.30 mm (0.012 in)
(4.5 - 6.5 lbf ft) for run-in bearings.
SM 1968 4-00 5
Section 160-0030
18. Remove sun gear shaft (17) from driver (25) and MAINTENANCE
position in planet carrier (18) in mesh with planet Proper lubrication of the axle group is essential if
gears (19). axles are to deliver the service intended. Section
300-0020, LUBRICATION SYSTEM gives full
19. Coat the face of planet carrier (18) with Loctite information on the proper lubrication intervals and the
574 sealing compound. Install planet carrier (18) lubricant which should be used.
assembly into hub (10) and secure with bolts (22).
SPECIAL TOOLS
20. Place a new 'O' ring (23) on plug screw (24) and The special tools referenced throughout this section
thread assembled plug screw into the outer face of are available from your dealer. Refer to Section
planetary carrier (18). Tighten plug screw (24) to a 300-0070, SERVICE TOOLS, for part numbers of
torque of 80 Nm (60 lbf ft). general service tools and sealants required.
21. Install brake calliper. Refer to Section 165-0010,

BRAKE PARTS - REAR. AXLE DIAGNOSIS
Noises originating in the tyres, transmission, brakes
22. Install differential drain plug. Add gear oil of the or drivelines might be attributed by mistake to the
type specified in Section 300-0020, LUBRICATION axle components, therefore, all possible sources of
SYSTEM, through the differential filler/level hole until noise should be investigated before deciding the axle
the oil is level with the bottom of the filler/level hole. is at fault.
23. Fill the planetary assemblies up to the 'Oil Level

Check Line' with gear oil of the type specified in WARNING
Section 300-0020, LUBRICATION SYSTEM. To prevent personal injury and property
24. Refit road wheels, securing with wheel nuts (12). materials and lifting equipment are properly
Remove stands or timber supports and lower the secured and of adequate capacity to do the job
machine to the ground. Fully tighten wheel nuts to a safely.
torque of 590 Nm (435 lbf ft). Remove blocks from
the wheels. True axle noises may be located by lifting or jacking
the machine up until all tyres are clear of the floor or
Note: Wheel nuts should be checked and tightened if ground. Securely block the machine in this position.
necessary, after the first 10 hours of operation. Run power train at moderate speed. Be certain all
Check torque every 50 hours (weekly) thereafter. tyres are off the ground to prevent damage to the
differential and make sure that there is no brake drag.
AXLE DIAGNOSIS CHART

Noises Insufficient or incorrect lubricant Check level. Fill with proper type and grade of
lubricant.
Wheel bearings scored or rough Replace wheel bearings
Gear teeth in planetary chipped Replace gear
Loss of lubricant Lubricant foams excessively Drain and fill with proper type and grade of
lubricant
Worn or broken oil seal Replace oil seal
Loose nuts or bolts Tighten nuts or bolts
Gain of lubricant Incorrect lubricant Drain and fill with proper type and grade of
lubricant
Planetaries running hot Bearings seized Replace bearings
6 SM 1968 4-00
Section 160-0030

TORQUE
1 12 Wheel Nut 590 435
1 15 Lock Screw 79 58
1 22 Bolt 190 140
1 24 Plug Screw 80 60
1 32 Capscrew 295 220
* * * *
SM 1968 4-00 7
REAR AXLE GROUP - Wheel Rim and Tyre
Section 160-0050
SM - 1038
1 - Flanges
2 - 'O' Ring 5 - Wheel Rim 8 - Driver (if used)
3 - Bead Seat Band 6 - Valve Assembly 9 - Lock Washer
4 - Lock Ring 7 - Valve Cap 10 - Wheel Nut
Fig. 1 - Cutaway View of Wheel Rim
DESCRIPTION AND OPERATION One of the following pieces of hoisting equipment

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

machine, and dismounting tyre from rim, the use of WARNING
hand, hydraulic, and special tools, are described in this Before performing any service on the tyres or
section. rim components, to prevent personal injury
and property damage, completely deflate the
The rim assembly consists of the following tyre by removing the valve cap and core. Insert
components which are illustrated in Fig. 1: rim, inner a thin wire through valve to be sure valve is
and outer flange, 'O' ring, bead seat band, driver, and not plugged. Even a flat tyre, in some cases,
lock ring. will retain sufficient air pressure to blow off a
rim component with enough force to cause
When dismounting a tyre and rim assembly from the bodily injury or death.
machine, special equipment and careful handling are
required because of the size and weight of the tyres.
SM 1970 4-00 1
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
REMOVING TYRE AND RIM ASSEMBLY SM - 1039
FROM MACHINE
Note: If tyre and rim assembly is to be replaced pre-

assembled, it is not necessary to remove the tyre from
the rim. It may be removed as an assembly.
WARNING
safely.

parking brake and shutdown the engine.
2. Block all road wheels, except the one to be raised,

and place the battery master switch in the 'Off'
position.
1 - Outer Flange 4 - Lock Ring
3. Break wheel nuts (10) loose with tyre still on the 2 - Driver (if used) 5 - Wheel Rim
ground, but do not remove from wheel studs. 3 - Bead Seat Band 6 - Inner Flange
Fig. 2 - Typical Rim Assembly

4. Jack up the axle to the height required to allow
removal of the tyre and rim assembly.
SM - 205
5. Place safety blocks under the axle.
6. Support tyre and rim assembly with a suitable sling

and attach a suitable lifting device.
7. Remove wheel nuts (10) and lock washers (9)

securing wheel rim (5) to the wheel. Fig. 3 - Pry Bar
8. With lifting device, remove tyre and rim assembly SM - 206

from the wheel and lift clear of the vehicle.
DISMOUNTING TYRE FROM RIM

Note: The following instructions apply to use of hand

tools. For procedures and tooling required to dismount
the tyre from the rim using hydraulic tools, contact the
relevant tyre manufacturer.
Fig. 4 - Breaking Typical Tyre Bead
2 SM 1970 4-00
Section 160-0050
14. Using suitable lifting equipment, remove tyre from

WARNING rim. This completes the removal of the tubeless tyre.
When lifting tyre from the rim, be sure the
equipment is of sufficient capacity and properly 15. If necessary, remove inner flange (6).
secured to do the job safely.
Note: If tyre rim is on the vehicle, and no tyre lifting
1. Remove valve cap (7, Fig. 1) and valve core and equipment is available, 'walk' the tyre off the rim as
leave valve open to prevent trapping of air in tyre. Tape follows:
valve threads for protection.
Force bottom of tyre outward as far as possible; lower
2. If used, remove driver (2) from bead seat band (3) jack enough to allow weight of tyre to rest on ground;
and wheel rim (5). force top of tyre out as far as possible; raise jack to
original height and repeat the above until the tyre is off
3. Break outer tyre bead loose with pry bar shown in the rim.
Fig. 3.
4. Insert flat hooked end of pry bar into breaking slots INSPECTION
between bead seat band (3) and outer flange (1). See
Tyre
Fig. 4. A pipe over the straight end of the pry bar will
increase leverage. Check the interior surface of the tyre to determine its
condition. Inspect for cuts or fabric breaks that have
5. Twist pry bar toward tyre to break bead. penetrated the tyre body. The casing should be
inspected closely for any sharp , pointed object that
6. A second pry bar may be inserted in the space may have penetrated the tyre body but is invisible from
between bead seat band (3) and outer flange (1). Twist the outside. All dust, dirt, water or other foreign matter
the second pry bar to maintain the space gained by the should be cleaned from the inside of tyre.
first pry bar.
Rim Assembly
7. Move the first pry bar around wheel rim (5), twisting
and following with the second pry bar, until the outer Overloading, improper tyre inflation, rough terrain, high
tyre bead is loose. speed, accidents, dirt accumulation, and corrosion all
tend to reduce the service life of rims and rim
8. Pry bead seat band (3) away from lock ring (4) by components. It is recommended that rims be
placing hooked end of pry bar in the groove of wheel inspected, as below, not less often than at every tyre
rim (5), between ends of lock ring (4), and prying up change and that, as the warranty limit approaches,
with the pry bar. Using two pry bars, as in Step 7, work consideration be given to periodic replacement.
completely around wheel rim (5).
The rim and its components are designed with built-in
9. Pry lock ring (4) out in the same manner by starting safety factors, to prevent the components from flying
at prying notch in wheel rim (5) assembly, and work all off with killing force during inflation. Check
the way around wheel rim (5) with two pry bars. components for cracks, bends, distortion, or other
damage. If damage is found, the component must be
10. Remove and discard 'O' ring (2, Fig. 1). replaced.
11. Remove lock ring (4) then pry out and remove bead
seat band (3). WARNING
Never mix components of one manufacturer's
12. Breaking slots are provided inside the rims. The rims with those of another. Using the rim base
inner bead may be broken as described in Steps 4 of one manufacturer with the lock ring of
through 8. If the tyre and rim assembly is on the another or vice versa is dangerous. The lock
vehicle, the following procedure may be used for ring of one may not fully engage with the lock
breaking the inner bead. ring groove of the other. Always consult the
rim manufacturer for proper matching and
13. Place jack between inner flange (6) and vehicle assembly instructions.
frame. Extend jack until tyre bead is broken. Continue
around the rim until tyre bead is broken at all points.
SM 1970 4-00 3
Section 160-0050
SM - 207
WARNING (cont.)
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 tyre pressure causing serious
personal injury and property damage.
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 tyre.
The rim parts used with tubeless tyres form an

important part of the air chamber. Therefore, they
1 - Lock Ring 2 - Drive Lug
should be carefully checked for distortion or mutilation
that would prevent an effective air seal when the tyre Fig. 5 - Installing Typical Lock Ring
and rim are reassembled.
5. Install outer flange (1) on wheel rim (5).
Rubber 'O' rings are air seals for tubeless tyre and rim
assemblies and therefore should be carefully handled 6. Align lock ring driver notch in bead seat band (3)
to provide an airtight seal when the tyre is remounted with notch in wheel rim (5), and install bead seat band
on the rim. Always use new 'O' rings when mounting a on rim.
tubeless tyre.
7. On vehicles which use a driver (2), align driver slot
Note: Handle 'O' rings carefully, as damage will of bead seat band (3) with driver pocket of wheel rim
prevent an airtight seal for tyre inflation. (5) and install bead seat band (3) on wheel rim (5).
8. Install lock ring (4) in groove of wheel rim (5) so that

MOUNTING TYRE ON RIM lock ring lug engages both notches. Notches and lock
Numbers in parentheses refer to Fig. 2, unless ring lug must line up correctly. If necessary, use only a
otherwise specified. soft hammer to rotate the lug. Use pry bar for installing
lock ring (4), as shown in Fig. 5.
For mounting a tyre with rim on or off machine, the
procedure is basically the same. 9. 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 tyre to prevent
WARNING damage. Insert a new 'O' ring (2, Fig. 1) in groove of
When lifting tyre onto the rim, be sure the the rim behind lock ring (4). Lubricate area of front
equipment is of sufficient capacity and taper of bead seat band (3) adjacent to 'O' ring (2, Fig. 1),
properly secured to do the job safely. with a thin solution of soap and water or another
approved lubricant which is not harmful to rubber.
1. For off-machine installation, lay wheel rim (5) on Avoid using an excessive amount of lubricant.
blocks or mounting stand with 'O' ring groove up.
Wheel rim (5) should be off the floor enough to allow 10. If used, install driver (2). Make sure all rim
tyre to rest on rim and not the floor. Blocks are not to components are correctly assembled.
extend more than 13 mm (0.50 in) beyond rim base.
11. Lift the tyre upwards to effect a seal between bead
2. If removed, install inner flange (6) over wheel rim (5). seat band (3) and 'O' ring (2, Fig. 1). In some cases
the tyre will automatically spring out, making this step
3. Lubricate tyre beads and 'O' ring, with a thin solution unnecessary.
of vegetable base soap and water.
12. Refer to heading, 'Tyre Inflation' in this section for
4. Using suitable lifting equipment, lower tyre onto the proper procedure for inflating the tyre.
wheel rim (5). Seat tyre firmly against inner flange (6).
4 SM 1970 4-00
Section 160-0050
MOUNTING TYRE AND RIM ASSEMBLY

A.
ON MACHINE Use an air compressor and reservoir located
Numbers in parentheses refer to Fig. 1. inside a heated building, when available, so
that alcohol, methanol, or other flammable
antifreeze liquids are not needed in the air
WARNING tanks to prevent moisture freezing in the tank
To prevent personal injury and property and lines in subfreezing outside
damage, be sure blocking materials and lifting temperatures.
adequate capacity to do the job safely. B.
Make sure that paints, lacquers, paint
1. Support tyre and rim assembly with a suitable thinners, or similar materials that produce
chain, or rope sling. Attach sling to overhead lifting volatile, flammable vapours are not used or
device. Slide assembly onto wheel of the vehicle, with stored near the air intake of the compressor
lock ring (4) and bead seat band (3) facing outward. that supplies the air for inflating tyres. The
compressor should be isolated from all such
2. Install lock washers (9) and wheel nuts (10) on sources of flammable vapours.
wheel studs. Gradually tighten wheel nuts opposite
each other until all wheel nuts are snug. Tighten wheel C.
nuts (10) to a torque of 590 Nm (435 lbf ft). Tighten Be sure to thoroughly flush and blow off all
wheel nuts (10) again, after 10 hours of operation. flammable solvents used for cleaning the air
compressor inlet screen before using the
compressor for tyre inflation, or any other
TYRE INFLATION purpose.
D.
WARNING Do not charge batteries, either in or out of a
To prevent personal injury and property machine, near the air inlet of a compressor
damage, the tyre and rim assembly should be used for inflating tyres. Charging batteries
placed in a safety cage before inflating. If no produces highly explosive hydrogen gas
safety cage is available or tyre is on the which can be readily drawn into a nearby
machine, the tyre and rim assembly should be compressor inlet and pumped into the tyre.
wrapped with safety chains or with lash cables
before inflating. E.
Never exceed the specified concentration of
Even with these precautions remember that alcohol when adjusting the alcohol vaporizer,
air-blast is a potential hazard. Tyre inflation or adding alcohol to the auxiliary air tank,
should be carried out away from busy working used on machine air systems to prevent
areas. freezing or moisture condensate in below-
freezing temperatures. Excessive alcohol,
WARNING added to the machines air tanks in this
To avoid personal injury and property damage, manner can produce flammable vapours that
never stand or sit in front of a mounted tyre will be pumped into a tyre when this air
during tyre inflation. Use a clip-on air chuck supply is used for tyre inflation if the tyre
with a long hose and stand to one side while inflation kit is not equipped with a moisture
the tyre is being inflated. filter. Alcohol added to machine air systems
in recommended concentration to prevent
WARNING condensate freezing are below hazardous
To prevent personal injury and property levels for tyre inflation.
damage, always prevent flammable vapours
that could produce tyre explosions, from being F.
pumped into tyres during inflation, by Another source of hazardous flammable
observing the following precautions: vapours in tyres is the tyre bead lubricant.
Always use bead lubricants that do not
introduce flammable vapours into the tyre.
SM 1970 4-00 5
Section 160-0050
SM - 208 All machines whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on the body
or frame.
Nitrogen gas improves tyre pressure retention,

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

should be used for nitrogen inflation. Tyre valves
formerly used with air inflation are entirely satisfactory
for use with nitrogen gas.
Nitrogen Tyre Inflation Kit
WARNINGS
Fig. 6 - Typical Safety Cage DO NOT USE charging assembly, Part No.
9359489, for tyre inflation because this
assembly does not include a pressure
Inflation regulator, safety relief valve, and adequate
Note: Always use tyre inflation equipment with an air pressure gauging which is mandatory for tyre
filter that removes moisture from the air supply, when inflation purposes. Tyre volume is as much as
available, to prevent moisture corrosion of internal rim 90 times greater than the average accumulator
parts. volume and hence it takes very much longer to
inflate a tyre - up to 40 minutes or more for
1. Inflate tyre to 1 bar (15 lbf/in) initially to seat very large tyres.
components and tap lock ring lightly to ensure correct
seating. Visually check that all components are in Nitrogen gas cylinders used to inflate
place, then continue inflation observing all safety tyres are generally charged to approximately
precautions. (See Step 2). 152 bar (2 200 lbf/in2). A tyre blowout and/or
rim failure could occur if inflation equipment is
2. If the tyre is off the machine, place it in a safety not properly used. Proper nitrogen charging
cage after initially inflating to 1 bar (15 lbf/in) to seat equipment and personnel training for its use is
components. See Fig. 6. a must to avoid over inflation.
3. Inflate tyres to 5.2 bar (75 lbf/in) to seat beads and 1. A nitrogen tyre inflation kit is available from your
seal the 'O' ring, then adjust to the recommended dealer and consists of the following. Refer to Fig. 7.
inflation pressure.
a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with
4. For recommended operating air pressure, refer to two dual pressure gauges.
the 'Tyre Inflation Pressures' table.
b. Safety relief valve, 8.6 bar (125 lbf/in), that will
assure an upper limit to the pressure available for tyre
NITROGEN TYRE INFLATION inflation.
Note: All Warnings and procedures under 'Tyre
Inflation' will apply, except for differences covered by c. A 15.2 m (50 ft) length of flexible hose with
this passage. interconnecting fittings. On the tyre end of the hose is
a large bore quick connect/disconnect clip-on chuck.
In certain environments it is recommended that tyres
be inflated with dry nitrogen gas, and that the resulting 2. The pressure regulator is connected to a nitrogen
oxygen content of the inflation does not exceed 5%. compressed gas cylinder available from local suppliers.
6 SM 1970 4-00
Section 160-0050
SM - 1040 Re-inflation of a Mounted Tyre

To re-inflate a tyre with dry nitrogen gas which is now
inflated with air, proceed as follows:
1. Exhaust the tyre until only air at atmospheric

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

4.15 bar (60 lbf/in) gauge as a minimum, or to bead-
seating pressure as a maximum.
3. Adjust to the service inflation pressure required:
a. If the required service inflation pressure is LESS

than 4.1 bar (60 lbf/in), remove the clip-on chuck and
adjust the pressure with the tyre gauge in the usual
manner.
b. If the required service inflation pressure is greater

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

Fig. 7 - Nitrogen Tyre Inflation Kit
To newly mount or remount a tyre to its rim, use only
dry nitrogen gas; this includes the pressure required to
3. The usual procedure for using this type of seat the beads. After seating the tyre beads, remove
equipment is as follows: the clip-on chuck and adjust the pressure with the tyre
gauge in the usual manner.
a. Connect nitrogen tyre inflation kit to nitrogen
compressed gas supply. DO NOT connect clip-on Note: Although a little more nitrogen gas is used to
chuck to the tyre valve at this time. seat beads than that used for re-inflation of a mounted
tyre, refer to 'Re-inflation of a Mounted Tyre', its cost is
b. Open valve on nitrogen supply. generally negligible in comparison to the time and
labour saving and, longer tyre life achievable with the
c. With flexible hose and clip-on chuck connected to reduced oxygen content which results.
nitrogen tyre inflation kit assembly but not connected
to the tyre, adjust pressure regulator so that its output
pressure is not more than 1.4 bar (20 lbf/in) higher TYRE EXPLOSION HAZARD
than the desired tyre inflation pressure.
d. Connect clip-on chuck to the tyre valve. The tyre will WARNING
now inflate. Tyre pressure can be monitored by Whenever a machines tyre(s) is (are) exposed
observing the gauge at the pressure regulator. STAY to excessive heat such as a machine fire or
AWAY FROM THE TYRE. extremely hot brakes the hazard of a
subsequent violent tyre explosion must be
e. When desired inflation pressure has been achieved, recognized. All persons must avoid
back off the regulator or close the valve on the approaching the machine so as not to be
compressed gas cylinder. physically endangered in the event of an
explosion of the tyre and rim parts.
f. Remove the clip-on chuck and adjust the tyre
pressure with the tyre gauge in the usual manner.
SM 1970 4-00 7
Section 160-0050
SM - 1041
WARNING (cont.)
The machine should be moved to a remote AT LEAST AT LEAST
15 m (50 ft) 460 m (1 500 lbf ft)
area, but only when this can be done with
complete safety to the operator operating or
towing the machine. All other persons should
stay clear of the machine. The fire or
overheated brakes, wheel, etc. should be
extinguished or cooled from a safe distance.
Do not attempt to extinguish the fire or cool
the machine by use of hand-held fire
extinguishers.
If it is absolutely necessary to approach a

machine with a suspect tyre, approach only
from the front or the back. Stay at least 15 m
(50 ft) from the tread area. Keep observers out
of the area and at least 460 m (1 500 ft) from
the tyre sidewall. Refer to Fig. 8. The tyre(s)
should be allowed at least eight (8) hours
cooling time after the machine is shut down or
the fire extinguished before approaching
closer.
Fig. 8 - APPROACH AREA.
Do Not Approach Tyre in Shaded Area
There is always a possibility of a tyre
explosion whenever the smell of burning
rubber or excessively hot brakes is detected. TYRE AND WHEEL RIM MAINTENANCE
The danger is also present when a fire on the
machine reaches the tyre and wheel area. Tyre Repairs
Under such conditions, all personnel must Prompt repair of tyre injuries will prevent small injuries
avoid approaching the machine in a manner from enlarging and causing tyre failure. Use the best
that could result in injury should an explosion tyre facilities available. If good repair facilities are not
actually occur. Move the machine to a remote available, have the nearest dealer make the necessary
area only if it can be done without endangering repairs.
the operator or other personnel in the area.
Minor cuts, snags, or punctures should be repaired
upon discovery. Skive with a sharp pointed knife
WARNING around any cut in the tyre tread area that is of
DO NOT WELD ON OR HEAT RIM sufficient depth or shape to hold pebbles or dirt. The
COMPONENTS. For several years the company angle of the skive should be no more than sufficient to
and tyre and rim manufacturers have warned expel all foreign material and should extend no deeper
users never to weld rim components with the than the breaker. The skive should go to the bottom of
tyre mounted on the rim. The gases that build the hole. Tyres with shallow cuts, if treated promptly,
up inside the tyre during arc welding or may be allowed to continue in service. If the cut
heating on rim components can ignite, extends deeper into the tyre carcass, the tyre should
resulting in one of these explosive-like failures be removed for repair.
of the tyre and rim. This warning also applies
to nitrogen inflated tyres. Ignition will not The tyre must be removed from the rim to repair larger
occur in the nitrogen atmosphere, but the punctures or cuts. Irregular shaped punctures or cuts
pressure buildup from the heat of welding may less than 13 mm (0.50 in) in size can be repaired with
be sufficient to cause a blowout severe enough a plug and hot patch. Insert a repair plug into the hole
to injure or kill. It is recommended to scrap the to keep out moisture and to back up the hot patch.
part if heat is necessary to repair any rim Trim the plug off flush with the inside of the casing,
component. buff, and apply the hot patch according to the
instructions supplied with the hot patch equipment.
8 SM 1970 4-00
Section 160-0050
Punctures 13 mm (0.50 in) or larger, large cuts, or Inspect Tyres Regularly

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

The most common cause of tyre damage is improper The best of care given to tyres in service by operators
inflation. Both over-inflation and under-inflation are and maintenance personnel can be completely
detrimental to tyre life. Tyre pressure should be nullified by careless storage. Time is not the only
checked daily, preferably before the machine is placed contributing factor to the deterioration of rubber
in operation. Refer to 'Tyre Inflation Pressures' table. products. Therefore, tyres that are to be stored must
be protected from light, heat, oils, dirt, moisture, and
The valve cores should be checked for leaks. Keep in ozone. Stored tyres should be carefully covered with a
mind that valve cores are delicate mechanisms that tarpaulin or some other suitable material, such as
wear out in service; therefore, they should be replaced opaque plastic sheeting, to prevent contact with the
with new ones when they become worn. Each tyre contaminants listed above.
should be equipped with a valve cap to prevent dirt
from damaging the valve core and causing air leakage.
Proper Handling of Tyres and Wheel Rim
Parts
Maintain Good Haul Roads Tyres should be stored vertically. Horizontal stacking
Because haul roads are considered temporary roads may compress the tyre walls, making inflation difficult. If
they are frequently neglected. The better the haul road, tyres are stored in racks, the lower supporting members
the longer the tyre and machine life of off-highway should provide as broad a surface as possible to the tyre
machines. tread to avoid a concentration of load.
Although it takes time and effort to maintain good haul The beads of tubeless tyres must be protected from
roads, the delay and cost of tyres and machine damage or a faulty air seal will result. Do not use
breakdowns caused by poor haul roads is many times hooks, cables, or chains in contact with the tyre beads
greater.
SM 1970 4-00 9
Section 160-0050
when lifting these tyres. If forklift trucks are used for 'O' rings are seals and should be carefully stored in a
handling, they should be equipped with broad, well- cool, dry place where they will not be injured or
rounded arms to distribute the load and prevent damaged.
damage to the tyre bead. When handling tyres with the
fork truck do not scrape the fork across the bead. Valve cores should also be stored in a cool, dry and
clean place.
Tubeless tyre 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 MAINTENANCE
because they must mate properly to form part of the Check tyre pressures daily, preferably before the
basic air chamber. Since the rim base and bead seat machine is placed in operation. Refer to 'Tyre Inflation
band are mating surfaces, distortion may prevent easy Pressures' table.
assembly as well as possibly resulting in no seal.
Every 50 hours of operation (weekly), torque tighten
Never drop, tumble, or roll rim parts. wheel rim nuts to 590 Nm (435 lbf ft).
If rim parts are stored outdoors, they should be given a Check tyres regularly and replace or repair if required.
protective coat of a good commercial primer.
Similar parts should be stacked neatly to prevent distortion. SERVICE TOOLS

The nitrogen tyre inflation kit shown in Fig. 7 is
Babbit or lead hammers, not sledge hammers, should available from your dealer. Refer to Section 300-0070,
be used in assembling rim parts. SERVICE TOOLS for part numbers of general service
tools required.
TYRE INFLATION PRESSURES (BRIDGESTONE)

FRONT CENTRE AND REAR
2
MODEL TYRE SIZE bar lbf/in bar lbf/in2
23.5 R 25** 4 58 4.8 69
TA30
30/65 R 25 4.3 62 4.3 62
10 SM 1970 4-00
Section 160-0050
TUBELESS TYRE LEAK DIAGNOSIS

Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of leakage,
the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be checked
using a soap solution.
This table lists various causes of air loss and possible remedy.
CAUSE REMEDY
Defective valve Tighten parts. Replace defective parts. Use valve caps.
Cracked rim or weld Replace defective part
WARNING
Do not attempt repair of wheel components.
Twisted or damaged 'O' ring Replace 'O' ring (lubricate)
Tyre cuts and snags Repair tyre damage
Bead area awl holes Repair inner liner (preferred)
Leakage between tyre bead trim With tyre removed from rim:
Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5 degree tapered bead seat band and the rim base in the bead
seating area to determine if the transverse weld trims are flat or concave.
Replace defective part(s).
Note: Weld trim should follow rim contour.
Mount tyre using a lubricant such as Murphy's Tyre and tube Mounting
Compound, or equivalent, on tyre beads and rim bead seat area.

TORQUE
1 10 Wheel Nut 590 435
* * * *
SM 1970 4-00 11
BRAKE PARTS - Brake Parts - Rear
Section 165-0010
SM - 048
1 - Capscrew 3 - Brake Heads

2 - Brake Disc 4 - Bolt 5 - Washer
Fig. 1 - Cutaway View of Typical Brake Head and Disc Mounting
DESCRIPTION AND OPERATION GENERAL INSPECTION

The service brakes are of the calliper disc-type. The 1. Inspect brake pads for wear. If the brake pad
calliper brake head is designed for use with hydraulic friction material is worn down to 3 mm (0.12 in)
brake fluid. The head is bolted to a mounting plate on thickness, the pads must be replaced.
the axle housing. The disc is bolted to the wheel. There
is one brake head and one brake disc at each wheel. 2. Inspect brake disc as follows:
Each calliper brake head assembly consists of a a. Measure original thickness of disc at outside
torque plate, two brake pads, one on each side of the diameter (this area is not contacted by brake pad
brake disc, and four brake pistons, two on each side friction material).
of the brake disc.
b. Measure thickness of disc at three points on the
The brake is actuated by hydraulic brake fluid brake pad friction material contact circumference and
entering the brake head through one of the bleeder determine the average disc thickness.
ports. The piston bores on each side of the torque
plate are interconnected by internal passages. c. Subtract 'b' from 'a'. If difference is 3 mm (0.12 in)
or greater, the disc must be replaced.
When the brake is actuated, the hydraulic pressure
forces the pistons against the brake pads which are, Note: Refer to Section 160-0030, AXLE GROUP
in turn, forced against each side of the brake disc, (HUB), for brake disc replacement instructions.
slowing or stopping the disc and wheel rotation.
SM 1962 4-00 1
Brake Parts - Brake Parts - Rear
Section 165-0010
SM - 049
1 - Bleeder Valve 5 - Torque Pin 9 - Piston Plug 13 - Packing

2 - Screw 6 - Bolt 10 - Seal 14 - Backup Ring
3 - Torque Pin 7 - Washer 11 - Piston 15 - Dust Cap
4 - Brake Pads 8 - Cover Plate 12 - Boot 16 - Torque Plate
Fig. 2 - Exploded View of Typical Brake Head
BRAKE PAD REMOVAL AND 1. Position the vehicle in a level work area, apply the
INSTALLATION parking brake and switch off the engine.
2. Block all road wheels, except the wheel to be
removed, and place the battery master switch in the
WARNINGS 'Off' position.
damage, be sure wheel blocks, blocking 3. Remove wheel from the machine following
materials and lifting equipment are properly instructions in Section 160-0050, WHEEL RIM AND
secured and of adequate capacity to do the job TYRE.
safely.
4. Loosen bolts (2) securing large torque pins (3) at
To prevent personal injury and property the end of torque plate (16). It is not necessary to
damage, the procedure for removing tyre and loosen or remove the two smaller torque pins (5) at
rim assembly described in Section 160-0050, opposite end.
WHEEL RIM AND TYRE, must be strictly
followed. 5. Move the two unlocked torque pins (3) away from
Keep brake fluid reservoir full at all times.
6. Remove dust cap (15) from bleeder valve (1) and
2 SM 1962 4-00
Section 165-0010
attach a bleeder hose to bleeder valve. Open bleeder BRAKE REMOVAL AND DISASSEMBLY
valve (1). Use a screwdriver or pry bar inserted Numbers in parentheses refer to Fig. 2, unless
between brake disc (2, Fig. 1) and brake pads (4) to otherwise specified.
press pistons (11) back as far as possible, into the
piston bores of torque plate (16). Close bleeder valve.
WARNINGS
7. Rotate brake pads (4) out of the opened end of To prevent personal injury and property
torque plate (16). damage, be sure wheel blocks, blocking
8. Install new brake pads (4) by placing friction secured and of adequate capacity to do the job
material next to the disc and rotating into position in safely.
torque plate (16).
9. Push the two unlocked pins (3) towards the disc. damage, the procedure for removing tyre and
10. Thread the two loosened bolts (2) in until bolts WHEEL RIM AND TYRE, must be strictly
seat in grooves of torque pins (3). This can be followed.
checked by limited axial movement of pins as the
bolts are being seated. Tighten bolts (2) to a torque of 1. Position the vehicle in a level work area, apply the
30 - 38 Nm (22 - 28 lbf ft). parking brake and switch off the engine.
Note: Make sure torque pins (3 & 5) do not touch 2. Block all road wheels, except the wheel to be
brake disc (2, Fig. 1). If they do, loosen bolts (2) and removed, and place the battery master switch in the
adjust torque pins to clear disc by 1.5 - 3.0 mm 'Off' position.
(0.06 - 0.12 in). Check to make sure that bolts (2)
fully engage in torque pin grooves and retighten bolts. 3. Remove wheel from the machine following
instructions in Section 160-0050, WHEEL RIM AND
11. Pump brake pedal until brake pads (4) contact TYRE.
4. Remove hydraulic fluid inlet line at brake head
12. When new brake pads are installed on a machine, assembly. Plug line and brake head to prevent
the brake pad friction material should be burnished in ingress of dirt.
accordance with the following procedure to achieve
maximum braking performance: 5. Remove bolts (4, Fig. 1) and washers (5, Fig. 1)
from mounting at axle housing and remove brake
a. Drive vehicle at 8 - 30 km/h (5 - 20 mile/h) with head assembly to a clean working area.
brakes applied at just enough pressure to produce a
noticeable drag. Heavy smoke and foul odour from
the brake pad friction material is normal during this WARNING
procedure. Hydraulic fluid may cause irritation. Avoid
skin and eye contact with fluid.
b. Continue cycle until the brake disc achieves a
temperature of 315 - 370 C (600 - 700 F). A 6. Disassemble brake head assembly in sequence of
surface pyrometer applied to the disc after stopping index numbers in Fig. 2. Items (1, 2 & 3) may be left in
will determine temperature. torque plate (16) when servicing packings (13), seals
(10), backup rings (14), and boots (12) if desired.
c. Permit disc to cool to less than 95 C (200 F).
Note: Repair kits are available which include new
d. Repeat Steps a and b. boots (12), backup rings (14), packings (13) and
seals (10), in quantities sufficient to rebuild a calliper
e. Allow brake to cool to within 10 C (50 F) of brake head. Refer to vehicle parts book for repair kit
ambient temperature. part number. All parts included in a repair kit should
be replaced each time a brake head is rebuilt.
f. Repeat Steps a and b until full braking performance
(per applicable government regulations) is achieved.
SM 1962 4-00 3
Section 165-0010
7. Inspect brake pads (4) per Step 1 in 'General 7. Attach cover plate (8) to torque plate (16) and
Inspection' procedure. secure with bolts (6) and washers (7). Tighten bolts (6)
8. Clean torque plate (16) making sure no solvent
remains in fluid passages or grooves. Inspect boot 8. When installing torque pins (3 & 5) and bolts (2)
(12) and seal (10) grooves, and land areas between make sure the groove in the pin is directly under the
grooves for damage or cracks. Minor nicks and bolt so the bolt can perform its locking and retaining
scratches may be blended with crocus cloth. Replace function.
torque plate (16) if corrosion is excessive or boot
(12) and seal (10) grooves are damaged, prohibiting Note: Lubricate torque pins (3 & 5) with a corrosion
proper rebuild of the brake head. resistant lubricant prior to installation to facilitate next
pin removal.
9. Inspect pistons (11) for minor scratches and nicks
and blend with crocus cloth. If piston (11) is badly 9. Inspect brake disc (2, Fig. 1), if worn, per
nicked or scratched, or if the chrome plate is worn instructions under 'General Inspection' in this section.
off, replace piston (11). Refer to Section 160-0030, AXLE GROUP (HUB) for
brake disc replacement instructions.
10. Torque pins (3 & 5) that are deeply grooved
should be replaced.
INSTALLATION
ASSEMBLY otherwise specified.
WARNINGS
1. Lubricate seals (10), packings (13) and pistons To prevent personal injury and property
(11) with grease provided in seal kit or automotive damage, be sure wheel blocks, blocking
brake fluid (SAE J 1703) or castor oil. Do not use materials and lifting equipment are properly
petroleum type oils or lubricants. secured and of adequate capacity to do the job
safely.
2. Install backup rings (14), packings (13) and boots
(12) in torque plate (16) piston bores. Lubricate per To prevent personal injury and property
Step 1. damage, the procedure for installing tyre and
3. Install pistons (11) in torque plate (16) as follows: WHEEL RIM AND TYRE, must be strictly followed.
Position lubricated piston (11) into boot (12) and piston
bore, holding piston at a slight angle. Insert forefinger 1. Install washers (5) on bolts (4).
between piston (11) and boot (12) and rotate forefinger
around outside diameter of piston (11), lifting inside 2. Position brake head (3) over brake disc (2) on
diameter of boot (12) over outside diameter of piston brake mounting plate, aligning bolt holes. Install
(11). Make sure outside diameter lip of boot (12) remains assembled bolts (4) and washers (5) through
in the groove in piston (11) bore. mounting plate and into torque plate. Tighten bolts (4)
4. After piston (11) is through boot (12), centre piston
by feel over packing (13). Apply by hand, a turning Note: Make sure torque pins (3 & 5, Fig. 2) do not
thrusting pressure, working piston (11) into and touch brake disc (2). If they do, loosen bolts (2, Fig.
through packing (13). 2) and adjust pins to clear disc by 1.5 - 3.0 mm
(0.06 - 0.12 in). Check to make sure that bolt (2, Fig. 2)
5. When assured pistons (11) are through packings fully engages in pin groove and tighten bolt (2, Fig. 2)
(13), pressure other than hand pressure may be used to a torque of 30 - 38 Nm (22 - 28 lbf ft).
to press pistons the remainder of the way into the
piston bores. Snap open end of boot (12) into groove 3. Attach hydraulic inlet lines at brake head
of piston (11). assembly.
6. Lubricate seals (10) and install seals and piston 4. Install wheel on the vehicle following instructions in
plugs (9) in open end of piston bores of torque plate (16). Section 160-0050, WHEEL RIM AND TYRE.
4 SM 1962 4-00
Section 165-0010
BLEEDING Inspect brake head assembly to ensure that all bolts

Numbers in parentheses refer to Fig. 2. are tight and there are no leaks. Inspect for boot
deterioration.
In order to obtain satisfactory braking, the system
should be bled as follows to eliminate any air in the Every 250 Hours (Monthly)
hydraulic brake lines. Check pads and discs for wear and adjust or replace
where necessary. Test for proper function.
1. Fill the hydraulic fluid reservoirs with hydraulic
brake fluid specified in Section 300-0020, Note: This service interval applies to normal driving.
LUBRICATION SYSTEM. Check the pads more frequently under more severe
conditions.
2. Remove dust cap (15) from bleeder valve (1) and
connect a bleeder hose to bleeder valve (1). Place Thickness of pad friction material should never be
loose end of hose in clean container. allowed to wear below 3 mm (0.12 in).
Note: Keep fluid reservoirs filled during bleeding process. Note: Repair kits are available which include new
boots (12), backup rings (14), packings (13) and
3. Actuate brake treadle valve several times. seals (10), in quantities sufficient to rebuild a calliper
brake head. Refer to vehicle parts book for repair kit
4. Apply brake and open bleeder valve (1). After fluid part number. All parts included in a repair kit should
flow stops, close bleeder valve (1) and release the be replaced each time a brake head is rebuilt.
brake.
Every 2 000 Hours (Annually)
Note: If loose end of bleeder hose is kept submerged Drain brake fluid, refill reservoirs and bleed the
in brake fluid, bleeder valve (1) need not be closed brakes. Refer to Section 300-0020, LUBRICATION
each time brake is released. SYSTEM for brake fluid specification and system
capacities.
5. Repeat procedure in Step 4 until no air bubbles are
observed in fluid coming from bleeder valves.
SERVICE TOOLS
6. Repeat Steps 1 through 5 at each brake head There are no special tools required for the
assembly. procedures outlined in this section. Refer to Section
300-0070, SERVICE TOOLS, for part numbers of
general service tools. These tools are available from
MAINTENANCE your dealer.
Every 10 Hours (Daily)

Inspect brake fluid level and add brake fluid if low.
Refer to Section 300-0020, LUBRICATION SYSTEM.

TORQUE
1 4 Bolt 510 380
2 2 Bolt 30 - 38 22 - 28
2 6 Bolt 380 280
* * * *
SM 1962 4-00 5
BRAKE PARTS - Brake Parts - Front
Section 165-0020
SM - 2477
1,5
4,5
4,5
1,5
1 - Capscrew 3 - Brake Head

2 - Brake Disc 4 - Bolt 5 - Washer
Fig. 1 - Cutaway View of Typical Brake Head and Disc Mounting
DESCRIPTION AND OPERATION GENERAL INSPECTION

The service brakes are of the calliper disc-type. The 1. Inspect brake pads for wear. If the brake pad
calliper brake head is designed for use with hydraulic friction material is worn down to 3 mm (0.12 in)
brake fluid. The head is bolted to a mounting plate on thickness, the pads must be replaced.
the axle housing. The disc is bolted to the wheel. There
are two brake heads and one brake disc at each 2. Inspect brake disc as follows:
wheel.
a. Measure original thickness of disc at outside
Each calliper brake head assembly consists of a diameter (this area is not contacted by brake pad
torque plate, two brake pads, one on each side of the friction material).
brake disc, and four brake pistons, two on each side
of the brake disc. b. Measure thickness of disc at three points on the
brake pad friction material contact circumference and
The brake is actuated by hydraulic brake fluid determine the average disc thickness.
entering the brake head through one of the bleeder
ports. The piston bores on each side of the torque c. Subtract 'b' from 'a'. If difference is 3 mm (0.12 in)
plate are interconnected by internal passages. or greater, the disc must be replaced.
When the brake is actuated, the hydraulic pressure Note: Refer to Section 160-0030, AXLE GROUP
forces the pistons against the brake pads which are, (HUB), for brake disc replacement instructions.
in turn, forced against each side of the brake disc,
slowing or stopping the disc and wheel rotation.
SM 1961 4-00 1
Brake Parts - Brake Parts - Front
Section 165-0020
SM - 049
1 - Bleeder Valve 5 - Torque Pin 9 - Piston Plug 13 - Packing

2 - Screw 6 - Bolt 10 - Seal 14 - Backup Ring
3 - Torque Pin 7 - Washer 11 - Piston 15 - Dust Cap
4 - Brake Pads 8 - Cover Plate 12 - Boot 16 - Torque Plate
Fig. 2 - Exploded View of Typical Brake Head
BRAKE PAD REMOVAL AND 1. Position the vehicle in a level work area, apply the
INSTALLATION parking brake and switch off the engine.
2. Block all road wheels, except the wheel to be
removed, and place the battery master switch in the
WARNINGS 'Off' position.
damage, be sure wheel blocks, blocking 3. Remove wheel from the machine following
materials and lifting equipment are properly instructions in Section 160-0050, WHEEL RIM AND
secured and of adequate capacity to do the job TYRE.
safely.
4. Loosen bolts (2) securing large torque pins (3) at
To prevent personal injury and property the end of torque plate (16). It is not necessary to
damage, the procedure for removing tyre and loosen or remove the two smaller torque pins (5) at
rim assembly described in Section 160-0050, opposite end.
WHEEL RIM AND TYRE, must be strictly
followed. 5. Move the two unlocked torque pins (3) away from
Keep brake fluid reservoir full at all times.
2 SM 1961 4-00
Section 165-0020
6. Remove dust cap (15) from bleeder valve (1) and f. Repeat Steps a and b until full braking performance
attach a bleeder hose to bleeder valve. Open bleeder (per applicable government regulations) is achieved.
valve (1). Use a screwdriver or pry bar inserted
between brake disc (2, Fig. 1) and brake pads (4) to
press pistons (11) back as far as possible, into the BRAKE REMOVAL AND DISASSEMBLY
piston bores of torque plate (16). Close bleeder Numbers in parentheses refer to Fig. 2, unless
valve. otherwise specified.
7. Rotate brake pads (4) out of the opened end of

torque plate (16). WARNINGS
8. Install new brake pads (4) by placing friction damage, be sure wheel blocks, blocking
material next to the disc and rotating into position in materials and lifting equipment are properly
torque plate (16). secured and of adequate capacity to do the job
safely.
9. Push the two unlocked pins (3) towards the disc.
10. Thread the two loosened bolts (2) in until bolts damage, the procedure for removing tyre and
seat in grooves of torque pins (3). This can be rim assembly described in Section 160-0050,
checked by limited axial movement of pins as the WHEEL RIM AND TYRE, must be strictly
bolts are being seated. Tighten bolts (2) to a torque of followed.
30 - 38 Nm (22 - 28 lbf ft).
Note: Make sure torque pins (3 & 5) do not touch parking brake and switch off the engine.
brake disc (2, Fig. 1). If they do, loosen bolts (2) and
adjust torque pins to clear disc by 1.5 - 3.0 mm 2. Block all road wheels, except the wheel to be
(0.06 - 0.12 in). Check to make sure that bolts (2) removed, and place the battery master switch in the
fully engage in torque pin grooves and retighten bolts. 'Off' position.
11. Repeat steps 4 to 10 for second brake calliper. 3. Remove wheel from the machine following
instructions in Section 160-0050, WHEEL RIM AND
12. Pump brake pedal until brake pads (4) contact TYRE.
4. Remove hydraulic fluid inlet line at brake head
13. When new brake pads are installed on a machine, assembly. Plug line and brake head to prevent
the brake pad friction material should be burnished in ingress of dirt.
accordance with the following procedure to achieve
maximum braking performance: 5. Remove bolts (4, Fig. 1) and washers (5, Fig. 1)
from mounting at axle housing and remove brake
a. Drive vehicle at 8 - 30 km/h (5 - 20 mile/h) with head assembly to a clean working area.
brakes applied at just enough pressure to produce a
noticeable drag. Heavy smoke and foul odour from
the brake pad friction material is normal during this WARNING
procedure. Hydraulic fluid may cause irritation. Avoid
skin and eye contact with fluid.
b. Continue cycle until the brake disc achieves a
temperature of 315 - 370 C (600 - 700 F). A 6. Disassemble brake head assembly in sequence of
surface pyrometer applied to the disc after stopping index numbers in Fig. 2. Items (1, 2 & 3) may be left in
will determine temperature. torque plate (16) when servicing packings (13), seals
(10), backup rings (14), and boots (12) if desired.
c. Permit disc to cool to less than 95 C (200 F).
d. Repeat Steps a and b. boots (12), backup rings (14), packings (13) and
seals (10), in quantities sufficient to rebuild a calliper
e. Allow brake to cool to within 10 C (50 F) of brake head. Refer to vehicle parts book for repair kit
ambient temperature.
SM 1961 4-00 3
Section 165-0020
part number. All parts included in a repair kit should 6. Lubricate seals (10) and install seals and piston
be replaced each time a brake head is rebuilt. plugs (9) in open end of piston bores of torque plate (16).
7. Inspect brake pads (4) per Step 1 in 'General 7. Attach cover plate (8) to torque plate (16) and
Inspection' procedure. secure with bolts (6) and washers (7). Tighten bolts (6)
8. Clean torque plate (16) making sure no solvent
remains in fluid passages or grooves. Inspect boot 8. When installing torque pins (3 & 5) and bolts (2)
(12) and seal (10) grooves, and land areas between make sure the groove in the pin is directly under the
grooves for damage or cracks. Minor nicks and bolt so the bolt can perform its locking and retaining
scratches may be blended with crocus cloth. Replace function.
torque plate (16) if corrosion is excessive or boot
(12) and seal (10) grooves are damaged, prohibiting Note: Lubricate torque pins (3 & 5) with a corrosion
proper rebuild of the brake head. resistant lubricant prior to installation to facilitate next
pin removal.
9. Inspect pistons (11) for minor scratches and nicks
and blend with crocus cloth. If piston (11) is badly 9. Inspect brake disc (2, Fig. 1), if worn, per
nicked or scratched, or if the chrome plate is worn instructions under 'General Inspection' in this section.
off, replace piston (11). Refer to Section 160-0030, AXLE GROUP (HUB) for
brake disc replacement instructions.
10. Torque pins (3 & 5) that are deeply grooved
should be replaced.
INSTALLATION
ASSEMBLY otherwise specified.
WARNINGS
1. Lubricate seals (10), packings (13) and pistons To prevent personal injury and property
(11) with grease provided in seal kit or automotive damage, be sure wheel blocks, blocking
brake fluid (SAE J 1703) or castor oil. Do not use materials and lifting equipment are properly
petroleum type oils or lubricants. secured and of adequate capacity to do the job
safely.
2. Install backup rings (14), packings (13) and boots
(12) in torque plate (16) piston bores. Lubricate per To prevent personal injury and property
Step 1. damage, the procedure for installing tyre and
3. Install pistons (11) in torque plate (16) as follows: WHEEL RIM AND TYRE, must be strictly followed.
Position lubricated piston (11) into boot (12) and piston
bore, holding piston at a slight angle. Insert forefinger 1. Install washers (5) on bolts (4).
between piston (11) and boot (12) and rotate forefinger
around outside diameter of piston (11), lifting inside 2. Position brake head (3) over brake disc (2) on
diameter of boot (12) over outside diameter of piston brake mounting plate, aligning bolt holes. Install
(11). Make sure outside diameter lip of boot (12) remains assembled bolts (4) and washers (5) through
in the groove in piston (11) bore. mounting plate and into torque plate. Tighten bolts (4)
4. After piston (11) is through boot (12), centre piston
by feel over packing (13). Apply by hand, a turning Note: Make sure torque pins (3 & 5, Fig. 2) do not
thrusting pressure, working piston (11) into and touch brake disc (2). If they do, loosen bolts (2, Fig.
through packing (13). 2) and adjust pins to clear disc by 1.5 - 3.0 mm
(0.06 - 0.12 in). Check to make sure that bolt (2, Fig. 2)
5. When assured pistons (11) are through packings fully engages in pin groove and tighten bolt (2, Fig. 2)
(13), pressure other than hand pressure may be used to a torque of 30 - 38 Nm (22 - 28 lbf ft).
to press pistons the remainder of the way into the
piston bores. Snap open end of boot (12) into groove 3. Attach hydraulic inlet lines at brake head
of piston (11). assembly.
4 SM 1961 4-00
Section 165-0020
4. Install wheel on the vehicle following instructions in MAINTENANCE

Section 160-0050, WHEEL RIM AND TYRE. Numbers in parentheses refer to Fig. 2.
Every 10 Hours (Daily)

BLEEDING Inspect brake fluid level and add brake fluid if low.
Numbers in parentheses refer to Fig. 2. Refer to Section 300-0020, LUBRICATION SYSTEM.
In order to obtain satisfactory braking, the system Inspect brake head assembly to ensure that all bolts
should be bled as follows to eliminate any air in the are tight and there are no leaks. Inspect for boot
hydraulic brake lines. deterioration.
1. Fill the hydraulic fluid reservoirs with hydraulic Every 250 Hours (Monthly)
brake fluid specified in Section 300-0020, Check pads and discs for wear and adjust or replace
LUBRICATION SYSTEM. where necessary. Test for proper function.
2. Remove dust cap (15) from bleeder valve (1) and Note: This service interval applies to normal driving.
connect a bleeder hose to bleeder valve (1). Place Check the pads more frequently under more severe
loose end of hose in clean container. conditions.
Note: Keep fluid reservoirs filled during bleeding process. Thickness of pad friction material should never be
allowed to wear below 3 mm (0.12 in).
3. Actuate brake treadle valve several times.
4. Apply brake and open bleeder valve (1). After fluid boots (12), backup rings (14), packings (13) and
flow stops, close bleeder valve (1) and release the seals (10), in quantities sufficient to rebuild a calliper
brake. brake head. Refer to vehicle parts book for repair kit
part number. All parts included in a repair kit should
Note: If loose end of bleeder hose is kept submerged be replaced each time a brake head is rebuilt.
in brake fluid, bleeder valve (1) need not be closed
each time brake is released. Every 2 000 Hours (Annually)
Drain brake fluid, refill reservoirs and bleed the
5. Repeat procedure in Step 4 until no air bubbles are brakes. Refer to Section 300-0020, LUBRICATION
observed in fluid coming from bleeder valves. SYSTEM for brake fluid specification and system
capacities.
6. Repeat Steps 1 through 5 at each brake head
assembly.
SERVICE TOOLS
There are no special tools required for the
procedures outlined in this section. Refer to Section
general service tools. These tools are available from
your dealer.

TORQUE
1 4 Bolt 510 380
2 2 Bolt 30 - 38 22 - 28
2 6 Bolt 380 280
* * * *
SM 1961 4-00 5
PARKING BRAKE - Parking Brake and Mounting
Section 170-0010
SM - 1908
17
14
4
19
5 9
18 8
15
16
12
13
6
2 3 6
1
11 10
14 - Brake Calliper
9 - Bolt 15 - Brake Pads
1 - Brake Disc 5 - Washer 10 - Parking Brake Guard 16 - Slack Adjuster
2 - Lockwasher 6 - Nut 11 - Bolt 17 - Actuator
3 - Bolt 7 - Torque Plate 12 - Nut 18 - Block
4 - Bolt 8 - Torque Plate 13 - Lockwasher 19 - Block
Fig. 1 - Parking Brake Mounting
the parking brake off.

WARNING
When servicing parking brake parts, do not Operation is by air pressure directed from the parking
create dust by grinding or sanding brake pads, brake control valve in the cab. When the control valve
or parking brake parts. A water dampened is in the 'RELEASE' position, air pressure compresses
cloth should be used for cleaning parking the coil spring in actuator (17), releasing brake pads
brake parts. Some brake parts may contain (15) from brake disc (1).
asbestos fibres which can become airborne if
dust is created during servicing. Breathing Placing the brake control valve in the 'PARK' position
dust containing asbestos fibres may cause cuts off air pressure and exhausts actuator (17)
serious bodily harm. through the brake control valve, allowing the coil spring
to expand. This movement exerts force on slack
adjuster (16), which is splined to the operating shaft, to
DESCRIPTION AND OPERATION apply the parking brake.
Brake calliper (14), including brake pads (15), is free to
The parking brake consists of a sliding calliper acting float on torque plates (7 & 8) bolted to brackets welded
on a brake disc on a rear driveline. The parking brake on the trailer frame. It is important that torque plates (7
is of 'Inverted Design' i.e. requiring air pressure to hold & 8) and brake calliper (14) slots are kept clean and
SM 1967 4-00 1
Parking Brake - Parking Brake and Mounting
Section 170-0010
lubricated regularly to avoid unequal wear on brake 7. Support brake calliper (14) assembly and remove
pads (15). It is also important that the lubricant does bolts (4), washers (5), blocks (18 & 19) and nuts (6)
not contact the disc braking surfaces. securing torque plates (7 & 8) to mounting bracket on
the frame.
Placing the brake control valve in the 'EMERGENCY'
position will apply the service brakes on the machine. 8. Remove torque plates (7 & 8) and brake calliper
(14) assembly from the dumptruck. Set brake calliper
Note: The parking brake will automatically apply when (14) aside for 'Disassembly'.
air pressure in the primary air tank drops below
3.1 bar (45 lbf/in).
DISASSEMBLY
REMOVAL
Numbers in parentheses refer to Fig. 1, unless 1. Remove calliper head assembly as described under
otherwise specified. 'Removal'.
2. Remove snap ring (16) from power screw shaft (21).

WARNINGS
To prevent personal injury and property 3. Slide slack adjuster (17) from power screw shaft (21).
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly 4. Remove and discard washer (19), wave spring
secured and of adequate capacity to do the job washer (18) and packing (20) from power screw
safely. shaft (21).
When necessary to drive out or drive on 5. Remove bolts (2) and washers (3) securing cap
components during disassembly/assembly, be assembly (25) to calliper (7).
sure to use a soft drift to prevent property
damage and personal injury. 6. Remove as a unit, power screw shaft (21), piston
(6) and cap assembly (22 thru 25) from calliper (7).
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure body in 7. Slide power screw shaft (21) and piston (6) from
partially raised position. cap assembly (25).
2. Switch off the engine and block all road wheels. 8. Unscrew piston (6) from power screw shaft (21).
3. Position parking brake control lever in the 9. Remove and discard thrust bearing (22) from power
'RELEASE' position. Open drain cocks in the air tanks screw shaft (21) and gasket (23) from cap
and drain air pressure from the machine. assembly (25).
4. Release spring tension on slack adjuster clevis pin 10. Remove and discard piston seal (5) from calliper (7).
(9, Fig. 2) by unscrewing tensioning bolt on slack
adjuster (16) until clevis pin (9, Fig. 2) feels loose.
Remove cotter pin (10, Fig. 2) and clevis pin INSPECTION
(9, Fig. 2) from actuator (17). Numbers in parentheses refer to Fig. 2.
5. Disconnect and cap air line from actuator (17). Plug 1. Thoroughly clean all parts. Inspect journal bearing
port in actuator (17) to prevent ingress of dirt. (24) in cap assembly (25) for wear. Replace if
necessary.
6. Remove nuts (12, Fig. 2), lockwashers (13, Fig. 2)
and washers (14, Fig. 2) securing actuator (17) to cap 2. Replace cap assembly (25) if excessively worn.
assembly (25, Fig. 2). Remove actuator (17) from cap
assembly (25, Fig. 2). 3. Inspect all brake parts for cracks, excessive wear or
scoring. Replace brake parts as required.
2 SM 1967 4-00
Section 170-0010
SM - 1914
21
22
23 15
25
7
14
13 11
12 8
9
3
27 2
24 10
1 20
18
19
26 5 17
6 16
1 - Brake Pad 8 - Clevis 15 - Actuator

2 - Bolt 9 - Clevis Pin 16 - Snap Ring 22 - Thrust Bearing
3 - Washer 10 - Cotter Pin 17 - Slack Adjuster 23 - Gasket
4 - Plug 11 - Jam Nut 18 - Wave Spring Washer 24 - Journal Bearing
5 - Piston Seal 12 - Nut 19 - Washer 25 - Cap Assembly
6 - Piston 13 - Lockwasher 20 - Packing 26 - Plug
7 - Calliper 14 - Washer 21 - Power Screw Shaft 27 - Pressure Relief Fitting
Fig. 2 - Exploded View of Parking Brake Assembly
ASSEMBLY thrust bearing (22) ID lip is towards splined end of

Numbers in parentheses refer to Fig. 2. power screw shaft (21).
1. Install new piston seal (5) into seal groove in 4. Lubricate threads of power screw shaft (21) with
calliper (7). grease (Lubriplate Aero or equivalent) and screw
power screw shaft (21) into piston (6).
2. Apply grease (Lubriplate Aero or equivalent) to flat
face of new thrust bearing (22). 5. Coat outside of piston (6) with grease (Lubriplate
Aero or equivalent) then slide assembled power screw
3. Install and seat new thrust bearing (22) over splined shaft (21) and piston (6) into cap assembly (25), shaft
end of power screw shaft (21) with greased side of end first.
thrust bearing (22) against thrust collar of power screw
shaft (21). 6. Line up gasket (23) with holes in cap assembly (25)
and bolt cap assembly (25), with assembled power
Note: Ensure correct installation of thrust bearing (22) screw shaft (21) and piston (6), to calliper (7) using
by verifying that installation was made over the larger bolts (2) and washers (3). Torque tighten bolts (2) to
diameter end of power screw shaft (21), and, that 176 - 203 Nm (130 - 150 lbf ft).
SM 1967 4-00 3
Section 170-0010
Note: Care should be taken not to push piston seal (5) 3. Using suitable lifting device, position brake calliper
out of seal groove in calliper (7) when assembling cap (14) assembly in position on torque plate (7). Install
assembly (25), with piston (6) and power screw shaft torque plate (8) on brake calliper (14) and secure to
(21), to calliper (7). rear frame mounting bracket with bolts (4), washers
(5) and nuts (6). Torque tighten nuts (6) to 278 Nm
7. Install new packing (20), wave spring washer (18) (205 lbf ft).
and washer (19) over power screw shaft (21), in the
order as shown in Fig. 2. 4. Re-mount actuator (17) on cap assembly (25, Fig. 2)
and install washers (14), lockwashers (13) and nuts
8. Mount actuator (15) on cap assembly (25) and (12). Tighten nuts (12) finger tight at this stage.
secure with nuts (12), lockwashers (13) and washers
(14). Tighten nuts (12) finger tight only at this stage. 5. Reconnect air line to actuator (17)
9. Apply coat of grease (Lubriplate Aero or equivalent) 6. Place brake control lever in the 'RELEASE' position
to mounting spline of slack adjuster (17). to retract actuator (17) cylinder when engine is started.
Ensure drain cocks on air tanks are closed, start the
10. With adjusting screw facing away from actuator engine and build up air pressure in the air tanks.
(15) slide slack adjuster (17) onto power screw shaft
(21) aligning slack adjuster (17) arm with clevis (8). 7. Connect slack adjuster (16) to actuator (17) by
inserting clevis pin (9, Fig. 2) through clevis
11. Install snap ring (16) on power screw shaft (21). (8, Fig. 2) on actuator (17). Secure clevis pin
(9, Fig. 2) with cotter pin (10, Fig. 2).
12. Remove nuts (12), lockwashers (13) and washers
(14) securing actuator (15) to cap assembly (25). 8. Align actuator (17) to slack adjuster (16) and tighten
Remove actuator (15) from cap assembly (25) to aid in nuts (12) securely.
'Installation'.
9. Rotate slack adjuster (16) adjusting screw until
brake pads (15) in brake calliper (14) head assembly
INSTALLATION are tight against brake disc (1). Back off adjusting
Numbers in parentheses refer to Fig. 1, unless screw on slack adjuster (16) until a total clearance of
otherwise specified. 1 - 1.5 mm (0.04 - 0.06 in) is obtained. The parking
brake is now operational.
specified, to standard torques listed in Section 10. If fitted, install parking brake guard (10) to
300-0080, STANDARD BOLT AND NUT TORQUE mounting brackets and secure in place with bolts (11),
SPECIFICATIONS. lockwashers (13) and nuts (12). Torque tighten nuts
(12) to 153 Nm (113 lbf ft).
WARNING
To prevent personal injury and property MAINTENANCE
materials and lifting equipment are properly Brake Pad Replacement
secured and of adequate capacity to do the job Replace brake pads when lining thickness is 3 mm
safely. (0.12 in) or less.
1. If removed, install brake disc (1) on mounting flange 1. Remove calliper head assembly as described under
and secure with bolts (3) and lockwashers (2). Torque 'REMOVAL'.
tighten bolts (3) to 49 Nm (36 lbf ft).
2. Replace worn brake pad and carrier assemblies.
2. Install torque plate (7) on rear frame mounting
bracket and secure in place with bolts (4), washers (5), 3. Install calliper head assembly and adjust slack
blocks (18 & 19) and nuts (6). Torque tighten nuts (6) adjuster as described in 'Installation'.
to 278 Nm (205 lbf ft).
4 SM 1967 4-00
Section 170-0010
SERVICE SPECIAL TOOLS

Every 1 000 hours check pads and disc for wear. There are no special tools required for procedures
Lubricate slack adjuster as described in Section outlined in this section. Refer to Section 300-0070,
300-0020, LUBRICATION SYSTEM. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
Test parking brake for proper operating function. dealer.
Replace parking brake pads when lining thickness is
3 mm (0.12 in) or less.

TORQUE
1 3 Bolt 49 36
1 6 Nut 278 205
1 12 Nut 153 113
2 2 Bolt 176 - 203 130 - 150
* * * *
SM 1967 4-00 5
SUSPENSION SYSTEM - Front Suspension
Section 180-0020
SM - 2485
22
30
A B C D E F
36 22
26
24
11 23
22
27
24
33
36
28
31 34 32
37
25
5 29 30
6 7 9
8,7 7 35
1 16 14
15,21
9
32 13 19
4
3
20
18 17
3
31
2
10 37
12
1 - Shock Absorber 12 - Nut 23 - Bellows

2 - Bolt 13 - Mounting Pin 24 - Clamp Ring 34 - Chain
3 - Washer 14 - Wear Washer 25 - Clamp Plate 35 - Lockwasher
4 - Locknut 15 - Shim 26 - Clamp Plate 36 - Levelling Valve
5 - Rod 16 - Spherical Bearing 27 - Ring 37 - Gasket
6 - Rubber Joint 17 - Bolt 28 - Bumpstop 38 - Adaptor
7 - Washer 18 - Lockwasher 29 - Nut 39 - Adaptor
8 - Bolt 19 - Lube Fitting 30 - Locknut 40 - Adaptor Elbow
9 - Nut 20 - Dowel Pin 31 - Nut 41 - Hardened Washer
10 - Suspension Frame 21 - Shim 32 - Bolt 42 - Nylon Tube
11 - Bolt 22 - Air Spring Assembly 33 - Bent Plate 43 - Reducer Bushing
Fig. 1 - Exploded View of Front Suspension
DESCRIPTION through levelling valve (36) maintains a constant ride

Numbers in parentheses refer to Fig. 1. height. Refer to Section 180-0021, LEVELLING
VALVE for air spring ride height adjusting instructions.
The front axle is carried on the leading arms of
suspension frame (10), which pivots on the main Note: Refer to Section 180-0022, AIR SPRING, for
frame. Suspension is by flexible air bellows (23) with details on servicing items 22 through 30.
four heavy duty shock absorbers (1). Air pressure
SM 1979 4-00 1
Suspension System - Front Suspension
Section 180-0020
REMOVAL 12. Remove locknuts (30) securing air spring

Numbers in parentheses refer to Fig. 1. assemblies (22) to the front frame assembly.
13. Lower front end of suspension frame (10)

WARNING assembly onto a suitable trolley.
damage, be sure wheel blocks, blocking 14. Using suitable lifting equipment, support rear arms
materials and lifting equipment are properly of suspension frame (10) assembly.
safely. 15. Remove bolts (17) and lockwashers (18) securing
mounting pins (13) to the front frame assembly.
1. Position the vehicle in a level work area, lower body Withdraw mounting pins (13) and shims (15 & 21) from
completely, apply the parking brake and switch off the front frame assembly and suspension frame (10)
engine. assembly.
2. Block rear wheels, place the steering lock bar and 16. Carefully lower suspension frame (10) assembly
oscillation lock pin in the 'Locked position and the onto the trolley and remove suspension frame
battery master switch in the 'Off' position. assembly out from under the front frame. Remove
wear washers (14) and dowel pins (20) from the front
3. Whilst the front road wheels are still on the ground, frame assembly.
loosen the wheel nuts.
17. Remove cap from shock absorber (1) mounting
4. Using suitable lifting equipment, raise the tractor nuts and remove nuts securing shock absorbers (1) to
frame until both front tyres are off the ground. Support the front frame assembly.
the vehicle with suitable stands and blocking
equipment at the front frame and articulation pivot 18. Remove nut (31) and bolt (32) securing chain (34)
area. to the front frame.
5. Support one tyre and rim assembly with suitable 19. Remove mounting hardware securing levelling
lifting equipment and remove wheel nuts and valve (36) to the front frame assembly and remove
lockwashers securing the rim to the axle. Remove tyre levelling valve.
and rim assembly from the machine.
6. Repeat Step 5 for the opposite tyre and rim DISASSEMBLY

assembly. Numbers in parentheses refer to Fig. 1.
7. Disconnect nylon tubes from air spring assemblies

(22). WARNING
8. Jack up suspension frame (10) to allow removal of damage, be sure lifting equipment is properly
shock absorbers (1), air spring assemblies (22), chain secured and of adequate capacity to do the job
(34) and levelling valve (36). safely.
9. Remove locknuts (4), washers (3) and bolts (2) 1. Remove locknuts (30) securing air spring
securing shock absorbers (1) to suspension frame assemblies (22) on suspension frame (10). Refer to
(10) assembly. Section 180-0021, AIR SPRING, for further
disassembly, inspection and assembly of air spring
10. Remove nuts (9), lockwasher (35), washers (7) assembly (22).
and bolt (8) securing levelling valve rubber joint (6) to
suspension frame (10) assembly. 2. Remove nuts (12), bolts (11), hardened washers
(37) and bent plates (33) securing front axle assembly
11. Remove nut (31) and bolt (32) securing chain (34) on suspension frame (10).
to suspension frame (10) assembly.
3. Using suitable lifting equipment remove front axle
assembly from suspension frame (10).
2 SM 1979 4-00
Section 180-0020
4. If damaged, press spherical bearings (16) out of SM - 1171
bores in suspension frame (10).
FRONT
FRAME
ASSEMBLY
ASSEMBLY
GAP 'B'
WARNING
safely.
1. If removed, install new spherical bearings (16) in

suspension frame (10) ensuring bearings are
centralised in suspension frame (10).
2. Position air spring assemblies (22) on suspension

frame (10) and secure with locknuts (30). Tighten
locknuts cape and corner to ensure even contact.
Tighten locknuts (30) to a torque of 23 Nm (17 lbf ft).
GAP 'A'
3. Using suitable lifting equipment, position front axle

assembly on suspension frame (10) and secure with
bolts (11), hardened washers (37), bent plates (33) 10 - Suspension Frame
and nuts (12). Tighten nuts (12) to a torque of 610 Nm 13 - Mounting Pin 17 - Bolt
(450 lbf ft). 14 - Wear Washer 18 - Lockwasher
15 - Shim 19 - Lube Fitting
16 - Spherical Bearing 20 - Dowel
INSTALLATION Fig. 2 - Sectional View of Pivot Arrangement
Numbers in parentheses refer to Figs. 1 & 2.
Note: Tighten all fasteners without special torques locking nut to a torque of 68 - 74 Nm (50 - 55 lbf ft).
specified to standard torques listed in Repeat for remaining three shock absorbers.
TORQUE SPECIFICATIONS. 4. Position suspension frame (10) assembly and
trolley under front frame assembly with hinge lugs up
and to the rear.
WARNING
To prevent personal injury and property 5. Install dowel pins (20) in the front frame assembly
damage, be sure lifting equipment is properly ensuring they protrude 12 mm (0.5 in) from front frame
secured and of adequate capacity to do the job assembly. Hang wear washers (14) on
safely. dowel pins (20).
1. Secure levelling valve (36) assembly on the front 6. Using suitable lifting equipment, raise suspension
frame with mounting hardware removed during frame and install to front frame assembly. Mark
removal. outside of mounting pins (13) to show position of
grease outlet and install pins with grease outlet down
2. Secure chain (34) on front frame assembly with in 6 o'clock position. Secure mounting pins (13) with
bolt (32) and nut (31). bolts (17).
3. Install shock absorber (1) on front frame assembly 7. Position suspension frame (10) completely to one
and secure with locking nut. Hold dust cover on shock side and take a measurement of the gap between
absorber (1) with a suitable strap wrench and tighten boss on the front frame and inside face of mounting
SM 1979 4-00 3
Section 180-0020
pin (13). Half this size to obtain the thickness of shim 15. Lower suspension frame (10) onto chain (34).
pack required for Gap 'B' (Fig. 2) at both sides.
16. Install nylon tubes to air spring assemblies (22)
Note: Gap 'B' at both sides should be equalised within with the long nylon to LH air spring and short nylon to
0.25 mm (0.01 in) maximum. the RH air spring.
8. Shim Gap 'B' at both sides with shims (15 & 21). 17. Using suitable lifting equipment, position one tyre
Ensure that a small running clearance of 0.25 mm and rim assembly on the front axle and secure with
(0.01 in) maximum at wear washers (14) is obtained. wheel nuts and lockwashers.
9. Remove bolts (17) and reinstall with lockwashers 18. Using suitable lifting equipment, position opposite
(18). Tighten bolts (17) to a torque of 74 Nm (55 lbf ft). tyre and rim assembly on the front axle and secure
with wheel nuts and lockwashers.
10. If removed, install and secure lube fittings (19) in
mounting pins (13). Lubricate suspension frame 19. Using suitable lifting equipment, raise front frame
spherical bearing (16) through lube fittings (19) with assembly sufficiently to remove stands and blocking
grease specified in Section 300-0020, LUBRICATION equipment from front frame assembly and articulation
SYSTEM, until excess lube is seen. pivot area. Lower vehicle to the ground and remove
lifting equipment.
11. Lift suspension frame (10) at front end ensuring
that mounting studs on air spring assemblies (22) pass 20. With the vehicle lowered to the ground, tighten all
through holes in front frame assembly mounts. Secure wheel nuts to a torque of 590 Nm (435 lbf ft).
air spring assemblies (22) to front frame assembly with
nuts (30). Tighten nuts (30) to a torque of 23 Nm 21. Remove wheel blocks from the rear road wheels,
(17 lbf ft). place the steering lock bar and oscillation lock pin in
the 'Stowed' position and the battery master switch in
Note: Apply 'Adsil' to mounting bolts (2) and rubber the 'On' position.
mounts on shock absorbers (1) prior to fitting.
12. Install shock absorbers (1) between anchor MAINTENANCE

brackets on suspension frame (10) and install bolts Numbers in parentheses refer to Fig. 1.
(2), washers (3) and locknuts (4). Install bolts (2) from
inside with locknuts (4) on the outside. Tighten Pre-Starting Inspection: Visually inspect shock
locknuts (4) until a measured distance of 47 mm absorbers (1), suspension frame (10) and air spring
(1.85 in) across the rubber is achieved on any one assemblies (22) for debris, leaks and damage.
rubber.
Every 50 Hours: Lubricate suspension frame
13. Secure chain (34) on suspension frame (10) with spherical bearing (16) through lube fittings (19) with
bolt (32) and nut (31). grease specified in Section 300-0020, LUBRICATION
SYSTEM, until excess lube is seen.
14. Secure levelling valve rubber joint to mounting
bracket on suspension frame (10) with bolt (8),
washers (7), lockwasher (35) and nuts (9). Refer to SERVICE TOOLS
Section 180-0022, LEVELLING VALVE for adjustment There are no special tools required for the procedures
and setting procedures. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS for part numbers of general service
tools required. These tools are available from your
dealer.
4 SM 1979 4-00
Section 180-0020

TORQUE
1 12 Nut 610 450
1 17 Bolt 74 55
1 30 Locknut 23 17
- - Shock Absorber Locking Nut 68 - 74 50 - 55
- - Wheel Nuts 590 435
* * * *
SM 1979 4-00 5
SUSPENSION SYSTEM - Air Spring
Section 180-0021
SM - 1067
1 - Top Clamp Plate

2 - Top Clamp Ring
3 - Bellows
4 - Centre Ring
5 - Bottom Clamp Ring
6 - Bottom Clamp Plate
7 - Bump Stop
8 - Nut
Fig. 1 - Sectional View of Air Spring
DESCRIPTION 1. Drive machine onto a level, solid concrete floor,

Numbers in parentheses refer to Fig. 1. apply the parking brake and switch off the engine.
The air springs are hermetically sealed assemblies 2. Chock the appropriate road wheels.
which have flexible walls, no reciprocating parts and
no sliding seals. The air springs are virtually 3. Using suitable lifting equipment, raise the frame
frictionless in operation and maintenance free. Each until the suspension has reached its maximum
spring consists of a top clamp plate (1), top clamp rebound travel. Support the frame on workshop
ring (2), bellows (3), centre ring (4), bottom clamp stands.
ring (5), bottom clamp plate (6) and bump stop (7).
4. Open the primary tank drain valve and allow all of
The air springs are installed between the suspension the air to drain out.
frame and front frame cross member. The spring ride
height is controlled by a levelling valve mounted to 5. Disconnect and remove the connecting rod from
the frame cross member. Refer to Section 180-0022, the levelling valve control lever and lower mounting
LEVELLING VALVE for information and adjustment. bracket. Store connecting rod in a safe place to
prevent damaging it.
A rubber bump stop (7) is attached to bottom clamp
plate (6). In the event of an air loss in the suspension 6. Move the levelling valve control lever
system it is capable of supporting a fully loaded unit. approximately 30 below the neutral or horizontal
position. Hold the lever in this position until all the air
has been exhausted from the air springs.
REMOVAL
Numbers in parentheses refer to Fig. 1. 7. Disconnect the air line to the air spring at the top
clamp plate.
WARNING 8. Remove mounting nuts (8) which attach the top

To prevent personal injury and property and bottom clamp plates to the suspension frame and
damage, be sure wheel chocks, blocking front frame cross member.
secured and of adequate capacity to do the job 9. Remove the complete air spring assembly from the
safely. vehicle.
SM 1480 9-98 1
Suspension System - Air Spring
Section 180-0021
1. Remove top and bottom clamp plates (4 & 3) and

clamp rings (2) from bellows (1).
2. Remove centre ring (5) from bellows (1)

convolutions.
3. If necessary, remove nut (7) and bump stop (6)

from bottom clamp plate (3). A sealing compound is
applied to bump stop mounting face at assembly, it is
necessary to break the seal to remove bump stop.
INSPECTION
1. Clean clamp rings (2), bottom clamp plate (3), top

clamp plate (4) and centre ring (5) in solvent to
remove all contamination. Thoroughly dry all parts.
2. Inspect all parts for damage and excessive

corrosion. Replace all worn or damaged parts.
ASSEMBLY
1. If bump stop (6) was removed from bottom clamp

plate (3), coat the bump stop mounting face with
sealing compound, such as 'Heldite' or equivalent. 1 - Bellows 5 - Centre Ring
Bolt the bump stop to the lower clamp plate with 2 - Clamp Ring 6 - Bump Stop
3 - Bottom Clamp Plate 7 - Nut
nut (7). Torque tighten nut (7) to 23 Nm (17 lbf ft). 4 - Top Clamp Plate 8 - Nut
2. Install centre ring (5) on bellows (1). Fig. 2 - Exploded View of Air Spring
3. Lightly coat the top and bottom beads of the 1. Install air spring assembly between the frame
bellows (1) with silicon or soapy water to aid in cross member and suspension frame. Torque tighten
assembly of clamp rings (2) and clamp plates nuts (8) to 23 Nm (17 lbf ft). Do not overtighten.
(3 & 4).
2. Connect the air line to the air spring assembly.
4. Install clamp rings (2) and bottom and top clamp
plates (3 & 4) on bellows (1). 3. Raise frame, remove workshop stands and lower
frame.
INSTALLATION
Numbers in parentheses refer to Fig. 1. 4. Install levelling valve control lever on mounting
bracket.
WARNING 5. Close primary air tank drain cock and start engine
To prevent personal injury and property to charge air system to system pressure. Check
damage, be sure wheel chocks, blocking connections for air leaks.
secured and of adequate capacity to do the job 6. Refer to Section 180-0022, LEVELLING VALVE,
safely. for air spring ride height adjusting instructions.
* * * *
2 SM 1480 9-98
SUSPENSION SYSTEM - Levelling Valve
Section 180-0022
SM - 978
1 - Clamp Ring 12 - Compression Spring 23 - Key 34 - Control Lever

2 - Protection Cap 13 - Piston Pin 24 - Sealing Ring 35 - Clamp
3 - Screw 14 - Grooved Pin 25 - Reducer 36 - Connecting Rod
4 - Washer 15 - Washer 26 - Roll 37 - Nut
5 - Diaphragm 16 - Spiral Back Ring 27 - Washer 38 - Lockwasher
6 - Supporting Ring 17 - 'O' Ring 28 - Driver 39 - Washer
7 - Felt Ring 18 - Housing 29 - Nut 40 - Bolt
8 - Locknut 19 - Valve Head 30 - Bolt 41 - Nut
9 - Stud 20 - Compression Spring 31 - Washer 42 - Lockwasher
10 - Piston 21 - Sealing Ring 32 - Joint 43 - Washer
11 - Pin 22 - Reducing Nipple 33 - Split Pin 44 - Bolt
Fig. 1 - Exploded View of Levelling Valve
SM 1481 9-98 1
Suspension System - Levelling Valve
Section 180-0022
DESCRIPTION ADJUSTMENT
The levelling valve is an air operated valve mounted to Numbers in parentheses refer to Fig. 1.
a chassis crossmember and attached to the front
suspension frame. Refer to Section 180-0020, FRONT
SUSPENSION. WARNING
There are four ports on the valve as follows: damage be sure wheel chocks, blocking
Port 'A' - Inlet from primary air tank secured and of adequate capacity to do the job
Ports 'B' - Supply ports to air springs safely.
Port 'C' - Exhaust port
Checking and Adjusting Ride Height

OPERATION The height of the air springs determines the ride height.
Numbers in parentheses refer to Fig. 1. This is initially set at 175 mm (7 in) and is measured
directly at the air springs, as shown in
The purpose of the levelling valve is to control the air Fig. 2. The ride height is adjusted by varying the length
flow to and from the air springs to maintain a constant of connecting rod (36) between the levelling valve and
air spring stiffness under all load conditions. The valve the front suspension frame.
control lever (34) is mechanically linked to the
suspension frame by connecting rod (36). 1. Position the unloaded machine on level ground,
apply the parking brake and switch off the engine.
The unloaded height is set by adjusting the length of Block all road wheels securely and drain the air from
connecting rod (36). Air passing through the levelling the primary air tank.
valve either deflates the air springs until control lever
(34) assumes a horizontal (neutral) position. In the 2. Using suitable lifting equipment, raise the front
horizontal (neutral) position there is no air flow between chassis until the front wheels are just clear of the
the valve and the air springs. ground. Block the chassis in this position.
Increasing or decreasing loads alter the height between 3. Jack up front suspension frame until a measurement
the chassis and front suspension frame. This change of 175 mm (7 in) is obtained at the air springs. Refer to
is sensed by the levelling valve. Fig. 2. Control lever (34) should now be in the
horizontal (neutral) position.
A load increase is sensed by connecting rod (36) which
moves control lever (34) up. This upward movement SM - 031
permits air to flow from the primary air tank, through

valve housing (18), to the air springs causing the
springs to inflate until control lever (34) reaches its
horizontal (neutral) position. There is no air flow through 175 mm
valve housing (18) in this position. (7 in)
A load decrease causes connecting rod (36) to move

control lever (34) downwards. This exhausts air from
the air springs causing them to deflate until control
lever (34) reaches its horizontal (neutral) position.
There is no air flow through valve housing (18) in this
Fig. 2 - Measuring Ride Height
position.
2 SM 1481 9-98
Suspension System - Levelling Valve
Section 180-0022
4. If control lever (34) is not in the horizontal (neutral) MAINTENANCE

position, disconnect connecting rod (36) and allow The air suspension levelling valve does not require
control lever (34) to return to the horizontal position. any particular maintenance. It is recommended
Alter length of connecting rod (36) until rod length is however that a visual inspection of the control lever,
set to enable it to be fitted to control lever (34) in the connecting rod and joints should be made at regular
horizontal position. Secure connecting rod (36) in this intervals. In the event of a continuous air loss from
position to maintain set length. exhaust port 'C', it is recommended that the levelling
valve should be replaced as an assembly.
* * * *
SM 1481 9-98 3
SUSPENSION - Rear Suspension
Section 180-0040
SM - 1427
13,36 13,37,44 13,36

46 47,48,49 47,48,49
23 11 13
6 9 14
15 50 50
12
B 10 38 36 38 35 36 38
36 38
24 17
25 A
B
A
6 8 7
5 8 17
7 16
27 B 24
32 45
39 25 39 16 B
28 30 31 26
16 51B 23
26 13 19 41
20 18
23 21 1 3130
51 5121
10 41 27 34 29
27 12 9 2139
3130 30 18 5 22
15 11 31 2 40
B
14 46 B 17 5139 32
42 23 B
B 16 21 19 20 28 A
32 B
28 3 B
B 17 B 25 33 25 43
45 B
42
B 17 B
27 B
17
4
B 32
B 28
1 - Bracket Assembly 14 - Bolt 27 - Bolt 40 - Bolt

2 - Bracket Assembly 15 - Lockwasher 28 - Locknut 41 - Plate
3 - Bracket Assembly 16 - Interleaf Mount 29 - Locknut 42 - Adaptor Plate
4 - Bracket Assembly 17 - Control Link 30 - Bolt 43 - Locknut
5 - Bracket Assembly 18 - Panhard Rod 31 - Lockwasher 44 - Elbow
6 - Equaliser Beam 19 - Spherical Bearing 32 - Hardened Washer 45 - Bolt
7 - Bushing 20 - Lockring 33 - Bolt 46 - Locknut
8 - 'V' Seal 21 - Plug 34 - Hardened Washer 47 - Clip
9 - Retainer 22 - Suspension Bush 35 - Manifold 48 - Washer
10 - Lockwasher 23 - Lockwasher 36 - Elbow 49 - Bolt
11 - End Cap 24 - Bolt 37 - Nipple 50 - Clip
12 - Bolt 25 - Hardened Washer 38 - Hose Assembly 51 - Washer
13 - Lube Fitting 26 - Socket Screw 39 - Pin Assembly
Fig. 1 - Exploded View of Rear Suspension
DESCRIPTION Lubrication of bushings (7) in equaliser beams (6) and

Numbers in parentheses refer to Fig. 1. spherical bearings (19) in panhard rods (18) is through
lube fittings (13). Control links (17) are rubber bushed
Each axle is coupled to the chassis by three rubber and do not require any lubrication.
bushed control links (17) which provide longitudinal
location and control torque reactions. Lateral location
is by means of two panhard rods (18) fitted with REMOVAL
spherical bearings (19). The centre and rear axles are Numbers in parentheses refer to Fig. 1.
linked by longitudinal equaliser beams (6) which pivot
on either side of the chassis.
WARNING
Loads acting on the axles are balanced by equaliser To prevent personal injury and property
beams (6), with bonded rubber/metal laminated damage, be sure wheel blocks, blocking
interleaf mounts (16) between the axles and beam materials and lifting equipment are properly
ends providing the cushioning medium. secured and of adequate capacity to do the job
safely.
SM 1978 4-00 1
Suspension System - Rear Suspension
Section 180-0040
1. Position the vehicle in a level work area, raise the 14. Remove bolts (14) and lockwashers (15) securing
body and install the body safety prop to secure the end cap (11) to equaliser beam (6). Remove end
body in the partially raised position. cap (11).
2. Apply the parking brake and switch off the engine. 15. Remove bolts (12) and lockwashers (10) securing
retainer (9) to spindle on the frame. Remove retainer (9).
3. Block the front road wheels, place the steering lock
bar and oscillation lock pin in the 'Locked' position and 16. Using suitable lifting equipment, support equaliser
the battery master switch in the 'Off' position. beam (6) and withdraw from spindle on the frame.
4. Using suitable blocking equipment, block equaliser 17. Remove and discard 'V' seal (8) from bushing (7).
beams (6) to prevent movement when raising the If required, remove bushing (7) from spindle on the
trailer frame. frame.
5. Whilst the rear road wheels are still on the ground, 18. Repeat steps 13 through 16 to remove the
loosen the wheel nuts. opposite equaliser beam (6).
6. Using suitable lifting equipment, raise the trailer 19. Remove locknuts (43), hardened washers (25) and
frame until the rear wheels are off the ground. Support bolts (33) securing centre control links (17) to cross
the vehicle with suitable stands and blocking shaft mounting brackets.
equipment at the trailer frame, articulation pivot area
and centre and rear axles. 20. Remove locknuts (29), hardened washers (34) and
bolts (40) securing centre control links (17) to bracket
7. Support one tyre and rim assembly with suitable assemblies (5). Remove centre control links (17).
lifting equipment and remove wheel nuts and
lockwashers securing the rim to the axle. Remove tyre 21. Remove locknuts (29), hardened washers (34) and
and rim assembly. bolts (40) securing control link (17) to bracket
assembly (4) on the rear axle and the LH frame
8. Repeat step 7 for the remaining rear tyre and rim mounting bracket. Remove control link (17).
assemblies.
22. Remove locknuts (29), hardened washers (34) and
9. With a suitable container in position, disconnect bolts (40) securing control link (17) to bracket
hydraulic brake lines from the tee piece between the assembly (3) on the centre axle and the LH frame
centre and rear axle assemblies. Cap lines and fittings mounting bracket. Remove control link (17).
to prevent entry of dirt. Remove clips securing brake
lines to centre control rods (17). 23. Remove locknuts (29), hardened washers (34) and
bolts (40) securing control link (17) to bracket
10. Remove mounting hardware connecting brake line assembly (2) on the rear axle and the RH frame
guards to axle brackets and remove brake line guards. mounting bracket. Remove control link (17).
11. Disconnect hose assemblies (38) from elbows (36) 24. Remove locknuts (29), hardened washers (34) and
in panhard rods (18) and plate on RH equaliser beam bolts (40) securing control link (17) to bracket
(6). Remove bolts (49), washers (48), clips (47 & 50) assembly (1) on the centre axle and the RH frame
and hose assemblies (38) from the vehicle. mounting bracket. Remove control link (17).
12. Remove blocking materials from equaliser 25. Remove bolts (30), lockwashers (31) and washers
beams (6). Remove locknuts (46), lockwashers (23) (51) securing pin assemblies (39) to bracket
and bolts (45) securing interleaf mounts (16) to assemblies (1 & 2) and frame mounting brackets.
equaliser beams (6). Remove pin assemblies (39) and panhard rods (18)
from bracket assemblies (1 & 2) and frame mounting
13. Remove socket screws (26) and lockwashers (23) brackets.
securing interleaf mounts (16) to bracket assemblies
(1 & 2), plates (41) and adaptor plates (42). Remove 26. Remove bolts (24) and lockwashers (25) securing
interleaf mounts (16). bracket assemblies (5) to the centre and rear axles.
Remove bracket assemblies (5).
2 SM 1978 4-00
Section 180-0040
27. Remove locknuts (28), hardened washers (32), 7. Apply Loctite 243 to bolts (24) and secure brackets (5)
bolts (27), bracket assemblies (2 & 4), plate (41) and to the centre and rear axles with bolts (24) and
adaptor plate (42) from the rear axle. hardened washers (25). Tighten bolts (24) to a torque
of 325 Nm (240 lbf ft).
28. Remove locknuts (28), hardened washers (32),
bolts (27), bracket assemblies (1 & 3), plate (41) and 8. If bushings (7) were removed from spindle on the
adaptor plate (42) from the centre axle. frame, thoroughly clean spindles with Loctite activator
'N' and allow to dry. Apply Loctite 638 retaining
29. If either axle assembly requires to be removed compound all over bushing (7) contact area of the
from under the vehicle; raise axle assembly with spindles and install bushings (7) on the spindles.
suitable lifting equipment, remove blocking from under
the axle assembly and lower axle assembly onto a Note: A curing time of fifteen minutes is required for
suitable trolley. Slide the axle assembly from under the acceptable handling strength.
vehicle to a suitable work area.
9. Install new 'V' seals (8) over bushings (7) with the
lip to the outside, as shown in Fig. 2.
INSTALLATION
Numbers in parentheses refer to Figs. 1, 2 & 3. 10. Clean bores on equalising beams (6) and, using
suitable lifting equipment, install beams onto bushings
(7). Apply Loctite 243 to bolts (12) and secure
WARNING retainers (9) to spindles with bolts (12) and
To prevent personal injury and property lockwashers (10). Tighten bolts (12) to a torque of
damage, be sure wheel blocks, blocking 150 Nm (110 lbf ft).
secured and of adequate capacity to do the job 11. Apply Loctite 243 to bolts (14) and Loctite 574
safely. gasket eliminator to mounting face of end caps (1).
Secure end caps (1) to equalising beams (6) with bolts
1. Ensure centre and rear axle assemblies are (14) and lockwashers (15). Tighten bolts (14) to a
correctly positioned and securely blocked below the torque of 75 Nm (55 lbf ft).
frame.
SM - 1425
2. Install bracket assembly (1) on RH side of the
centre axle and secure with plate (41), bolts (27), 9 7
hardened washers (32) and locknuts (28). Tighten 12,10
bolts (27) to a torque of 610 Nm (450 lbf ft).
3. Install bracket assembly (3) to bottom LH side of the

centre axle and secure with adaptor plate (42), bolts 11
(27), hardened washers (32) and locknuts (28).
4. Install bracket assembly (2) on RH side of the rear

axle and secure with plate (41), bolts (27), hardened
washers (32) and locknuts (28). Tighten bolts (27) to a 13
5. Install bracket assembly (4) to bottom LH side of the

rear axle and secure with adaptor plate (42), bolts 14,15
(27), hardened washers (32) and locknuts (28). 6 8
6 - Equaliser Beam 11 - End Cap
7 - Bushing 12 - Bolt
6. Apply Loctite 243 to socket screws (26) and secure 8 - 'V' Seal 13 - Lube Fitting
interleaf mounts (16) to bracket assemblies (1 & 2), 9 - Retainer 14 - Bolt
plates (41) and adaptor plates (42) with socket screws 10 - Lockwasher 15 - Lockwasher
(26) and lockwashers (23). Tighten socket screws (26)
Fig. 2 - Sectional View of Equaliser Beam Installation
SM 1978 4-00 3
Section 180-0040
12. If removed, install lube fittings (13) in end caps (1). SM - 1428
Lubricate with grease specified in Section 300-0020, 34
LUBRICATION SYSTEM, until excess lube is seen.
29 40 TYP. 10 PLACES
13. Apply Loctite 243 to bolts (45) and secure interleaf
mounts (16) to equaliser beams (6) with bolts (45),
lockwashers (23) and locknuts (46). Tighten bolts (45)
14. Install suspension bushes (22) in bracket

assemblies (1 to 5) and frame mounting brackets, as
shown in Fig. 3.
15. Install centre control links (17) between bracket 22 22

assemblies (5) and cross shaft mounting brackets and
secure with bolts (33), hardened washers (25) and
locknuts (52). Tighten bolts (33) to a torque of
556 Nm (410 lbf ft). 22 - Suspension Bush 34 - Hardened Washer
29 - Locknut 40 - Bolt
Note: Install bolts with bolt heads to the outside on RH Fig. 3 - Sectional View of Typical Control Link Mounting
and LH side control links (17).
21. Install panhard rod (18) between bracket assembly
16. Install control link (17) between bracket (2) and RH frame mounting bracket and install pin
assembly (1) and RH frame mounting bracket and assemblies (39). Secure pin assemblies (39) to
secure with bolts (40), hardened washers (34) and bracket assembly (2) and RH frame mounting bracket
locknuts (43). Tighten bolts (40) to a torque of with bolts (30), lockwashers (31) and washers (51).
1 085 Nm (800 lbf ft). Tighten bolts (30) to a torque of 75 Nm (55 lbf ft).
17. Install control link (17) between bracket 22. Connect hose assemblies (38) to elbows (36) in
assembly (3) and LH frame mounting bracket and panhard rods (18) and plate on RH equaliser beam (6)
secure with bolts (40), hardened washers (34) and and secure hose assemblies (38) with bolts (49),
locknuts (29). Tighten bolts (40) to a torque of washers (48) and clips (47 & 50).
1 085 Nm (800 lbf ft).
23. If removed, install lube fittings (13) in plate on RH
18. Install control link (17) between bracket equaliser beam (6). Lubricate panhard rods (18)
assembly (2) and RH frame mounting bracket and through lube fittings (13) with grease specified in
secure with bolts (40), hardened washers (34) and Section 300-0020, LUBRICATION SYSTEM, until
locknuts (29). Tighten bolts (40) to a torque of excess lube is seen.
1 085 Nm (800 lbf ft).
24. Remove caps and connect hydraulic brake lines to
19. Install control link (17) between bracket the tee piece between the centre and rear axle
assembly (4) and LH frame mounting bracket and assemblies. Clip brake lines to centre control rods (17)
secure with bolts (40), hardened washers (34) and with clips removed during removal.
locknuts (29). Tighten bolts (40) to a torque of
1 085 Nm (800 lbf ft). 25. Connect brake line guards to axle brackets and
secure with mounting hardware removed during
20. Install panhard rod (18) between bracket assembly removal.
(1) and RH frame mounting bracket and install pin
assemblies (39). Secure pin assemblies (39) to 26. Using suitable blocking equipment, block equaliser
bracket assembly (1) and RH frame mounting bracket beams (6) to prevent movement when installing the
with bolts (30), lockwashers (31) and washers rear tyre and rim assemblies.
(51). Tighten bolts (30) to a torque of 75 Nm (55 lbf ft).
4 SM 1978 4-00
Section 180-0040
27. Using suitable lifting equipment, position one tyre MAINTENANCE

and rim assembly on one rear wheel and secure with Numbers in parentheses refer to Fig. 1.
wheel nuts and lockwashers.
Pre-Starting Inspection: Visually check condition and
28. Repeat step 27 for remaining tyre and rim assemblies. mounting of equaliser beams (6), interleaf mounts
(16), control links (17) and panhard rods (18).
29. Using suitable lifting equipment, raise the trailer
frame sufficiently to remove stands and blocking Every 50 Hours: Lubricate bushings (7) in equaliser
equipment from the centre and rear axles, articulation beams (6) and spherical bearings (19) in panhard rods
pivot area and trailer frame. Lower vehicle to the (18) through lube fittings (13), with grease specified in
ground and remove the lifting equipment. Section 300-0020, LUBRICATION SYSTEM, until
excess lube is seen.
30. With the vehicle lowered to the ground, tighten all
wheel nuts to a torque of 590 Nm (435 lbf ft).
SERVICE TOOLS
31. Place the battery master switch in the 'On' There are no special tools required for the procedures
position, start the engine and check hydraulic brake outlined in this section. Refer to Section 300-0070,
lines for leaks. Bleed all air from the hydraulic brake SERVICE TOOLS, for part numbers of general service
lines as described in Section 250-0020, HYDRAULIC tools and adhesives required during the removal and
BRAKING SYSTEM SCHEMATIC. installation of the rear suspension. These tools and
32. Remove wheel blocks from the front road wheels
and place the steering lock bar and oscillation lock pin
in the 'Stowed' position.

TORQUE
1 12 Bolt 150 110
1 14 Bolt 75 55
1 24 Bolt 325 240
1 26 Socket Screw 165 122
1 27 Bolt 610 450
1 40 Bolt 1 085 800
1 30 Bolt 75 55
1 33 Bolt 556 410
1 45 Bolt 165 122
- - Wheel Nut 590 435
* * * *
SM 1978 4-00 5
ELECTRICAL SYSTEM - Circuit Diagrams
Section 190-0000
COMPONENT DESIGNATIONS
A4 - Radio/Cassette K1 - Starter Relay S4 - W/L Test Switch
A5 - Radio/Cassette Speaker K4 - Dir Ind Flasher Unit S5 - Engine Oil Press Switch
K5 - Air Cond Compress Clutch S8 - Blower Switch
B2 - Coolant Temp Sender K5 - Air Cond Compress Relay S9 - Washer Switch, F
B8 - Fuel Level Sender K14 - Start Interlock Relay S10 - Wiper Switch, F
B9 - Air Pressure Sender K15 - Headlamp Relay S11 - Rear Wash/Wipe Switch
B13 - Rotational Speed Sensor K17 - Reverse Relay S13 - Horn Button
B21 - Trans Oil Temp Sender K21 - Trans Shift Clutch S14 - Hazard w/l Switch
B22 - Engine Oil Press Sender K22 - Lockup Clutch S15 - Direction Ind Switch
B31 - Engine Load Sender K23 - Ignition Relay S16 - Stoplight Switch
B32 - Trans Oil Ret Temp Sender K34 - Horn Relay S18 - Lights Switch
B33 - Air Cond Temp Sender K35 - Body up Relay S19 - Dipswitch
K36 - Body Float Relay S20 - Headlamp Flash Switch
E3 - Interior Light K37 - Body Hyd System Relay 12V S22 - Body Up Switch
E5 - Reverse Light K43 - Radio/Cassette Relay S24 - Low Fuel Level Switch
E7 - Instrument Panel Lights S26 - Brake O'travel Limit Sw
E11 - Side Marker Light, L L3 - Reverse Alarm S27 - Low Air Press w/l Switch
E12 - Taillight, L L4 - Buzzer S29 - Retarder Request Switch
E13 - Side Marker Light, R L5 - Electric Horn S31 - Park Brake w/l Switch
E14 - Taillight, R S37 - Axle Difflock Switch
E15 - High/Low Beam H'lamp, L M1 - Starter Motor S38 - Filter Diff w/l Press Switch
E16 - High/Low Beam H'lamp, R M3 - Cab Vent Blower Motor S39 - Filter Diff w/l Temp switch
E19 - Rear Fog Lamp M4 - Washer Motor, F S40 - Gear Shift Selector
E21 - Rotating Beacon M5 - Wiper Motor, F S41 - Auxiliary Lights Switch
E23 - Work Light M6 - Wiper Motor, B S43 - Air Cond Press Switch
E26 - High Beam H'lamp, L M7 - Washer Motor, B S57 - Steering Press Switch
E27 - High Beam H'lamp, R M10 - Cab Fan Motor S60 - Difflock Request Switch
E34 - Flashing Reverse Light M13 - Air Seat Compressor S71 - Air Cond Rheostat/Switch
E35 - Heated Mirror S74 - Kickdown Switch
N3 - Voltage Convertor 12V S77 - Trans Difflock Switch
G1 - Generator N4 - Frequency Divider S78 - Body joystick Emergency
G2 - Battery Supply Switch
P1 - Speedometer/Odometer S79 - Heated Mirror Switch
H2 - Warning Light P2 - Tachometer/Hourmeter
H5 - Direction Indicator w/l P3 - Coolant Temp Gauge X1 - Handlamp Socket
H6 - Direction Indicator; F, L P4 - Fuel Gauge
H7 - Direction Indicator; B, L P5 - Engine Oil Press Gauge Y1 - Fuel Solenoid
H8 - Direction Indicator; F, R P6 - Air Press Gauge Y3 - Retarder Valve
H9 - Direction Indicator; B, R P15 - Retarder Temp Gauge Y7 - Difflock Valve
H10 - Brake Light, L Y26 - Body Raise Solenoid
H11 - Brake Light, R S1 - Battery Master Switch Y27 - Body Lower Solenoid
H12 - High Beam w/l S2 - Starter Keyswitch Y28 - Radiator Fan Thermostat
H27 - Trans Stop w/l Bypass Solenoid
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552

Wire Colours
L - LEFT, R - RIGHT, F - FRONT, B - BACK B - Black O - Orange
CABLES TWISTED N - Brown Y - Yellow
DIODE FUSE 30 TURNS / metre U - Blue P - Purple
R - Red W - White
G - Green S - Slate
SCREENED L - Light Green K - Pink
INDICATOR LIGHT RESISTOR
CABLES
SM 1946 Rev 1 11-00 1

Electrical System - Circuit Diagrams
Section 190-0000
FUSES
Location Fuse No. Circuit Current Rating
1 Ignition Sensed Relay Contacts (Heater) 30A
2 Keyswitch 15A
3 Cab Fan Ventilator Blower 15A
4 Rear Wash/Wipe 10A
5 Horn Relay Coil, Front Wash/Wipe 10A
Fuse Box - 6 Air Seat Compressor 10A
Column A 7 Lights Supply 10A
8 Main Beam 10A
9 Wiper Park Front and Rear 7.5A
10 Hazards 7.5A
11 Transmission System Ignition Supply 7.5A
12 Reverse System 7.5A
13 Brake Lights 5A
14 Interior Light, Handlamp 5A
15 Direction Indicators/Rocker Switch Lights 5A
16 Alarm Brake/Steering System 3A
17 Warning Lights 3A
Fuse Box - 18 Fuel Solenoid 3A
Column B 19 Gauges/Ignition Sensed Relay Coils 3A
20 Spare -
21 Neutral Start 3A
22 Washers, Front 3A
23 Washers, Rear 3A
24 Horn 10A
25 Ignition Sensed Relay Contacts (Air Conditioning) 30A
26 Air Cond Compressor & Radiator Fan Solenoid 15A
27 Spare -
28 Ignition Auxilary Supply Option 10A
29 Rear Working Lights 15A
Fuse Box - 30 Rotating Beacon 5A
Column C 31 Cab Fan 3A
32 Transmission System Battery Supply 7.5A
33 Body Hydraulic System 5A
34 Alternator Drive Signal 3A
35 Heated Mirrors 15A
36 Spare -
Radio Harness 38 Radio/Cassette Supply (Glass Fuse) 7A
39 Radio/Cassette Supply (Glass Fuse) 1A
43 Radio/Cassette Voltage Convertor Supply (Blade Fuse) 15A
Battery Box 44 Alternator Charge Cable (Power Fuse) 100A
45 Cab Busbar Supply Cable (Power Fuse) 100A
SM - 2571
RELAYS
F1 F13 F25
F2 F14 F26 K23 K17 K4 K23 - Ign/Sense Opt. K35 - Body Up
F3 F15 F27
F4 F16 F28 K23 - Ign/Sense K4 - Flashers
F5 F17 F29 K23 K14 K33 K37
F6 F18 F30 K34 - Horn K33 - Radiator Fan
F7 F19 F31
F8 F20 F32 K34 K5 K23 K43 K15 - Headlights K23 - Engine Ignition
F9 F21 F33
F10 F22 F34
K15 K35 K36
K17 - Rev. Alarm/Lts. K36 - Body Float
F11 F23 F35
F12 F24 F36 K14 - Neutral/Start K37 - Body Hyd (12V)
K5 - Air Conditioner K43 - Radio/Cassette
2 SM 1946 Rev 1 11-00

Section 190-0000
ZF EST-37 ELECTRONIC MODULE HARNESS CABLE ROUTINGS

PLUG PIN WIRE PLUG PIN PLUG PIN WIRE PLUG PIN
X8 1 GE2 X1 19 X25 1 630 X58
X8 2 BL2 X56 X25 2 634 X1 15
X8 3 SW3 X1 41 X25 3 638 X51
X8 4 BL3 X56 X25 4 642 X1 18
X8 5 RT4 X1 42 X2 2 650 X58
X8 6 BL4 X56 X2 4 654 X1 43
X8 7 430 X1 10 X2 5 658 X55
X8 8 434 X1 56 X2 6 662 X1 64
X8 9 438 X1 32 X2 7 666 X1 63
X8 10 442 X1 55 X2 8 670 X1 65
X8 11 446 X1 9 X2 10 674 X1 29
X8 12 450 X1 51 X7 1 800 X58
X8 13 454 X57 X7 2 804 X55
X8 14 458 X1 39 X7 3 808 X1 7
X8 15 462 X59 X7 6 820 X1 21
X8 17 484 X50 X7 8 828 X1 30
X8 18 488 X50 X7 9 832 X1 23
X8 19 492 X50 X7 10 836 X1 68
X8 21 500 X1 4 X7 11 840 X1 66
X8 22 504 X1 62 X7 12 844 X1 52
X9 1 508 X58 X7 14 852 X51
X9 2 510 X1 24 X7 15 856 X51
X9 3 514 X1 37 X7 16 860 X1 22
X9 4 518 X1 38 X7 19 872 X1 36
X9 7 530 X1 34 X7 20 876 X54
X9 8 534 X53 X7 21 880 X54
X9 9 540 X1 57 X7 22 884 X54
X9 10 544 X53 X56 900 X1 3
X9 11 550 X1 11 X57 904 X1 12
X9 12 554 X53 X57 908 X1 13
X9 15 570 X1 49 X58 916 X1 45
X9 16 574 X59 X1 1 920 X51
X9 17 580 X58 X1 26 924 X52
X9 18 584 X1 17 X1 27 928 X52
X6 1 590 X58 X55 936 X1 67
X6 3 594 X51 X1 8 948 X53
X6 2 598 X1 14 X1 2 952 X51
X4 1 610 X1 25 X1 53 980 X53
X4 2 614 X52 X59 984 X1 46
X4 4 622 X1 28
SM 1946 Rev 1 11-00 3

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HORIZONTAL
DRAWING

Section 190-0000
SM - 2458A
4 SM 1946 Rev 1 11-00

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HORIZONTAL
DRAWING

SM - 2458B Section 190-0000
SM 1946 Rev 1 11-00 5

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HORIZONTAL
DRAWING

Section 190-0000
SM - 2458C
6 SM 1946 Rev 1 11-00

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HORIZONTAL
DRAWING

SM - 2458D Section 190-0000
SM 1946 Rev 1 11-00 7

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HORIZONTAL
DRAWING

Section 190-0000
SM - 2458E
8 SM 1946 Rev 1 11-00

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HORIZONTAL
DRAWING

SM - 2458F Section 190-0000
SM 1946 Rev 1 11-00 9

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HORIZONTAL
DRAWING

Section 190-0000
SM - 2458G
10 SM 1946 Rev 1 11-00

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HORIZONTAL
DRAWING

SM - 2458H Section 190-0000
SM 1946 Rev 1 11-00 11

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HORIZONTAL
DRAWING

Section 190-0000
SM - 2458I
12 SM 1946 Rev 1 11-00

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HORIZONTAL
DRAWING

SM - 2458J Section 190-0000
SM 1946 Rev 1 11-00 13

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HORIZONTAL
DRAWING

Section 190-0000
SM - 2458K
* * * *
14 SM 1946 Rev 1 11-00
ELECTRICAL SYSTEM - Switches and Sensors
Section 190-0270
SM - 2574
4 5 5
ENGINE
1
2
13 FRONT BRAKE 4 WAY PRESSURE

TANK PROTECTION VALVE
3
5
FRONT PRESSURE
PARK/EMERGENCY CONVERTOR
BRAKE VALVE PRIMARY
TANK
9 8
7
10
6
AIR CLEANER
HYDRAULIC
MAIN PUMP TANK
FUEL
TANK
12
11
1 - Engine Coolant Temperature Sender 5 - Low Air Pressure Switch 9 - Hydraulic Oil Pressure Switch
2 - Switch - 5 bar Sender 6 - Parking Brake Pressure Switch 10 - Air Cleaner Restriction Gauge
3 - Stop Light Pressure Switch 7 - Low Steering Pressure Switch 11 - Fuel Level Transmitter
4 - Air Pressure Sender 8 - Hydraulic Oil Temperature Switch 12 - Body Up Microswitch
13 - Engine Load Sensor
Fig. 1 - Layout View of Switches and Sensors
DESCRIPTION Engine
Numbers in parentheses refer to Fig. 1, unless Engine Coolant Temperature Sender (1) - Located
otherwise specified. in the right hand side of the engine. Sends a signal
indicating engine coolant temperature to engine
This section describes the location and function of coolant temperature gauge (10, Fig. 2).
various switches and sensors fitted to the vehicle to
monitor all major components and systems. Gauges Engine Coolant Temperature Gauge (10, Fig. 2) -
and warning lights located in the dash panel, relay this Indicates the engine coolant temperature. The gauge
information to the operator. Refer to Section 120-0010, should read in the green zone after the engine has
TRANSMISSION AND MOUNTING, for switches and warmed. If the gauge reads in the red zone, stop the
sensors fitted to the transmission. engine and investigate the cause.
Note: Always make sure all gauges, warning lights Switch, 5 Bar Sender (2) - The normally closed (NC)
and controls are working properly before operating the sender/switch is located in the engine oil rifle at the
vehicle. rear left hand side of the engine. This sender/switch
SM 1959 Rev 1 11-00 1

Electrical System - Switches and Sensors
Section 190-0270
SM - 2474
9 10 11 12 13 14 15
15 20 30
10 RPM x100 20 20
20 MPH 20
10 40
5 25
km/h 20
0 30 0 50
1 STOP
20
2 5 16 21
6 17
3 1 2
22
120
4 P 7 140
18 23
ENG 50 TRANS
150
WATER TEMP ENG OIL
SERVICE TEMP
8 AIR PRESS OIL PRESS
19
1 - Engine Oil Pressure W/L 16 - Transmission Stop W/L

2 - Hydraulic Oil Filter Restriction W/L 9 - Tachometer/Hourmeter 17 - Differential Lock Ind/L
3 - Tractor Brakes Overstroke W/L 10 - Engine Coolant Temperature Gauge 18 - Headlight Main Beam Ind/L
4 - Low Brake Air Pressure W/L 11 - Air Pressure Gauge 19 - Blank
5 - Low Fuel W/L 12 - Fuel Level Gauge 20 - Blank
6 - Body Up W/L 13 - Engine Oil Pressure Gauge 21 - Emergency Steering W/L
7 - Trailer Brakes Overstroke W/L 14 - Transmission Oil Temperature Gauge 22 - Alternator Charging W/L
8 - Parking Brake Ind/L 15 - Speedometer/Odometer 23 - Direction Indicators Ind/L
Fig. 2 - Layout View of Instruments and Indicator/Warning Lights
opens when engine oil pressure rises above 0.48 bar X9 (located to the right hand side of fuse box). Turn
(7 lbf/in2) and combines two functions: ignition 'On' and check for the following readings;
a. Engine oil pressure sender sends a signal indicating Idle: 0.5 Volts
oil pressure to engine oil pressure gauge (13, Fig. 2). Full Load: 3.4 Volts
b. Engine oil pressure switch sends a signal to Note: outwith these parameters, fault code 23 or 24
illuminate engine oil pressure warning light (1, Fig. 2) will occur. Refer to Section 120-0010,
when the engine oil pressure drops below the safe TRANSMISSION AND MOUNTING, for diagnostic
operating pressure. code details.
Engine Oil Pressure Gauge (13, Fig. 2) - Indicates Tachometer/Hourmeter (9, Fig. 2) - Driven from the
the engine oil pressure. The gauge should read in the alternator, the tachometer indicates the number of
green zone during engine operation. If the gauge engine crankshaft revolutions per minute (rev/min).
reads in the red zone, stop the engine and investigate Never accelerate the engine to speeds indicated by
the cause. the red zone on the dial face. A digital hourmeter is
incorporated in the tachometer to record total hours of
Engine Load Sensor (13) - Located on the left hand engine operation.
side of the engine, the engine load sensor sends a
signal to the transmission ECU indicating the engine Tachometer Calibration
load (throttle position) thus allowing the transmission 1. Determine the impulse setting required. Reference
to shift up or down gear in accordance with the engine tachometer calibration table.
revs. To check the load sensor is operating within the
required parameters, test the load sensor electrically. 2. Using a suitable screwdriver, depress and hold
Insert a voltmeter between pins 2 & 4 on harness plug calibration button at the rear of the tachometer and
2 SM 1959 Rev 1 11-00

Section 190-0270
Tachometer Calibration Table - Braking System

All units with standard tyres Stop Light Pressure Switch (3) - The normally open
Unit Engine Pulses/revolution (NO) pressure switch is located in a tee in the supply
port of the front pressure convertor. As brake apply
TA25 Cummins C Series 17.40
pressure increases to 0.28 bar (4 lbf/in2) and above,
TA27 Cummins C Series 17.40
the circuit closes and sends a signal to illuminate the
TA30 Cummins M11 16.68
brake lights at the rear of the vehicle. As pressure
TA35 DD Series 60 18.66
drops below 0.28 bar (4 lbf/in2) the circuit opens and
TA40 DD Series 60 18.66
the brake lights go out.
turn the ignition keyswitch to position '1'. Release Air Pressure Sender (4) - Located in port 'B' of the
button when PULSE is displayed. front brake air tank, the air pressure sender sends a
signal indicating air reservoir pressure on air pressure
3. After a few seconds, the digits will flash in gauge (11, Fig. 2).
sequence. Depress the button until the desired
number is displayed the release the button for a few Air Pressure Gauge (11, Fig. 2) - Indicates air
seconds until the next digit flashes. reservoir pressure. During normal operation, the
needle in this gauge should be showing in or
4. Repeat step 3 to obtain the desired impulses/ approaching the centre of the green zone. Do not
revolution. The tachometer is now calibrated. operate the vehicle if the needle remains in the red
zone.
Speedometer/Odometer (15, Fig. 2) - Driven by a
signal from the ECU, the speedometer indicates travel
speed in kilometres per hour and miles per hour. A WARNING
digital odometer is incorporated in the speedometer to Never release the parking brake or move the
record the distance travelled by the vehicle at any vehicle until the needle is at least approaching
given time. the centre of the green zone.
Speedometer Calibration Low Air Pressure Switch (5) - There are 3 normally
1. Determine the impulse setting required. Reference open (NO) pressure switches located in air system.
speedometer calibration table. One located in port 'A' of the primary air tank and two
on the pressure protection valve at ports '21' and '22'.
Speedometer Calibration Table - The switches send a signal to illuminate low brake air
All units with standard tyres pressure warning light (4, Fig. 2) if air pressure falls
below 4.1 bar (60 lbf/in2). If the warning light
Unit Transmission Pulses
illuminates, stop the machine, apply the parking brake
TA25 6 WG 210 333650 and investigate the cause.
TA27 6 WG 210 333650
TA30 6 WG 260 232100 Parking Brake Pressure Switch (6) - The normally
TA35 6 WG 310 231900 closed (NC) pressure switch is located in a tee from
TA40 6 WG 310 217130 the parking/emergency brake control valve. The
pressure switch opens at a pressure of 0.7 bar
2. Depress and hold calibration button at the front of (10 lbf/in2) and sends a signal to illuminate parking
the speedometer and turn the ignition keyswitch to brake indicator light (8, Fig. 2), indicating that the
position '1'. Release button when PULSE is displayed. parking brake is applied.
3. After a few seconds, the digits will flash in Pressure Converter Overstroke Switches - A
sequence. Depress the button until the desired normally open (NO) contact switch assembly is
number is displayed the release the button for a few located in both the front and rear pressure converter
seconds until the next digit flashes. assemblies. When the pressure converter stroke has
been exceeded, because of a loss of hydraulic
4. Repeat step 3 to obtain the desired impulses/ pressure in the brake system, the switch in the contact
revolution. The speedometer is now calibrated. assembly closes and sends a signal to illuminate front
SM 1959 Rev 1 11-00 3

Section 190-0270
or rear brake system warning light (3 or 7, Fig. 2). An Air Cleaner

audible alarm also sounds. Refer to Section 250-0260, Air Cleaner Restriction Gauge (10) - Mounted on the
PRESSURE CONVERTER, for instructions on how to air cleaner, the restriction gauge indicates the degree
reset the pressure converter. of air cleaner element restriction as the red panel rises
in the gauge window. The filter element should be
replaced if the red band locks in place when the
Steering System engine is shut down. Reset the gauge by pressing the
Low Steering Pressure Switch (7) - The normally button on the gauge with the engine running.
closed (NC) pressure switch is located in a block at
the top port of the main hydraulic pump. The pressure
switch sends a signal to illuminate steering pressure Fuel Tank
warning light (20, Fig. 2) when steering pressure drops Fuel Level Transmitter (11) - Located in the left hand
to 4.8 bar (70 lbf/in2) or lower. An audible alarm also side of the fuel tank, the fuel level transmitter has two
sounds. functions:
a. Sends a signal to fuel level gauge (12, Fig. 2) to

Hydraulic System indicate the amount of fuel left in the tank.
Hydraulic Oil Pressure Switch (8) - The normally
open (NO) oil pressure switch is located beside b. Sends a signal to illuminate low fuel warning light
hydraulic oil temperature switch (9) in the centre cover (5, Fig. 2) to indicate when the fuel tank content falls
plate on top of the hydraulic tank. The oil pressure below 68 litres (18 US gal).
switch will close and illuminate hydraulic oil filter
restriction warning light (2, Fig. 2) when the restriction Body
pressure exceeds 2.7 bar (40 lbf/in2), indicating a filter
element change is required. Body Up Proximity Switch (12) - Mounted off the
inside of the trailer right hand frame rail. When the
Hydraulic Oil Temperature Switch (9) - The normally body is raised off the trailer frame, the switch sends a
open (NO) oil temperature switch closes when a signal to illuminate body up warning light (6, Fig. 2).
temperature of 50 C (122 F) is reached. The oil
temperature switch is connected in series with Note: Never move the vehicle until body up warning
hydraulic oil pressure switch (8), therefore, hydraulic light (6, Fig. 2) goes out, indicating that the body is
oil filter restriction warning light (2, Fig. 2) will not fully lowered onto the trailer frame.
illuminate until the oil rises above 50 C (122 F).
Note: The proximity sensor prevents the body being
fully powered down onto the chassis. At a
predetermind height, the sensor automatically defaults
the body control valve to the detented 'Float' condition.
* * * *
4 SM 1959 Rev 1 11-00

FUEL SYSTEM - Fuel Tank, Lines and Mounting
Section 200-0040
SM - 2454
4,5
3 6
2
15
1 13
14
19
13
13 7 8 9 10
11
12
14
18
13
20 16
17
1 - Fuel Tank 6 - Fuel Strainer 11 - Cover 16 - Plug
2 - Key 7 - Gasket 12 - Bolt 17 - Drain Plug
3 - Padlock 8 - Fuel Level Transmitter 13 - Washer 18 - Rubber Pad
4 - Filler Cap 9 - Washer 14 - Spring 19 - Bolt
5 - Filter Assembly 10 - Screw 15 - Locknut 20 - Locknut
Fig. 1 - Standard Fuel Tank and Mounting
DESCRIPTION amount of fuel left in the tank.

b. Sends a signal to illuminate the low fuel warning
The fuel tank is installed in the front right hand of the light to indicate when the fuel tank content falls below
tractor frame and secured with bolts (12 & 19), 68 litres (18 US gal).
washers (13), springs (14) and locknuts (15 & 20), as
shown in Fig. 1. Note: Refer to Section 300-0020, LUBRICATION
SYSTEM for fuel tank capacities and fuel
Integral with fuel tank (1) are fuel strainer (6) and fuel specifications.
level transmitter (8). Fuel strainer (6) helps prevent
foreign particles from entering fuel tank (1) during
filling. Fuel level transmitter (8), located in the left hand OPERATION
side of fuel tank (1), has two functions: Numbers in parentheses refer to Fig. 2.
a. Sends a signal to the fuel level gauge to indicate the Fuel is drawn from fuel tank (16) through fuel line (3),
SM 1942 4-00 1
Fuel System - Fuel Tank, Lines and Mounting
Section 200-0040
SM - 2466
12
16 11
9,10
8,9
3 7 2
13
6
14
4,5 1
15
11 - Plug
1 - Fuel Line 6 - Elbow 12 - Fuel Filter Bracket
2 - Fuel Line 7 - Elbow 13 - Connector
3 - Fuel Line 8 - Bolt 14 - Fuel Filter/Water Separator
4 - Elbow 9 - Lockwasher 15 - Fuel Pump
5 - Reducer Bushing 10 - Bolt 16 - Fuel Tank
Fig. 2 - Fuel Lines
fuel filter/water separator (14) and fuel line (2) by fuel REMOVAL
pump (15). Leaving fuel pump (15) under pressure, Numbers in parentheses refer to Fig. 1, unless
the fuel flows to the fuel injectors in the cylinder head otherwise specified.
through passages integral with the cylinder head.
Surplus fuel exits from the cylinder head, just above
the fuel inlet, and returns to fuel tank (16) through fuel WARNING
line (1). To prevent personal injury and property
A fuel tank breather/filter assembly (5, Fig.1) is materials and lifting equipment are properly
incorporated into the fuel cap (4, Fig. 1), allowing fuel secured and of adequate capacity to do the job
tank (16) to vent to atmosphere, preventing pressure safely.
from building up within fuel tank (16) assembly.
2 SM 1942 4-00
Section 200-0040
2. Block all road wheels and place the battery master washer (13) and locknut (20), as shown in Fig. 1.
switch in the 'Off' position. Tighten locknut (20) until spring compresses to a
length of 31.75 mm (1.25 in).
3. Remove padlock (3) and remove filler cap (4) from
fuel tank (1). 4. Secure the rear of fuel tank (1) assembly to the
tractor frame with bolts (12), washers (13), springs (14),
4. Remove fuel strainer (6) from fuel tank (1) and washers (13) and locknuts (15), as shown in Fig. 1.
clean with clean diesel fuel. Tighten locknuts (15) until spring compresses to a
length of 31.75 mm (1.25 in).
5. Remove cover (11) from fuel level transmitter (8)
and disconnect electrical connections at fuel level 5. Remove blanking caps and secure fuel lines
transmitter (8). (1 & 3, Fig. 2) to elbows (4 & 6, Fig. 2), as identified at
removal.
6. With a suitable container in position, remove drain
plug (17) from the underside of fuel tank (1) and drain 6. Connect electrical connections to fuel level
fuel from fuel tank (1). Reinstall drain plug (17) and transmitter (8) and install cover (11).
tighten securely when fuel tank (1) is completely
drained. 7. Install fuel strainer (6) in fuel tank (1).
7. Identify and tag fuel lines (1 & 3, Fig.2) and, with a 8. Fill fuel tank (1) assembly with clean diesel fuel
suitable container available to catch leakage, specified in Section 300-0020, LUBRICATION
disconnect fuel lines (1 & 3, Fig.2). Cap open line ends SYSTEM.
and elbows (4 & 6, Fig. 2) to prevent entry of dirt.
9. Install filler cap (4) assembly on fuel tank filler neck.
8. Remove locknuts (15 & 20), bolts (12 & 19), Tighten filler cap (4) securely and secure in place with
washers (13) and springs (14) securing fuel tank (1) padlock (3).
assembly in the tractor frame. Using a suitable lifting
device, remove fuel tank (1) assembly from the 10. Place the battery master switch in the 'On'
vehicle. position, start the engine and run for a few minutes to
ensure fuel is being supplied to the engine. Check for
9. If required, remove rubber pads (18) from the tractor leaks at fuel lines (1 & 3, Fig. 2) and tighten if required.
frame. Be sure to remove all rubber and adhesive from
the tractor frame. 11. Remove wheel blocks from all road wheels.
INSTALLATION MAINTENANCE
WARNING WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure lifting equipment is properly damage, be sure wheel blocks and blocking
secured and of adequate capacity to do the job materials are properly secured and of adequate
safely. capacity to do the job safely.
1. If removed, apply a suitable adhesive to new rubber

pads (18) and position on the tractor frame. General
Refill fuel tank (1) at the end of each day's operation to
2. Using suitable lifting equipment, position fuel tank (1) prevent condensation from contaminating the fuel.
assembly in the tractor frame. When filling fuel tank (1), check that there is no buildup
of dirt and sludge at fuel strainer (6) and filler cap (4).
3. Secure the front of fuel tank (1) assembly to the Remove and clean fuel strainer and filler cap as
tractor frame with bolt (19), washer (13), spring (14), required.
SM 1942 4-00 3
Section 200-0040
From time to time, remove cover (11) and check Install new fuel filter/water separator on the filter head
condition of electrical connections at fuel level and tighten by hand until the gasket contacts the filter
transmitter (8). head surface. Tighten fuel filter/water separator per
filter manufacturer's instructions.
Every 10 Hours/Daily Note: Mechanical tightening of the filter is not

Make a visual check for fuel leaks at all fuel lines and recommended and may result in seal and/or cartridge
connections. Make sure that fuel lines (1, 2 & 3, Fig.2) damage. Tighten filter by hand only.
are not resting on or touching rotating components,
heated surfaces including exhaust manifolds, or sharp
edges. If fittings have loosened or cracked, or if lines Every 500 Hours
have ruptured or worn through, take corrective action Remove drain plug (17) from the underside of fuel tank
immediately. (1) and drain off any water or sediment which has
gathered. Check condition of filler cap (4) and clean
Fuel Filter/Water Separator (14, Fig. 2) - Drain the fuel strainer (6) and filler cap (4) with clean fuel. Check
water and sediment from the separator daily. the condition of all fuel lines and replace if required.
Position the vehicle on a level work area, apply the

parking brake, shut off the engine and, with a suitable Every 1 000 Hours
container below the drain valve to catch spillage, open Remove filler cap (4) from filler neck. With the handle
the drain valve by hand. Turn the valve anticlockwise in the up and rotated position, remove the two screws
approximately 1.5 to 2 turns until draining occurs. Drain securing the filter assembly (5) to the cap. Discard
the filter sump until clear fuel is visible. Turn the valve 'O' rings. Clean top of filler cap (4) and valve cavity.
clockwise to close the drain valve. Install new filter assembly (5) to filler cap (4) using
new screws and 'O' rings (supplied with new filter).
Note: Do not overtighten the drain valve as Tighten screws to 10 - 13 in lbs.
overtightening can damage the threads.
Diesel Fuel Oil
Every 250 Hours The sulphur content of diesel fuel oil should be as low
Fuel Filter/Water Separator (14, Fig. 2) - Clean the as possible to avoid premature wear of piston rings
area around the filter head and replace the fuel filter/ and line, excessive deposit formation, and minimise
water separator. sulphur dioxide exhausted into the atmosphere.
Limited amounts can be tolerated, but the amount of
Position the vehicle on a level work area, apply the sulphur in the fuel and engine operating conditions can
parking brake and switch off the engine. Using a strap influence corrosion and deposit formation tendencies.
type filter wrench, remove the fuel filter/water separator The use of diesel fuel oil with a MAXIMUM sulphur
and discard the thread adaptor sealing ring. Clean the content of 0.5% is recommended for use. Refer to
gasket surface of the filter head. Section 300-0020, LUBRICATION SYSTEM.
Install the new thread adaptor sealing ring (supplied

with new filter) and apply a film of clean engine oil to SERVICE TOOLS
lubricate the filter seal. Fill the new fuel filter/water Refer to Section 300-0070, SERVICE TOOLS, for part
separator with clean fuel specified in Section numbers of general service tools and adhesives
300-0020, LUBRICATION SYSTEM. required. These tools and adhesives are available
from your dealer.
* * * *
4 SM 1942 4-00
COOLING SYSTEM - Cooling System
Section 210-0000
SM - 2499
11
14
12
17
16
9
10
3
5 13
TO RADIATOR
(FRONT L.H.)
8
15
7 2
6
6 - Coolant Inlet Pipe 12 - Coolant Outlet Pipe

1 - Radiator Assembly 7 - Water Pump 13 - Bleed Nipple
2 - Make-up Line 8 - DCA4 Water Filter 14 - Header Tank
3 - Coolant Outlet Pipe 9 - Aftercooler 15 - Make-up Line
4 - Transmission Oil Cooler 10 - Thermostat Housing 16 - Deaeration Line
5 - Elbow 11 - Deaeration Line 17 - Overflow Line
Fig. 1 - Cooling Lines
DESCRIPTION OPERATION
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
A water cooling system is installed in these vehicles The engine water pump (7) draws coolant from
to maintain desired engine operating temperatures. transmission oil cooler (4) through coolant inlet pipe
(6) and also from header tank through make-up line
The engine portion of the cooling system is covered (15). The coolant passes through DCA4 water filter
in the engine 'Operation and Maintenance Manual'. (8), aftercooler (9) and through the engine block to
thermostat housing (10).
The main components of the cooling system are;
radiator assembly (1), header tank (14), transmission When the coolant is below operating temperature, the
oil cooler (4), water pump (7), DCA4 water filter (8), engine thermostat remains closed and coolant flowing
aftercooler (9) and thermostat housing (10). to thermostat housing (10) returns to engine water
pump (7) and is re-circulated through the engine again.
SM 1983 4-00 1
Cooling System - Cooling System
Section 210-0000
Aerated coolant is drawn off to header tank (14) from Every 10 hours/Daily
left hand radiator tank and engine vent port through Check coolant level and add if low. Fill the radiator
deaeration lines (11 & 16). Excess coolant at header header tank with coolant until the coolant reaches the
tank (14) is discharged through overflow line (17) on bottom of the filler neck and holds at that level.
the filler neck.
Note: Any time a significant amount of coolant is
When the coolant reaches proper operating added, the DCA4 concentration MUST be checked
temperature, the engine thermostat opens allowing and the appropriate action taken. Refer to
coolant to flow through coolant outlet tube (12) and instructions under 'Coolant Recommendations' in this
into the right hand radiator tank. Coolant travels section.
through the radiator core, where heat is drawn off by
air circulating through the core, and into the left hand Note: Removal of the filler cap when the system is
radiator tank. Coolant then travels through coolant hot vents the pressure in the system; if the filler cap
outlet pipe (3), into transmission oil cooler (4) and re- is reinstalled while the system is hot, normal system
circulated back through the system. build up to the rated pressure will not take place. This
may result in a serious temporary reduction of
Note: Refer to Section 210-0060, TRANSMISSION coolant flow due to cavitation at the water pump inlet,
OIL COOLER, for transmission oil flow through particularly if the machine is being operated at high
transmission oil cooler (4). altitude.
The use of antifreeze is mandatory with the cooling Check fan for cracks, loose rivets, and bent or loose
system. The lack of radiator flow with the blades. Check fan mounting and tighten if required.
thermostats closed allows the coolant in the radiator Replace the fan if damaged. Visually inspect the fan
to freeze under low ambient temperatures. belt for wear and tension. Refer to Section 110-0030,
ENGINE AND MOUNTING.
PREVENTIVE MAINTENANCE Check all coolant lines, pipes and components for
To ensure the continued efficient functioning of the leaks and wear.
cooling system, certain checks and operations
should be performed at regular intervals.
Every 250 hours
Check and replenish the DCA4 concentration as
WARNING described under 'Coolant Recommendations' in this
Do not remove the filler cap from the radiator section.
header tank or attempt to drain the coolant
until the engine has cooled to below 50 C Replace DCA4 coolant filter if required. When testing
(120 F). When removing filler cap, always the DCA4 concentration, depending on the level of
partially unscrew cap slowly to release DCA4, the coolant filter may not require to be
pressure from the system. Remove filler cap changed. Refer to instructions under 'Coolant
slowly, as the sudden release of pressure from Recommendations' in this section.
a heated cooling system can result in a loss of
coolant and possible personal injury. Note: Under concentration of the DCA4 coolant
additive can result in liner pitting and system
corrosion. Over concentration can result in water
As Required pump seal leakage. Always maintain DCA4
Tighten water manifold, water pump, oil coolers and concentration at recommended levels.
radiator mounting bolts. Clean radiator core fins.
Note: Turn the coolant shut off valve to the 'Off'
Note: Under extreme conditions it may be necessary position before removing DCA4 water filter.
to clean radiator core fins several times per shift.
2 SM 1983 4-00
Section 210-0000
Every 4 000 hours

Drain and flush the cooling system as described WARNING
under 'Cleaning The Cooling System' in this section. Do not remove the filler cap from the radiator
Fill the cooling system with the correct mixture of header tank or attempt to drain the coolant
antifreeze, water and DCA4 liquid as described under until the engine has cooled to below 50 C
'Coolant Recommendations' in this section. (120 F).
Visibly inspect the water pump for indications of 5. Shut off the engine and drain the cooling system.
coolant or oil leakage at the weep hole.
Note: To greatly increase the radiator fill time, open
Note: A streak or slight chemical build up at the bleed nipple (13, Fig. 1) on elbow (5, Fig. 1) at initial
weep hole is not justification for water pump fill. The bleed nipple should be left open until coolant
replacement. If a steady flow of coolant or oil is starts to leak from the nipple, indicating that all air in
observed, replace the water pump with a new or the system up to this level has escaped.
rebuilt unit.
6. Fill the cooling system with clean water and
operate the engine at high idle for 5 minutes with the
Cleaning The Cooling System coolant temperature above 85 C (185 F).
WARNING WARNING
Do not remove the filler cap from the radiator Do not remove the filler cap from the radiator
header tank or attempt to drain the coolant header tank or attempt to drain the coolant
until the engine has cooled to below 50 C until the engine has cooled to below 50 C
(120 F). When removing filler cap, always (120 F).
partially unscrew cap slowly to release
pressure from the system. Remove filler cap 7. Shut off the engine and drain the cooling system.
slowly, as the sudden release of pressure from
a heated cooling system can result in a loss of Note: If the water being drained is still dirty, the
coolant and possible personal injury. system must be flushed again until the water is
clean.
Note: It is recommended to use a cleaner such as
Fleetguard RESTORE, or equivalent, when cleaning 8. Refill the cooling system with the proper mix of
the cooling system. antifreeze and water and install new precharge filter
and correct concentration of DCA4 liquid. Refer to
1. Drain the cooling system. Do not allow the cooling instructions under 'Coolant Recommendations'.
system to dry out or remove the DCA4 water filter.
9. Install filler cap on the radiator header tank,
2. Add 3.8 litres (1 US gal) of cleaner for each operate the engine and check for coolant leaks.
38 - 57 litres (10 - 15 US gal) of cooling system
capacity, and fill the system with plain water.
COOLANT RECOMMENDATIONS
Note: Fleetguard RESTORE contains no antifreeze Heavy duty diesel engines installed in these vehicles
and the cooling system should not be allowed to require a heavy duty coolant for optimum
freeze during the cleaning operation. performance. Heavy duty coolant is defined as a
correct mixture of good quality water, low silicate
3. Slide the heater temperature control to high to antifreeze and supplemental coolant additives (SCA's).
allow maximum coolant flow through the heater core.
The blower switch does not have to be on. Water quality is important for cooling system
performance. Excessive levels of calcium and
4. Operate the engine at normal operating magnesium contribute to scaling problems, and
temperature, at least 85 C (185 F) for 1 - 1.5 hours. excessive levels of chlorides and sulphates cause
cooling system corrosion.
SM 1983 4-00 3
Section 210-0000
It is recommended to use a low silicate antifreeze

DCA4 Test Kit
concentrate that meets ASTM D4985 specifications The test kit must be used:
(less than 0.1% silicate). Low silicate antifreeze must
be mixed with quality water at a 50/50 ratio (40 to 1. When excessive coolant loss occurs.
60% working range). A 50/50 mixture of antifreeze
and water gives a -37 C (-34 F) freeze point and a 2. After every 250 hours of operation.
boiling point of 109 C (228 F). The actual lowest
freeze point of ethylene glycol antifreeze is at 68%. 3. If the concentration is known to be above the high
Using higher concentrations of antifreeze will raise limit of 0.8 units per litre. Test at each subsequent oil
the freeze point of the solution and increase the change until the concentration decreases below the
possibility of a silicate gel problem. A refractometer high limit.
must be used to accurately measure the freeze point
of the coolant. Refer to 'Special Tool and Test Kit'. Note: Do not use the test kit to omit or extend the
service intervals unless the concentration is above
Supplemental coolant additives (DCA4), or 0.8 units per litre.
equivalent, are used in conjunction with water and
antifreeze to prevent liner pitting, corrosion and scale The test strip container is marked with an expiration
deposits in the cooling system. The cooling system date and the plastic container must be securely
must be precharged with the correct concentration of tightened to protect the moisture sensitive strips.
DCA4. Refer to the relevant 'Precharge Chart' in this Discard the strips if there is any doubt about the test
section. When coolant is replaced in the field, it must strip quality.
be replaced with heavy duty coolant precharged with
DCA4. In addition, a service coolant filter must be
installed. Together, this will result in a total precharge
Test Instructions
of approximately 0.33 DCA4 units per litre of coolant. 1. Collect coolant sample from the radiator or
petcock. DO NOT collect from the coolant recovery
Proper blending of heavy duty coolant is achieved as or overflow system. Coolant must be between 10 C
follows: and 54 C when tested.
a. Pour water into a suitable clean container. 2. Remove one strip from the bottle and replace cap
immediately. DO NOT touch the pads on the end of
b. Add the same quantity of low silicate antifreeze to the strip.
the water.
Note: Discard kit if unused strips have turned light
c. Add the correct quantity of DCA4 liquid for the brown or pink.
cooling system capacity required. Refer to the
relevant 'Precharge Chart' in this section for DCA4 3. Dip strip in coolant sample for one second,
quantities. Refer to Section 300-0020, LUBRICATION remove, and shake strip briskly to remove excess
SYSTEM for cooling system capacity. liquid.
d. Thoroughly blend all components. 4. 45 seconds after dipping strip compare and record
results in the following order:
Note: Following the correct order for mixing the
heavy duty coolant will prevent additive dropout a. Compare Freeze Point (end pad) to colour chart
during the mixing process. and record the result.
Note: The cooling system must be clean before b. Next, compare Sodium Molybdate (middle pad) to
adding DCA4 liquid. colour chart and record the result.
Note: Do not use soluble oils in the cooling system. c. Finally, compare Sodium Nitrate test to colour
The use of soluble oils will lead to cylinder lining chart and record the result.
pitting, corrode brass and copper, damage heat
transfer surfaces and damage seals and hoses. 5. All three readings must be completed no later
than 75 seconds after dipping the strip.
4 SM 1983 4-00
Section 210-0000
6. It is okay to estimate a value between colour Treatment Instructions

blocks, but if uncertain about the colour match, pick If the concentration is:
the lower numbered block.
Below 0.3 units per litre - Add both the normal
7. Determine where the Sodium Molybdate level amount of DCA4 liquid as specified in the respective
intersects the Sodium Nitrite level on the chart. The service chart' and the amount specified in the
amount of SCA units per litre in the cooling system is respective 'Precharge Chart'. Replace the DCA4
given where the Sodium Molybdate row intersects the coolant filter.
Sodium Nitrite column.
Between 0.3 and 0.8 units per litre - Add the normal
Note: For best results follow test times carefully. amount of DCA4 liquid as specified in the respective
Use a stopwatch or clock with a sweep second hand. 'Service Chart'. Replace the DCA4 coolant filter.
Comparing the test strip to the colour chart too soon
before, or too late after, the required test time will Above 0.8 units per litre - Do not replace the DCA4
result in incorrect readings and improper treatment, filter or add liquid DCA4 until the concentration drops
and could result in liner pitting and engine damage. below 0.8 units per litre. The concentration must be
tested at every subsequent 250 hour service interval
8. All readings should be recorded on the truck until concentration decreases below 0.8 units per
maintenance record for future reference. litre.
SPECIAL TOOL AND TEST KIT

Refer to Section 300-0070, SERVICE TOOLS, for
part numbers of the refractometer and coolant test kit
referenced in this section. These items are available
from your dealer.
Precharge Chart Service Chart

Cooling System Amount of DCA4 Liquid Required Cooling System Amount of DCA4 Liquid Required
Capacity - Litres Capacity - Litres
Units Litres Units Litres
78 - 115 40 3.8 78 - 115 10 1.0
116 - 191 60 5.7 116 - 190 15 1.4
192 - 285 90 8.5 191 - 285 20 1.9
286 - 380 120 11.4 286 - 379 25 2.4
381 - 569 180 17.0 380 - 569 40 3.8
SM 1983 4-00 5
Section 210-0000
COOLING SYSTEM DIAGNOSIS CHART

Engine coolant temperature Low coolant level Fill cooling system to correct fill level
too high
Check for leaks and repair
Front of radiator obstructed Remove obstruction and clean radiator
preventing free flow of air fins
Fan drive belt broken or slipping Adjust or replace fan belt if broken.
Thermostat not opening Replace thermostat
Cooling system clogged with rust or Flush cooling system
scale
Water pump not functioning properly Repair or replace water pump
Engine coolant temperature Thermostat remains open or opens Replace thermostat
too low at too low a temperature
Extremely cold weather Cover radiator or install radiator
shutters
* * * *
6 SM 1983 4-00
COOLING SYSTEM - Radiator, Header Tank and Mounting
Section 210-0040
SM - 2497
10
1 11
12 22
18 2
19
5
13
20
21 6 9
3
7
8
4
15 14
17 16
15 - Adaptor
1 - Radiator Assembly 8 - Rubber Mount 16 - Drain Cock
2 - Fan Guard 9 - Nut 17 - Plug
3 - Fan Shroud 10 - Bolt 18 - Bolt
4 - Fan Cowl 11 - Washer 19 - Rubber Mount
5 - Support Bracket 12 - Nut 20 - Snubbing Washer
6 - Bolt 13 - Elbow 21 - Nut
7 - Washer 14 - Hose Assembly 22 - Coolant Inlet Pipe
Fig. 1 - Typical Radiator Mounting
DESCRIPTION REMOVAL
Radiator assembly (1) is mounted in front of the

engine cooling fan at the front end of the vehicle. It is WARNING
fed from header tank (8) located in front of the Do not remove the filler cap from the radiator
operators compartment and mounted to the goalpost header tank or attempt to drain the coolant
support assembly. until the engine has cooled to below 50 C
(120 F). Once the engine has cooled, use
A fan shroud (3) improves the engine cooling fan extreme caution when removing the cap. When
efficiency, provides a more uniform distribution of air removing filler cap, always partially unscrew
over radiator core (7, Fig. 2) and helps restrict cap slowly to release pressure from the
recirculation of air within the engine compartment. system. Remove filler cap slowly, as the
sudden release of pressure from a heated
Recirculation baffle plates around radiator assembly cooling system can result in a loss of coolant
(1) prevent hot air from the engine cooling fan being and possible personal injury (scalding) from
reintroduced into the cooling air circuit. the hot liquid.
SM 1987 4-00 1
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040
SM - 2496
13 15
16 17 11
3 18
12
20
1 21
19 18
22
10
5
8
10
7
8
14
15
16
9
10
2
9
21
20 16 15
12 4 14
22
11
16 15 10
13
1 - Left Hand Tank 7 - Radiator Core

2 - Right Hand Tank 8 - Gasket 13 - Stud 18 - Lockwasher
3 - Top Support 9 - Stiffening Strip 14 - Bolt 19 - Nut
4 - Bottom Support 10 - Stiffening Strip 15 - Lockwasher 20 - Lockwasher
5 - Cross Brace 11 - Bolt 16 - Nut 21 - Nut
6 - Cross Brace 12 - Washer 17 - Bolt 22 - Stiffening Strip
Fig. 2 - Exploded View of Radiator Assembly
3. Remove hood assembly from the vehicle. Refer to

WARNING Section 100-0040, HOOD AND MOUNTING.
damage, be sure wheel blocks, blocking 4. Remove filler cap carefully from filler neck on
materials and lifting equipment are properly header tank (1, Fig. 3).
safely. 5. With a suitable container in position, remove plug
(17) and open drain cock (16) at the bottom of
1. Position the vehicle in a level work area, apply the radiator assembly (1) and drain the cooling system.
parking brake and switch off the engine. Close drain cock (16) and reinstall plug (17) when
coolant is completely drained.
switch in the 'Off' position. 6. Ensure hydraulic lines connected to hydraulic oil
cooler mounted at front of radiator assembly (1) are
2 SM 1987 4-00
Section 210-0040
SM - 2498
11
17
6 1
7
7
8
11
2
12 10
9 9
15
TO ENGINE
13
VENT PORT 20
3 4
21
5
2 18 19
14
13
TO ENGINE 16
WATER PUMP
INLET
TO TOP OF
RADIATOR L.H.S
1 - Header Tank 8 - Locknut 15 - Elbow

2 - Clamp 9 - Clamp 16 - Plate Assembly
3 - Hose 10 - Overflow Tube 17 - Cap
4 - Hose 11 - Elbow 18 - Tube
5 - Elbow 12 - Hose Assembly 19 - Pipe Clamp
6 - Bolt 13 - Hose Assembly 20 - Adaptor
7 - Washer 14 - Elbow 21 - Reducer
Fig. 3 - Radiator Header Tank and Mounting
identified for ease of installation and with suitable and hydraulic oil cooler on the front of radiator
containers available to catch leakage, disconnect assembly (1). Move baffle plates and hydraulic oil
hydraulic lines. Fit blanking caps to open lines and cooler clear from radiator core to facilitate removal.
ports.
10. Remove mounting hardware securing fan guards
7. Slacken clamps and remove coolant inlet pipe (22) (2) to fan shroud (3) and remove fan guards (2) from
from radiator assembly (1) and engine thermostat the vehicle.
housing.
11. Remove bolt (6), washer (7) and locknut (9)
8. Disconnect deaeration line (13, Fig. 3) from elbow securing radiator support bracket (5) to radiator
(14, Fig. 3) at the top of radiator left hand tank. Fit steady bracket on engine.
blanking caps to open lines and ports.
12. If isolation mount (7) is damaged, remove and
9. Remove mounting hardware securing baffle plates replace with a new rubber mount (7).
SM 1987 4-00 3
Section 210-0040
13. Using suitable lifting equipment attached to lifting DISASSEMBLY

points on the radiator assembly (1), support radiator Numbers in parentheses refer to Fig. 2, unless
assembly. otherwise specified.
Note: Under no circumstances should eye bolts be Note: Position radiator assembly on wooden blocks
fitted to the bosses on the top of radiator (1) for the with fan shroud (3, Fig. 1) up to protect radiator core
purpose of lifting complete radiator assembly (1). during 'Disassembly'.
14. If required, remove bolts (10), washers (11), nuts 1. Remove mounting hardware securing fan shroud
(12) and radiator support bracket (5) from radiator (3, Fig. 1) and fan cowl (4, Fig. 1) to radiator
assembly (1). assembly (1, Fig. 1). Remove fan shroud and cowl
from radiator assembly.
15. Remove locknuts (21), snubbing washers (20)
and bolts (18) securing radiator assembly (1) to the 2. Remove bolts (17) and lockwashers (18) from both
vehicle. Remove radiator assembly (1) from the ends of cross brace (6). Remove lockwashers (18)
vehicle. and nuts (19) from both ends of cross brace (5).
Remove cross braces from radiator assembly (1, Fig.
Note: The thin fins and tubes of the radiator core are 1).
easily damaged, therefore, handle radiator assembly
(1) with care. 3. Remove bolts (11), washers (12), lockwashers
(20) and nuts (21) securing top and bottom supports
16. If rubber mounts (19) are damaged, remove from (3 & 4) to left hand tank (1) and right hand tank (2).
mounting brackets on the frame and replace with new Remove top and bottom supports (3 & 4).
rubber mounts (19).
4. Remove nuts (16), lockwashers (15), bolts (14),
studs (13) and stiffening strips (9, 10 & 20) securing
Header Tank left hand tank (1) to core assembly (7).
5. Remove left hand tank (1) from core assembly (7)
1. With suitable container in position, remove drain and discard gasket (8).
plug to ensure coolant has been drained from header
tank (1). 6. Remove nuts (16), lockwashers (15), bolts (14),
studs (13) and stiffening strips (9, 10 & 20) securing
2. Slacken band clamp (2) and pull hose (3) off of right hand tank (2) to core assembly (7).
pipe at bottom of header tank (1).
7. Remove right hand tank (2) from core assembly
3. Ensure deaeration lines (12 & 13) are identified for (7). Discard gasket (8).
ease of installation and disconnect deaeration lines
from elbows (11) in header tank (1). Fit blanking caps 8. If required, remove drain cock assembly (13
to open lines and fittings. through 17, Fig. 1) assembly from bottom of right
hand tank (2).
4. Disconnect overflow tubing (10) from filler neck.
5. Using suitable lifting equipment, support header Header Tank

tank (1) and remove bolts (6), washers (7) and nuts Numbers in parentheses refer to Fig. 1.
(8) securing header tank (1) to the goalpost support
assembly. 1. If required, remove elbows (11) from header tank
(1) noting orientation of elbows to aid in assembly.
6. Remove header tank (1) assembly from the
vehicle. 2. If required, remove filler cap (17) from filler neck.
4 SM 1987 4-00
Section 210-0040
INSPECTION bolts (17) and lockwashers (18). Tighten all nuts (19)
Numbers in parentheses refer to Fig. 2. and bolts (17).
1. Steam clean all parts thoroughly with a suitable 6. Install fan shroud (3, Fig. 1) and fan cowl (4, Fig.
solvent. 1)to radiator assembly (1, Fig. 1) and secure with
mounting hardware.
2. Examine radiator core (7) core carefully for
possible damage. Repair any damage discovered if
equipped to do so, or, have repairs made at a Header Tank
reputable radiator repair shop. Numbers in parentheses refer to Fig. 1.
3. Clean radiator left hand tank (1) and right hand 1. If removed, apply Loctite 225 to elbows (11) and
tank (2) of all traces of corrosion, scale and old joint install in header tank (1), noting orientation of elbows
material. as identified at disassembly.
2. Install filler cap (17) on filler neck.

ASSEMBLY
otherwise specified. INSTALLATION
Note: Tighten all fasteners to standard torques listed otherwise specified.
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE. Note: Tighten all fasteners without special torques
Note: Use a gasket sealer such as Permatex No. 2, 300-0020, STANDARD BOLT AND NUT TORQUE
or equivalent, during assembly to ensure leakproof SPECIFICATIONS.
joints.
1. If removed, install drain cock assembly (13 WARNING

through 17, Fig. 1) on bottom of right hand tank (2). To prevent personal injury and property
2. Install new gasket (8), coated with sealer, to right secured and of adequate capacity to do the job
hand tank (2). Attach stiffening strips (9, 10 & 20) to safely.
core assembly (7) and right hand tank (2) with bolts
(14), studs (13), lockwashers (15) and nuts (16). 1. If removed, install new rubber isolation mounts
(19) in mounting brackets on the frame. If removed,
3. Install new gasket (8), coated with sealer, to left install new rubber isolation mount (8) in radiator
hand tank (1). Attach stiffening strips (9, 10 & 20) to support bracket.
core assembly (7) and left hand tank (1) with bolts
(14), studs (13), lockwashers (15) and nuts (16). 2. Using suitable lifting equipment, position radiator
assembly (1) on rubber mounts (19). Secure radiator
Note: Tighten left hand tank (1) and right hand tank assembly to mounting brackets with bolts (18),
(2) to core assembly (7) from the centre out to snubbing washers (20) and locknuts (21). Torque
ensure an evenly spread load. tighten bolts (18) to 74 Nm (55 lbf ft).
4. Secure top and bottom supports (3 & 4) to left and Note: The thin fins and tubes of the radiator core are
right hand tanks (1 & 2) with bolts (11), washers (12), easily damaged, therefore, handle radiator assembly
lockwashers (20) and nuts (21). (1) with care.
5. Secure cross braces (5) to radiator assembly (1, 3. Secure radiator support bracket (5) to radiator
Fig. 1) with lockwashers (18) and nuts (19). Secure assembly (1) with bolts (10), washers (11) and nuts
cross braces (6) to radiator assembly (1, Fig. 1) with (12). Secure radiator support bracket (5) to radiator
SM 1987 4-00 5
Section 210-0040
steady bracket on engine with bolt (6), washer (7) system through filler neck in header tank (1) with
and locknut (9). Tighten all nuts (9 & 12) and bolts (6 coolant until coolant level stabilizes at the bottom of
& 10) to secure radiator assembly (1) in position. filler neck.
4. Remove lifting equipment and connect all lines and 14. Check all line and pipe connections for leaks prior
tubes to radiator (1) assembly, as tagged at to starting the vehicle. Tighten as required.
Removal.
15. Switch the battery master switch to the 'On'
5. Secure baffle plates and hydraulic oil cooler position, start up the engine and check for leaks.
assembly to the front of radiator (1) assembly with Tighten lines and fittings and top up coolant level as
mounting hardware, as removed at Removal. required.
6. Install fan guards (2) to fan shroud (3) with 16. Install filler cap (17) on filler neck after the
mounting hardware, as removed at Removal. coolant level has stabilized at the bottom of filler
neck.
7. Ensure drain cock assembly (13 through 17) and
all lines and pipes are securely tightened to prevent 17. Install hood assembly on the vehicle. Refer to
leaks at initial fill and start up. Section 100-0040, HOOD AND MOUNTING.
Note: If Header Tank (1) was removed and has not 18. Remove wheel blocks from road wheels.
yet been installed, proceed from step 8, however, if
header tank (1) was not removed or has been
reinstalled, proceed from step 13. CLEANING
8. Fit header tank (1) assembly to goal post support Internal Cleaning - Water Tubes
assembly and secure with bolts (6), washers (7) and If scale deposits are present inside the water tubes of
nuts (8). the radiator, it is necessary to use a suitable scale
remover such as 'Powdered Scale Solvent', or
9. Remove blanking caps from deaeration lines equivalent. This material is a free-flowing powder,
(12 & 13) and connect to elbows (11) on header tank inhibited to prevent attack on the cooling system
(1), as noted at Removal. materials.
10. Connect hose (3) to pipe at bottom of header tank

(1) and secure in place with band clamp (2). WARNING
Take care to avoid contact of skin or eyes with
11. Connect overflow tube (10) to filler neck. the solvent. If contact is made it should be
washed off immediately with clean water and
12. Secure all lines with clips and tie clips as medical advice should be taken.
removed during Removal. Ensure no lines are
chaffing on sharp edges or resting against areas For general cleaning use it is recommended to use a
where heat will be evident. concentration of 50 - 100 kg/m of water at a
temperature of up to 60 C. Rapid circulation or
13. Refer to Section 210-0000, COOLING SYSTEM agitation with compressed air will reduce the time for
for correct selection of coolant. Fill the cooling cleaning.
6 SM 1987 4-00
Section 210-0040
Note: If scale deposits within the radiator are 4. Leave radiator core to dry before reinstalling the
exceptionally heavy, concentrations up to 200 kg/m cooling equipment.
may be used.
Note: In the case of grossly fouled surfaces which
The most convenient method of use is to prepare a are not cleaned adequately in steps 1 through 4, the
concentrated solution by mixing the powder in hot following procedure may be used.
water in a tank and then adding the concentrated
solution to water contained in the radiator. 5. Ensure that the radiator core is dry.
Note: The solvent must always be added carefully to 6. Liberally brush on to both sides of the radiator core
water, not water to solvent. an emulsifying cleaner such as 'Gunk', or equivalent,
and leave to soak for at least 1 hour.
External Cleaning 7. Apply a high pressure steam jet at 100 - 300 kN/m,
Note: If a build up of dirt is apparent during routine or compressed air at 500 - 700 kN/m on to the
inspection, the following cleaning procedure should be treated surfaces, from several different angles,
adopted. forcing the fouling material out from the radiator core.
8. For surfaces with stubborn deposits, it may be

WARNING necessary to repeat steps 5 through 7, brushing the
To prevent possible injury when using surfaces between stages using a stiff bristle brush.
compressed air or steam jet, wear adequate
eye protection and do not exceed pressure 9. Leave radiator core to dry before reinstalling the
values stated. cooling equipment.
1. Direct a steam jet at 100 - 300 kN/m, or

compressed air at 500 - 700 kN/m on to the faces of MAINTENANCE
the radiator core. Refer to Section 210-0000, COOLING SYSTEM for
recommended preventive maintenance procedures,
2. Liberally brush a liquid detergent on to those service intervals and coolant selection procedures.
surfaces which were not satisfactorily cleaned at
step 1. Leave to soak for at least 1 hour.
SPECIAL TOOLS
3. Apply a high pressure steam jet at 100 - 300 kN/m, There are no special tools required for procedures
or compressed air at 500 - 700 kN/m on to the outlined in this section. Refer to Section 300-0070,
treated surfaces, forcing the fouling material out from SERVICE TOOLS, for part numbers of general
the radiator core. service tools and adhesives required. These tools and
SM 1987 4-00 7
Section 210-0040

TORQUE
1 18 Bolt 74 55
* * * *
8 SM 1987 4-00
COOLING SYSTEM - Transmission Oil Cooler
Section 210-0060
SM - 2484
30
10 TO
24 TRANSMISSION
13 TO ENGINE RETARDER
10 24
23
29
27,28
FROM RADIATOR
L.H. TANK
21 26 25 10
12
15
35 10
34 TO ENGINE 22 16
19 18
14 16 32
33
31 6
10 10
A
11 20 9
32 33 B 10
10 31
7 18
4
19 2
10 17
C
1
8 10
D
FRAME REF.
3 2
5
25 - Oil Return Line

1 - Heat Exchanger 9 - Sleeve 17 - Hose 26 - Locknut
2 - Viton Seal 10 - Clamp 18 - P- Clip 27 - Bolt
3 - Cooler Flange - 90 11 - Sleeve 19 - Elbow - 90 28 - Bolt
4 - Cooler Flange 12 - Outlet Pipe 20 - Tube Assembly 29 - Lockwasher
5 - Socket Screw 13 - Sleeve 21 - Oil Inlet Line 30 - Block
6 - Coolant Inlet Tube 14 - Bleed Nipple 22 - Oil Return Line 31 - Clamp
7 - Coolant Outlet Elbow 15 - Sleeve 23 - Elbow - 90 32 - Bolt
8 - Elbow 16 - Clamp 24 - 'O' Ring 33 - Lockwasher
Fig. 1 - Exploded View of Transmission Oil Cooler
DESCRIPTION AND OPERATION through the engine water jacket and, when
Numbers and letters in parentheses refer to Fig. 1. thermostats are open, returns through coolant inlet
tube (6) at port 'A'. Coolant circulates through cooler
The transmission oil cooler is connected in the tubes in heat exchanger (1), cooling transmission oil
cooling and transmission oil circuits, between the around the tubes, and exits at port 'D'.
radiator and transmission. The purpose of the
transmission oil cooler is to maintain transmission oil Transmission oil to be cooled enters heat exchanger
within its required operating temperature range. Refer (1), through oil inlet line (21) at port 'C', circulates
to Section 120-0010, TRANSMISSION AND around cooler tubes, exits at port 'B' through oil return
MOUNTING and Section 210-0000, COOLING line (22) to the transmission.
SYSTEM.
Note: Oil flow must always flow in the opposite
Coolant is drawn from port 'D', through coolant outlet direction to coolant flow through transmission oil cooler.
elbow (7) by the engine water pump. It then circulates
SM 1977 4-00 1
Cooling System - Transmission Oil Cooler
Section 210-0060
REMOVAL CLEANING AND DISASSEMBLY

Note: In the event of a major mechanical failure, the

WARNING transmission oil cooler assembly should be cleaned
To prevent personal injury and property thoroughly or replaced. Do not attempt to clean
damage, be sure wheel blocks and lifting cooler cores after a transmission failure in which
equipment are properly secured and of metal particles from worn or broken parts are
adequate capacity to do the job safely. released into the oil. Replace the cooler cores.
1. Position the vehicle in a level work area, apply the In many areas, raw water is extremely corrosive or
parking brake and switch off the engine. scale forming and should be treated to prevent
damage to the transmission oil cooler. A properly
2. Block all road wheels and place the battery master maintained cooling system will significantly reduce
switch in the 'Off' position. cleaning intervals. Refer to Section 210-0000,
COOLING SYSTEM.
3. Open drain cock on the underside of the radiator
and drain the coolant into a suitable container. Refer Cleaning Oil Side
to Section 210-0000, COOLING SYSTEM.
4. Remove drain plug from underside of the WARNING

transmission and drain the transmission oil into a Dangerous fumes. To prevent personal injury,
suitable container. Refer to Section 120-0010, use trichloroethane only in the open or in a
TRANSMISSION AND MOUNTING. well ventilated room.
5. Remove mounting hardware securing front grille on 1. Clean transmission oil cooler before sludge
the hood. Remove front grille from the hood. hardens. After transmission oil cooler is completely
drained, circulate a solution of trichloroethane
6. Loosen clamp (10) and slide coolant inlet tube (6) through the passages surrounding the cooler tubes in
and sleeve (9) from connection at port 'A'. Drain heat exchanger (1) to remove sludge.
coolant from coolant inlet tube (6) and cooler flange
(4) into a suitable container. 2. If cooler tubes are badly clogged, circulate an
oakite or alkaline solution through heat exchanger
7. Loosen clamp (10) and slide coolant outlet elbow (1). Solution should be circulated through heat
(7) and elbow (8) from connection at port 'D'. Drain exchanger (1), in the reverse direction to normal flow,
coolant from coolant outlet elbow (7) and cooler for approximately 15 minutes, after soaking for 10
flange (3) into a suitable container. minutes. The duration of circulation depends on how
badly clogged the cooler tubes are. Flush thoroughly
8. Remove drain plug from underside of heat with clean hot water.
exchanger (1) and drain oil into a suitable container.
Reinstall drain plug in heat exchanger (1).
Cleaning Water Side
9. Remove oil inlet line (21) and tube assembly (20) 1. Match mark cooler flanges (3 & 4) and heat
from elbow (19) at port 'C' on heat exchanger (1). exchanger (1) to aid in assembly.
Drain any oil in the line into a suitable container.
2. Remove socket screws (5) securing cooler flanges
10. Remove oil return line (22) from elbow (19) at (3 & 4) to heat exchanger (1). Remove cooler flanges
port 'B' on heat exchanger (1). Drain any oil in the line (3 & 4) from heat exchanger (1) and discard viton
into a suitable container. seals (2).
11. Support transmission oil cooler assembly with a 3. Make up a solution composed of 1/3 muriatic acid
suitable lifting device and remove bolts (32), washers and 2/3 water. To each 9.5 litres (2.5 gal) of solution,
(33) and clamps (31). Remove transmission oil add 227 g (0.5 lb) of oxalic acid.
cooler assembly from the inside of the front bumper.
2 SM 1977 4-00
Cooling System - Transmission Oil Cooler
Section 210-0060
4. Immerse heat exchanger (1) in the cleaning 1. Using suitable lifting equipment, position
solution. Cleaning action is noticeable by bubbling transmission oil cooler assembly on mounting points
and foaming. The process must be carefully in the inside of the front bumper. Secure with bolts
observed and when bubbling stops, usually between (32), washers (33) and clamps (31).
30 - 60 sec., remove heat exchanger (1) from
cleaning solution and flush thoroughly with clean, hot 2. If removed, install elbows (19) in ports 'B' and 'C'
water. After cleaning, dip heat exchanger (1) in light on heat exchanger (1). Install oil inlet line (21) and
oil. tube assembly (20) on elbow (19) in port 'C', and oil
outlet line (22) on elbow (19) in port 'B'.
Note: Severely fouled cooler tubes can be cleaned
by use of a rotary brush if normal cleaning is not 4. Install coolant outlet elbow (7) and elbow (8) on
sufficient. connection at port 'D' and secure with clamps (10).
5. Install coolant inlet tube (6) and sleeve (9) on

ASSEMBLY connection at port 'A' and secure with clamps (10).
6. If removed, install drain plug in underside of
Note: Tighten all fasteners to standard torques listed transmission and fill transmission with lubricant, as
in Section 300-0080, STANDARD BOLT AND NUT specified in Section 300-0020, LUBRICATION
TORQUE SPECIFICATIONS. SYSTEM.
1. Install new viton seals (2) to cooler flanges (3 & 4) Note: Open bleed nipple (14) on coolant outlet elbow
and align cooler flanges to heat exchanger (1), as (7) at initial fill. The bleed nipple should be left open
match marked at disassembly. until coolant starts to leak from the nipple, indicating
that all air in the system up to this level has escaped.
2. Secure cooler flanges (3 & 4) to heat exchanger
(1) with socket screws (5). Tighten socket screws (5) 7. Ensure drain cock on underside of radiator is
alternately to give an even seal around cooler flange closed and fill radiator header tank with coolant
area. specified in Section 210-0000, COOLING SYSTEM.
8. Place the battery master switch in the 'On'

INSTALLATION position, start the engine and check for leaks. Tighten
Numbers and letters in parentheses refer to Fig. 1. lines and fittings as required.
Note: Tighten all fasteners to standard torques listed 9. Install front grille assembly to the hood with
in Section 300-0080, STANDARD BOLT AND NUT mounting hardware removed during removal.
10. Remove wheel blocks from all road wheels.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all SERVICE TOOLS
'O' rings where used. There are no special service tools required for the
procedures outlined in this Section. Refer to
Section 300-0070, SERVICE TOOLS, for part
WARNING numbers of general service tools required. These
To prevent personal injury and property tools are available from your dealer.
damage, be sure wheel blocks and lifting
* * * *
SM 1977 4-00 3
COOLING SYSTEM - Hydraulic Oil Cooler
Section 210-0100
SM - 2494
DIVERTOR TUBE
ON HYD. TANK
10 1
10
2
3 A
IN
6
B 8
5 OUT
4
6
9
1 - Hydraulic Oil Cooler 6 - Connector

2 - Bracket Assembly 7 - Elbow - 90
3 - Bracket Assembly 8 - Inlet Line
4 - Bolt 9 - Outlet Line
5 - Hardened Washer 10 - 'O' Ring
Fig. 1 - Exploded View of Hydraulic Oil Cooler and Mounting
DESCRIPTION AND OPERATION REMOVAL

Numbers and letters in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
The air cooled hydraulic oil cooler is mounted on the

front of the radiator assembly, with the purpose of WARNING
cooling hydraulic oil circulating through the hydraulic To prevent personal injury and property
tank. damage, be sure wheel blocks and lifting
Hydraulic oil enters hydraulic oil cooler (1) at port 'A', adequate capacity to do the job safely.
through inlet line (8), from the diverter connector on
the hydraulic tank. 1. Position the vehicle in a level work area, lower the
body completely and apply the parking brake. Switch
The hydraulic oil is cooled by the air flow through the off the engine and secure shipping bar in the 'Locked'
fins and exits from port 'B', through outlet line (9) and position.
flows back to the opposite fitting on the diverter
connector. 2. Block all road wheels and place the battery master
Note: The fitting closest to the spud on the diverter
connector is the supply with the other fitting being the 3. Remove drain plug from hydraulic tank remote drain
return. fitting. Drain oil in the hydraulic tank into a suitable
container and re-install drain plug.
SM 1976 4-00 1
Cooling System - Hydraulic Oil Cooler
Section 210-0100
4. Remove mounting hardware securing front grille on Note: Tighten all hydraulic lines fitted with ORFS
the hood assembly. Remove front grille from the hood. connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all
5. Remove inlet line (8) from elbow (7) and connector 'O' rings where used.
(6) in port 'A' of hydraulic oil cooler (1). Drain oil from
inlet line (8) into a suitable container. Plug inlet line
and cap port 'A' to prevent ingress of dirt. WARNING
6. Remove outlet line (9) from connector (6) in port 'B' damage, be sure wheel blocks and lifting
of hydraulic oil cooler (1). Drain oil from outlet line (9) equipment are properly secured and of
into a suitable container. Plug outlet line and cap port adequate capacity to do the job safely.
'B' to prevent ingress of dirt.
1. If removed, secure bracket assemblies (2 & 3) to
7. Remove remove mounting hardware securing the radiator assembly with bolts (4) and hardened
hydraulic oil cooler (1) to bracket assemblies (2 & 3). washers (5).
Remove hydraulic oil cooler (1) from its mounting.
2. Secure hydraulic oil cooler (1) to bracket
8. If required, remove bolts (4) and hardened washers assemblies (2 & 3) with mounting hardware, as
(5) securing bracket assemblies (2 & 3) to the radiator removed at 'Removal'.
assembly.
3. Install inlet line (8) and outlet line (9) in their
respective ports, as removed at 'Removal'.
CLEANING AND INSPECTION
1. Inspect fins on hydraulic oil cooler carefully, for 4. Fill hydraulic tank with oil. Refer to Section
trapped debris and damage. If hydraulic oil cooler fins 230-0040, HYDRAULIC TANK, for correct fill level and
show signs of leakage or are excessively damaged, it Section 300-0020, LUBRICATION SYSTEM for
must be replaced as an assembly. specifications of oil to be used.
2. Check connectors in hydraulic oil cooler ports for 5. Place the battery master switch in the 'On' position,
damaged threads. Replace if required. start engine and operate the body hydraulics several
times to circulate the oil. Check hydraulic oil cooler (1)
and lines for leaks. Tighten fittings as required.
WARNING
Dangerous fumes. To prevent personal injury, 6. Install front grille assembly to the hood with
use trichloroethane only in the open or in a mounting hardware, as removed at 'Removal'.
well ventilated room.
7. Secure shipping bar in the 'Stowed' position and
3. After hydraulic oil cooler is completely drained, remove wheel blocks from all road wheels.
circulate a solution of trichloroethane through the
cooler tubes.
MAINTENANCE
4. If cooler tubes are badly clogged, circulate an oakite Check and clean hydraulic oil cooler every 4 000
or alkaline solution through the hydraulic oil cooler, in hours, or more frequently, if required. Debris in the
the reverse direction to normal flow, for approximately cooling fins can restrict the flow of air through the
15 minutes. The duration of circulation depends on cooler which significantly reduces the cooling effect.
how badly clogged the cooler tubes are. Flush
thoroughly with clean hot water. Note: In the event of a hydraulic failure, hydraulic oil
cooler should be removed and cleaned of any debris,
to prevent clogging.
INSTALLATION
Numbers and letters in parentheses refer to Fig. 1.
Note: Tighten all fasteners to standard torques listed

* * * *
2 SM 1976 4-00
STEERING SYSTEM - Steering Schematic
Section 220-0000
DESCRIPTION Internally there is a baffle plate which divides the tank

Numbers in parentheses refer to Figs. 2 through 5. assembly into a body hoist compartment and a
steering compartment. Should oil level drop below this
The operation of the steering system is hydrostatic. baffle level, the tank assembly operates as two
That is to say, there is no mechanical connection separate tanks.
between the steering column and the steered wheels.
Instead there are hydraulic pipes and lines between
the steering components and the steering cylinders. Main Hydraulic Pump (2)
Actuating pressure for steering operation is supplied Refer to Section 230-0050, MAIN HYDRAULIC PUMP.
by main hydraulic pump (2).
Mounted off the transmission power takeoff, the main
When the steering wheel is turned, steering valve (4) hydraulic pump supplies hydraulic oil for operating the
meters an oil volume proportional to the amount of steering and body hoist systems.
turn. This volume of oil flows to the appropriate side of
steering cylinders (7). Steering valve (4) returns Hydraulic oil is drawn from the hydraulic tank (1) and
automatically to its neutral position when turning is pumped through the priority valve (5). A priority spool
completed. within the priority valve (5) directs oil supply from the
main hydraulic pump to the steering valve (4).
Emergency steering pressure is provided by a ground
driven emergency steering pump (3) on the The main hydraulic pump is a multiple gear type pump
transmission. A warning light (on the right hand bank which operates in the one direction only (it is
of warning lights in the cab) illuminates to warn of a assembled for right hand (clockwise) rotation, as
fault in the steering system supply pressure. If the light viewed from the driveshaft end).
illuminates, stop the vehicle and investigate the cause.
Note: Never drive a pump in the wrong direction of
Note: The steering system warning light illuminates rotation, as pump seizure may result.
when the ignition is turned on and should go out when
the engine starts.
Steering Valve (4)
A brief description of the individual components shown Refer to Section 220-0090, STEERING VALVE.
in the steering system are listed below. Detailed
service and operating instructions for the individual Mounted off the underside of the cab floor, the steering
components can be found in their relative component valve is connected to the steering column and controls
sections in this manual. hydraulic oil flow to the steering cylinders.
The steering valve is of a closed centre design,

Hydraulic Tank (1) indicating oil is dead headed at the valve until it is
Refer to Section 230-0040, HYDRAULIC TANK. operated.
Mounted off the tractor frame at the rear of the cab, There are five ports on the steering valve housing as
the hydraulic tank is the common oil reservoir for the follows:
steering and body hydraulic systems.
Port 'P' - Supply from pump via priority valve
Integral with the tank assembly are two suction Port 'T' - Return to tank
screens, filter element, relief valve, adaptor plate, Port 'R' - Cylinder supply for right hand turn
access covers and filler neck assembly. Two sight Port 'L' - Cylinder supply for left hand turn
gauges on the right hand side of the tank assembly Port 'LS' - From Load Sensing port on priority valve
indicate hydraulic oil level. Located on top of the tank
assembly are a breather, pressure switch and
temperature switch.
SM 1943 4-00 1
Steering System - Steering Schematic
Section 220-0000
Priority Valve (5) Diagnostic Test Point

Refer to Section 220-0105, PRIORITY VALVE. Mounted on the rear right hand side of the tractor
frame are diagnostic test points. The steering system
The priority valve is mounted off the rear right hand has one diagnostic test point which enables the
fender support. The valve is installed in the lines service engineer to obtain an accurate steering system
between the steering valve (4) and body control valve. pressure reading.
Hydraulic oil is pumped to the priority valve (5) and
depending on the position of the spool within the Steering system pressure is set at 241 bar (3 500 lbf/in).
priority valve (5), oil is directed to the steering or body
hoist systems.
'O' RING FACE SEALS (ORFS)
There are six ports on the priority valve housing as Where hydraulic lines are fitted with ORFS
follows: connections, the following procedure should be carried
out during 'Installation'. Refer to Fig. 1.
Port 'P' - Pump Inlet Port - Supply from pump
Port 'PP' - Pilot Pressure - Plugged SM - 1335
Port 'CF' - Control Flow - Supply to steering valve

Port 'EF' - Excess Flow - Supply to body hoist valve FITTING NUT
Port 'LS' - Load Sensing - To LS port on steering valve TUBE
Port 'T' - Relief Return - Return to tank
Emergency Valve (6)

Refer to Section 220-0140, EMERGENCY VALVE.
Mounted off the right hand cab leg, the emergency SLEEVE
'O' RING 'O' RING
valve forms part of the emergency steering system. It
is connected to the main output line of the ground
driven Emergency Steering Pump (3) mounted on Fig. 1 - Assembly of Typical ORFS Connector
the transmission.
a. Ensure 'O' ring/seal is in place and that the joining
surfaces are clean. If necessary, retain 'O' ring/seal in
Steering Cylinders (7)
place with a light coating of grease or vaseline.
Refer to Section 220-0120, STEERING CYLINDER.
b. Initially, the nuts should be tightened by hand.
There are two single stage, double acting steering
cylinders on the machine. The cylinder base end is c. Where a hose is fitted, ensure that it is not twisted or
connected to the articulation and oscillation pivot, and, kinked when the nuts are tightened so that it is allowed
the piston rod end is connected to the front frame. to adopt a natural position.
Single stage double acting means that the piston rod
can have oil applied to either side, extending or d. Where a tube is fitted, ensure that the connection is
retracting the piston rod. aligned correctly.
Cylinder mounting is by pins, spacers, seals and, e. Tighten the nut a further 1/4 to 1/2 a turn using the
spherical bearings secured with circlips. Spherical correct size spanner (wrench).
bearings permit a limited amount of cylinder
misalignment when travelling over rough terrain. f. Check that a satisfactory hose or tube routing has
been achieved.
2 SM 1943 4-00
Section 220-0000
FILLING AND BLEEDING THE STEERING MAINTENANCE

SYSTEM Maintenance instructions, intervals and warnings, in
1. Fill hydraulic tank to maximum level. Be ready to the individual steering and body hydraulic component
add oil when the engine is started. Do not let oil drop sections of this manual, should be adhered to at all
below the pump suction line to prevent air entering the times.
system.
2. Start engine and let it idle. Immediately add oil to the

SERVICE TOOLS
tank as required. When no more oil can be added and It is recommended that the following service tools are
oil is clear, proceed as follows: used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
a. Turn the steering wheel from lock to lock to bleed along with other general service tools, are available
the air in the steering cylinders and lines. from your dealer. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of these tools.
Note: Immediately upon valve spool actuation oil must
be added to the hydraulic tank to replenish the oil
moving into the circuit.
Multi-Gauge
The multi-gauge is basically four pressure gauges in
one. Continuous system pressure readings are
WARNING indicated on one of three simultaneously reading
Do not operate the machine until all air is bled gauges through a pressure range of 30 in of vacuum
from the oil. to 5 000 lbf/in.
b. When the oil in the tank is clear (not cloudy or

creamy), the system is free of air.
Non-contact Infrared Thermometer
The infrared thermometer can be used to spot heat
Note: Slight creep or drift of the steering wheel is problems early in electrical, mechanical and hydraulic
normal. systems. Hand held and easy to use, you simply aim,
pull the trigger, and read the temperature. Since there
c. Fill hydraulic tank to the recommended level and is no need to touch what you are measuring,
install the filler cap. temperatures of hard-to-reach or moving components
can be taken without getting burned or shocked.
Hydraulic Oil
The steering system should be kept filled with
hydraulic oil as listed in Section 300-0020,
LUBRICATION SYSTEM.
SM 1943 4-00 3
Section 220-0000
SM - 2455A
COMPONENTS
1 - Hydraulic Tank
2 - Main Hydraulic Pump 7 7
3 - Emergency Steering Pump
4 - Steering Valve L R
5 - Priority Valve
4
6 - Emergency Valve
7 - Steering Cylinder
8 - Oil Pressure Switch
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
Orange - Pilot Pressure
Yellow - Static Oil
T LS P
TO BODY
CONTROL VALVE
PORT (P)
LS CF EF
5
SV
P 6
TO BODY HOIST
CE
PILOT SUPPLY
VALVE
T
GP
8 3
2
Fig. 2 - Steering System Schematic Diagram - Engine Running, Steering Valve Neutral
4 SM 1943 4-00
Section 220-0000
SM - 2455B
COMPONENTS
1 - Hydraulic Tank
7 7
2 - Main Hydraulic Pump
5 - Priority Valve 4
6 - Emergency Valve
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
T LS P
TO BODY
CONTROL VALVE
PORT (P)
LS CF EF
5
SV
P 6
TO BODY HOIST
CE
PILOT SUPPLY
VALVE
T
GP
8 3
2
Fig. 3 - Steering System Schematic Diagram - Engine Running, Steering Valve Right Turn
SM 1943 4-00 5
Section 220-0000
SM - 2455C
COMPONENTS
1 - Hydraulic Tank
2 - Main Hydraulic Pump 7 7
5 - Priority Valve
4
6 - Emergency Valve
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
T LS P
TO BODY
CONTROL VALVE
PORT (P)
LS CF EF
5
SV
P 6
TO BODY HOIST
CE
PILOT SUPPLY
VALVE
T
GP
8 3
2
Fig. 4 - Steering System Schematic Diagram - Engine Running, Steering Valve Left Turn
6 SM 1943 4-00
Section 220-0000
SM - 2455D
7
COMPONENTS
1 - Hydraulic Tank
2 - Main Hydraulic Pump 7
5 - Priority Valve
4
6 - Emergency Valve
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
T LS P
TO BODY
CONTROL VALVE
PORT (P)
LS CF EF
5
SV
P 6
TO BODY HOIST
CE
PILOT SUPPLY
VALVE
T
GP
8 3
2
Fig. 5 - Steering System Schematic Diagram - Engine Running, Steering Cylinder Shock Load
* * * *
SM 1943 4-00 7
STEERING SYSTEM - Steering Valve
Section 220-0090
SM - 2016
12 11 10 8 16 7 6 5 4
1
15
19
2
17
18 14
20 13 9 3
1 - Capscrew 7 - Valve Housing 13 - Bearing Race 19 - Gerotor Gear

2 - End Cap 8 - Sleeve 14 - 'O' Ring 20 - Retainer
3 - 'O' Ring 9 - Ball - Check 15 - Dust Seal 21 - 'O' Ring
4 - Gerotor Housing 10 - Pin 16 - Spool 22 - 'O' Ring
5 - Spacer Plate 11 - Centring Springs 17 - Seal 23 - Roll Pin
6 - Driveshaft 12 - Needle Bearing 18 - Backup Ring 24 - Ball valve
Fig. 1 - Sectional View of Steering Valve
DESCRIPTION the road shock, to the opposite end of the cylinders.

Numbers in parentheses refer to Fig. 1. This shock, if left unchecked, might damage steering
linkage components.
The steering valve can be identified as item 4 in Section
220-0000, STEERING SYSTEM SCHEMATIC. The main components of the steering valve are valve
housing (7), gerotor housing (4), gerotor gear (19),
The steering valve, mounted off the underside of the driveshaft (6), sleeve (8) and spool (16).
cab floor and connected to the steering column,
controls hydraulic flow in the steering system. The There are five ports on valve housing (7) as follows:
steering valve is of a closed centre design, which
means that the valve does not have any flow through it Port 'P' - Supply from pump via priority valve
when it is in the neutral or no steering position. The Port 'T' - Return to tank
steering valve has integral cylinder relief valves which Port 'R' - Cylinder supply for right hand turn
relieve shock loads on the steering cylinders by Port 'L' - Cylinder supply for left hand turn
transferring excessive pressure applied to the oil by Port 'LS' - Load Sensing
SM 1986 Rev 1 11-00 1

Steering System - Steering Valve
Section 220-0090
Turning action of the steering wheel is transmitted SM - 282
through the steering column to sleeve (8) and
POCKETS
driveshaft (6), which is fastened to the sleeve with
centring pin (10). Rotation of driveshaft (6) causes
gerotor gear (19) to rotate in gerotor housing (4).
When gerotor gear (19) rotates, oil in gerotor housing
(4) pockets (see Fig. 2) is forced out and flows through
spool (16) and sleeve (8) to the steering cylinder port.
Spool (16) contains porting matched to sleeve (8) and

rotates within sleeve (8) to provide directional control
of the oil. See Fig. 3.
GEROTOR HOUSING GEROTOR GEAR
OPERATION Fig. 2 - Gerotor Gear Set

SM - 283
When the operator turns the steering wheel a certain RIGHT LEFT
number of degrees for either a left or right hand turn, SYSTEM TURN TURN
the movement is transmitted through the steering PRESSURE FEED FEED
column to spool (16). After a minimum rotation of 2.5 METER TO
PORTS TANK
degrees, the ports in spool (16) start to align with ports
in sleeve (8). When the steering wheel is rotated to a
maximum of 10 degrees the ports are fully aligned
allowing full oil flow. After 10 degrees of travel in either
direction the spool and sleeve rotate as an assembly
through centring pin (10).
Oil from the priority valve flows into valve housing (7)
at port 'P' and is channelled through sleeve (8) and
spool (16) to gerotor housing (4). Porting in gerotor
housing (4) permits oil to flow into pockets formed by Fig. 3 - Porting of Spool and Sleeve
gerotor housing (4) and gerotor gear (19). As spool
(16) rotates, driveshaft (6) also rotates which, in turn, REMOVAL
rotates gerotor gear (19) to which it is splined. When
gerotor gear (19) rotates it progressively forces oil out Numbers in parentheses refer to Fig. 4.
of the pockets (see Fig. 2) of gerotor housing (4). The
oil is channelled through sleeve (8) and spool (16) and
exits valve housing (7) through port 'R' for a right hand WARNING
turn, or port 'L' for a left hand turn. Oil then travels To prevent personal injury and property
through steering lines to the steering cylinders. damage, be sure wheel blocks, blocking
As the steering cylinder pistons move, oil forced out of secured and of adequate capacity to do the job
the steering cylinders returns to valve housing (7). The safely.
return oil passes through valve sleeve (8) and spool
(16) and exits through port 'T' to tank. 1. Position the vehicle in a level work area, apply the
When the steering effort is released, centring spring
(11) which was put under tension by the rotation of 2. Block all road wheels, except the front right hand
spool (16), forces sleeve (8) to rotate back to its and place the battery master switch in the 'Off'
original position. This puts the ports out of alignment position.
and stops pump oil flow to the steering cylinders. The
vehicle stops turning further but will hold the present
turning radius until spool (16) is rotated past the 2.5
degree minimum.
2 SM 1986 Rev 1 11-00

Section 220-0090
SM - 2493
20
13
12
19
31
30
18
28
14 29
17 34
7 33
15
3,6 32
16
27 21
5 29
4 28 25
9
3
26
24
2
10 23 21
1 8 22
11
20
1 - Steering Valve 10 - Bolt

2 - Locknut 11 - Lockwasher 19 - Bellows 27 - Bracket Assembly
3 - Washer 12 - Nut 20 - Steering Shaft 28 - Bolt
4 - Rubber Mount 13 - Steering Wheel & Cap 21 - Bearing 29 - Bearing
5 - Mounting Plate 14 - Bolt 22 - Bolt 30 - Bolt
6 - Washer 15 - Washer 23 - Gas Strut 31 - Lockwasher
7 - Bolt 16 - Nut 24 - Bolt 32 - Washer
8 - Steering Column 17 - Coupling 25 - Nut 33 - Washer
9 - Nitrile Seal 18 - Flex Coupling 26 - Pivot Fork Assembly 34 - Washer
Fig. 4 - Exploded View of Steering Valve Installation
3. Remove hydraulic tank remote drain plug and drain 6. Slide bellows (19) over steering column (8) to allow
hydraulic oil into a suitable container. Reinstall drain access and loosen bolt (14), washer (15) and nut (16)
plug in hydraulic tank remote drain fitting. which tightens coupling (17) onto steering column (8).
4. Remove front right hand wheel from the vehicle, as 7. Support steering valve (1) and remove mounting
described in Section 160-0050, WHEEL RIM AND bolts (10) and lockwashers (11) securing steering
TYRE. valve (1) to mounting plate (5). Remove steering valve
(1) to a clean area for disassembly.
5. Clean outer area of steering valve (1) with a suitable
solvent. Ensure all hydraulic lines connected to 8. If required, remove bolts (7), washers (3 & 6),
steering valve (1) are identified for ease of installation locknuts (2), rubber mounts (4) and mounting plate (5)
and with suitable containers available to catch from the floor plate. Discard rubber mounts (4), if
leakage, disconnect hydraulic lines. Cap all lines and damaged.
plug all ports to prevent entry of dirt.
SM 1986 Rev 1 11-00 3

Section 220-0090
SM - 2017
9 11 13 12 13
16 20 14 17 18 15
3 4 19 21 5
1
22
6
8
10
24
23
1 - Capscrew 7 - Valve Housing 13 - Bearing Race 19 - Gerotor Gear

2 - End Cap 8 - Sleeve 14 - 'O' Ring 20 - Retainer
3 - 'O' Ring 9 - Ball - Check 15 - Dust Seal 21 - 'O' Ring
4 - Gerotor Housing 10 - Pin 16 - Spool 22 - 'O' Ring
5 - Spacer Plate 11 - Centring Springs 17 - Seal 23 - Roll Pin
6 - Driveshaft 12 - Needle Bearing 18 - Backup Ring 24 - Ball valve
Fig. 5 - Exploded View of Steering Valve

otherwise specified. 19
Note: Steering valves fitted with anti-cavitation valves

must be disassembled and assembled in the vertical
postion to prevent ball valves (24) becoming trapped in
the wrong cavities within the valve housing (7).
1. Clamp steering valve assembly horizontally in a soft

jawed vice and break loose the seven capscrews (1).
With capscrews (1) loosened, place steering valve
vertically in vice, end cap (2), up.
19 - Gerotor Gear
Note: Hidden pin. If tension on this pin is released
Fig. 6 - Gerotor Gear and Splined Drive Engaged
4 SM 1986 Rev 1 11-00

Section 220-0090
SM - 2019 before these parts are fully disengaged and the pin is
not horizontal, the pin can drop and lockup can occur.
11
19
2. Remove cap screws (1) securing end cap (2),
gerotor housing (4) and spacer plate (5) to valve
housing (7). Remove end cap (2) from valve
housing (7) and discard 'O' ring (3).
3. Remove gerotor housing (4) and gerotor gear (19)

from valve housing (7). Remove and discard 'O' ring
(21) from gerotor housing (4).
10 4. Remove spacer plate (5) from valve housing (7).

10 - Pin 19 - Gerotor Gear
11 - Centring Springs 5. Remove and discard 'O' ring (22) from valve
Fig. 7 - Compressing Centering Spring housing (7).
6.Using a cloth to protect the hand, place gerotor gear

SM - 2020
(19) over end of drive shaft (6) and engage special tool
with splined end of spool (16). Refer to Fig. 6.
19
7. Hold gerotor gear (19) and prevent drive shaft (6)
from turning. Twist special tool to compress centering
spring (11) radially CW or CCW, decreasing the coil
diameter of the centering spring (11) allowing spool
and sleeve assembly to be removed. Refer to Fig. 7.
8. With drive held stationary and centering spring (11)

compressed, carefully push spool (16), sleeve (8), ball
checks (9), drive shaft (6), pin (10), bearing races (13),
retainer (20) and needle thrust bearing (12), as a complete
19 - Gerotor Gear assembly, from valve housing (7). Refer to Fig. 8.
Fig. 8 - Removing Spool and Sleeve Assembly 9. Remove bearing race (13) and needle thrust
bearing (12) from spool and sleeve assembly.
SM - 2021
10. Using suitable pliers, remove retainer (20) and
bearing race (13) from spool (16) and sleeve (8)
6 8 11 13
assembly. Refer to Fig. 9.
20
11. Remove centering spring (11) from spool (16) and
sleeve (8) assembly. Refer to Fig. 9.
12. Remove pin (10) and slide drive shaft (6) from
spool (16) and sleeve (8) assembly. Refer to Fig. 9.
13. Carefully remove spool (16) and ball checks (9)

from sleeve (8). Refer to Fig. 9.
9 9 10 16 14. Use a soda straw as a guide tool to remove the roll

pin (23) and ball valve (24) from the anti-cavitation
6 - Driveshaft 11 - Centring Springs valve ports. Insert two soda straws, one in each anti-
8 - Sleeve 13 - Bearing Race cavitation valve bore. Remove valve housing (7) from
9 - Ball - Check 16 - Spool
10 - Pin 20 - Retainer vice and tilt until roll pins (23) and ball valves (24) slide
Fig. 9 - Sectional View of Spool and Sleeve Assembly
SM 1986 Rev 1 11-00 5

Section 220-0090
SM - 2022 through the straws and out of the valve housing (7).
PORT FACE Refer to Fig. 10.
15. Remove and discard 'O' ring (14), seal (17) and
backup ring (18) from valve housing (7).
16. Using a thin blade screwdriver, pry dust seal (15)

PORT
FACE
from valve housing (7). Take care not to damage dust
seal seat.
TOP
VIEW INSPECTION
24 1. Clean all metal parts in a suitable solvent and blow
Anti-Cavitation Valves -
Insert Soda Straws (2), dry with compressed air. Do not wipe dry with cloth or
one into each of these paper towel as lint or other matter may get into the
two threaded holes. 23 hydraulic system and cause damage.
2. Check all mating surfaces and replace any parts that

TILT have scratches or burrs that could cause leakage.
HOUSING
3. Do not use course grit or try to file any metal parts.
SODA STRAW
Note: Replace all 'O' rings and seals with new 'O' rings
and seals at 'Assembly'. Lubricate all 'O' rings and
23 - Roll Pin
24 - Ball Valve
seals with a petroleum jelly.
Fig. 10 - Removing Ball Valves

ASSEMBLY
SM - 2023
PORT FACE otherwise specified.
23
300-0080, STANDARD BOLT AND NUT TORQUE
24 SPECIFICATIONS.
Note: Steering valves fitted with anti-cavitation valves

GUIDE TOOL must be disassembled and assembled in the vertical
(Soda Straw)
postion to prevent ball valves (24) becoming trapped in
the wrong cavities within the valve housing (7).
Anti-Cavitation Valves 1. Use a soda straw as a guide tool to insert the roll pin
(23) and ball valve (24) into the anti-cavitation valve
ports. Insert soda straw, into anti-cavitation valve bore.
Drop ball valve (24) through straw into bore. Remove
straw and drop roll pin (23) into bore. Repeat for
second anti-cavitation valve bore. Refer to Fig. 11.
2. Apply a light coating of clean hydraulic fluid to spool

(16). Slide spool (16) and ball checks (9) into sleeve
(8). Refer to Fig. 12.
23 - Roll Pin
24 - Ball Valve 3. Insert drive shaft (6) into spool (16) in sleeve (8)
Fig. 11 - Installing Ball Valves
6 SM 1986 Rev 1 11-00

Section 220-0090
SM - 2024 SM - 2027
6 8 11 13
6 8
16
10
6 - Drive Shaft
8 - Sleeve
9 - Ball Check
10 - Pin 9 9 10 16
16 - Spool
9
Fig. 12 - Installing Spool and Ball Checks
SM - 2025
17
6 16
18
6 - Drive Shaft
20
8 - Sleeve
9 - Ball Check 12 14
8 10 10 - Pin
11 - Centring Springs 16 - Spool
12 - Needle Bearing 17 - Seal
6 - Drive Shaft 10 - Pin 13 - Bearing Race 18 - Backup Ring
8 - Sleeve 16 - Spool 14 - 'O' Ring 20 - Retainer
Fig. 13 - Installing Centring Pin and Drive Shaft Fig. 15 - Sectional View of Seals and Bearings
SM - 2026 end of spool (16). Compress centring spring (11)

radially (CCW) and engage free end of spring into slot
in spool (16). See Fig. 14.
5. Install bearing race (13) onto spool (16). Using

suitable pliers install retainer (20) onto spool (16). See
Fig. 14.
6. Apply a light coating of petroleum jelly to the inside

11 16 13 20 diameter of dust seal (15) and install in valve housing (7).
7. Apply a light coating of petroleum jelly to needle

11 - Centring Springs 16 - Spool thrust bearing (12), bearing race (13), 'O' ring (14),
13 - Bearing Race 20 - Retainer
seal ring (17) and backup ring (18). Install each item
Fig. 14 - Installing Bearing Race and Retainer onto spool (16), as shown in Fig. 15.
Note: Needle thrust bearing is positioned between the

carefully so that holes line up. Install pin (10) through two bearing races (13) and must be centerd around
sleeve (8), spool (16) and drive shaft (6) assembly retainer (20).
until pin (10) becomes flush at both sides of sleeve (8).
See Figs. 12 & 13. Note: Clamp steering valve housing (7) vertically in a
soft jawed vice.
4. Position one end of centring spring (11) into slotted
SM 1986 Rev 1 11-00 7

Section 220-0090
SM - 2028 SM - 2029
Fig. 16 - Compressing Centering Spring Fig. 17 - Installing Spool and Sleeve Assembly
SM - 2030
7
3 4 19 21 5
1
22
1 - Capscrew 4 - Gerotor Housing 19 - Gerotor Gear

2 - End Cap 5 - Spacer Plate 21 - 'O' Ring
3 - 'O' Ring 7 - Valve Housing 22 - 'O' Ring
Fig. 18 - Installing Seals and Gerotor Assembly
8. Using a cloth to protect the hand, place gerotor gear valve housing (7). Align bolt holes in spacer plate (5) with
(19) over end of drive shaft (6). Insert special tool tapped holes in valve housing (7). Refer to Fig. 18.
through valve housing (7) and engage with splined
end of spool (16) and sleeve (8) assembly. Twist tool 13. Lubricate and install new 'O' ring (21) in groove in
to compress centering spring (11) radially CW or spacer plate (5). Refer to Fig. 18.
CCW. Refer to Fig. 16.
14. Install gerotor housing (4) on valve housing (7).
9. Keep centering spring (11) compressed and Align bolt holes in gerotor housing (4) with tapped
carefully insert assembled parts into valve housing (7), holes in valve housing (7). Refer to Fig. 18.
15. Align gerotor gear (19) on driveshaft (6) and
10. Release tension on centering spring (11) and gerotor housing (4), as shown in Fig. 18.
remove special tool and gerotor gear (19).
16. Lubricate and install new 'O' ring (3) in groove in
11. Lubricate and install new 'O' ring (22) in groove in gerotor housing (4).
valve housing (7). Refer to Fig. 18.
17. Install end cap (2) on gerotor housing (4), as
12. Install spacer plate (5) with the 'O' ring groove up, on shown in Fig. 18.
8 SM 1986 Rev 1 11-00

Section 220-0090
SM - 313 5. Remove plugs from steering valve ports and caps

from steering lines and install steering lines to steering
valve (1), as identified at removal.
6. Fill hydraulic tank with hydraulic oil, as specified in

Section 300-0020, LUBRICATION SYSTEM. Refer to
'Filling and Bleeding The Steering System'.
7. Install the front right hand wheel on the machine, as

described in Section 160-0050, WHEEL RIM AND
Fig. 19 - Cap Screw Tightening Sequence
TYRE. Lower the machine from blocking equipment.
18. Align cap screw (1) holes and install seven dry cap 8. Remove wheel blocks from all road wheels, place
screws (1) in end cap (2). Pre-tighten cap screws (1) to the battery master switch in the 'On' position and start
17 Nm (12.5 lbf ft) then tighten to a torque of 34 Nm the engine. Operate the steering and check hydraulic
(25 lbf ft), in the sequence shown in Fig. 19. lines for leaks. Tighten lines and fittings as required.
INSTALLATION FILLING AND BLEEDING THE STEERING

Numbers in parentheses refer to Fig. 4. SYSTEM
1. Fill hydraulic tank to Maximum level. Be ready to
Note: Tighten all fasteners to standard torques listed add oil when the engine is started. Do not let oil drop
in Section 300-0080, STANDARD BOLT AND NUT below the pump suction line to prevent air entering the
TORQUE SPECIFICATIONS. system.
Note: Tighten all hydraulic lines fitted with ORFS 2. Start engine and let it idle. Immediately add oil to the
connections, as described in Section 220-0000, steering and brake control tank as required. When no
STEERING SYSTEM SCHEMATIC. Renew all more oil can be added and oil is clear, proceed as
'O' rings where used. follows:
a. Turn the steering wheel from lock to lock to bleed

WARNING the air in the steering cylinders and lines.
damage, be sure wheel blocks, blocking Note: Immediately upon valve spool actuation oil must
materials and lifting equipment are properly be added to the hydraulic tank to replenish the oil
secured and of adequate capacity to do the job moving into the circuit.
safely.
1. Make certain, area of installation is clean. WARNING

Do not operate the vehicle until all air is bled
2. If removed, secure rubber mounts (4) and mounting from the oil.
plate (5) to cab floor plate with bolts (7) washers (3 &
6) and locknuts (2). b. When the oil in the tank is clear (not cloudy or
creamy), the system is free of air.
3. Install nitrile seal (9) to steering column (8). Install
steering valve (1) through mounting plate (5) and Note: Slight creep or drift of the steering wheel is normal.
secure to steering column (8) and mounting plate (5)
with bolts (10) and washers (11). c. Fill hydraulic tank with hydraulic oil specified in
Section 300-0020, LUBRICATION SYSTEM. Refer to
4. Tighten bolt (14), washer (15), nut (16) and coupling Section 230-0040, HYDRAULIC TANK, for correct fill
(17) onto steering column (8). Slide bellows (19) down level. Install filler cap on tank.
over steering column (8) and tuck lower lip under cab
floor plate.
SM 1986 Rev 1 11-00 9

Section 220-0090
Hydraulic Oil SPECIAL TOOLS

The steering system should be kept filled with Refer to Section 300-0070, SERVICE TOOLS, for part
hydraulic oil as specified in Section 300-0020, number of the special tool referenced in this section.
LUBRICATION SYSTEM. This tool are available from your dealer.

TORQUE
5 1 Capscrew 34 25
STEERING CONTROL DIAGNOSIS

Steering wheel does not centre Binding in steering linkage to valve Align as required
Worn gerotor Replace parts
Broken centring springs Replace centring springs, drain
and flush system
Burrs on sleeve or spool Disassemble and repair or replace
parts
Apparent inability to steer when Dirt in system Drain and flush system. Refill with
wheel is turned slowly clean oil
Slow steering Excessive wear in sleeve and spool Replace sleeve and spool
Excessive wear in gerotor Replace gerotor
Hard steering See 'Slow Steering'
Opposite steering Lines hooked up incorrectly Reconnect correctly
Wrong orientation between gerotor Realign per instructions
and gerotor drive
Steering wheel rocking back See 'Opposite Steering'
and forth
Steering wheel continues to turn Input linkage binding Align as required
Burr on sleeve or spool Disassemble and repair or replace
Dirt in system Drain and flush system. Refill with
clean oil
Broken centring springs Replace centring springs, drain and
flush system
No steering action Sleeve and spool locked together Disassemble and repair or replace
* * * *
10 SM 1986 Rev 1 11-00

STEERING SYSTEM - Priority Valve
Section 220-0105
SM - 1954
1 12
CF EF LS
METERING EDGE
7
10 4
9
3
PP T
6
8
P
2 5 11
1 - Valve Body 5 - Washer 9 - Damping Orifice

2 - Spool 6 - Plug 10 - Case
3 - Spring 7 - 'O' Ring 11 - 'O' Ring
4 - Relief Valve 8 - Damping Orifice 12 - Damping Orifice
Fig. 1 - Sectional View of Priority Valve
DESCRIPTION This allows the valve to modulate flow and pressure

The priority valve can be identified as item 5 in to the steering circuit and body hoist circuit to meet
Section 220-0000, STEERING SYSTEM each circuits flow and pressure requirements.
SCHEMATIC.
There are six ports on the priority valve housing as
The priority valve is mounted off the right hand fender follows:
support bracket. The valve is installed in the lines
between the main hydraulic pump, steering valve and Port 'P' - Pump Inlet Port - Supply from pump
body control valve. Hydraulic oil is pumped to the Port 'PP' - Pilot Pressure - Plugged
priority valve and depending on the position of the Port 'CF' - Control Flow - Supply to steering valve
spool within the priority valve, oil is directed to the Port 'EF' - Excess Flow - Supply to body hoist valve
steering or body hoist systems. Port 'LS' - Load Sensing - To LS port on steering
valve
The spool in the priority valve has 2 metering edges. Port 'T' - Relief Return - Return to tank
SM 1947 4-00 1
Steering System - Priority Valve
Section 220-0105
OPERATION 5. Clean priority valve housing (1) and surrounding

Numbers in parentheses refer to Fig. 1. area with a suitable solvent. Identify and tag all
hydraulic lines connected to priority valve, to aid in
Steering valve in neutral position 'Installation'.
With the steering valve in the neutral position, oil
from the main hydraulic pump enters the priority 6. With suitable containers available to catch
valve at port 'P'. Oil pressure within the internal spillage, disconnect hydraulic lines from priority
galleries of the priority valve act on the spool, moving valve. Drain the oil from the lines into the container
it to the right. and discard all 'O' rings. Cap hydraulic lines and
priority valve ports to prevent ingress of dirt.
The oil flows from port 'P' through the 'EF' port, to the
body hoist control valve. The oil at the load sensing 7. Support priority valve and remove mounting
'LS' port is open to the tank return port in the steering hardware securing priority valve and mounting
valve. bracket to the right hand cab leg. Remove priority
valve and mounting bracket from the machine and
Steering valve operating transfer to a clean area for disassembly.
When the steering valve is actuated left or right, oil at
the load sensing 'LS' port is pressurised causing the
spool in the priority valve to move to the left. DISASSEMBLY
The oil from the main hydraulic pump is then directed
from port 'P' to the 'CF' port in the priority valve. The
oil is then directed to port 'P' on the steering valve. WARNING
Spring loaded parts. Use care when removing
In this position all oil flow is directed to the steering end cap, retainers and plugs to prevent
system giving it priority. sudden release of spring tension behind these
parts. Personal injury or property damage
could result if care is not taken.
REMOVAL
Numbers in parentheses refer to Fig. 1. Note: Clean entire priority valve assembly with a
suitable solvent and dry thoroughly prior to
disassembly.
WARNING
damage, be sure wheel blocks are properly Valve Body
secured and of adequate capacity to do the job 1. If required, remove mounting hardware securing
safely. priority valve to mounting bracket. Remove mounting
bracket.
parking brake and switch off the engine. 2. If required, remove adaptor and elbow from port 'P'
in valve housing (1). Discard 'O' rings.
2. Block all road wheels, except the front right hand,
and place the battery master switch in the 'Off' 3. If required, remove elbow, adaptors and check
position. valve from port 'CF' in valve housing (1). Discard 'O'
rings.
3. Remove hydraulic tank anti-spill drain cap, install
drain tube connection and drain oil into a suitable 4. If required, remove adaptor and elbow from port
container. Remove drain tube connection and 'EF' in valve housing (1). Discard 'O' rings.
reinstall cap.
5. If required, remove adaptor from port 'LS' in valve
4. Remove the front right hand wheel from the housing (1). Discard 'O' ring.
machine, as described in Section 160-0050, WHEEL
RIM AND TYRE. 6. If required, remove elbow from port 'T' in valve
housing (1). Discard 'O' ring.
2 SM 1947 4-00
Section 220-0105
Relief Valve Valve Body

1. Clean the entire priority valve assembly with a 1. If removed, secure priority valve to mounting
suitable solvent and dry thoroughly. Remove caps bracket using mounting hardware as removed at
from valve housing (1) ports. 'Disassembly'.
2. If desired, clamp priority valve assembly in a soft 2. If removed, install new 'O' rings on adaptor and
jawed vice. Take care to avoid damaging valve elbow and secure in port 'P' of valve housing (1).
housing (1) machined surfaces.
3. If removed, install new 'O' rings on elbow, adaptors
3. Release and withdraw relief valve (4) assembly and check valve and secure in port 'CF' of valve
from case (10) bore in valve housing (1). Discard 'O' housing (1).
rings.
4. If removed, install new 'O' ring on adaptor and
elbow and secure in port 'EF' of valve housing (1).
INSPECTION
Numbers in parentheses refer to Fig. 1. 5. If removed, install new 'O' ring on adaptor and
secure in port 'LS' of valve housing (1).
1. Clean all parts thoroughly and examine for wear
and/or damage. 6. If removed, install new 'O' ring on elbow and
secure in port 'T' of valve housing (1).
2. Inspect valve housing (1) bores for grooves, deep
scratches or excessive wear.
INSTALLATION
Note: If condition of valve housing (1) bores indicate Numbers in parentheses refer to Fig. 1.
that they require to be replaced, the priority valve
should be replaced as an assembly. Note: Tighten all fasteners to standard torques listed
3. If relief valve (4) is damaged, it should be TORQUE SPECIFICATIONS.
replaced.
1. Position valve and mounting bracket and secure to
right hand cab leg with mounting hardware as
ASSEMBLY removed at 'Removal'.
2. Reconnect all hydraulic lines to priority valve, as
Note: Lightly lubricate all components with hydraulic tagged at removal.
oil. Refer to Section 300-0020, LUBRICATION
SYSTEM, for recommended oil specifications. 3. Fill hydraulic oil tank with hydraulic oil as specified
in Section 300-0020, LUBRICATION SYSTEM. Refer
Note: Tighten all fasteners to standard torques listed to Section 230-0040, HYDRAULIC TANK, for
in Section 300-0080, STANDARD BOLT AND NUT hydraulic oil levels. Install filler cap on hydraulic tank
TORQUE SPECIFICATIONS. filler neck.
4. Adjust the system relief valve according to the

Relief Valve instructions in 'Adjustments'.
1. If removed, install new 'O' ring on relief valve (4)
assembly and secure in case (10) bore in valve 5. Place the battery master switch in the 'On'
housing (1). position, start the engine and bring hydraulic oil to
operating pressure.
Note: The front right hand wheel is still removed from

machine at this point.
SM 1947 4-00 3
Section 220-0105
6. Check priority valve and hydraulic line connections port 'T', relief valve. Remove adaptor from port and
for leaks and tighten as required. cap hydraulic line to prevent ingress of dirt.
7. Install front right hand wheel on the machine, as 4. Operate the steering, against either steering stop
described in Section 160-0050, WHEEL RIM AND with the engine at wide open throttle. Check system
TYRE. pressure.
8. Remove wheel blocks from all road wheels. 5. Turn allen screw, located inside relief valve port, to
adjust pressure setting.
ADJUSTMENTS Note: Turning allen screw 'IN' will increase relief

Numbers in parentheses refer to Fig. 1. valve pressure, turning allen screw 'OUT' will reduce
relief valve pressure. One turn is approximately
62 - 69 bar (900 - 1 000 lbf/in).
Steering System Pressure Adjustment
Steering system pressure setting and adjustment can 6. Install adaptor and re-connect hose in relief valve
be carried out as follows: port 'T'.
7. Check oil level in hydraulic tank and top up with

WARNING hydraulic oil as specified in Section 300-0020,
To prevent personal injury and property LUBRICATION SYSTEM. Refer to Section 230-0040,
damage, be sure wheel blocks, blocking HYDRAULIC TANK, for hydraulic oil levels. Install
materials and lifting equipment are properly filler cap on hydraulic tank filler neck.
safely. 8. Check priority valve assembly and hydraulic lines
for leaks. Tighten as required.
1. Connect a hydraulic gauge, capable of recording a
pressure of 0 - 345 bar (0 - 5 000 lbf/in), to remote
diagnostic pressure point and take a note of the MAINTENANCE
reading before continuing. Limited repair of the priority valve is with replacement
of parts only.
Note: Steering system pressure should be set at
241 bar (3 500 lbf/in).
SERVICE TOOLS
2. Position the vehicle in a level work area, apply the There are no special tools required for the
parking brake and leave the engine running. procedures outlined in this section. Refer to Section
3. With suitable containers available to catch general service tools and adhesives. These tools and
spillage, disconnect hydraulic line from priority valve adhesives are available from your dealer.
* * * *
4 SM 1947 4-00
STEERING SYSTEM - Steering Cylinder
Section 220-0120
SM - 2467
24
23 23
15 12,13 1 9 5 9 7
8 7
4 14 2 11 10 3 6 8
6
6
18
18
19
20 19
20
17 17
PART OF
FRAME PART OF
FRAME
ORIENTATION OF
CUSHION SLEEVE
22 ROD 21 BASE
END END
1 - Cylinder Body 7 - Spherical Bearing 13 - Back Up Ring 19 - Lockwasher

2 - Piston Rod 8 - Circlip 14 - Rod Seal 20 - Hardened Washer
3 - Piston 9 - Wear Ring 15 - Wiper 21 - Spacer
4 - End Cap 10 - Piston Seal 16 - Cushion Sleeve 22 - Seal
5 - Grub Screw 11 - 'O' Ring 17 - Pin 23 - Elbow
6 - Lube Fitting 12 - 'O' Ring 18 - Bolt 24 - Hose Assembly
Fig. 1 - Sectional View of Steering Cylinder and Mounting
DESCRIPTION (21) and spherical bearings (7) secured with circlips

(8). Spherical bearings (7) permit a limited amount of
cylinder misalignment when travelling over rough
terrain.
The steering cylinders can be identified as item 7 in
Section 220-0000, STEERING SYSTEM
SCHEMATIC. OPERATION
When the operator turns the steering wheel for a
There are two single stage, double acting cushioned
steering operation, movement of the piston rod
steering cylinders on the machine. The cylinder base
generates force required to pivot the tractor frame.
end is connected to the articulation and oscillation
pivot, and, piston rod (2) end is connected to the front
In the neutral position, with the steering valve
frame. Single stage double acting means that piston
centralized, oil movement between the steering
rod (2) can have oil applied to either side, extending or
cylinders and the steering valve is stopped. Trapped
retracting the piston rod.
oil in the system locks both steering cylinders and the
angle of steering set by the operator is maintained.
Rod end cylinder mounting is by pins (17), seals (22)
Refer to Section 220-0090, STEERING VALVE, for
and spherical bearings (7) secured with circlips (8).
operation of the steering valve.
Base end cylinder mounting is by pins (17), spacers
SM 1955 4-00 1
Steering System - Steering Cylinder
Section 220-0120
REMOVAL DISASSEMBLY
WARNING WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure lifting equipment is properly
materials and lifting equipment are properly secured and of adequate capacity to do the job
secured and of adequate capacity to do the job safely.
safely.
1. Ensure clean working conditions, remove any port
1. Position the vehicle in a level work area, apply the plugs thus allowing easy entry of air into the cylinder,
parking brake and switch off the engine. preventing a vacuum when parts are withdrawn from
cylinder body (1).
switch in the 'Off' position. 2. Remove circlips (8) from base end of cylinder body
(1) and piston rod (2) end. Press out spherical
3. Identify, tag and with a suitable container in position bearings (7).
to catch the spillage, disconnect all hydraulic lines on
one steering cylinder. Cap all lines and fittings to 3. Using special tool which can be fabricated as shown
prevent ingress of dirt. in Fig. 2, unscrew end cap (4) until thread is
disengaged from cylinder body (1).
4. Support steering cylinder with a suitable lifting
device. 4. Pull end cap (4) and piston rod (2) out of cylinder
body (1) as an assembly.
5. Remove bolt (18), lockwasher (19) and hardened
washer (20) securing pin (17) at piston rod (2) end of 5. Place piston rod (2) on supports which will not
the cylinder. Remove pin (17) securing piston rod (2) damage the chrome piston rod diameter.
end to the front frame.
6. Remove and discard piston seal (10) and wear rings
6. Remove bolt (18), lockwasher (19) and hardened (9) from piston (3).
washer (20) securing pin (17) at base end of the
cylinder. Remove pin (17) securing base end to the 7. Remove grub screw (5) from wear ring groove in
articulation and oscillation pivot. piston (3).
7. Remove cylinder assembly from the machine. 8. Provide an anti-torsion device through piston rod (2)
Spacers (21) and seals (22) will come free at this time. eye to allow unscrewing of piston (3). Using special
tool which can be fabricated as shown in Fig. 3,
8. Remove cylinder assembly to a clean area for unscrew piston (3) from piston rod (2).
disassembly. Drain oil from cylinder assembly into a
suitable container. 9. Remove and discard 'O' ring (11) from piston (3).
Remove and retain cushion sleeve (16) from piston
9. Repeat steps 3 through 8 for opposite steering rod (2).
cylinder assembly.
10. Pull end cap (4) assembly off piston rod (2).
Remove and discard back up ring (13) and 'O' ring
(12) from end cap (4) outer grooves. Remove and
discard wiper (15) and rod seal (14) from end cap (4)
inner grooves.
11. If damaged, remove lube fitting (6) from cylinder

body (1) and piston rod (2).
2 SM 1955 4-00
Section 220-0120
INSPECTION 8. Insert piston grub screw (5), through wear ring

Numbers in parentheses refer to Fig. 1 groove in piston (3), into groove machined in piston
rod (2). Tighten grub screw (5) to a torque of 49 Nm
1. Clean all parts of the cylinder with a suitable solvent (36 lbf ft). Ensure the extreme of grub screw (5) is
and dry with clean, lint-free cloths. Clean all grooves below the level of wear ring groove.
carefully to remove any foreign material.
9. Insert new piston seal (10) and new wear rings (9)
2. Check cylinder body (1), end cap (4) grooves and in piston (3) external grooves.
outer diameter of piston (3) for scratches, cracks or
other signs of damage. Remove ridges, nicks and 10. Fully grease piston (3) OD and 'O' ring (12) in end
scratches with a fine stone and re-clean. Replace any cap (4).
components which cannot be repaired.
11. Ensure bore of cylinder is well lubricated with
3. Inspect piston rod (2) for distortion, cracks or other hydraulic oil. Carefully insert piston rod (2) and end
defects. Replace piston rod (2) if defective area is cap (4) assembly into cylinder body (1).
irreparable.
12. Engage end cap (4)/cylinder body (1) thread screw
4. Check spherical bearings (7) for wear and replace if up fully. Using special tool which can be fabricated as
necessary. shown in Fig. 2, tighten end cap (4) to a torque of
542 - 610 Nm (400 - 450 lbf ft).
ASSEMBLY 13. Replace lube fittings (6) if required.

INSTALLATION
WARNING Numbers in parentheses refer to Fig. 1.
damage, be sure lifting equipment is properly Note: Tighten all fasteners to standard torques listed
secured and of adequate capacity to do the job in Section 300-0080, STANDARD BOLT AND NUT
safely. TORQUE SPECIFICATIONS.
1. Press spherical bearings (5) in base end of cylinder Note: Tighten all hydraulic lines fitted with ORFS
body (1) and piston rod (2) end. Secure spherical connections, as described in Section 220-0000,
bearings (5) with circlips (6). STEERING SYSTEM SCHEMATIC. Renew all
'O' rings where used.
2. Install new rod seal (14) into bore of end cap (4)
with the lip pointing towards the internal face of end
cap (4). Install new wiper (15) into bore of end cap (4). WARNING
3. Install new back up ring (13) and 'O' ring (12) in damage, be sure lifting equipment is properly
xternal groove of end cap (4). secured and of adequate capacity to do the job
safely.
4. Guide end cap (4) assembly onto piston rod (2),
taking care not to damage rod seal (14) on the thread. 1. Install a suitable strap, or other lifting device, around
one cylinder assembly and position cylinder assembly
5. Install cushion sleeve (16) into piston rod (2) on the vehicle, with base end of cylinder ready for
counter bore. Note correct orientation, spigot face mounting.
abuts counter bore face (see Fig. 1).
2. Install spacers (21) on base end of cylinder and
6. Install new 'O' ring (11) into internal groove of piston insert pin (17). Secure pin (17) to articulation and
(3). oscillation pivot with bolt (18), lockwasher (19) and
hardened washer (20).
7. Using special tool which can be fabricated as shown
in Fig. 3, screw piston (3) on piston rod (2). Tighten 3. Install seals (22) on piston rod (2) end of cylinder
piston (3) to a torque of 746 - 813 Nm (550 - 600 lbf ft). and insert pin (17). Secure pin (17) to front frame with
bolt (18), lockwasher (19) and hardened washer (20).
SM 1955 4-00 3
Section 220-0120
4. Connect hydraulic lines to steering cylinder ports, as start the engine and operate the steering, from lock to
tagged during removal. lock several times, to purge air out of the hydraulic
lines. Check hydraulic lines and fittings for leaks.
5. Repeat steps 1 through 4 for installation of opposite Tighten lines and fittings as required.
steering cylinder.
6. Lubricate pins (17) through lube fittings (6) with MAINTENANCE

lubricant, as specified in Section 300-0020, Inspect steering cylinders regularly for leaks or
LUBRICATION SYSTEM. damage, repair as required. Lubricate cylinder pins
every 50 hours, as specified in Section 300-0020,
7. Check oil level in hydraulic tank and add oil if low. LUBRICATION SYSTEM.
Refer to Section 230-0040, HYDRAULIC TANK, for
correct fill level. Refer to Section 300-0020,
LUBRICATION SYSTEM, for the type of oil used. SPECIAL TOOLS
Special tools can be fabricated as shown in Figs. 2 & 3.
8. Remove wheel blocks. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools
9. Place the battery master switch in the 'On' position, are available from your dealer.
SM - 407
DRILL
RAD
DEEP
RAD TYP
BURN OUT
SQUARE
SECURE ALUMINIUM DRILL AND REAM THROUGH

COLLAR WITH (3) M8 AND FIT 12 (0.472)
CAP SCREWS HARDENED DOWEL
TORQUE PINS 2 PLACES
Dimensions in mm (inches)
Fig. 2 - End Cap Torque Tool
4 SM 1955 4-00
Section 220-0120
SM - 633
SILVER STEEL
SQUARE
OUTER SHIELD TO BE SECURED DOM TUBE

TO INNER BODY WITH 2BA CAPSCREWS
Fig. 3 - Piston Torque Tool

TORQUE
1 3 Piston 746 - 813 550 - 600
1 4 End Cap 542 - 610 400 - 450
1 5 Grub Screw 49 36
* * * *
SM 1955 4-00 5
STEERING SYSTEM - Emergency Valve
Section 220-0140
SM - 2279
4 2
8 3
7
10 GP
13
6 T
14
11 1
5
14
15
SV
12
15
SECTIONAL VIEW
OF PILOT CARTRIDGE
CE
1 - Valve Body 5 - Cage 9 - 'O' Ring

2 - Pilot Cartridge 6 - Spool 10 - 'O' Ring 13 - Backup Washer
3 - Relief Valve 7 - Spring 11 - 'O' Ring 14 - Backup Washer
4 - Retainer 8 - Spring 12 - 'O' Ring 15 - Backup Washer
Fig. 1 - Exploded View of Emergency Valve
DESCRIPTION the right. The emergency steering pump draws oil from
The Emergency Valve can be identified as item 6 in the hydraulic tank and pumps it to port 'GP' of the
Section 220-0000, STEERING SYSTEM SCHEMATIC. emergency valve. The oil is directed through the
emergency valve, exits at port 'T' and returns to the
Mounted off the right hand cab leg, the emergency hydraulic tank.
valve forms part of the emergency steering system. It
is connected to the main output line of the gear driven
emergency steering pump on the transmission. Emergency Steering
Relief valve (3) assembly opens and allows oil to flow
back to the hydraulic tank when pressure exceeds In the event of loss of pressure from the main
207 bar (3 000 lbf/in) hydraulic pump, spool (6) will spring return to the left.
The emergency steering pump draws oil from the
hydraulic tank and pumps it to port 'GP' of the
OPERATION emergency valve. The oil is directed through the
emergency valve and exits at port 'SV' to supply the
Normal Steering steering system.
A pressure switch, installed in the block at the outlet
During normal operation, pilot pressure from the main port on the main hydraulic pump, sends a signal to
hydraulic pump enters the valve body (1) at port 'CE', illuminate the steering pressure warning light to
pushing spool (6), within pilot cartridge assembly (2) to indicate a fault in the steering system supply pressure.
SM 1944 4-00 1
Steering System - Emergency Valve
Section 220-0140
REMOVAL INSTALLATION
WARNING TORQUE SPECIFICATIONS.
damage, be sure wheel blocks are properly Note: Tighten all hydraulic lines fitted with ORFS
secured and of adequate capacity to do the job connections, as described in Section 220-0000,
safely. STEERING SYSTEM SCHEMATIC. Renew all
'O' rings where used.
parking brake and switch off the engine. 1. Install emergency valve assembly to the mounting
bracket and secure with mounting hardware removed
2. Block all road wheels and place battery master during removal.
2. Remove blanking caps and connect hydraulic lines
3. Clean outer area of the emergency valve with a to the emergency valve as tagged at removal.
suitable solvent. Ensure all hydraulic lines connected
to the emergency valve are identified for ease of 3. Check oil level in hydraulic tank and add oil as
installation and, with suitable containers available to required. Refer to Section 230-0040, HYDRAULIC
catch leakage, disconnect hydraulic lines. Fit blanking TANK, for correct fill level and Section 300-0020,
caps to all open lines. LUBRICATION SYSTEM, for oil specification.
4. Remove mounting hardware securing emergency 4. Place the battery master switch in the 'On' position,
valve assembly and remove emergency valve remove all wheel blocks and start the engine. Check all
assembly. lines and fittings for leaks and tighten as required.
MAINTENANCE
Limited repair of the emergency valve is with
replacement of parts only. Refer to vehicle parts book
for list of kits available.
* * * *
2 SM 1944 4-00
BODY SYSTEM - Body System Schematic
Section 230-0000
DESCRIPTION The main hydraulic pump is a multiple gear type pump

Numbers in parentheses refer to Fig. 2 through 5. which operates in the one direction only (it is
assembled for right hand (clockwise) rotation, as
The body system schematic primarily covers operation viewed from the driveshaft end).
of the body hoist system. However, as the hydraulic
tank and main hydraulic pump are common to the Note: Never drive a pump in the wrong direction of
body hoist and steering circuit, several components of rotation, as pump seizure may result.
the steering system are also covered in the schematic.
A brief description of the individual components shown Body Control Valve (3)
in the body system schematic are listed below. Refer to Section 230-0060, BODY CONTROL VALVE.
Detailed service and operating instructions for the
individual components can be found in their relevant The single spool body control valve is mounted behind
component sections in this manual. the front right hand wheel, on a mounting bracket
mounted to the frame rail. The main components of
the control valve assembly are a four position control
Hydraulic Tank (1) spool, check valve plunger, relief valve and valve
Refer to Section 230-0040, HYDRAULIC TANK housing.
Mounted off the tractor frame at the rear of the cab, The four positions of the control spool are 'Raise',
the hydraulic tank is the common oil reservoir for the 'Hold', 'Lower' (Power Down) and 'Float'. The 'Float'
steering and body hydraulic systems. position is detented and control spool should be kept
in this position at all times, except when Raising or
Integral with the tank assembly are two suction Lowering the body.
screens, filter element, relief valve, adaptor plate,
access covers and filler neck assembly. Two sight A relief valve assembly, at pressure inlet, opens and
gauges on the right hand side of the tank assembly allows oil to flow through hydraulic oil cooler (7) and
indicate hydraulic oil level. Located on top of the tank back to the hydraulic tank when pressure in the
assembly are a breather, pressure switch and hydraulic system exceeds 221 bar (3 200 lbf/in).
temperature switch.
Movement of control spool (1) is controlled by
Internally there is a baffle plate which divides the tank electrical signals from the body control joystick in the
assembly into a body hoist compartment and a operators compartment. Refer to Section 230-0081,
steering compartment. Should oil level drop below this BODY CONTROL JOYSTICK.
baffle level, the tank assembly operates as two
separate tanks.
Pilot Supply Valve (4)
Refer to Section 230-0121, PILOT SUPPLY VALVE.
Main Hydraulic Pump (2)
Refer to Section 230-0050, MAIN HYDRAULIC PUMP. Mounted off the rear right hand cab leg, the pilot
supply valve is a direct acting pressure reducing valve
Mounted off the transmission power takeoff, the main which steps down the supply pressure to 30 bar
hydraulic pump supplies hydraulic oil for operating the (435 lbf/in). Intregal of the pilot supply valve is a relief
body hoist and steering systems. valve which opens at 45 bar (652 lbf/in).
Hydraulic oil is drawn from the hydraulic tank (1) and Mounted off the hydraulic tank, above the pilot supply
pumped through the priority valve (5). A priority spool valve, the accumulator (6) is pre-charged with
within the priority valve (5) directs oil supply from the nitrogen, to a pressure of 30 bar (435 lbf/in).
main hydraulic pump to the body control valve (3).
SM 1949 Rev 1 11-00 1

Body System - Body System Schematic
Section 230-0000
Body Cylinders (5) SM - 1335
FITTING NUT
Refer to Section 230-0130, BODY CYLINDER.
TUBE
There are two single stage, double acting body hoist
cylinders on the vehicle. The cylinder base end is
connected to the trailer frame and the piston rod end is
connected at the body. Single stage double acting
means that the piston rod can have oil applied to either
side, extending or retracting the piston rod.
SLEEVE
'O' RING 'O' RING
Cylinder mounting is by pins, spacers and spherical
bearings secured in place with circlips. Spherical bearings Fig. 1 - Assembly of Typical ORFS Connector
permit a limited amount of cylinder misalignment.
d. Where a tube is fitted, ensure that the connection is
aligned correctly.
Pressure Test Points
There are two pressure check points within the body e. Tighten the nut a further 1/4 to 1/2 a turn using the
hoist system. Pressure readings at these points should correct size spanner (wrench).
be as follows:
f. Check that a satisfactory hose or tube routing has
Test Point A - Mounted on diagnostic plate at rear been achieved.
right hand side of the tractor.
System Relief Pressure - 221 bar (3 200 lbf/in)
Hydraulic Oil
Test Point B - Located in tee piece at port 'U' of pilot The hydraulic oil tank should be kept filled with
supply valve (4). hydraulic oil as specified in Section 300-0020,
Pilot Valve Pressure - 30 bar (435 lbf/in) LUBRICATION SYSTEM. Refer to Section 230-0040,
HYDRAULIC TANK, for correct fill level and procedure.
Body Control Valve - Pilot Pressures
Position Port 'P1' Port 'P2' MAINTENANCE
Raise 30 bar 0 bar Maintenance instructions, intervals and warnings, in
Hold 0 bar 0 bar the individual hydraulic component sections of this
Float 0 bar 30 bar manual, should be adhered to at all times.
Lower 0 bar 13.5 bar
SERVICE TOOLS
'O' RING FACE SEALS (ORFS) It is recommended that the following service tools are
Where hydraulic lines are fitted with ORFS used when carrying out pressure and temperature
connections, the following procedure should be carried checks during maintenance procedures. These tools,
out during 'Installation'. Refer to Fig. 1. along with other general service tools, are available
from your dealer. Refer to Section 300-0070,
a. Ensure 'O' ring/seal is in place and that the joining SERVICE TOOLS, for part numbers of these tools.
surfaces are clean. If necessary, retain 'O' ring/seal in
place with a light coating of grease or vaseline.
Multi-Gauge
b. Initially, the nuts should be tightened by hand. The multi-gauge is basically four pressure gauges in
one. Continuous system pressure readings are
c. Where a hose is fitted, ensure that it is not twisted or indicated on one of three simultaneously reading
kinked when the nuts are tightened so that it is allowed gauges through a pressure range of 30 in of vacuum
to adopt a natural position. to 5 000 lbf/in.
2 SM 1949 Rev 1 11-00

Section 230-0000
Non-contact Infrared Thermometer pull the trigger, and read the temperature. Since there
The infrared thermometer can be used to spot heat is no need to touch what you are measuring,
problems early in electrical, mechanical and hydraulic temperatures of hard-to-reach or moving components
systems. Hand held and easy to use, you simply aim, can be taken without getting burned or shocked.
BODY SYSTEM DIAGNOSIS

Body raise time too slow, Worn pump. Pump output should Repair or replace pump.
should be 12 sec, loaded. be as specified in Section 000-0000,
Check pump driveshaft.
Hydraulic oil pressure too GENERAL INFORMATION.
low, should be 221 bar Pump cavitation Check oil level in hydraulic tank. Refer to
(3 200 lbf/in). Section 230-0040, HYDRAULIC TANK.
Check for suction leak at pump inlet port.
Check for obstruction in hydraulic lines.
Dirt or foreign particles lodged Replace relief valve assembly. Refer to
between relief valve control Section 230-0060, BODY CONTROL
poppet and seat VALVE.
Relief valve worn Check relief valve setting, as described in
Section 230-0060, BODY CONTROL
VALVE. Replace relief valve assembly if
worn.
Control valve spool not stroking Check spool travel, as described in Section
completely 230-0060, BODY CONTROL VALVE.
Body cylinder binding or Repair or replace body cylinder.
obstruction in oil passage
Incorrect pilot pressure from the Check pilot pressure. Replace valve if
pilot control valve necessary (non-servicable item).
Body lower time too slow, Return oil from body cylinders is Check hydraulic lines for restrictions.
should be 7.5 sec in 'Power being restricted in hydraulic lines Check control valve spool for correct 'Float'
Down' or body control valve position. Refer to Section 230-0060, BODY
CONTROL VALVE.
Incorrect pilot pressure from the Check pilot pressure. Replace valve if
pilot control valve necessary (non-servicable item).
Body will not hold Oil bypassing between control Replace body control valve assembly.
spool and control valve body
Control spool not centred Repair body control valve.
Oil bypassing body cylinder seals Repair body cylinders.
Body will not raise or lower Pump failure Repair or replace pump.
Relief valve pressure too low Check and adjust relief valve setting, as
described in Section 230-0060, BODY
CONTROL VALVE.
Electrical failure at joystick or body Check and replace joystick and/or control
control valve solenoids solenoids.
SM 1949 Rev 1 11-00 3

Section 230-0000
SM - 2459A
6 P2 T2 U2
4
30
bar
45
5 5 bar
P1 T1 U1
L T R
3
P2 P1
T2 T1
P
(PORT LS) TO
STEERING
(PORT P) VALVE
LS CF EF
9
TO EMERGENCY
VALVE
(PORT CE)
7 2
COMPONENTS COLOUR CODES

1 - Hydraulic Tank 5 - Body Cylinder Red - Pressurized Oil
2 - Main Hydraulic Pump 6 - Accumulator Blue - Exhaust or Return Oil
3 - Body Control Valve 7 - Hydraulic Oil Cooler Green - Intake Oil
4 - Pilot Supply Block 8 - Check Valve Orange - Pilot Pressure
9 - Priority Valve Yellow - Static Oil
Fig. 2 - Body Hoist System Schematic - Body Control Valve in the 'Float' Position
4 SM 1949 Rev 1 11-00

Section 230-0000
SM - 2459B
6 P2 T2 U2
4
30
bar
45
5 5 bar
P1 T1 U1
L T R
3
P2 P1
T2 T1
P
(PORT LS) TO
STEERING
(PORT P) VALVE
LS CF EF
9
TO EMERGENCY
VALVE
(PORT CE)
7 2

Fig. 3 - Body Hoist System Schematic - Body Control Valve in the 'Lower' Position
SM 1949 Rev 1 11-00 5

Section 230-0000
SM - 2459C
6 P2 T2 U2
4
30
bar
45
5 5 bar
P1 T1 U1
L T R
3
P2 P1
T2 T1
P
(PORT LS) TO
STEERING
(PORT P) VALVE
LS CF EF
9
TO EMERGENCY
VALVE
(PORT CE)
7 2

Fig. 4 - Body Hoist System Schematic - Body Control Valve in the 'Hold' Position
6 SM 1949 Rev 1 11-00

Section 230-0000
SM - 2459D
6 P2 T2 U2
4
30
bar
45
5 5 bar
P1 T1 U1
L T R
3
P2 P1
T2 T1
P
(PORT LS) TO
STEERING
(PORT P) VALVE
LS CF EF
9
TO EMERGENCY
VALVE
(PORT CE)
7 2

Fig. 5 - Body Hoist System Schematic - Body Control Valve in the 'Raise' Position
* * * *
SM 1949 Rev 1 11-00 7
BODY SYSTEM - Hydraulic Tank
Section 230-0040
SM - 2461
9 25
22
10 28
23 26
3 24 27
6
4
3
8 11,12 4
6 7
13 2
41
40 5 37
31
14 3 37
4 41
6
1 30
16
29
35
17 36
21
15
18
32
33
19
34
20
38
39
1 - Tank Assembly 11 - Relief Valve 21 - Sight Gauge 31 - Isolation Mount

2 - Filler Cap 12 - Adaptor Plate 22 - Breather 32 - Bolt
3 - Bolt 13 - Filter Element 23 - Coupling 33 - Washer
4 - Lockwasher 14 - Gasket 24 - Nipple 34 - Locknut
5 - Filler Neck Assembly 15 - Carrier 25 - Cover 35 - Lockwasher
6 - Gasket 16 - Bolt 26 - Pressure Switch 36 - Washer
7 - Access Cover 17 - End Cap 27 - Reducer 37 - Washer
8 - Access Cover 18 - Suction Screen 28 - Temperature Switch 38 - Washer
9 - Wing Nut 19 - End Cap 29 - Bolt 39 - Anti Spill Drain Plug
10 - Rod 20 - Locknut 30 - Bracket 40 - Sealing Strip
41 - Nut
Fig. 1 - Exploded View of Hydraulic Tank and Mounting
DESCRIPTION Integral with tank assembly (1) are two suction screens
Numbers in parentheses refer to Fig. 1. (18), filter element (13), relief valve (11), adaptor plate
(12), access covers (7 & 8) and filler neck assembly
The hydraulic tank is the common oil reservoir for the (5). Two sight gauges (21) on the right hand side of
steering and body hoist systems. It is mounted to the tank assembly (1) indicate hydraulic oil level. Located
tractor frame, at the rear of the cab, and secured with on top of tank assembly (1) are breather (22), pressure
four bolts (32), washers (33) and locknuts (34). switch (26) and temperature switch (28).
SM 1950 4-00 1
Body System - Hydraulic Tank
Section 230-0040
SM - 1913
E
F
C
D
B
Fig. 2 - Hydraulic Tank Port Locations - Viewed from Underside of Hydraulic Tank
Internally there is a baffle plate which divides tank A tube connected at port 'E' allows return oil from the
assembly (1) into a steering compartment and a body body control valve to enter tank assembly (1). The oil
hoist compartment. Should oil level drop below this is filtered through filter element (13) before entering
baffle level, tank assembly (1) operates as two tank assembly (1) storage area. Relief valve (11)
separate tanks. allows the oil to bypass filter element (13) when it is
cold or blocked.
OPERATION Hydraulic oil from tank assembly (1) is cooled through

Numbers in parentheses refer to Fig. 1. Refer to a hydraulic oil cooler mounted on the front of the
Fig. 2 for port locations. radiator. These lines are connected to the tube
assembly at port 'E'. Refer to Section 210-0100,
Hydraulic oil is drawn from port 'A', through suction HYDRAULIC OIL COOLER, for oil flow through the
screen (18), by the emergency steering pump cooler.
mounted at the front of the transmission. Oil is then
pumped to the emergency steering valve in the Hydraulic oil is drawn from port 'F', through suction
steering system. screen (18), by the main hydraulic pump mounted at
the rear of the transmission. Oil is then pumped
Port 'B' is plugged. through the priority valve to the body hoist system or
the steering system, depending on the priority valve
Return oil from the steering valve and emergency spool position.
steering valve enters tank assembly (1) at port 'C'. The
oil is filtered through filter element (13) before entering Should filter element (13) become blocked, relief valve
tank assembly (1) storage area. Relief valve (11) (11) assembly will open, allowing oil to flow around
allows the oil to bypass filter element (13) when it is filter element (13) and into the body of tank assembly
cold or blocked. (1). Restriction pressure is picked up by pressure
switch (26), installed in access cover (7) which
An anti-spill drain cap is fitted at port 'D'. Install an anti- registers on the hydraulic oil filter warning light on the
spill drain connector to drain hydraulic oil from tank dash.
assembly (1).
Note: Hydraulic oil filter warning light illuminates at
2 SM 1950 4-00
Section 230-0040
2.75 bar (40 lbf/in) restriction, indicating filter element Replacing Hydraulic Oil
(13) requires to be changed. The hydraulic tank should be drained, cleaned and
hydraulic oil changed every 2 000 hours. Refer to
Temperature switch (28), installed in access cover (7), Section 300-0020, LUBRICATION SYSTEM, for
opens when a temperature of 50 C (122 F) is hydraulic oil used in the system.
reached. Temperature switch (28) is connected in
series with pressure switch (26), therefore, hydraulic
oil filter warning light on the dash will not illuminate Replacing Filter Element
until the hydraulic oil temperature rises above 50 C Clean filter housing and install new filter element (13)
(122 F). when hydraulic oil filter warning light illuminates, or
after every 2 000 hours of operation, whichever comes
Relief valve (11) in filter element (13) will open when a first.
pressure of 3.5 bar (50 lbf/in) is reached within the
filter compartment of the hydraulic tank. Note: When hydraulic oil in tank assembly (1) is being
replaced due to a hydraulic failure, or at recommended
Installed in access cover (8) is a breather which allows change interval, filter element (13) should be replaced.
any air entering tank assembly (1) to escape to
atmosphere, preventing air pressure build up within 1. Position the vehicle in a level work area, be sure the
tank assembly (1). body is completely lowered, apply the parking brake
and switch off the engine.
MAINTENANCE 2. Block all road wheels and place the battery master
Numbers in parentheses refer to Fig. 1. switch in the 'Off' position.
Note: Tighten all fasteners to standard torques listed 3. Lift window guard from tank (1) to allow access to
in Section 300-0080, STANDARD BOLT AND NUT access cover (7).
4. Remove bolts (3) and lockwashers (4) securing
access cover (7) to tank (1). Remove and discard
WARNING gasket (6) from tank (1).
damage, be sure wheel blocks, blocking 5. Remove cap from anti-spill drain plug (39), install
materials and lifting equipment are properly drain tube connection and drain hydraulic oil, to below
secured and of sufficient capacity to do the job the level of filter element (13), into a suitable container.
safely. Remove drain tube connection and reinstall cap.
6. Remove wing nuts (9) from rods (10). Slide relief

Checking Oil Level valve (11), adaptor plate (12), filter element (13) and
1. Operate the body hoist and steering systems gasket (14) over rods (10) and remove from tank assembly
several times to bring the oil to correct operating (1). Discard filter element (13) and gasket (14).
temperature.
2. Position the vehicle in a level work area, be sure the WARNING

body is completely lowered, apply the parking brake Splashing liquid. Wear a suitable face shield
and switch off the engine. when using compressed air to dry hydraulic
tank and components.
3. Check oil level and add oil if low. The bottom sight
gauge (21) should show full. If oil is required, remove 7. Clean out filter element (13) compartment in tank
filler cap (2) and fill tank assembly (1) with hydraulic oil assembly (1) with a suitable solvent and dry with
as specified in Section 300-0020, LUBRICATION compressed air.
SYSTEM. Install filler cap (2) on filler neck assembly
(5).
SM 1950 4-00 3
Section 230-0040
8. If damaged, remove and replace rods (10) from tank suitable container. Remove drain tube connection and
assembly (1). reinstall cap.
9. Install new gasket (14), new filter element (13), 6. Unscrew and remove both carrier assemblies
adaptor plate (12) and relief valve (11) over rods (10) (15 through 20) from the interior of tank assembly (1).
and into filter element compartment in tank assembly
(1). Secure relief valve (11), adaptor plate (12) and 7. Remove bolts (16) and locknuts (20) securing end
filter element (13) in position with wing nuts (9). caps (17 & 19) and suction screen (18) to one
carrier (15).
10. Install new gasket (6) on access cover (7)
mounting flange. Secure access cover (7) to tank
assembly (1) with bolts (3) and lockwashers (4). WARNING
Splashing liquid. Wear a suitable face shield
11. Refill tank assembly (1) with hydraulic oil, as specified when using compressed air to dry hydraulic
in Section 300-0020, LUBRICATION SYSTEM. Install tank and components.
filler cap (2) on filler neck assembly (5).
8. Clean carrier (15), end caps (17 & 19) and suction
12. Place the battery master switch in the 'On' position, screen (18) in a suitable solvent and dry with
remove wheel blocks, start the engine and operate compressed air.
steering and body hoist systems to circulate the
hydraulic oil. 9. Inspect suction screen (18) for damage and replace
if required.
13. Switch off the engine and check for leaks. Tighten
lines and fittings as required. Check hydraulic oil tank 10. Install end caps (17 & 19) and suction screen (18)
level as described under 'Checking Oil Level'. on carrier (15). Secure carrier (15) assembly together
with bolts (16) and locknuts (20).
Replacing or Cleaning Suction Screens 11. Install carrier assembly (15 through 20) in tank
Suction screens (18) should be cleaned every time assembly (1) and secure.
tank assembly (1) is fully drained for any reason. Refer
to 'Replacing Hydraulic Oil' for oil change interval. 12. Repeat steps 7 through 11 for other carrier (15)
assembly.
1. Position the vehicle in a level work area, be sure the
body is completely lowered, apply the parking brake 13. Install new gaskets (6) on access cover (8) and
and switch off the engine. filler assembly (5) mounting flanges. Secure access
cover (8) and filler assembly (5) to tank (1) assembly
2. Block all road wheels and place the battery master with bolts (3) and lockwashers (4).
14. Refill tank assembly (1) with hydraulic oil, as specified
3. Lift window guard from tank assembly (1) to allow in Section 300-0020, LUBRICATION SYSTEM. Install
access to access cover (8) and filler neck assembly (5). filler cap (2) filler neck assembly (5).
4. Remove bolts (3) and lockwashers (4) securing 15. Place the battery master switch in the 'On' position,
access cover (8) and filler neck assembly (5) to tank remove wheel blocks, start the engine and operate
assembly (1). Remove and discard gaskets (6) from steering and body hoist systems to circulate the
tank assembly (1). hydraulic oil.
5. Remove cap from anti-spill drain plug (39), install 16. Switch off the engine and check for leaks. Tighten
drain tube connection and drain hydraulic oil, to below lines and fittings as required. Check hydraulic oil tank
the level of the top of carrier (15) assembly, into a level as described under 'Checking Oil Level'.
4 SM 1950 4-00
Section 230-0040
TANK ASSEMBLY 9. Secure a suitable lifting device on tank assembly (1)

Numbers in parentheses refer to Fig. 1. and remove bolts (32), washers (33) and locknuts (34)
securing tank assembly (1) to tank mountings on the
frame.
Removal
10. Carefully remove tank assembly (1) from the
vehicle to a clean area for disassembly.
WARNINGS
damage, be sure wheel blocks, blocking Disassembly
materials and lifting equipment are properly 1. Remove internal components from tank assembly (1)
secured and of adequate capacity to do the job as previously described under maintenance.
safely.
2. Remove breather (22), coupling (23) and nipple (24)
Hydraulic fluid pressure will remain from access cover (8).
within the body hoist system after engine
shutdown. To prevent personal injury and 3. Remove pressure switch (26), reducer (27) and
property damage, press and hold down body temperature switch (28) from access cover (7).
hoist bleed down switch and operate the body
control joystick continually to relieve pressure 4. Remove sight gauges (21) from tank assembly (1).
in the system.
5. If required, remove bolts (29), washers (36 & 37),
1. Position the vehicle in a level work area, be sure the lockwashers (35), bracket (30), nuts (41) and isolation
body is completely lowered, apply the parking brake mounts (31) from tank assembly (1).
and switch off the engine.
2. Press and hold down body hoist bleed down switch Inspection
and operate the body control joystick continually to
relieve pressure in the body hoist system.
WARNING
3. Block all road wheels and place the battery master Splashing liquid. Wear a suitable face shield
switch in the 'Off' position. when using compressed air to dry hydraulic
tank and components.
4. Remove cap from anti-spill drain plug (39), install
drain tube connection and drain hydraulic oil into a 1. Clean tank assembly (1) and components with a
suitable container. Remove drain tube connection and suitable solvent and dry with compressed air.
reinstall cap.
2. Inspect tank assembly (1) for weld cracks and
5. Remove window guard assembly from tank security of internal pipes and weld fitments.
assembly (1) and cab to allow access to tank
assembly (1). 3. Inspect filter element (13), suction screens (18) and
breather (22) for damage. Replace if required.
6. Disconnect supports securing hydraulic lines to
pivot guard, and secure clear of tank assembly (1).
Support pivot guard and remove mounting hardware Assembly
securing guard to tank assembly (1). Remove guard to 1. Renew all gaskets and install all internal
allow access to tank assembly (1). components in tank assembly (1), as previously
described under 'Maintenance'.
7. Tag and disconnect all hydraulic lines and fittings
attached to tank assembly (1), to aid in 'Installation'. 2. Install nipple (24), coupling (23) and breather (22)
Plug all lines and fittings to prevent ingress of dirt. on access cover (8).
Remove all wiring connections from tank assembly (1).
3. Install reducer (27), pressure switch (26) and
8. Disconnect exhaust mounting hardware from tank temperature switch (28) on access cover (7).
assembly (1).
SM 1950 4-00 5
Section 230-0040
4. Install sight gauges (21) on tank assembly (1). 4. Install all hydraulic lines and fittings to tank
assembly (1) as tagged at 'Removal'. Connect all
5. If removed, install bolts (29), washers (36 & 37), wiring lines to tank assembly (1) as disconnected at
lockwashers (35), bracket (30), nuts (41) and isolation 'Removal'.
mounts (31) on tank assembly (1).
5. Install pivot guard to tank assembly (1) and secure
using mounting hardware removed at 'Removal'.
Installation Secure hydraulic lines to pivot guard using supports as
Note: Tighten all fasteners to standard torques listed in removed at 'Removal'.
TORQUE SPECIFICATIONS. 6. Install window guard assembly to cab and tank
assembly (1) and secure.
connections, as described in Section 230-0000, BODY 7. Remove filler cap (2) from filler neck assembly (5) and
SYSTEM SCHEMATIC. Renew all 'O' rings where refill tank assembly (1) with hydraulic oil, as specified in
used. Section 300-0020, LUBRICATION SYSTEM. Install filler
cap (2) on filler neck assembly (5).
WARNING 8. Place the battery master switch in the 'On' position,

To prevent personal injury and property remove wheel blocks, start the engine and operate
damage, be sure lifting equipment is properly steering and body hoist systems to circulate the
secured and of adequate capacity to do the job hydraulic oil.
safely.
9. Switch off the engine and check for leaks. Tighten
1. Using a suitable lifting device, position tank lines and fittings as required. Check hydraulic oil tank
assembly (1) carefully in position on the vehicle. level as described under 'Checking Oil Level'.
2. Secure tank assembly (1) to tank mounting brackets

on the frame with bolts (32), washers (33) and SERVICE TOOLS
locknuts (34). There are no special tools required for the procedures
3. Secure exhaust to tank assembly (1) with mounting SERVICE TOOLS, for part numbers of general service
hardware as disconnected at 'Removal'. tools required. These tools are available from your
dealer.
* * * *
6 SM 1950 4-00
BODY SYSTEM - Main Hydraulic Pump
Section 230-0050
SM - 1897
21 4 5
1 12
10 6
9 8 14 13 8 9 22
18
20 19
7 11 7 2 15 16
3
17
8.5 mm
3
19
APPLY GREASE
10 mm APP.
11
18
20
SEALANT POSITION
4 mm
17
1 - Body Housing 7 - Bearing

2 - Front Cover 8 - Wear Plate Seal 13 - Wear Plate 18 - Seal
3 - Mounting Flange 9 - Backup Seal 14 - Wear Plate 19 - Location Sleeve
4 - Nut 10 - Ring Seal 15 - Capscrew 20 - Seal
5 - Washer 11 - Driveshaft and Gear 16 - Capscrew 21 - Seal
6 - Gasket 12 - Driven Gear 17 - Multistep Push Clip 22 - Stud
Fig. 1 - Exploded View of Hydraulic Pump
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. Refer to
Fig. 2 for typical pump operation.
The main hydraulic pump can be identified as item 2 in
Section 230-0000, BODY SYSTEM SCHEMATIC. SM - 1864
DRIVE GEAR
Mounted off the transmission power takeoff (PTO), the
main hydraulic pump supplies hydraulic oil for
operating the body hoist and steering systems.
The major pump components are; body (1), front cover DRIVE
(2), mounting flange (3), driveshaft and gear (11), INLET OUTLET
driven gear (12), wear plates (13 & 14), wear plate
seals (8) and bearings (7). DRIVEN
There are two ports on the hydraulic pump:
Port 'A' - Suction side from hydraulic tank

DRIVEN GEAR
Port 'B' - Pressure supply to body control valve via
priority valve Fig. 2 - Typical Gear Pump Operation
SM 1951 4-00 1
Body System - Main Hydraulic Pump
Section 230-0050
As driveshaft and gear (11) rotates, driven gear (12) 6. Support pump assembly with suitable lifting
rotates in the opposite direction. Pockets between the equipment. Remove nuts (4) and lockwashers (5)
drive and driven gear teeth carry oil from inlet port 'A', securing pump assembly to the transmission PTO.
around gear housing (2) ID, to outlet port 'B'. As the Remove pump assembly from the transmission PTO
gear teeth re-mesh, oil is forced out of outlet port 'B' to and discard gasket (6).
the priority valve. Refer to Section 220-0105,
PRIORITY VALVE. 7. Wash outside of the pump assembly thoroughly,
with a suitable solvent, and move to a clean work area
The maximum oil delivery of the hydraulic pump is for disassembly.
fixed by the width of its respective gear set and the
speed at which driveshaft and gear (11) rotates.
DISASSEMBLY
Note: Never drive a pump in the wrong direction of Numbers in parentheses refer to Figs. 1.
rotation, as pump seizure may result.
1. Place pump assembly in a soft-jawed vice, and
clamp on body (1) casing. Match mark port body (1),
REMOVAL front cover (2) and mounting flange (3) to aid in
Numbers in parentheses refer to Fig. 1. assembly.
Note: Do not clamp vice on machined surfaces of the

WARNINGS pump at any time.
damage, be sure wheel blocks, blocking 2. Remove capscrews (16) securing mounting flange
materials and lifting equipment are properly (3) and front cover (2) together.
safely. 3. Tap mounting flange (3) with a soft hammer and
remove it from front cover (2).
Hydraulic fluid pressure will remain
within the body hoist system after engine Note: Do not attempt to pry the pump units apart with
shutdown. To prevent personal injury and a large screwdriver or pry bar. The machined surfaces
property damage, press and hold down body of the mounting flange (3) or front cover (2) may be
hoist bleed down switch and operate the body damaged.
control joystick continually to relieve pressure
in the system. 4. Remove and discard shaft seals (18 & 20).
1. Position the vehicle in a level work area, apply the 5. Remove capscrews (15) securing front cover (2)
parking brake and switch off the engine. and body housing (1) together.
2. Press and hold down body hoist bleed down switch 6. Tap front cover (2) with a soft hammer and remove
and operate the body control joystick continually to from body housing (1).
Note: Do not attempt to pry the pump units apart with
3. Block all road wheels and place the battery master a large screwdriver or pry bar. The machined surfaces
switch in the 'Off' position. of the body housing (1) or front cover (2) may be
damaged.
4. Remove hydraulic tank anti-spill drain cap, install
drain tube connection and drain oil into a suitable 7. Remove and discard ring seal (10) from body
container. Remove drain tube connection and reinstall housing (1).
cap.
8. Remove wear plate (13), wear plate seal (8) and
5. Clean pump housing and tag and disconnect inlet backup seal (9) from shaft front cover (2). Note the
and outlet lines from pump assembly. Drain oil in position of wear plate seal (8) in wear plate (13)
hydraulic lines into a suitable container. Cap hydraulic groove, for proper assembly.
lines and plug pump ports to prevent ingress of dirt.
9. Remove driveshaft gear (11) and driven gear (12)
from body housing (1).
2 SM 1951 4-00
Section 230-0050
10. Remove wear plate (14) and wear plate seal (8) SM - 1865
from body housing (1). Note the position of wear plate
7
seal (8) in wear plate (14) groove, for proper
assembly.
11. Using a suitable puller, remove bearings (7) from OUTLET INLET
shaft front cover (2), only if they are being replaced. (SMALL PORT) (LARGE PORT)
INSPECTION
Numbers in parentheses refer to Figs. 1.
VIEW SHOWING FRONT COVER
ITEM 2 ONLY
1. Clean all parts in a suitable solvent and dry with
compressed air.
LUBRICATION
7 GROOVE TYP.
2. Check driveshaft and gear (11) and driven gear (12)
carefully for wear. Remove burrs or light score marks
from gear faces and teeth with an India stone. Heavy
scoring, grooving or burring of gear teeth OD requires INLET OUTLET
(LARGE PORT) (SMALL PORT)
gear replacement. Nicked, grooved or fretted gear
tooth mating surfaces also requires gear replacement.
Any wear of gear hubs in excess of 0.025 mm BEARING SPLIT LINE
INSTALL BEARING IN
(0.001 in), or detectable by touch, requires gear POSITION SHOWN
WITHIN 5 TYP.
replacement. VIEW SHOWING
BODY HOUSING
Note: Since both driveshaft and gear (11) and driven ITEM 1 ONLY
gear (12) of a set are matched, they must be replaced
as a set if one is worn or damaged. Fig. 3 - Bearing Lubrication Groove Position
3. If gears are replaced, bearings (7) must be replaced

6. Replace all wear plate seals (8), backup seals (9),
at the same time. Bearings (7) should fit into their
ring seal (10) and lip seals (18 & 19).
bores with a heavy press fit.
7. Clean parts in a suitable solvent and dry with
4. Check the centre of wear plates (13 & 14) at the
compressed air after deburring surfaces.
point of meshing of driveshaft and gear (11) and driven
gear (12). Erosion indicates contaminated oil. Pitting
indicates cavitation or aeration of the oil supply. ASSEMBLY
Discoloured wear plates are a sign of the pump over
heating.
1. If removed, install bearings (7) in front cover (2) and
Wear plate (13 & 14) side wear permits oil to bypass
body housing (1) using an arbor press. Lightly oil
gears and allows internal oil slippage and reduced
bearing (7) outside diameter with mineral oil prior to
pump efficiency. Check wear plate (13 & 14) wear
insertion.
against the size of new wear plates. Replace wear
plates (13 & 14) if worn in excess of 0.05 mm
Note: Assemble bearings (7) in body housing (1)
(0.002 in).
bores with the bushing split line positioned at
3 o'clock. The lubrication groove will be positioned at
5. Deburr all machined surfaces of port end body
1 o'clock.
housing (1), front cover (2) and mounting flange (3)
with a medium grit India stone. Replace gear housing
Note: Assemble bearings (7) in the front cover (2)
(2) if wear on machined surfaces exceeds 0.127 mm
bores with the bushing split line positioned at
(0.005 in).
9 o'clock. The lubrication groove will be positioned at
11 o'clock, as shown in Fig. 3.
SM 1951 4-00 3
Section 230-0050
Note: Ensure bearings (7) are pressed to insertion SM - 1866
depth indicated in Fig. 4.
2. Install new lip seals (20) and location sleeve (19) to

front cover (2), as shown in Fig. 1. BEARING
(ITEM 7)
3. Apply a thin film of grease on new wear plate seal
(8) and backup seal (9) and install in wear plate (14),
as shown in Fig. 5.
BODY HOUSING
4. Install wear plate (14) into body housing (1) bore, (ITEM 1)
with wear plate seal (8) facing down.
1.50/1.75 mm
Note: The relief groove in wear plate (14) should face
the outlet side of the pump. Fig. 4 - Bearing Insertion Depth
5. Lightly oil gear faces, gear flanks and journals with

SM - 1867
mineral oil prior to assembly.
BACKUP BACKUP
SEAL SEAL
(ITEM 9) (ITEM 9) 45 CHAMFER
6. Slide driven gear (12) and drive shaft (11) into its WEARPLATE WEARPLATE
bearing in body housing (1). SEAL (ITEMS 13 & 14)
(ITEM 8)
Note: When installing the original gear sets, align as

OUTLET INLET
match marked at disassembly. BACKUP
SEAL
(ITEM 9)
Z
7. Apply a thin film of grease on second wear plate WEARPLATE
seal (8) and backup seal (9) and install in second wear SEAL
Z (ITEM 8)
plate (13), as shown in Fig. 5.
WEARPLATE ALTERNATIVE CUT
SEAL
(ITEM 8) SEAL AND BACKUP SEAL
8. Install wear plate (13) assembly on gear shaft end
SECTION Z - Z
(11) and body housing (1) bore, with wear plate seal
Fig. 5 - Wearplate Seal Fitting
(8), and backup seal (9) facing up.
Note: The relief groove in wear plate (13) should face 13. Secure body housing (1) and front cover (2)
the outlet side of the pump. together with four capscrews (15). Tighten capscrews
(15) alternately to ensure correct alignment of parts.
9. Fit ring seal (10) to body housing (1) machined face. Rotate driveshaft (11) to check for internal binding of
Ring seal (10) to be fitted dry. parts. If no binding is evident, tighten capscrews (15)
alternately to a torque of 772 Nm (569 lbf ft).
10. Coat special sleeve tool, which can be fabricated
as shown in Fig. 8, with grease and install driveshaft 14. Apply a continuous beading (1 - 1.5 mm dia.) of
and gear (11) in the sleeve tool, as shown in Fig. 6. sealant to flange mounting (3) face, approximately
10 mm from locating sleeve (19) before installing
11. Position assembled front cover (2) over gear shaft mounting flange (3). Tap mounting flange (3) with soft
ends (11 & 12). Tap front cover (2) with a soft hammer hammer until it rests against front cover (2).
until it rests against wear plate (14) in body housing
(1), as shown in Fig. 7. Take care not to damage ring 15. Secure mounting flange (3) to front cover (2)
seal (10) and seal (20). together with three capscrews (16). Tighten
capscrews (16) alternately to ensure correct alignment
Note: Make sure index marks on front cover (2) and body of parts. Rotate driveshaft (11) to check for internal
housing (1) match up, as marked at disassembly. binding of parts. If no binding is evident, tighten
capscrews (16) alternately to a torque of
12. Remove sleeve tool from drive of driveshaft and gear 162 Nm (119 lbf ft).
(11) and cover the gear set with hydraulic oil specified in
4 SM 1951 4-00
Section 230-0050
SM - 1868
3. Remove cap from the inlet line and install a new
'O' ring in the split flange fitting. Secure inlet line to
inlet port 'A' on the pump with bolts and lockwashers,
as removed during removal.
4. Before connecting the outlet line to outlet port 'B' on the

pump, fill the pump with hydraulic oil as specified in
5. Remove cap from the outlet line and install a new

'O' ring in the split flange fitting. Secure outlet line to
outlet port 'B' on the pump with bolts and lockwashers,
as removed during removal.
Fig. 6 - Installing Driveshaft and Gear in Body Housing Note: It is very important that the pump cavity is filled
with hydraulic oil. This will ensure proper lubrication of
SM - 1869
the internal parts of the pump when it is initially
operated.
6. Fill hydraulic tank to the proper level. Refer to

Section 230-0040, HYDRAULIC TANK for correct oil
level and, Section 300-0020, LUBRICATION SYSTEM
for oil specification.
START-UP PROCEDURE
Before starting the engine and running the pump,
back-off the system relief valve on the priority valve,
until the adjusting screw spring tension is relieved.
Refer to Section 220-0105, PRIORITY VALVE, for
Fig. 7 - Installing Front Cover details. This avoids the possibility of immediate
damage to the pump if the relief valve pressure setting
had been increased, beyond the recommended
INSTALLATION operating pressure, before removal of the pump.
Numbers in parentheses refer to Fig. 1. Loosen the bolts at flange fitting on outlet line at port
'B' on the pump to allow entrapped air to bleed out at
Note: Tighten all fasteners to standard torques listed initial start-up.
TORQUE SPECIFICATIONS. Start the engine and operate the pump at least two
minutes at zero pressure at engine idle speed. When
oil runs out of pump outlet port 'B' in a steady stream,
WARNING tighten outlet line flange fittings. During the break-in
To prevent personal injury and property period, the pump should run free and not develop an
damage, be sure blocking materials and lifting excessive amount of heat. If the pump becomes hot to
equipment are properly secured and of touch, it is binding and might seize. In this instance the
adequate capacity to do the job safely. pump will have to be rebuilt with extra care to prevent
binding.
1. Coat pump driveshaft spline with high grade plating-
type molybdenum disulphide grease 15% minimum If the pump is running properly, engine speed and
(typical) and install gasket (20) on mounting face of the hydraulic system pressures can gradually be
pump assembly. increased to normal operating values. Adjust the
system relief valve to the proper setting as described
2. With suitable lifting equipment position pump on in Section 220-0060, PRIORITY VALVE.
mounting studs. Secure with nuts (4) and lockwashers
(5), as removed during removal.
SM 1951 4-00 5
Section 230-0050
Note: Always use accurate pressure gauges when fresh hydraulic oil installed to eliminate all metal
adjusting the relief valve. particles or foreign matter.
Check pump mounting and hydraulic line connections Refer to Section 300-0020, LUBRICATION SYSTEM,
for leaks. Tighten lines and fittings as required. for recommended periodic oil change periods and oil
specifications.
Remove wheel blocks from all road wheels.
SPECIAL TOOL
LUBRICATION The special sleeve tool for installing the driveshaft and
All pump parts are lubricated by the hydraulic oil. The gear in the pump can be fabricated from steel bar as
oil, therefore, must be kept clean to minimize pump shown in Fig. 8. Refer to Section 300-0070, SERVICE
wear. Whenever there is a hydraulic system failure, TOOLS, for part numbers of general service tools
the oil should be drained, the entire system flushed, oil required. These tools are available from your dealer.
filters replaced, oil screens thoroughly cleaned and
SM - 647
6 mm (0.25 in)
Drill Thru Hole
SPECIAL SLEEVE TOOL DIMENSIONS
DIMENSION mm in
A 85.7 3.375
B 114.3 4.50
C Radius 14.3 0.56
D Diameter 34.9758 + 0.000 1.377 + 0.000
- 0.0508 - 0.002
E Diameter 31.75 + 0.050 1.250 + 0.002
- 0.000 - 0.000
F Chamfer 1.6 x 60 0.063 x 60
Fig. 8 - Special Sleeve Tool Dimensions

TORQUE
1 15 Capscrew 772 569
1 16 Capscrew 162 119
* * * *
6 SM 1951 4-00
BODY SYSTEM - Body Control Valve
Section 230-0060
SM - 2464
22
20
13,14
18
13,14 19
23
12
17
24
25 21
26 20
A
11 B
3 28
10
7
5
6
3
8
9
1 3 2
3
4
6
34 35 15,16
36
29 30
31
32
33 38 39
C
E 37 27
D 39
F 36
1 - Control Spool 14 - Capscrew 27 - Cap

2 - Retainer 15 - Shim 28 - Valve Housing
3 - 'O' Ring 16 - Shim 29 - Locknut
4 - Spool Cap 17 - End Cap 30 - Adjusting Screw
5 - Spool Cap 18 - Seal 31 - 'O' Ring
6 - Spring Retainer 19 - Plug 32 - Spring
7 - Spring 20 - Mounting Block 33 - Poppet
8 - Washer 21 - 'O' Ring 34 - Cap
9 - Capscrew 22 - Capscrew 35 - Ring
10 - End Cap 23 - Capscrew 36 - 'O' Ring
11 - Seal Retainer 24 - Lockwasher 37 - Relief Valve
12 - Capscrew 25 - Blanking Plate 38 - 'O' Ring
13 - Pressure Reducing Valve 26 - 'O' Ring 39 - 'O' Ring
Fig. 1 - Exploded View of Body Control Valve
DESCRIPTION front right hand wheel, onto a bracket mounted to the

Numbers and letters in parentheses refer to Fig. 1. frame rail. The main components of the control valve
assembly are a four position control spool (1), relief
The body control valve can be identified as item 3 in valve (37), check valve assembly and valve housing
Section 230-0000, BODY SYSTEM SCHEMATIC. (28).
The single spool body control valve, which is fitted with The position of the control spool is controlled by the
electro hydraulic operation, is mounted behind the body control joystick by means of electrical signals to
SM 1952 4-00 1
Body System - Body Control Valve
Section 230-0060
the pressure reducing valves (13). Refer to Section valve (37) assembly, into the right hand side of control
230-0081, BODY CONTROL JOYSTICK. The body spool (1), unseats check valve plunger, flows out of
control joystick has a pre-feel ramp which controls the port 'D' and into the base end of the cylinders.
current to the pressure reducing valve such that the
pressure into the end cap moves the spool to the Oil returning from the rod end of the cylinders enters
'Power Down' position. Further selection of the control valve housing at port 'C', flows into and out of
joystick, beyond the ramp position, allows full current control spool (1) and into the tank return passage. Oil
to reach the pressure reducing valve such that full pilot exits from port 'B' to the hydraulic oil tank.
pressure is seen in the end cap. Full selection then
occurs and the 'Float' position is achieved. When the body control joystick is released, spring (7)
returns control spool (1) to the 'Hold' position.
The four positions of the control spool are 'Raise',
'Hold', 'Lower' (Power Down) and 'Float'. The 'Float'
position is detented and control spool (1) should be Lower Position (Power Down)
kept in this position at all times, except when Raising Numbers in parentheses refer to Fig. 1.
or Lowering the body.
The 'Lower' or 'Power Down' position is only used to
Control valve housing (28) has six ports as follows: start lowering the body. Once the body has started to
come down, the control joystick should be placed into
Port 'A' - Capped with blanking plate (25). the detented 'Float' position.
Port 'B' - Tank Return Port and return lines from pilot
supply valve and steering priority valve. Oil from the pump enters valve housing (28) at port 'F',
Ports 'C' & 'D' - Body Cylinder Ports. flows around relief valve (37) assembly, into the left
Port 'E' - Fitted with adaptor and connected to hand side of control spool (1), exits from port 'C' and
hydraulic system diagnostic test point. flows into the rod end of the cylinders.
Port 'F' - Supply from main hydraulic pump via steering
priority valve. Oil from the base end of the cylinders enters control
valve housing (28) at port 'D'. The returning oil unseats
Relief valve (37) assembly at the pressure inlet opens check valve plunger and flows into the tank return
and allows oil to flow back to the hydraulic tank when passage. Oil exits from port 'B' to the hydraulic oil tank.
pressure in the hydraulic system exceeds 221 bar
(3 200 lbf/in).
Float Position
OPERATION
Moving the body control joystick to the 'Float' position,
Hold Position moves control spool (1) to a position within the valve
Numbers in parentheses refer to Fig. 1. housing (28) which allows the body to lower by it's own
weight.
When control spool (1) is in the 'Hold' position, oil from
the pump enters port 'F', flows around relief valve (37) In the 'Float' position, because of the design of control
assembly and control spool (1), and out of port 'B' to spool (1), the body cylinder rod and base end ports
the hydraulic tank. Cylinder ports 'C' and 'D' are are connected together at the control valve.
blocked by control spool (1) and oil is trapped between
the control valve and the cylinders. In this position the Oil from the pump enters valve housing (28) at port 'F',
body can be in any partially raised position. flows around relief valve (37) assembly, past control
spool (1), and, if the oil is not required by the cylinders,
exits from port 'B' to the hydraulic oil tank.
Raise Position
Relief Valve
Pushing the body control joystick into the 'Raise' Numbers in parentheses refer to Fig. 1.
position and holding it there, moves control spool (1)
position within the valve housing (28). Relief valve (37) assembly, in valve housing (28), is
set to relieve oil pressure in excess of 221 bar
Oil from the pump enters port 'F', flows around relief (3 200 lbf/in).
2 SM 1952 4-00
Section 230-0060
Should oil at the inlet side of the valve exceed 7. Support body control valve with a suitable lifting
221 bar (3 200 lbf/in), pilot poppet (33) will be forced device and remove mounting hardware securing body
off its seat. Oil will flow through an internal passage control valve to mounting bracket on the frame.
and exit from port 'B' to the hydraulic oil tank. When Remove body control valve from the machine and
pressure is relieved, tension of spring (32) will force transfer to a clean area for disassembly.
pilot poppet (33) to re-seat.
DISASSEMBLY
REMOVAL Numbers and letters in parentheses refer to Fig. 1.
WARNING
WARNINGS Spring loaded parts. Use care when removing
To prevent personal injury and property end cap, retainers and plugs to prevent sudden
damage, be sure wheel blocks, blocking release of spring tension behind these parts.
materials and lifting equipment are properly Personal injury or property damage could
secured and of adequate capacity to do the job result if care is not taken.
safely.
Note: Clean entire control valve assembly with a
Hydraulic fluid pressure will remain suitable solvent and dry thoroughly prior to
within the body hoist system after engine disassembly.
shutdown. To prevent personal injury and
property damage, press and hold down body
hoist bleed down switch and operate the body Valve Body
control joystick continually to relieve pressure 1. If required, remove adaptor and 'O' ring from port 'E'
in the system. in valve housing (28). Discard 'O' ring.
1. Position the vehicle in a level work area, apply the 2. If required, remove bolts (23), lockwashers (24),
parking brake and switch off the engine. blanking plate (25) and 'O' ring (26) from port 'A' in
valve housing (28). Discard 'O' ring (26).
2. Press and hold down body hoist bleed down switch
relieve pressure in the body hoist system. Control Spool
1. Clean the entire body control valve assembly with a
3. Block all road wheels, place the steering lock bar in suitable solvent and dry thoroughly. Remove caps
the 'Locked' position and the battery master switch in from valve housing (28) ports.
the 'Off' position.
2. If required, clamp body control valve assembly in a
4. Remove hydraulic tank anti-spill drain cap, install soft jawed vice. Take care to avoid damaging valve
drain tube connection and drain oil into a suitable housing (28) machined surfaces.
container. Remove drain tube connection and reinstall
cap. 3. Remove capscrews (14) securing pressure
reducing valve (13) from mounting block (20).
5. Clean body control valve housing (28) and Withdraw pressure reducing valve (13) from mounting
surrounding area with a suitable solvent. Identify and block (20).
tag all hydraulic and servo control lines connected to
body control valve, to aid in 'Installation'. 4. Remove capscrews (22) securing mounting block
(20) to end cap (10). Remove mounting block (20) and
6. With suitable containers available to catch spillage, discard 'O' ring (21).
disconnect hydraulic and servo control lines from
control valve. Drain the oil from the lines into the 5. If required, remove plug (19) from mounting block
container and discard all 'O' rings. Cap hydraulic lines (20) and discard 'O' ring (18).
and control valve ports to prevent ingress of dirt.
6. Repeat steps 3 to 5 for opposite end of valve
housing (28), end cap (17).
SM 1952 4-00 3
Section 230-0060
7. Remove capscrews (12) securing end cap (10) to BOTH parts should be replaced by new parts.
valve housing (28). Remove end cap (10).
Note: Do not lap or grind poppet (33) to relief valve
8. Carefully withdraw spool and spring pack assembly (37) assembly.
from valve housing (28). Remove and discard 'O' rings
(3).
ASSEMBLY
Note: 'O' rings (3) can be replaced without Numbers and letters in parentheses refer to Fig. 1.
disassembly of the spring mechanism.
Note: Lightly lubricate all components with hydraulic
9. If necessary, the centring mechanism can be oil. Refer to Section 300-0020, LUBRICATION
removed from the spool assembly. Remove capscrew SYSTEM, for recommended oil specifications.
(9) to release washer (8), spring seats (6), spring (7)
and shims (15 & 16). Note: Tighten all fasteners to standard torques listed
Relief Valve
1. Clean the entire body control valve assembly with a
suitable solvent and dry thoroughly. Remove caps Valve Body
from valve housing (28) ports. 1. If removed, install new 'O' ring (26) on port 'A' of
valve housing (28). Install blanking plate (25) and
2. If desired, clamp body control valve assembly in a secure using bolts (23) and lockwashers (24).
soft jawed vice. Take care to avoid damaging valve
housing (28) machined surfaces. 2. If removed, install new 'O' ring on adaptor and
secure in port 'E' of valve housing (28).
3. Release locking nut (29) and slacken adjusting
screw (30) until loose.
Control Spool
4. Remove cap (34) from valve housing (28) and 1. If required, reassemble spring seats (6), shims
discard 'O' ring (36). (15 & 16), spring (7) and washer (8) and secure
assembly to spool cap (4) using capscrew (9).
5. Withdraw spring (32) and poppet (33) from valve
housing (28) bore. Note: Apply 3 drops of Loctite 243 to the spool cap (4)
threads prior to reassembly.
6. Remove cap (27) from the opposite end of valve
housing (28) and discard 'O' ring (36). 2. Replace 'O' rings (3) on spool and spring pack
assembly.
7. Push out relief valve (37) assembly from bore in
valve housing (28). Discard 'O' rings (38 & 39). 3. Refit spool and spring pack assembly to valve
housing (28).
INSPECTION 4. Install end cap (10) to valve housing (28) and

Numbers in parentheses refer to Fig. 1. secure using capscrews (12).
1. Clean all parts thoroughly and examine for wear 5. If removed, install end cap (17) to valve housing
and/or damage. (28) and secure using capscrews (12).
2. Inspect valve housing (28) bores and control spool 6. If required, install new 'O' ring (18) on plug (19) and
(1) for grooves, deep scratches or excessive wear. refit to mounting block (20).
Note: If condition of valve housing (28) bores or 7. Install new 'O' rings (21) and secure mounting blocks
control spool (1) indicates that they require to be (20) to end caps (10 & 17) using capscrews (22).
replaced, the body control valve should be replaced as
an assembly. 8. Install pressure reducing valves (13) to mounting
blocks (20) and secure using capscrews (14). Tighten
3. If either poppet (33) or relief valve (37) are damaged, capscrews (14) to a torque of 2 Nm (1.5 lbf ft).
4 SM 1952 4-00
Section 230-0060
Relief Valve Note: Be sure to use new 'O' rings with the split flange
1. Install new 'O' rings (38 & 39) on relief valve (37) fittings.
assembly. Install relief valve (37) assembly into relief
valve bore in valve housing (28). 4. Fill hydraulic oil tank with hydraulic oil as specified
in Section 300-0020, LUBRICATION SYSTEM. Refer
Note: Push relief valve (37) assembly fully in until the to Section 230-0040, HYDRAULIC TANK, for hydraulic
snap ring on the outer sleeve locates in the recess in oil levels. Install filler cap on hydraulic tank filler neck.
the relief valve bore.
5. Adjust the system relief valve according to the
2. Install a new 'O' ring (36) on plug (27) and install instructions in 'Adjustments'.
cap (27) in valve housing (28). Tighten plug (27) to a
torque of 40 - 45 Nm (30 - 34 lbf ft).
ADJUSTMENTS
3. Install poppet spring (32) and poppet (33) in cap Numbers in parentheses refer to Fig. 1.
(34). Install a new 'O' ring (36) on cap (34).
Relief Valve Adjustment
4. Install cap (34) assembly, adjusting screw (30) and This type of relief valve is very sensitive to adjustment.
locking nut (29) in valve housing (28) bore. Tighten Relief valve setting and adjustment can be carried out
cap (34) to a torque of 40 - 45 Nm (30 - 34 lbf ft). as follows:
5. Leave adjusting screw loose prior to pressure

setting. Refer to 'Adjustments' for correct pressure WARNING
setting. To prevent personal injury and property
INSTALLATION secured and of adequate capacity to do the job
Numbers in parentheses refer to Fig. 1. safely.
Note: Tighten all fasteners to standard torques listed 1. Position the vehicle in a level work area, apply the
in Section 300-0080, STANDARD BOLT AND NUT parking brake and switch off the engine.
2. Block all road wheels and place steering lock bar in
Note: Tighten all hydraulic lines fitted with ORFS the locked position.
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all 3. Connect a hydraulic gauge, capable of recording a
'O' rings where used. pressure of 0 - 345 bar (0 - 5 000 lbf/in), to remote
diagnostic pressure point.
WARNING 4. Start engine and raise body completely.

damage, be sure wheel blocks, blocking 5. Check reading on pressure gauge. Slacken locking
materials and lifting equipment are properly nut (29) and turn adjusting screw (30) until a pressure
secured and of adequate capacity to do the job reading of 221 bar (3 200 lbf/in) is recorded on the
safely. pressure gauge.
1. Using a suitable lifting device, position body control Note: Turning adjusting screw (30) 'IN' will increase
valve on the machine and secure to mounting bracket relief valve pressure, turning adjusting screw (30)
with mounting hardware as removed at 'Removal'. 'OUT' will reduce relief valve pressure.
2. Reconnect all servo control lines to body control 6. Secure locking nut (29) in place and operate body.
valve, as tagged at 'Removal'. Re-check relief valve pressure and adjust if required.
3. Install new 'O' rings in split flange line fittings and 7. Check body control valve assembly and hydraulic
install all hydraulic lines to body control valve, as lines for leaks. Tighten as required.
tagged at 'Removal'.
8. Remove all blocking from road wheels and place
SM 1952 4-00 5
Section 230-0060
steering lock bar in the stowed position. SERVICE TOOLS

There are no special tools required for the procedures
MAINTENANCE SERVICE TOOLS, for part numbers of general
Relief valve pressure should be checked on a regular service tools and adhesives. These tools and
basis to ensure correct operating pressures are being adhesives are available from your dealer.
maintained. Limited repair of the control valve is with
replacement of parts only.
BODY CONTROL VALVE DIAGNOSIS

CONDITION REASON CHECK AND/OR REMEDY
Valve leaks at 'O' rings Defective 'O' ring Partially pull out control spool and replace the
defective 'O' ring.
Control spool does not Faulty return spring Replace return spring.
return to 'Hold' position Corrosion or contamination Disassemble control spool assembly, clean parts and
replace any worn parts.
System does not build up Defective relief valve Check relief valve pressure. Adjust as required.
pressure
Load drops with control Excessive clearance Replace control valve assembly.
spool in 'Hold' position between control spool and
bore
* * * *
6 SM 1952 4-00
BODY SYSTEM - Body Control Joystick
Section 230-0081
DESCRIPTION SM - 1833
The body control joystick is mounted on the right hand

side dash panel, between the transmission shift 1
controller and the document location. 2
OPERATION
The body control joystick controls the hydraulic control
valve operation, by means of electrical signals to the
pressure reducing valves, which in turn operates the
body hoist cylinders. The four operating positions of
the joystick from front to rear are as follows:
'FLOAT' - The joystick should be moved to this 3

position while the body is lowering by gravity and
should remain in this position until the body must be
operated again. The control joystick should always be
kept in 'FLOAT' while the machine is in motion.
'LOWER' - Pushing the joystick forward and holding it 1 - Body Control 2 - Screw
in this position provides hydraulic force to power-down Joystick 3 - Harness
the body. It is needed when the body cannot be Fig. 1 - Body Control Joystick Installation
started downward from the fully raised position by
gravity. When the body starts lowering by gravity, the
joystick can be released and internal valve springs will MAINTENANCE
move the joystick to the 'HOLD' position. Numbers in parentheses refer to Fig. 1.
'HOLD' - Moving the joystick to this position while the The body control joystick is a non-serviceable item
body is being raised or lowered traps the oil in the and should be replaced completely, if damaged, as
body hoists to stop and hold the body at any desired follows:
height. The joystick will remain in the 'HOLD' position
when released. Note: Tighten all fasteners to standard torques listed
'RAISE' - Pushing the joystick back and holding it in
this position directs oil to extend the body hoists and
raise the body. When released, the joystick will be
WARNINGS
spring-returned to the 'HOLD' position.
Note: The body control lever must remain in the
'FLOAT' position until it is necessary to operate the
body again. Failure to comply to this could result in
safely.
overheating the hydraulic oil and failure of the
hydraulic system components.
Note: A proximity sensor prevents the body being fully
powered down onto the chassis. At a predetermined
height, the sensor automatically defaults the body
control valve to the detented 'FLOAT' condition.
in the system.
Note: If an electrical failure occurs, 12V relay (K37 -
engine signal) ensures the body control valve
automatically defaults to the 'HOLD' condition. The
cause of the electrical fault must be investigated and
corrected. Refer to Section 190-0000, CIRCUIT
DIAGRAMS.
SM 1953 Rev 1 11-00 1

Body System - Body Control Joystick
Section 230-0081
2. Press and hold down body hoist bleed down switch Note: Ensure identifying mark on the body control joystick
and operate the body control joystick continually to casing is orientated towards the rear of the cab.
8. Reconnect harness (3) to connector port on the
3. Block all road wheels, place the steering lock bar in bottom of the body control joystick (1).
the 'Off' position. 9. Place the battery master switch in the 'On' position,
start the engine and bring hydraulic oil to operating
4. Disconnect harness (3) from connector port on the temperature. Operate the body control joystick (1) to
bottom of body control joystick (1). ensure correct operation.
5. Support body control joystick (1) and remove 10. Remove wheel blocks and place the steering lock
screws (2) securing body control joystick (1) to bar in the 'Stowed' position.
mounting bracket on the underside of the right hand
dash panel.
SPECIAL TOOLS
6. Remove body control joystick (1) from mounting There are no special tools required for procedures
location. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
7. Secure new body control joystick (1) to mounting tools required. These tools are available from your
bracket on the underside of the right hand dash panel dealer.
with screws (2).
* * * *
2 SM 1953 Rev 1 11-00

BODY SYSTEM - Pilot Supply Valve
Section 230-0121
SM - 1941
3
15
4
14
26
13
5
12
6
26
23
23 16
19
23
26 22
21
19
20
11
25 10
24
17
19
9 18
19
21 - 'O' Ring
1 - Valve Body 6 - Control Spool 11 - Spacer 16 - Plug 22 - Reducer
2 - Spring Cover 7 - Plug 12 - Pilot 17 - 'O' Ring 23 - Adaptor
3 - 'O' Ring 8 - 'O' Ring 13 - Spring 18 - Adaptor 24 - Bolt
4 - Control Spring 9 - Seat 14 - 'O' Ring 19 - Plug 25 - Lockwasher
5 - Spring Guide 10 - 'O' Ring 15 - Plug 20 - Plug 26 - Tee Piece
Fig. 1 - Exploded View of Pilot Valve
The pilot supply valve can be identified as item 4 in

Section 230-0000, BODY SYSTEM SCHEMATIC. P1 P2
30 bar (435 lbf/in)

Mounted off a bracket on the rear right hand cab leg,
the pilot supply valve is located in the hydraulic servo
control lines between the accumulator and the body
control valve. See Fig. 2 for schematic symbol. T1 T2
45 bar (652 lbf/in)

The pilot supply valve is a direct acting pressure
reducing valve which steps down the supply pressure
to 30 bar (435 lbf/in). Intregal of the pilot supply valve U1 U2
is a relief valve which opens at 45 bar (652 lbf/in).
Fig. 2 - Pilot Supply Valve Schematic Symbol
SM 1954 4-00 1
Body System - Pilot Supply Valve
Section 230-0121
REMOVAL 3. Remove plug (7) and 'O' ring (8) from valve body
Numbers in parentheses refer to Fig. 1. (1). Remove valve seat (9), 'O' ring (10) and spacer
(11) from valve body (1). Discard 'O' rings (8 & 10).
WARNINGS 4. Remove adaptor (18) and 'O' ring (17) from valve
To prevent personal injury and property body (1). Discard 'O' ring (17). If necessary remove
damage, be sure wheel blocks, blocking plug (19) from adaptor (18).
secured and of adequate capacity to do the job 5. Remove spring guide (15) and 'O' ring (14) from
safely. valve body (1). Discard 'O' ring (14).
Hydraulic fluid pressure will remain 6. Withdraw spring (13) and pilot (12) from valve body (1).
shutdown. To prevent personal injury and 7. Remove spring cover (2) and 'O' ring (3) from valve
property damage, press and hold down body body (1). Discard 'O' ring (3).
control joystick continually to relieve pressure 8. Withdraw control spring (4), spring guide (5) and
in the system. control spool (6) from valve body (1).

parking brake and switch off the engine. INSPECTION
and operate the body control joystick continually to 1. Clean all parts with a suitable solvent and dry with
relieve pressure in the body hoist system. compressed air.
3. Block all road wheels, place the steering lock bar in 2. Check ports threads and make sure they are not
the 'Locked' position and the battery master switch in damaged or stripped.
the 'Off' position.
3. Check valve seat (9), pilot (12), control spool (6)
4. Remove hydraulic tank anti-spill drain cap, install and spring guide (5). Ensure they are not worn,
drain tube connection and drain oil into a suitable nicked, cracked or scored.
container. Remove drain tube connection and reinstall
cap.
ASSEMBLY
5. Clean pilot valve (1) and surrounding area with a Numbers in parentheses refer to Fig. 1.
suitable solvent. Ensure all hydraulic lines connected
to pilot valve (1) are identified for ease of installation 1. Install new 'O' ring (3) to spring cover (2). Install
and, with suitable containers available to catch control spool (6), spring guide (5) and control spring
leakage, disconnect hydraulic lines. Fit blanking caps (4) into its bore in valve body (1).
to all open lines.
2. Install pilot (12) and spring (13) into its bore in valve
6. Remove bolts (24) and lockwashers (25) securing body (1). Install new 'O' ring (14) to spring guide (15)
pilot valve (1) to mounting bracket. Remove pilot valve and install in valve body (1).
(1).
3. Install new 'O' ring (8) to plug (7). Install spacer
(11), new 'O' ring (10) and valve seat (9) into its bore
DISASSEMBLY in valve body (1). Install plug (7) in valve body (1).
4. Install new 'O' ring (17) to adaptor (18). Install
1. Note location of tee pieces (26) and adaptors (23) adaptor (18) in valve body (1). If removed, install plug
and remove from valve body (1) and reducer (22). (19) in adaptor (18).
2. Remove reducer (22) and 'O' ring (21) from valve 5. Install new 'O' ring (21) to reducer (22). Install
body (1). Discard 'O' ring (21). reducer (22) in valve body (1).
2 SM 1954 4-00
BODY SYSTEM - Pilot Supply Valve
Section 230-0121
6. Install adaptors (23) and tee pieces (26) in valve 3. Fill hydraulic oil tank with hydraulic oil as specified
body (1) and reducer (22). in Section 300-0020, LUBRICATION SYSTEM. Refer
to Section 230-0040, HYDRAULIC TANK, for hydraulic
oil levels. Install filler cap on hydraulic tank filler neck.
INSTALLATION
Numbers in parentheses refer to Fig. 1. 4. Place the battery master switch in the 'On' position,
start the engine and bring hydraulic oil to operating
Note: Tighten all fasteners to standard torques listed temperature.
TORQUE SPECIFICATIONS. 5. Check pilot valve (1) and hydraulic line connections
for leaks and tighten as required.
connections, as described in Section 230-0000, BODY 6. Remove all blocking from road wheels and place
SYSTEM SCHEMATIC. Renew all 'O' rings where steering lock bar in the stowed position.
used.
1. Secure pilot valve (1) to mounting bracket with bolts SPECIAL TOOLS
(24) and lockwashers (25). There are no special tools required for procedures
2. Remove blanking caps from hydraulic lines and SERVICE TOOLS, for part numbers of general service
install lines to pilot valve (1) as identified during tools required. These tools are available from your
removal. dealer.
* * * *
SM 1954 4-00 3
BODY SYSTEM - Body Cylinder
Section 230-0130
SM - 2468
20 21 23 7 22,6 17,18 9 4 5 11 14 13 14 18 19 23 21 20
3 10 1 16 12 15
BODY MOUNTING FRAME MOUNTING

26
28
GROOVE 27
THIS SIDE
26
ORIENTATION OF 25
CUSHION SLEEVE
25
29
24 28 27
1 - Cylinder Body 8 - 'O' Ring 15 - Grub Screw 22 - Nylon Ring

2 - Piston Rod 9 - 'O' Ring 16 - 'O' Ring 23 - Lube Fitting
3 - End Cap 10 - Lock Ring 17 - Back Up Ring 24 - Upper Pin
4 - Cushion Sleeve 11 - Cushion Spear 18 - Cushion Sleeve 25 - Spacer
5 - Circlip 12 - Piston 19 - Circlip 26 - Bolt
6 - Rod Seal 13 - Piston Seal 20 - Spherical Bearing 27 - Lockwasher
7 - Wiper 14 - Wear Ring 21 - Circlip 28 - Washer
29 - Lower Pin
Fig. 1 - Sectional View Of Body Cylinder and Mounting
DESCRIPTION REMOVAL
The body cylinders can be identified as item 5 in

Section 230-0000, BODY SYSTEM SCHEMATIC. WARNINGS
There are two single stage, double acting body hoist damage, be sure wheel blocks, blocking
cylinders, cushioned at both ends of the stroke on the materials and lifting equipment are properly
vehicle. The cylinder base end is connected to the secured and of adequate capacity to do the job
trailer frame and piston rod (2) end is connected at the safely.
body. Single stage double acting means that piston
rod (2) can have oil applied to either side, extending or Hydraulic fluid pressure will remain
retracting the piston rod. within the body hoist system after engine
Cylinder mounting is by pins (24 & 29), spacers (25) property damage, press and hold down body
and spherical bearings (20) secured in place with hoist bleed down switch and operate the body
circlips (21). Spherical bearings (20) permit a limited control joystick continually to relieve pressure
amount of cylinder misalignment. in the system.
SM 1956 4-00 1
Body System - Body Cylinder
Section 230-0130
DISASSEMBLY
WARNING Numbers in parentheses refer to Fig. 1.
Exercise extreme caution when lowering
the cylinders from the body. The cylinders will
swing out sharply as they leave their WARNING
mountings. To prevent personal injury and property
1. Position the vehicle in a level work area, ensure the secured and of adequate capacity to do the job
body is fully lowered, apply the parking brake and safely.
switch off the engine.
1. Ensure clean working conditions, remove any port
2. Press and hold down body hoist bleed down switch plugs thus allowing easy entry of air into cylinder body
and operate the body control joystick continually to (1), preventing a vacuum when parts are withdrawn
relieve pressure in the body hoist system. from cylinder body (1).
3. Block all road wheels, place the steering lock bar in 2. Remove circlips (21) from base end of cylinder body
the 'Locked' position and the battery master switch in (1) and piston rod (2) end. Press out spherical bearings
the 'Off' position. (20).
4. Install a suitable strap around the cylinder and 3. Remove lock ring (10) from end cap (3).
attach to a lifting device.
4. Using special tool which can be fabricated as shown
5. Position a suitable container at the base end of one in Fig. 2, unscrew end cap (3) until thread is
cylinder. Identify and remove the hydraulic lines. Cap disengaged from cylinder body (1).
hydraulic lines and cylinder ports to prevent entry of
dirt. 5. Support piston rod (2) at the rod eye and withdraw
piston rod (2) from cylinder body (1). Ensure centre
6. Remove bolt (26), lockwasher (27), washer (28) and lines of piston rod (2) and cylinder body (1) remain
upper pin (24) connecting piston rod (2) end of the coincidental during removal of piston rod (2).
cylinder to the body.
6. Place piston rod (2) on supports which will not
7. Lower cylinder slowly and remove spacers (25). damage the piston rod diameter.
Note: Cylinder will swing out sharply as it leaves its 7. Remove and discard piston seals (13) and wear
mounting. rings (14) from piston (12).
8. Remove bolt (26), lockwasher (27), washer (28) and 8. Remove grub screw (15) from wear ring (14) groove
lower pin (29) connecting base end of the cylinder to in piston (12).
the frame.
9. Provide an anti-torsion device through piston rod (2)
9. Remove spacers (25) and remove cylinder assembly eye to allow unscrewing of piston (12). Using special
to a clean area for disassembly. tool which can be fabricated as shown in Fig. 3,
unscrew piston (12) from piston rod (2).
10. Repeat steps 4 through 9 for opposite cylinder.
10. Remove cushion spear (11) and 'O' rings (16) from
piston rod (2). Discard 'O' rings (16).
11. Remove cylinder end cap (3) from piston rod (2).
Remove and discard cushion sleeve (4), circlip (5), rod
seal (6), nylon ring (22), wiper (7), 'O' rings (8 & 9) and
back up ring (17).
2 SM 1956 4-00
Section 230-0130
INSPECTION 6. Ensure cushion sleeve (18) and circlip (19) are

Numbers in parentheses refer to Fig. 1 secure in piston (12).
1. Clean all parts of the cylinder with a suitable solvent 7. Insert new piston seal (13) and new wear rings (14)
and dry with clean, lint-free cloths. Clean all grooves in piston (12).
carefully to remove any foreign material.
8. Fully grease piston (12) OD and 'O' rings (8 & 9) in
2. Check cylinder body (1) and outer diameter of piston end cap (3).
(12) for scratches, cracks or other defects. Remove
ridges, nicks and scratches with a fine stone and re- 9. Sling assembled piston rod (2) in a manner to allow
clean. Replace any components which cannot be careful leading of the assembled piston rod into
repaired. cylinder body (1). Take care not to damage piston seal
(13) on cylinder body (1) threads.
3. Inspect piston rod (2) for distortion, cracks or other
defects. Replace piston rod if defective area is 10. After piston (12) is inserted in cylinder body (1), push
irreparable. the piston rod assembly into cylinder body (1) maintaining
coincidental centre lines of piston rod and cylinder body.
4. Check spherical bearing (20) for wear and replace if
necessary. 11. Before piston rod (2) is fully home and, with slings
still taking some of piston rod (2) weight, engage end
cap (3) thread and screw home.
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 12. Push piston rod (2) to the fully retracted position and
tighten end cap (3) to a torque of 237 Nm (175 lbf ft).
WARNING 13. Re-drill end cap (3) for lock ring (10), 3 x 12 mm
To prevent personal injury and property (0.125 x 0.50 in) deep, if necessary. Insert lock ring
damage, be sure lifting equipment is properly (10) in end cap (3).
safely.
INSTALLATION
1. Press spherical bearing (20) in base end of cylinder Numbers in parentheses refer to Fig. 1.
body (1) and piston rod (2) end. Secure spherical
bearings (20) with circlips (21). Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY
2. Install new cushion sleeve (4), circlip (5), rod seals (6), SYSTEM SCHEMATIC. Renew all 'O' rings where used.
nylon ring (22), 'O' rings (8 & 9) and back up (17) in end cap
(3). Load end cap (3) over piston rod (2) thread, taking care
not to damage rod seal (6) on the thread. WARNING
3. Install new 'O' rings (16) on piston rod (2) and damage, be sure lifting equipment is properly
replace cushion spear (11). secured and of adequate capacity to do the job
safely.
4. Apply Loctite 243 to first two threads of piston (12).
Using special tool which can be fabricated as shown in 1. Install a suitable strap around the cylinder and
Fig. 3, screw on piston (12) and tighten to a torque of position cylinder on unit with base end of cylinder ready
1 356 Nm (1 000 lbf ft). for mounting.
5. Insert piston grub screw (15) through wear ring (14) 2. Install spacers (25) in base end of cylinder and
groove in piston (12) and into groove machined in insert lower pin (23) through mounting bores, spacers
piston rod (2). Tighten grub screw (15) to a torque of 49 (25) and cylinder. Secure lower pin (23) with washer
Nm (36 lbf ft). Ensure the extreme of grub screw (15) is (28), lockwasher (27) and bolt (26). Tighten bolt (26) to
below the level of wear ring (14) groove. a torque of 66 Nm (49 lbf ft).
SM 1956 4-00 3
Section 230-0130
3. Install spacers (25) in rod end of cylinder, align start the engine, operate the body and check cylinder lines
spherical bearing with bores in body and install upper for leaks. Tighten lines and fittings as required.
pin (24) through mounting bores, spacers (25) and
cylinder. Secure upper pin (24) with washer (28), 8. Remove wheel blocks from road wheels.
lockwasher (27) and bolt (26). Tighten bolt (26) to a
MAINTENANCE
4. Connect the hydraulic oil lines to the cylinder ports Every 50 hours: Lubricate cylinder pins as described
as tagged during removal. in Section 300-0020, LUBRICATION SYSTEM. Inspect
cylinders for leaks, if leaks are found, replace seals
5. Lubricate pins at lube fittings (22) with lubricant as with seals contained in the Service Repair Kit, as
specified in Section 300-0020, LUBRICATION SYSTEM. specified in the parts book.
6. Check oil level in hydraulic tank and add if low.

Refer to Section 230-0040, HYDRAULIC TANK, for SPECIAL TOOLS
correct fill level. Refer to Section 300-0020, Special tools can be fabricated as shown in Figs. 2 & 3.
LUBRICATION SYSTEM, for the type of oil used. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools are
7. Place the battery master switch in the 'On' position, available from your dealer.
SM - 2469
50 25
160 (6.299) (1.9680) (0.984)
90 (3.54) 10
DRILL 13 (0.51) 11
RAD (0.394)
X 25 (0.984) (0.433)
DEEP
10 (0.394)
RAD TYP
150 (5.90) DIA
110 (4.33) DIA

120 (4.724)
(3.154 - 0.000 )
(4.724 - 0.005 )
+0.002
120.00 - 0.13
(1.9680)
80.10 - 0.00
+0.05
94 (3.7)
+
50
+
19 (0.75)
SQUARE
SECURE ALUMINIUM FIT 2 OFF B&T BUSH 12 (0.472) ID

COLLAR WITH (3) M8 25 65 18 (0.708) OD AND 2 OFF 12 DIA DOWEL
CAP SCREWS (0.984) (2.560) DRIVE FIT IN BUSH
110 (4.33)
Fig. 2 - End Cap Torque Tool
4 SM 1956 4-00
Section 230-0130
SM - 2470
89 (3.5)
38.1 (1.5)
(0.375)
9.525
DIA
(0.470)
11.938
124.45 - 0.000 (4.899 - 0.000 )
+0.005
DIA
90 - 0.05 (3.543 - 0.002 )
SILVER STEEL
136 (5.35)
+
25.4 (1.0)
SQUARE
+0.13
+
(0.500)
12.7
EN3B
DIA
MILD STEEL
OUTER SHELL TO BE SECURED DOM TUBE

TO INNER BODY WITH 2BA CAP SCREWS 10.16 25.4
(0.4) (1.0)
Fig. 3 - Piston Torque Tool

TORQUE
1 3 End Cap 237 175
1 12 Piston 1 356 1 000
1 15 Grub Screw 49 36
1 26 Bolt 66 49
* * * *
SM 1956 4-00 5
CLICK HERE FOR
HORIZONTAL
DRAWING
BRAKING SYSTEM - Air Braking System Schematic

Section 250-0000
SM - 2446
17
D
E
F
C
14
3
10
13
7
4
19
15
2
18
11
1
19
F
C B A
E
7
7
D
D
B
8
C
A
B
TOP OF TRANS
TO RETARDER
A
DIAGNOSTIC PLATE
CONTROL ON
13
14
12
16
20 17
1 - Fan Clutch 8 - Park/Emergency Control Valve 15 - Parking Brake Actuator

2 - Air Compressor 9 - Pressure Protection Valve 16 - Solenoid Valve
3 - Air Drier and Purge Tank Kit 10 - Rear Brake Tank 17 - Differential Lock Cylinder
4 - Treadle Valve 11 - Relay Emergency Valve 18 - Levelling Valve
5 - Primary Tank 12 - Air Solenoid 19 - Air Spring
6 - Front Brake Tank 13 - Pressure Converter 20 - Regulating Valve
7 - Drain Cock 14 - Air Breather
Fig. 1 - Air Braking System Schematic
SM 1948 4-00 1
Braking System - Air Braking System Schematic
Section 250-0000
DESCRIPTION Solenoid Valve (16) - When the solenoid valve is

The air brake system is an integral part of the service activated by the differential lock switch, air pressure
brake system. The system is used to supply air from the primary tank is directed to the differential lock
pressure for operating the front and rear pressure cylinders. The valve also exhausts air pressure from
converters which in turn, actuate the front and rear the differential lock cylinders.
brake hydraulic systems for applying the disc brakes.
The air system also supplies pressure for operating air Differential Lock Cylinders (17) - There are two
actuated accessories such as the transmission and differential lock cylinders on each machine. One
inter-axle differential locks, fan clutch, transmission mounted on the frame, adjacent to the transmission
retarder and the suspension system. and the other integral with the centre differential. When
actuated, the cylinders lock the transmission and inter-
The safety air brake system on the machine has the axle differentials. The transmission differential lock
following features: requires air pressure to hold it 'Off', whereas, the
centre axle differential lock requires pressure to hold it
1. Low air pressure warning light which illuminates 'On'.
when air pressure drops below 4.1 bar (60 lbf/in).
Levelling Valve (18) - Maintains the front suspension
2. Automatic brake apply when system air pressure at the proper ride height. Refer to Section 180-0022,
falls below 3.1 bar (45 lbf/in). LEVELLING VALVE, for detailed operating and
servicing procedures.
3. Separate front and rear braking circuits with
individual warning lights to warn if system pressure Air Springs (19) - Expand or retract according to the
falls. A buzzer also sounds when pressure falls. air flow from the levelling valve. Refer to Section
180-0021, AIR SPRING, for detailed operating and
4. Service brake apply to temporarily hold the machine servicing procedures.
stationary by moving the park/emergency control valve
lever into the 'EMERGENCY' position. When parking Differential Lock Warning Light (Amber) -
the machine for an extended period of time apply the Illuminates when the differential lock switch is
parking brake. activated to the 'ON' position to indicate transmission
and inter-axle differential locks are applied.
5. Air released - spring applied parking brake
controlled by the park/emergency control valve. Note: Refer to operators handbook for location and
Parking brake is applied when the control valve lever identification of warning light.
is in the 'PARK' position.
Air Pressure Gauge - Located on the instrument
6. Pressure converters which are equipped with an panel it indicates system air pressure.
overstroke indicator.
OPERATION
AIR SYSTEM AUXILIARY COMPONENTS Numbers in parentheses refer to Figs. 1.
Air from the engine driven air compressor (2) travels
The following is a list of auxiliary components used in through air drier kit (3) and into primary tank (5) and
the air system, with a brief description of each: front brake tank (6) via pressure protection valve (9).
Primary tank (5) is the outside tank positioned at the
Kysor DST Fan Clutch (1) - Direct temperature front left-hand side of the tractor frame.
sensing fan. Refer to Section 110-0040, KYSOR DST
FAN, for detailed operating and servicing procedures. Air is supplied to the suspension system levelling
valve (18) and coolant sensor valve from port 'F' in the
Pressure Protection Valve (9) - Supplies air to all primary tank (5). Air is supplied to solenoid valve (16)
three air tanks for the service brakes, secondary and regulating valve (20) via port 'D' in the primary
braking and accessory devices. Refer to Section tank (5). If air pressure in primary tank (5) falls below
250-0290, PRESSURE PROTECTION VALVE, for 4.1 bar (60 lbf/in), low pressure switch fitted in port 'A'
detailed operating and servicing procedures. sends a signal and the low pressure warning light
illuminates in the cab.
2 SM 1948 4-00
Section 250-0000
Air compression is controlled by unloader valve on air Treadle Valve (4) - Directs and controls air to the front
drier (3) stopping and starting delivery of air from air pressure converter and rear relay emergency valve
compressor (2), when maximum 8.4 bar (122 lbf/in) which controls air delivery to the rear pressure
and minimum 6.5 bar (95 lbf/in) pressures are converter. Refer to Section 250-0070, TREADLE
reached. VALVE, for detailed operating and servicing
procedures.
The pressure in the system should not exceed 8.4 bar
(122 lbf/in) if the system is operating normally. Air Tanks (5, 6 & 10) - Store compressed air until it is
However, if unloader valve malfunctions and the needed for brake or accessory operation. Brake tanks
pressure continues to rise, safety valve on air drier (3) maintain an air supply for normal brake application. Air
will open to protect the air system by relieving the pressure in the tanks is indicated on the air system
pressure at 10.7 bar (155 lbf/in). pressure gauge on the instrument panel in the
operators compartment. Refer to Section 250-0170,
AIR TANKS AND MOUNTING, for detailed operating
Suspension System and servicing procedures.
The suspension ride height is maintained by levelling
valve (18) controlling air flow to or from air springs Park/Emergency Control Valve (8) - In the
(19). If the ride height drops then air will flow from 'EMERGENCY' position, it controls air pressure
levelling valve (18) and into air springs (19). When the delivery to the rear relay emergency valve for
proper ride height is reached the lever on levelling actuation of the rear pressure converter to apply the
valve (18) shuts off the air flow to air springs (19). rear brakes and also exhausts the air from the spring
Refer to Section 180-0021, AIR SPRING and applied parking brake actuator, to apply the parking
Section 180-0022, LEVELLING VALVE. brake in an emergency. In the 'PARK' position it
continues to exhaust the air from the spring applied
parking brake actuator, keeping the parking brake
Differential Lock applied, and also exhausts air pressure from the rear
When the differential lock switch in the operators relay emergency valve releasing the rear brakes.
compartment is activated, solenoid valve (16) will open Refer to Section 250-0190, PARK/EMERGENCY
allowing air from primary tank (5) to flow through the CONTROL VALVE, for detailed operating and
valve and into differential lock cylinders (17). This servicing procedures.
applies the transmission and inter-axle differential
locks. Deactivating the differential lock switch releases Relay Emergency Valve (11) - Speeds the application
the differential locks. and release of air pressure converter. Automatically
applies rear service brakes when emergency line
pressure falls to approximately 3.1 bar (45 lbf/in).
AIR BRAKING SYSTEM COMPONENTS Refer to Section 250-0280, RELAY EMERGENCY
Numbers in parentheses refer to Fig. 1. VALVE, for detailed operating and servicing
procedures.
The following is a list of air control devices in the air
safety brake system, with a brief description of each: Pressure Converters (13) - Apply pressure to front
and rear brake hydraulic systems to operate wheel
Air Compressor (2) - Delivers air, through the air drier brakes when energized with air pressure directed by
kit, to the air tanks to operate the pressure converters the treadle valve or park/emergency control valve.
and air operated accessories. The air compressor is Refer to Section 250-0260, PRESSURE
mounted on the engine and has a capacity of CONVERTER, for detailed operating and servicing
6.23 litres/s (13.2 ft/min). procedures.
Air Drier and Purge Tank Kit (3) - Filters the air from Air Breather (14) - There are two non-pressurised air
the compressor to remove any oil and moisture in the breathers used in the air brake system, one on each of
air system. The intregal unloader valve controls supply the brake pressure converters. Air displaced on the
of air to the system, by stopping and starting delivery atmospheric side of the air piston in the pressure
of air by the compressor when maximum and converter exhausts through the air breather. Refer to
minimum pressures are reached. Refer to Section Section 250-0270, AIR BREATHER, for detailed
250-0200, AIR DRIER, for detailed operating and operating and servicing procedures.
servicing procedures.
SM 1948 4-00 3
Section 250-0000
Parking Brake Actuator (15) - Applies disc type compressor (2) when maximum 8.4 bar (122 lbf/in)
parking brake when park/emergency control valve and minimum 6.5 bar (95 lbf/in2) pressures are
lever is moved into the 'PARK' position by exhausting reached.
the air in the actuator.
The pressure in the system should not exceed
Brake Light Switch - Turns on the brake lights when 8.4 bar (122 lbf/in) if the system is operating normally.
the brakes are applied. However, if unloader valve malfunctions and the
pressure continues to rise, safety valve on air drier (3)
will open to protect the air system by relieving the
Warning Lights (Air System) pressure at 10.7 bar (155 lbf/in).
The following warning lights are controlled by pressure
switches and are located on the warning light panels in
the operators compartment: Service Brake
Depressing treadle valve (4) allows air to flow directly
Note: Refer to operators handbook for location and from front brake tank (6) into the air chamber part of
identification of warning lights. front pressure converter (13). This applies pressure to
the brake hydraulic fluid to apply the front service
Low Brake Air Pressure (Red) - Illuminates if air brakes. At the same time, air flows through the service
pressure falls below approximately 4.1 bar (60 lbf/in2). ports of rear relay emergency valve (11). This causes
If light illuminates while operating, stop the machine, rear relay emergency valve (11) pistons to move and
apply the parking brake and do not operate until the unseat their inlet valves allowing the air from rear
fault has been corrected. brake tank (10) to flow into the air chamber part of rear
pressure converter (13). This applies pressure to the
Parking Brake (Green) - Illuminates until the park/ brake hydraulic fluid to apply the rear service brakes.
emergency control lever is placed in either the
'EMERGENCY' or 'RELEASE' positions indicating that The amount of air that flows to pressure converters
the parking brake is released. (13) depends on how far treadle valve (4) pedal is
depressed. The farther the pedal is depressed the
Tractor Brakes Overstroke (Red) - Illuminates if the greater the air pressure released by relay emergency
front brake system pressure is low. A buzzer also valve (11), and the greater the braking force.
sounds. If light illuminates, stop the machine and
investigate the cause. The brakes are released when the treadle pedal is
released. Application pressure is exhausted through
Trailer Brakes Overstroke (Red) - Illuminates if the relay emergency valve (11) exhaust port. Air pressure
rear brake system pressure is low. A buzzer also is exhausted through treadle valve (4) exhaust port.
sounds. If light illuminates, stop the machine and
investigate the cause.
Park/Emergency Control Valve
Air line from port 'E' on primary tank (5) directs a constant
OPERATION supply of air to park/emergency control valve (8), via
Numbers in parentheses refer to Fig. 1. pressure protection valve (9), from primary tank (5).
Air from the engine driven air compressor (2) travels With park/emergency control valve (8) lever in the
through air drier kit (3) via pressure protection valve 'RELEASE' position, air flows from ports 'A' and 'C'.
(9) and into all three air tanks (5, 6 & 10). The air from port 'A' flows to parking brake actuator
(15), preventing the spring in the actuator from
Air flows from primary tank (5) to the park/emergency applying the parking brake. The air from port 'C' flows
brake valve (8). Air from front brake tank (6) flows to to the emergency port of rear relay emergency valve
the supply port of treadle valve (4), and, to port '21' of (11). For operation of relay emergency valve, refer to
pressure protection valve (9). The rear brake tank (10) Section 250-0280, RELAY EMERGENCY VALVE. The
supplies air to the rear relay valve (11). Air is supplied park/emergency control lever should always be in the
to the auxiliary components via port '23' of the 'RELEASE' position when driving the machine.
pressure protection valve (9).
With park/emergency control valve (8) lever in the
Air compression is controlled by unloader valve on air 'EMERGENCY' position, port 'B' is vented through port
drier (3) stopping and starting delivery of air from air 'C'. This allows the air in the lines from brake tank (10)
4 SM 1948 4-00
Section 250-0000
to flow into the air chamber part of rear pressure 5. Never exceed recommended pressure and always
converter (13). This applies pressure to the brake wear safety glasses when working.
hydraulic fluid to apply the rear service brakes. At the
same time, port 'A' is vented through port 'C', allowing 6. Never attempt to disassemble a component until
the spring in parking brake actuator (15) to apply the you have read and understood recommended
parking brake. The air from port 'C' flows to the procedures. Some components contain powerful
emergency port of relay emergency valve (11). For springs and injury can result if not properly
operation of relay emergency valve, refer to Section disassembled. Use only proper tools and observe all
250-0280, RELAY EMERGENCY VALVE. The safety precautions pertaining to use of those tools.
'EMERGENCY' position should only be used in an
EMERGENCY. For normal brake operation use the 7. Use only genuine factory replacement parts and
treadle valve. components.
With the park/emergency control valve (8) lever in the a) Only components, devices and mounting and
'PARK' position, port 'A' continues to vent through port attaching, specifically designed for use in hydraulic
'C' keeping the parking brake applied. At the same brake systems, should be used.
time, air is exhausted from the rear pressure converter
releasing the rear service brakes. b) Replacement hardware, tubes, lines, fittings, etc.
should be of equivalent size, type and strength as the
original equipment.
Automatic Brake Application
The first indication of a loss of air pressure in the 8. Devices with stripped threads or damaged parts
system is that the low air pressure warning light on the should be replaced. Repairs requiring machining
instrument panel will illuminate when the pressure falls should not be attempted.
below 4.1 bar (60 lbf/in ). If the pressure falls below
3.1 bar (45 lbf/in), relay emergency valve (11) opens
and allows the air in the line from rear brake tank (10) BRAKE FUNCTION CHECKS
to flow into the air chamber part of rear pressure
converter (13). This applies pressure to the brake
hydraulic fluid to apply the rear service brakes.
WARNING
Make sure the area around the machine is clear
BRAKE SYSTEM SAFETY PRECAUTIONS of personnel and obstructions before carrying
When working on or around brake systems and out these checks.
components, the following precautions, should be
observed: Note: The following checks are not intended to
measure maximum brake holding ability. If NEW brake
1. Always block vehicle wheels. Stop engine when pads are fitted, they MUST be burnished as per the
working under a vehicle. Keep hands away from manufacturers recommendations before carrying out
actuator push rods and slack adjusters; they may the checks.
apply as air system pressure drops.
Service Brake Holding Ability
2. Always carry out ALL servicing operations in
1. Depress service brake treadle pedal and move
conjunction with WARNINGS and procedures outlined
transmission gear shift selector to 1st gear.
in the individual component sections.
2. Move park/emergency control lever to
3. Always ensure there is no pressure in the air
'EMERGENCY' position, then move to 'RELEASE'
system before attempting to replace brake pads or
position.
shoes; the brakes will automatically apply as air
pressure drops.
3. Depress accelerator control and accelerate engine
to 1 350 rev/min. The machine should not move.
4. Never connect or disconnect a pipe or line
containing pressure; it may whip. Never remove a
4. Decelerate engine, shift transmission to 'NEUTRAL'
component or pipe plug unless you are certain all
and apply the parking brake before releasing the
system pressure has been released.
service brake.
SM 1948 4-00 5
Section 250-0000
Emergency Brake Holding Ability

1. Move park/emergency control lever to WARNING
'EMERGENCY' position and move transmission gear If the machine moves during the above
shift selector to 1st gear. checks, stop the machine, apply the parking
brake and do not operate until the fault has
2. Depress accelerator control and accelerate engine been corrected.
to 1 350 rev/min. The machine should not move.
3. Decelerate engine, shift transmission to 'NEUTRAL' MAINTENANCE

and apply the parking brake.
General
Perform all maintenance as outlined in individual air
General component sections, at the service intervals specified
Note: Brake holding effort required to hold a machine in those sections.
stationary at a specific rev/min can vary from machine
to machine due to differences in engine performance,
powertrain efficiency, etc., as well as differences in Every Year
brake holding ability. Check accuracy of air pressure gauge on the
instrument panel with a test gauge. Replace if
Note: As an indication of system deterioration, the difference is more than 0.3 bar (5 lbf/in).
engine rev/min at which point the machine moved, with
the service or emergency brakes applied, can be
compared against the engine rev/min your specific
machine was able to hold to on a previous check.
BRAKING SYSTEM DIAGNOSIS

Inadequate braking Low air pressure in brake system Trace brake lines by referring to Fig. 1.
only Install a test gauge at various points in the
system to determine location of trouble. Test
operation of faulty components as outlined in
air brake control component sections. Repair
or replace, as recommended. Check brake air
lines for leaks.
Treadle valve delivery pressure Check operation of air compressor, air drier,
below normal unloader and safety valve. Check air lines for
leaks.
Brake pads need replaced Refer to Section 165-0010, BRAKE PARTS.
Brakes do not apply No air pressure in break system Trace brake lines by referring to Fig. 1. Install
with normal treadle a test gauge at various points in the system to
valve application to determine location of trouble. Test operation
of faulty component as outlined in air brake
control component sections. Check brake air
lines for leaks.
Restricted or broken tubing or hose Replace tubing or hose line.
line
6 SM 1948 4-00
Section 250-0000
BRAKING SYSTEM DIAGNOSIS (Continued)

Brakes do not apply Defective treadle valve Repair or replace faulty component as
with normal treadle recommended in Section 250-0070, TREADLE
valve application VALVE.
Defective relay emergency valve Repair or replace faulty component as
recommended in Section 250-0280, RELAY
EMERGENCY VALVE.
Brakes apply too Low air pressure in the brake system Trace brake lines by referring to Fig. 1. Install
slowly a test gauge at various points in the system to
determine location of trouble. Test operation
of faulty component as outlined in air brake
control component sections. Repair or replace,
as recommended. Check brake air lines for
leaks.
Treadle valve delivery pressure Check operation of air compressor, air drier
below normal unloader valve and safety valve. Check air lines
for leaks.
Excessive leakage with brakes Trace brake lines by referring to Fig. 1. Install a
applied test gauge at various points in the system to
determine location of trouble. Test operation of
faulty component as outlined in air brake control
component sections. Repair or replace, as
recommended. Check brake air lines for leaks.
Restriction in tubing or hose line Replace tubing or hose lines.
Brakes do not Defective pressure converter Repair or replace faulty component as
release recommended in Section 250-0260, PRESSURE
CONVERTER.
Treadle valve not in fully released Repair or replace faulty component as
position recommended in Section 250-0070, TREADLE
VALVE.
Restriction in tubing or hose line Replace tubing or hose lines.
Brakes grab or pull Faulty operation of one or more Trace brake lines by referring to Fig. 1. Install a
brake air control components test gauge at various points in the system to
faulty component as outline in air control
Calliper pistons binding Check calliper operation as described in
Section 165-0010, BRAKE PARTS.
Air pressure too Pressure gauge registering Replace gauge and/or gauge sender unit.
high incorrectly
Faulty air drier, unloader valve Repair of replace faulty component. Refer to
Section 250-0200, AIR DRIER.
SM 1948 4-00 7
Section 250-0000

Air pressure too low Pressure gauge registering Replace gauge and/or gauge sender unit.
incorrectly
Defective compressor Repair or replace air compressor. Refer to
ENGINE MAINTENANCE MANUAL.
Excessive leakage. Trace brake lines by referring to Fig. 1. Install
test gauge at various points in the system to
Air tank drain cock open or leaking Tighten or install new drain cock.
Faulty air drier unloader valve Repair or replace air drier unloader valve. Refer
to Section 250-0200, AIR DRIER.
Compressor knocks Excessive backlash in drive gears or Correct backlash. Refer to ENGINE
continuously or drive coupling MAINTENANCE MANUAL.
intermittently Worn or burnt out bearings Replace faulty components or compressor.
refer to ENGINE MAINTENANCE MANUAL.
Excessive carbon deposits in Remove the compressor head and clean. Refer
compressor cylinder head to ENGINE MAINTENANCE MANUAL.
Brakes release too Defective pressure convertor Repair or replace faulty component as
slowly recommended in Section 250-0260, PRESSURE
CONVERTOR.
Treadle valve not returning to fully Repair or replace faulty component as
released position recommended in Section 250-0070, TREADLE
VALVE.
Exhaust port of treadle valve or relay Repair or replace faulty component as
valve restricted or plugged recommended in Section 250-0070, TREADLE
VALVE and 250-0280, RELAY EMERGENCY
VALVE.
Air pressure drops One or more faulty air control Trace brake lines by referring to Fig. 1. Install a
quickly with engine components in brake air line, or test gauge at various points in the system to
stopped and brakes leak in lines determine location of trouble. Test operation of
released faulty component as outlined in air brake control
Air pressure rises to Excessive leakage Trace brake lines by referring to Fig. 1. Install a
normal reading too test gauge at various points in the system to
slowly determine location of trouble. Test operation of
Engine speed too slow Correct condition. Refer to ENGINE
MAINTENANCE MANUAL.
8 SM 1948 4-00
Section 250-0000

Air pressure rises to Worn compressor Repair or replace. Refer to ENGINE
normal reading too MAINTENANCE MANUAL.
slowly Excessive carbon in compressor Clean the head and lines. Refer to ENGINE
cylinder head or discharge line. MAINTENANCE MANUAL.
Safety valve 'blows Safety valve out of adjustment Adjust as recommended in Section 250-0200,
off' AIR DRIER.
Air pressure in system above normal Check air drier unloader valve, adjust as
recommended. Refer to Section 250-0200, AIR
DRIER.
Excessive oil or Compressor passing excessive oil Service compressor as recommended in
water in the system ENGINE MAINTENANCE MANUAL.
Air drier not performing adequately Check desiccant cartridge, replace if required
Refer to Section 250-0200, AIR DRIER.
Air tanks not being drained often Drain all air tanks.
enough
Air pressure drops One or more faulty air control Trace brake lines by referring to Fig. 1. Install
quickly with engine components in brake air lines, or test gauge at various points in the system to
stopped and brakes leak in lines determine location of trouble. Test operation of
fully applied faulty component as outlined in air control
* * * *
SM 1948 4-00 9
BRAKING SYSTEM - Hydraulic Braking System Schematic
Section 250-0000
SM - 2491
1 1 1
FRONT
2 3
1 1 1
1 - Brake Head Assembly 2 - Pressure Converter 3 - Brake Fluid Reservoir
Fig. 1 - Hydraulic Braking System Schematic
DESCRIPTION When the brake is actuated, the hydraulic pressure

Numbers in parentheses refer to Fig. 1. forces the pistons against the brake pads which are in
turn forced against each side of the brake disc,
The hydraulic braking system is an integral part of the slowing or stopping the disc and wheel rotation.
service brake system with independent circuits for the
front and rear brake systems. Air pressure applied to
one end of the front and rear pressure converters (2) BLEEDING
results in hydraulic pressure at the other end. Refer to Numbers in parentheses refer to Fig. 1.
Section 250-0000, AIR BRAKING SYSTEM
SCHEMATIC and Section 250-0260, PRESSURE In order to obtain satisfactory braking, the system
CONVERTER. should be bled as follows to eliminate any air in the
hydraulic brake lines.
The service brakes are of the calliper disc type with
one hydraulic dry disc on each wheel with two heavy- 1. Fill the hydraulic brake fluid reservoirs (3) with
duty callipers per disc at the front and a single heavy- hydraulic brake fluid specified in Section 300-0020,
duty calliper per disc at the rear. Refer to Section LUBRICATION SYSTEM.
165-0010, BRAKE PARTS - REAR and Section
165-0020, BRAKE PARTS - FRONT.
WARNING
The brake is actuated by hydraulic brake fluid entering To prevent personal injury and property
brake head assembly (1) through the inlet port. The damage, ensure wheel blocks are properly
piston bores on each side of the torque plate are secured and of adequate capacity to do the job
interconnected by internal passages. Refer to Section safely.
300-0020, LUBRICATION SYSTEM, for hydraulic
brake fluid used in the system.
SM 1982 4-00 1
Braking System - Hydraulic Braking System Schematic
Section 250-0000
2. Start up the engine, place the park/emergency 5. Apply brake and open bleeder valve. After fluid flow
control valve in the 'Emergency' position, block all road stops, close the bleeder valve and release the brake.
wheels and place the steering lock bar in the 'Locked'
position. Note: If loose end of bleeder line is kept submerged in
brake fluid, the bleeder valve need not be closed each
3. Remove dust cap from bleeder valve on brake head time the brake is released.
assembly (1) and connect a clear bleeder line to the
bleeder valve. Place loose end of the line in a clean 6. Repeat procedure in step 4 until no air bubbles are
container. observed in fluid coming from bleeder valve.
Note: Keep brake fluid reservoirs (3) filled during 7. Repeat Steps 1 through 5 at each brake head
bleeding process. assembly (1).
4. Actuate brake treadle valve several times.
* * * *
2 SM 1982 4-00
BRAKING SYSTEM - Treadle Valve
Section 250-0070
SM - 2368
26
27
A
B
D 28
30
C E
29
F 16 17 18
G H
J 15
19
14 20
13
12
11
10
No. 1
DELIVERY PORT
No. 1
9 SUPPLY PORT
8 21
7 22
6 21
5 23
4 24
No. 2 3
DELIVERY PORT
No. 2
2 SUPPLY PORT
1 - Valve Body
1 25
2 - Inlet Valve EXHAUST
3 - Inlet Valve Seat
4 - Exhaust Valve Seat 13 - Primary Piston 22 - Passage
5 - Relay Piston 14 - Return Spring 23 - Screw
6 - Exhaust Passage 15 - Retainer Plate 24 - Sealing Ring
7 - Spring 16 - Spring Seat 25 - Rubber Exhaust Flap
8 - Valve Body 17 - Rubber Graduating Spring 26 - Treadle
9 - Transfer Holes 18 - Valve Stem 27 - Boot
10 - Inlet/ Exhaust Valve 19 - Vent 28 - Mounting Plate
11 - Inlet Valve Seat 20 - Air Filter 29 - Fulcrum Pin
12 - Exhaust Valve Seat 21 - Seal 30 - Stop Button
Fig. 1 - Cutaway View of Treadle Valve
DESCRIPTION There are 9 ports on the treadle valve as follows:

The treadle valve can be identified as item 4 in Port 'A' - Plugged
Section 250-0000, AIR BRAKING SYSTEM Port 'B' - Delivery to front pressure convertor and
SCHEMATIC. stop light switch
Port 'C' - Supply line from front brake tank
The treadle valve is mounted alongside the Port 'D' - Plugged
accelerator pedal on a mounting plate bolted to the Port 'E' - Plugged
cab floor. The treadle valve is the left hand pedal. Port 'F' - Delivery to relay emergency valve (rear)
Port 'G' - Supply line from rear brake tank
The treadle valve directs and controls air to the front Port 'H' - Plugged
pressure protection valve and rear relay emergency Port 'J' - Exhaust port
valve which control air delivery to the brake
chambers.
SM 1939 4-00 1
Braking System - Treadle Valve
Section 250-0070
OPERATION When the brake application force is reduced primary

Numbers in parentheses refer to Fig. 1. piston (13) will rise. Inlet/exhaust valve (10) remains
closed but exhaust valve seat (12) will uncover
When treadle is pressed down, force is exerted on exhaust passage (6) until the No. 1 delivery pressure
spring seat (16), rubber graduating spring (17) and falls sufficiently to restore the balance of forces on
primary piston (13). Primary piston (13) moves down, primary piston (13). Primary piston (13) and exhaust
its exhaust valve seat (12) closes exhaust passage valve seat (12) will then descend to close exhaust
(6) in inlet/exhaust valve (10). The continued passage (6) again. As the No. 1 circuit delivery
movement of primary piston (13) then pushes inlet/ pressure falls relay piston (5) will rise. Inlet valve (2)
exhaust valve (10) off inlet valve seat (11). The No. 1 remains closed but exhaust valve seat (4) will
circuit supply air now passes to the delivery port. uncover exhaust passage (6) until the No. 2 delivery
pressure falls sufficiently to restore the balance of
As the air flows to the No. 1 delivery port it also forces on relay piston (5). Relay piston (5) and
passes through transfer holes (9) to the relay piston exhaust valve seat (4) will then descend to close
(5). Owing to the downwards force of spring (7) on exhaust passage (6) again.
relay piston (5), the exhaust valve seat (4) has
already closed the exhaust passage in inlet valve (2). If the brake application force is increased, inlet/
The air pressure through transfer holes (9) now move exhaust valve (10) will open and the No. 1 circuit
relay piston (5) further down to push inlet valve (2) delivery pressure will rise until a balance of forces
off the inlet valve seat (3). The No. 2 circuit supply again exists across primary piston (13). The
air now passes to the delivery port. increased delivery pressure will be transmitted via
transfer holes (9) to relay piston (5). Relay piston (5)
Because only a small volume of air needs to pass will descend to open inlet valve (2). The No. 2
through transfer holes (9) to move relay piston (5), delivery pressure then rises until a balance of forces
the action of the No. 2 circuit is almost simultaneous again exists across relay valve (5).
with that of the No. 1 circuit. The No. 1 circuit leads
with a maximum differential of 0.2 bar (2.9 lbf/in) at a The No. 1 and No. 2 circuit delivery pressures are
delivery pressure of 1 bar (14.5 lbf/in). The therefore maintained at levels in proportion to the
differential diminishes until perfect balance is degree of mechanical force exerted by the operator.
achieved at about 5 bar (72 lbf/in). This self-lapping action will take place whenever the
brake application force is increaded or decreased.
The No. 1 delivery air flow continues until the
increasing air pressure under primary piston (13) Removal of the brake application force allows
together with the upward forces of return spring (14) primary piston (13) and valve stem (18) to make a
and the spring in inlet/exhaust valve (10) overcomes full upstroke. The No. 1 delivery pressure is then
the brake application force on primary piston (13). swiftly and completely released through exhaust
Primary piston (13) then lifts sufficiently to allow passage (6). As primary piston (13) rises, the head of
inlet/exhaust valve (10) to close on inlet valve seat valve stem (18) takes up the limited free movement
(11) and cut off the No. 1 supply air without letting between itself and relay piston (5). Relay piston (5) is
exhaust valve seat (12) uncover exhaust passage then pulled up against spring (7) to ensure a swift and
(6). The No. 1 circuit is now 'lapped' with both inlet/ complete release of the No. 2 circuit delivery
exhaust valve (10) and exhaust passage (6) closed. pressure through exhaust passage (6).
Similarly, the No. 2 delivery air flow continues until Should air pressure be lost from the No. 2 circuit, the
the increasing air pressure under relay piston (5) and No. 1 circuit will continue to function as described
the upward force of the spring in inlet valve (2) above. The seals (21) will effectively separate the
overcome the downward forces of spring (7) and the two brake circuits.
air pressure above relay piston (5). Relay piston (5)
then lifts sufficiently to allow inlet valve (2) to close If air pressure is lost from the No. 1 circuit, the No. 2
on inlet valve seat (3) and cut off the No. 2 supply circuit will continue to function as follows:
air without letting exhaust valve seat (4) uncover The brake application force will be transmitted to the
exhaust passage (6). The No. 2 circuit is now 'lapped' No. 2 circuit by primary piston (13) acting directly on
with both theinlet valve (2) and the exhaust passage relay piston (5) after taking up the limited movement
(6) closed. between relay piston (5) and valve stem (18).
2 SM 1939 4-00
Section 250-0070
Thereafter, relay piston (5) will operate the inlet/ ASSEMBLY AND INSTALLATION
exhaust valve (2) as previously described. Numbers in parentheses refer to Fig. 1.
Apart from the reduced vehicle braking efficiency, the Note: Tighten all fasteners to standard torques listed
effect of a loss of air pressure from No. 1 circuit will in Section 300-0080, STANDARD BOLT AND NUT
be a small increase in the operating plunger travel TORQUE SPECIFICATIONS.
and a moderate increase in the effort required to
depress the brake treadle. 1. If removed, install treadle (26) assembly on valve
body (1 & 8) assembly.
REMOVAL AND DISASSEMBLY 2. If removed, install treadle valve assembly to the
Numbers in parentheses refer to Fig. 1. toe plate with mounting hardware, as removed at
'Removal and Disassembly'.
WARNING Note: Treadle valve is the left hand pedal on the toe
To prevent personal injury and property plate.
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job 3. Install all air lines to the treadle valve assembly,
safely. as tagged at removal.
1. Position the vehicle in a level work area, apply the 4. Place the battery master switch in the 'On'
parking brake and switch off the engine. position, start the engine and allow air pressure in the
tanks to build up to correct operating pressure.
2. Block all road wheels and place the battery master Check for leaks at air lines and tighten as required.
5. Secure toe plate assembly to the cab floor with
3. Open drain cocks on air tanks and drain air from mounting hardware, as removed at 'Removal and
three main air tanks and auxiliary air tank. Close Disassembly'.
drain cocks on air tanks when air is exhausted.
6. Remove wheel blocks from all road wheels.
4. Remove mounting hardware securing toe plate
assembly to the cab floor.
ADJUSTMENTS
5. Manoeuvre the toe plate assembly to allow access Numbers in parentheses refer to Fig. 1.
and tag and remove all air lines from the treadle
valve assembly. If the treadle valve does not release promptly or does
not fully release, it indicates that exhaust valve is not
6. Release and remove mounting hardware securing opening sufficiently. This can be caused by:
treadle valve assembly to the toe plate assembly.
1. Lack of lubrication in valve body causing piston
7. Remove treadle valve assembly from the vehicle. and spring assembly to bind.
8. If required, separate valve body (1 & 8) assembly 2. Dirt or other foreign matter between the heel of
and treadle (26) assembly. treadle (26) and mounting plate (28).
Note: The treadle valve assembly should not be If the treadle valve does not apply promptly, or does
disassembled further as replacement of parts is by not apply fully, it indicates that inlet valve (10) is
treadle (26) assembly and/or valve body (1 & 8) not opening sufficiently. Check for correct operation
assembly only. Refer to 'Maintenance' procedures. and replace valve assembly, if required.
SM 1939 4-00 3
Section 250-0070
MAINTENANCE Coat valve body and exhaust port 'J' with soap suds
Numbers in parentheses refer to Fig. 1. to check for leakage and make and hold a full
pressure brake application. Any leakage from the
Every 250 hours exhaust port 'J' must not exceed a 25 mm (1 in)
Lubricate treadle roller and pin (29) with engine oil as diameter soap bubble in less than three seconds. If
specified in Section 300-0020, LUBRICATION excessive leakage is found, the treadle valve must
SYSTEM. be repaired or replaced.
Lift boot (27) away from mounting plate (28) and

place a few drops of oil between mounting plate (28) SPECIAL TOOLS
and plunger. Discard boot (27) and replace with a There are no special tools required for procedures
new boot. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general
service tools required. These tools are available from
your dealer.
* * * *
4 SM 1939 4-00
BRAKING SYSTEM - Air Tanks and Mounting
Section 250-0170
SM - 819
10 - Lockwasher
1 - Primary Tank 4 - Guard 7 - Lockwasher 11 - Nut
2 - Front Brake Tank 5 - 'U' Bolt 8 - Drain Cock 12 - Bolt
3 - Rear Brake Tank 6 - Nut 9 - Bolt 13 - Lockwasher
Fig. 1 - Air Tanks and Mounting
DESCRIPTION AND OPERATION Primary Tank:

There are three air tanks in the air system; primary Port 'A' - Pressure Switch
tank, front brake tank and rear brake tank. The primary Port 'B' and 'C' - Plugged
and front air tanks are located at the front left hand Port 'D' - Supply to diff lock solenoid valve and
side of the tractor frame, with the primary tank to the regulating valve
outside. The rear brake tank is located on the left hand Port 'E' - Supply to pressure protection valve port '24'
side of the trailer frame, forward of the frame cross Port 'F' - Supply to suspension levelling valve and
channel. coolant sensor valve
Drain Port
Air tanks store compressed air from the engine
compressor until it is required for brake or accessory Front Brake Tank:
operation. Brake tanks maintain an air supply for Port 'A' - Supply to pressure protection valve port '21'
normal brake application or for automatic safety brake and air pressure sender (gauge)
application, if pressure drops in the primary tank. Port 'B' - Supply to treadle valve
Drain Port
Air pressure in the tanks is indicated on the air system
pressure gauge located on the instrument panel in the Rear Brake Tank:
operators compartment. Port 'A' - Supply to pressure protection valve port '22'
Port 'B' - Supply to relay emergency valve
There are 7 ports on the primary tank, 3 ports on the Port 'C' - Plugged
front brake tank and 4 ports on the rear brake tank, as Drain Port
follows:
SM 1941 4-00 1
Braking System - Air Tanks and Mounting
Section 250-0170
REMOVAL 1. Install rear brake tank (3) on mounting brackets on

Numbers in parentheses refer to Fig. 1. trailer frame and secure with 'U' bolts (5), lockwashers
(7) and nuts (6).
1. Switch off engine, apply parking brake and place the
battery master switch in the 'Off' position. 2. Install all air lines to rear brake tank (3), as tagged
at 'Removal'.
2. Open drain cocks (8) and drain air from all three air
tanks. 3. Install front brake tank (2) in place on the machine
and secure to mounting bracket with bolt (12) and
3. Tag all air lines attached to air tanks for easy lockwasher (13).
identification at 'Installation'. Remove all air lines from
air tanks. 4. Position guard (4) in place under front brake tank (2)
and secure in place with 'U' bolt (5), bolts (9),
4. Remove nuts (6) and lockwashers (7) from 'U' bolts lockwashers (7 & 10) and nuts (6 & 11).
(5) securing primary tank (1) to front frame and guard
(4). Remove bolts (9), nuts (11) and lockwashers (10) 5. Install primary tank (1) in place on the machine and
securing guards (4) to frame crossmember. Remove secure to mounting bracket with bolt (12) and
guards (4) from the machine. lockwasher (13).
5. Remove bolt (12) and lockwasher (13) securing 6. Position guard (4) in place under primary tank (1)
primary tank (1) to mounting bracket on the frame. and secure in place with 'U' bolt (5), bolts (9),
Remove primary tank (1) from the machine. lockwashers (7 & 10) and nuts (6 & 11).
6. Remove bolt (12) and lockwasher (13) securing 7. Install all air lines on primary tank (1) and front
front brake tank (2) to mounting bracket on the frame. brake tank (2), as tagged at 'Removal'.
Remove front brake tank (2) from the machine.
7. Remove nuts (6) and lockwashers (7) from 'U' bolts MAINTENANCE
(5) securing rear brake tank (3) to trailer frame Numbers in parentheses refer to Fig. 1.
mounting brackets. Remove rear brake tank (3) from
the machine. The air tanks should be drained daily to prevent
excessive water build up in the system. It is also
important that the air tanks are drained after each shift.
INSTALLATION
Numbers in parentheses refer to Fig. 1. Before starting the shift make sure that drain cocks (8)
are tightly closed.
* * * *
2 SM 1941 4-00
BRAKING SYSTEM - Park/Emergency Control Valve
Section 250-0190
SM - 1947
10
13
11
12
14
15
8
5
9 7 6
1
3 4
1 - Control Lever 5 - Graduating Spring 9 - Plunger 'Upright Side' 13 - Handle

2 - Pivot 6 - Inlet Valve 10 - Outer Circlip 14 - Return Spring
3 - Cam 7 - Exhaust Valve 11 - Washer 15 - Locking Sleeve
4 - Plunger 'Inverse Side' 8 - Upper Piston 12 - Circlip
Fig. 1 - Sectional View of Park/Emergency Control Valve - Lever in 'Emergency' Brake Position
Note: Refer to Fig. 2 for port identification. OFF
The park/emergency control valve can be identified as EMERGENCY PARK

item 8 in Section 250-0000, AIR BRAKING SYSTEM
SCHEMATIC.
The park/emergency control valve is mounted on the

right hand side dash panel in the operators compartment.
There are 4 ports on the park/emergency control valve A

as follows: B
C
Port 'A' - Supply to parking brake actuator D
Port 'B' - Supply from front brake air tank via pressure
Fig. 2 - Park/Emergency Control Valve Ports
protection valve (port '23')
SM 1940 4-00 1
Braking System - Park/Emergency Control Valve
Section 250-0190
Port 'C' - Supply to relay emergency valve (rear) lifted by the control lever (1) and the pivot (2) allowing
Port 'D' - Exhaust the 'upright side' plunger (9) and the 'inverse side'
plunger (4) to lift and allowing the air pressure in the
The valve comprises an aluminium cover and an brake chambers to exhaust. The vehicle is now parked
aluminium body. The cover contains the actuating by the mechanical force exerted by the spring brakes.
mechanism and a control lever incorporating a spring
loaded locking mechanism which allows it to be locked
in the 'Park' position. REMOVAL
The body contains two graduating valve units, one
upright and one inverse. The output from each unit can
be set by means of adjusters in the bottom manifold. WARNING
Incorporated in the body are two air supply ports, one damage, be sure wheel blocks are properly
in the bottom manifold, the other in the rear manifold. secured and of adequate capacity to do the job
These supply ports provide a common feed to both safely.
graduating units. There are two delivery ports from
each graduating unit, one in the bottom manifold, the 1. Switch off the engine, move control lever (1) to the
other in the rear manifold. 'Park' position and place the battery master switch in
the 'Off' position.
OPERATION 2. Block all road wheels, open drain cocks on air tanks
Numbers in parentheses refer to Fig. 1. and drain air from all three air tanks. Close drain cocks
on air tanks when air is exhausted.
When control lever (1) is in the 'Off' position, the
'upright side' of the valve is delivering zero air 3. Tag and disconnect air lines and electrical
pressure to the brake chambers and the 'inverse side' connection from valve body, to aid in installation.
of the valve is delivering hold off pressure to the spring
brakes in order to maintain them in the brakes 4. Support valve body and remove mounting hardware
released condition. securing valve body to mounting bracket on underside
of dash panel. Remove valve body from the dash
As the control lever (1) is moved to make a panel.
'Emergency' brake application, it rotates the cam (3),
depressing the 'upright side' plunger (9), closing the
exhaust valve (7) and opening the inlet valve (6) INSPECTION
allowing air to pass to the brake chambers. As the Numbers in parentheses refer to Fig. 1.
pressure in the brake chambers increases, the air
pressure acting on the upper piston (8) causes it to To check the control lever shaft for damage or
move down against the pressure exerted by the deformation:
graduating spring (5), closing the inlet valve (6). This
procedure is repeated for further control lever (1) 1. Move the control lever (1) into the 'Park' position.
movement until full 'Emergency' brake position is
reached, when the air pressure delivered to the brake 2. Remove the outer circlip (10), washer (11) and
chambers is maximum. handle (13).
During this operation, the 'inverse side' of the valve, 3. Grip return spring (14) firmly and ease off circlip (12).
which was delivering maximum pressure when the
control lever (1) was in the 'Off' position, is exhausting, 4. Remove spring (14) and locking sleeve (15).
until, with the control lever (1) in the 'Emergency' brake
position the delivered pressure is zero. 5. Inspect control lever shaft.
When control lever (1) is moved from the 'Emergency' Note: If control lever shaft is bent then the complete
brake position to the 'Park' position, the cam (3) is valve must be replaced.
2 SM 1940 4-00
Braking System - Park/Emergency Control Valve
Section 250-0190
INSTALLATION When control lever (1) is moved to the 'Release'

Numbers in parentheses refer to Fig. 1. position, the pressure reading at port 'A' should be the
same as the inlet pressure at port 'B' and there should
Note: Tighten all fasteners to standard torques listed be no pressure at port 'C'.
TORQUE SPECIFICATION. Finally, when control lever (1) is moved to the 'Park'
position, there should be no pressure at ports 'A' and 'C'.
1. Secure valve body to mounting bracket on
underside of dash panel using mounting hardware as When testing for air leaks, start with the control lever
removed at 'Removal'. (1) in th 'Release' position. After the initial exhaust of
air, apply a soap solution to the exhaust port and valve
2. Install air lines and electrical connection to valve housing and check for leakage. No leakage is
body, as tagged at 'Removal'. permitted from the valve housing and any leakage
from the exhaust port must not exceed a 13 mm
3. Start engine and allow air pressure in the tanks to (0.5 in) diameter soap bubble in 5 seconds. Repeat
build up to correct operating pressure. Check for leaks test for 'Emergency' and 'Park' positions.
at air lines and tighten as required.
If the valve is found to be leaking, it must be replaced.
4. Check operation of park/emergency control valve
for correct operation in all three positions.
MAINTENANCE
The park/emergency control valve is a non-serviceable
TESTING item and should be replaced completely if damaged.
Numbers in parentheses refer to Figs. 1 and 2.
Block all road wheels and ensure air tanks are fully SPECIAL TOOLS
charged. With control lever (1) in 'Emergency' position, There are no special tools required for procedures
the air pressure at port 'C' should be the same as the outlined in this section. Refer to Section 300-0070,
inlet pressure at port 'B' and there should be no SERVICE TOOLS, for part numbers of general service
pressure at port 'A'. tools required. These tools are available from your
dealer.
* * * *
SM 1940 4-00 3
BRAKING SYSTEM - Air Drier
Section 250-0200
SM - 1942
5 8
7 6
3
4
1 - Air Drier 4 - Unloader Valve 7 - Orifice

2 - Air Compressor 5 - Desiccant Cartridge 8 - Purge Tank
3 - Safety Valve 6 - Check Valve
Fig. 1 - Air Drier Schematic
DESCRIPTION Air drier unloader valve (4) controls the supply of air to
Numbers in parentheses refer to Fig. 1. the system by stopping and starting delivery of air by
the compressor (2), when maximum and minimum
The air drier is mounted on the left hand side platform, system operating pressures are reached.
with the purge tank located inboard of the hood
assembly, mounted off the right hand side of the Orificed check valve (6 & 7) meters compressed air
goalpost support assembly. flowing into purge tank (8) and traps air in the primary
air tank during the purging cycle.
The purpose of the air drier is to filter the air from the
compressor to remove any oil and moisture before it
enters the air reservoirs. OPERATION
Note: An air system maintained to proper specification Delivery Air Flow

can lead to prolonged component life. It is important Numbers in parentheses refer to Fig. 1.
therefore to follow the servicing procedures contained
in this section. Air from air compressor (2) enters air drier (1) inlet
port, flows past safety valve (3), through desiccant
The external components of the air drier system are cartridge (5), orificed check valve (6 & 7) into purge
air compressor (2), purge tank (8) and air drier (1). tank (8) and air tank reservoirs via the pressure
protection valve.
Contained in air drier (1) body is a safety valve (3),
unloader valve (4), desiccant cartridge (5) and orificed Humid air from the compressor passes up and down
check valve (6 & 7). the air drier cartridge. The dirt in the air is collected in
the filter and water molecules adhere to the desiccant.
Safety valve (3) limits the maximum system pressure Air flows through the desiccant and out of air drier (1)
to 10.75 bar (156 lbf/in2). which results in clean dry air flowing into purge tank
(8) and the air reservoirs.
SM 1985 Rev 1 11-00 1

Braking System - Air Drier
Section 250-0200
SM - 2280
A B
7 E
4
1 - Purge Tank
5 C 6
2 - Desiccant
3 - Oil Filter C - Exhaust
4 - Unloader Valve 7 - Purge Valve D - Output to Compressor Unloading
5 - Check Valve A - Supply from Compressor Device
6 - Purge Choke B - Delivery to Press Protection Valve E - Delivery to Purge Tank
Fig. 2 - Typical Purging Air Flow
Purging Air Flow SM - 1944
When system pressure reaches 8.4 bar (122 lbf/in),

the air pressure overcomes spring tension in purge
valve which forces the spool down. This unloads air
compressor (2) by opening unloader valve (4) and
allowing the air to flow out of purge tank (8), through
orifice (7), unloader valve (4) and air drier (1) drain to
atmosphere.
SAFETY CHECK
Numbers in parentheses refer to Fig. 2. VALVE VALVE
1 2
When air pressure reaches 8.3 bar (120 lbf/in), air UNLOADER
2-1
enters unloader valve (4) moving the piston, allowing VALVE
air through to the purge valve (7). Once the purge
valve (7) is open, the air compressor now pumps air at SUPPLY
PORT DELIVERY
low pressure directly to atmosphere. Dirt and water
PURGE VOLUME PORT PORT
collected around unloader valve (4) flows out of
exhaust port (C) to atmosphere.
Fig. 3 - Port and Valve Identification
Dry air from purge tank (1) flows through the purge
choke (6) and desiccant (2) carrying the water This purging process continues until purge tank (1)
molecules out of exhaust port (C) to atmosphere. pressure is zero or until unloader valve (4) closes at
7.5 bar (109 lbf/in2) and once again compressed air
passes through the desiccant cartridge.
2 SM 1985 Rev 1 11-00

Section 250-0200
SM - 1945
17 18 16
21
2
15 14 13
19 20 3 11
3 7 6 5 4
1
12
CHECK VALVE
2 8 9 10
UNLOADER VALVE
EXHAUST
1 - Adjusting Bush 6 - Control Rod 11 - Check Valve Guide 16 - Safety Valve Body
2 - Protection Cap 7 - 'O' Ring 12 - Circlip 17 - Adjusting Screw
3 - Valve Retaining Cap 8 - Control Spring 13 - 'O' Ring 18 - Locknut
4 - Bonded Valve (Inner) 9 - Bonded Valve (Outer) 14 - Conical Spring 19 - Regulating Spring
5 - Pilot Valve Piston Bush 10 - Pilot Valve Piston 15 - Check Valve 20 - Ball
21 - Desiccant Cartridge
Fig. 4 - Air Drier Components
REMOVAL on air tanks when air is exhausted. Carefully loosen

the union nuts at purge port (2-1, Fig. 3) and delivery
port (2, Fig. 3) on air drier to relieve any trapped air.
WARNING
To prevent personal injury and property 3. Tag and carefully disconnect all air lines from the air
damage, be sure wheel blocks are properly drier body ports.
safely. Ensure steering lock bar is in place. Note: All ports on air drier have numbers cast into
housing for identification purposes.
1. Place the parking brake in the 'Park' position, switch
off the engine and place the battery master switch in 4. Remove mounting hardware securing the air drier to
the 'Off' position. the left hand side platform. Move the air drier
assembly to a clean work area for 'Disassembly'.
2. Place the steering lock bar in the 'Locked' position,
block all road wheels, open drain cocks on air tanks 5. Remove desiccant cartridge and 'O' ring from air
and drain air from all three air tanks. Close drain cocks drier body. Discard 'O' ring.
SM 1985 Rev 1 11-00 3

Section 250-0200
UNLOADER VALVE CHECK VALVE

Disassembly/assembly Disassembly/assembly
Numbers in parentheses refer to Fig. 4, unless Numbers in parentheses refer to Fig. 4.
Note: Check valve components should be replaced as
Note: Unloader valve components should be replaced a complete assembly when removed from air drier
as a complete assembly when removed from air drier assembly. Do not reassemble using old components.
assembly. Do not reassemble using old components.
1. Using suitable circlip pliers, remove and discard
1. Pull off and discard protection cap (2) from unloader circlip (12) from check valve assembly.
valve assembly.
2. Remove and discard check valve guide (11) and
2. Unscrew and discard valve retaining cap (3). Remove 'O' ring (13).
and discard adjusting bush (1) and 'O' ring (7).
3. Remove and discard spring (14) and check valve (15).
3. Remove and discard control spring (8) and control
rod (6). 4. Install new check valve (15) and spring (14) in valve
housing.
4. Remove and discard outer bonded valve (9) and
pilot valve piston bush (5). 5. Grease new 'O' ring (13) and fit to new check valve
guide (11).
5. Remove and discard pilot valve piston (10) and
inner bonded valve (4). 6. Lower check valve guide (11) and 'O' ring (13) into
recess, ensuring that the check valve stem locates in
Note: Air driers date coded 9401 onwards may have a the recess in the centre of the check valve guide (11).
filter located at the end of the air passage of delivery
port (2, Fig. 3). Should the filter appear to be blocked 7. Using suitable circlip pliers, install new circlip (12).
or contaminated, it should be removed (which will
destroy it) and replaced.
SAFETY VALVE
The entire body assembly should be cleaned using a
suitable cleaning fluid and thoroughly dried. Description
The safety valve protects the air brake system against
6. Install inner bonded valve (4), ensuring that the flat excessive air pressure build up. The valve consists of
solid surface is facing outwards. a spring loaded ball valve subjected to reservoir
pressure which will permit air to exhaust reservoir
7. Install pilot valve piston bush (5), ensuring that the pressure to atmosphere if reservoir pressure rises
two small holes are facing outwards. above the valves' pressure setting. The safety valve is
set to open at a pressure of 11 bar (160 lbf/in).
8. Install pilot valve piston (10).
9. Install outer bonded valve (9), ensuring that the flat Operation
solid surface faces inwards and is in contact with pilot Numbers in parentheses refer to Fig. 4.
valve piston (10).
When primary tank air pressure under ball (20)
10. Install control rod (6) and control spring (8). exceeds the maximum valve setting of 10.75 bar
(156 lbf/in), ball (20) is forced off its seat, permitting
11. Install 'O' ring (7) to valve retaining cap (3). Using air to escape through exhaust port 'A' to atmosphere.
special tool which can be fabricated as shown in As soon as sufficient air is bled from the reservoir so
Fig. 6, screw in adjusting bush (1) and fit to main body that the pressure drops below the maximum valve
assembly. setting, regulating spring (19) forces ball (20) back on
its seat, preventing any further loss of air.
12. If necessary, fit new filter in port 1, use a 7 mm
(0.38 in) dowel to push filter home.
4 SM 1985 Rev 1 11-00

Section 250-0200
Testing SM - 1946
Operating Test - The valve must open (exhaust)

when the pressure applied at the supply port 'P-1' is
above 10.75 bar (156 lbf/in). The valve should
exhaust sharply, with a 'pop' action. If the valve does
not relieve, ball (20) must be stuck on its seat. The
complete valve should be replaced.
Leakage Test - With the air system at operating

pressure, test for leakage by applying soap suds to
valve body (16) and exhaust port. If leakage exceeds
a 25 mm soap bubble in 5 seconds, replace the valve
assembly.
Adjustment
Adjust the safety valve opening pressure to 10.75 bar
(156 lbf/in) by loosening locknut (18) and turning
adjusting screw in to raise the pressure setting or out
to reduce the setting. Always tighten locknut (18) after
making adjustment.
Maintenance 11 10
Note: This is a non-serviceable item and should be
12 9
replaced with a new safety valve assembly, if
damaged. 13
8
14
PURGE VALVE 7
Removal
15 6
16 17 1,2 3 4 5
1. Remove 4 screws (5), silencer cover (15) and
perforated plate (3) from base of air drier. 1 - Screw 9 - 'O' Ring
2 - Lockwasher 10 - Purge Valve Piston
3 - Perforated Plate 11 - Return Spring
2. Remove and discard silencer element (16). 4 - Screw 12 - Purge Valve Housing
5 - Screw 13 - Retaining Ring
3. Remove 4 screws (4) and silencer housing (6) from 6 - Silencer Housing 14 - Gasket
air drier body. Remove and discard gasket (14). 7 - Circlip 15 - Silencer Cover
8 - 'O' Ring 16 - Silencer Element
17 - Purge Valve
4. Using suitable circlip pliers, remove and discard
circlip (7). Fig. 5 - Sectional View of Air Drier
5. Remove retaining ring (13) and 'O' ring (8) from

recess. Discard 'O' ring (8). Disassembly/assembly
6. Using suitable pliers, grip screw (1) head and pull
gently to remove purge valve assembly complete. 1. Remove and discard 'O' ring (9) from purge valve
assembly.
2. Remove screw (1) and lockwasher (2) from bottom

of purge valve assembly.
SM 1985 Rev 1 11-00 5

Section 250-0200
3. Remove and discard the bonded rubber/metal purge 4. Connect all air lines to the air drier body, as tagged
valve (17) and nylon purge valve housing (12). at 'Removal'.
4. Remove and discard return spring (11). 5. Start the engine and allow the air pressure in the air
tanks to build up to correct operating pressure. Refer
5. Using a suitable fluid, clean purge valve piston (10), to Section 250-0000, AIR BRAKING SYSTEM
screw (1) and lockwasher (2) and dry thoroughly. SCHEMATIC. Check for leaks at air lines and tighten
Clean purge valve body if necessary. as required.
6. Assemble new bonded rubber/metal purge valve

(17), purge valve housing (12), return spring (11), CHECKING AIR DRIER OPERATION
purge valve piston (10) and secure using screw (1) 1. Charge the air system until the unloader valve cut-
and lockwasher (2). Tighten screw (1) to a torque of out pressure is reached. Refer to Section 250-0000,
5.1 - 6.2 Nm (45 - 55 lbf ins). AIR BRAKING SYSTEM SCHEMATIC. At this point
the air drier unloader valve opens allowing air
7. Grease the groove on purge valve piston (10) and fit compressor output, purge tank air and collected water,
new 'O' ring (9). Grease 'O' ring (9). dirt and oil to flow out of the silencer at the bottom of
the air drier. If this does not happen, then check for a
8. Grease bores in air drier housing, position purge plugged drain, unloader valve pressure setting.
valve assembly and push home.
2. Using a test quality gauge, check the system
9. Grease recess and new 'O' ring (8). Manoeuvre 'O' pressure at which the unloader valve operates. It
ring (9) into recess. should be 8.3 0.2 bar (117 - 123 lbf/in), if it is
outside this range then adjust the valve using the
10. Install retaining ring (13) and using suitable circlip special tool shown in Fig. 6, (screw in to increase the
pliers, install new circlip (7). pressure). To check the adjustment deplete the
system pressure by repeatedly applying the brakes,
11. Lightly smear surface of silencer housing (6) with then allow the system to recharge.
grease to hold and retain new gasket (14) in place.
3. The unloading phase continues until the unloader
12. Refit silencer housing (6) to the air drier body with valve cut-in pressure is reached. Refer to
screws (4). Section 250-0000, AIR BRAKING SYSTEM
SCHEMATIC. This closes the unloader valve and the
13. Install new silencer element (16), perforated plate compressor starts charging the air system again. At
(3), silencer cover (15) and secure using screws (5). this point air flow coming out of the air drier silencer
stops. If air flow does not stop, check for a partially
open unloader valve or check cut-in pressure setting.
ASSEMBLY/INSTALLATION Cut-in pressure should be 7.1 to 7.9 bar
Numbers in parentheses refer to Fig. 4. (103 to 115 lbf/in) and is not adjustable. If pressure is
outside these limits, check cut-out pressure and re-
Note: Tighten all fasteners to standard torques listed adjust.
TORQUE SPECIFICATION. 4. Every 2 000 hours/12 months replace the desiccant
cartridge. The desiccant cartridge service life is
1. Install new 'O' ring on desiccant cartridge (21). determined by the air quality delivered by the air
compressor and the compressor charging time.
2. Install desiccant cartridge (21) assembly on drier Polluted air and long charging times reduce desiccant
body. cartridge service life.
Note: The new desiccant cartridge (21) must be kept 5. If water is present, the desiccant cartridge must be
in its plastic bag until it is installed. If not the desiccant replaced and the components in the air drier body
will absorb moisture and lose its efficiency. checked for proper operation.
3. Position air drier assembly on the left hand side

platform and secure in place with mounting hardware
as removed at 'Removal'.
6 SM 1985 Rev 1 11-00

Section 250-0200
AIR DRIER DIAGNOSIS SM - 1953
The following table lists some of the conditions which Shank should be about 8 in long
could prove responsible for air drier malfunctioning. and fitted with Tee handle
approx. 4 in long
The reasons and remedies to correct these conditions
0.218 in dia.
Machined
dia.
are listed opposite each condition. Length
0.343 in
0.480 in
0.475 in
1.00 in
0.75 in
WARNING
0.5 in dia.
Always shut off the engine, completely drain
bar
the air system, and make sure the air drier is
completely purged of all air pressure before
loosening air lines or fittings to prevent
personal injury. 0.938 in
Pins to be 0.072 in dia.
Fig. 6 - Unloader Valve Adjusting Bush Installation Tool

SERVICE TOOLS
Special tool can be fabricated as shown in Fig. 6.
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools. These tools are
available from your dealer.
AIR DRIER DIAGNOSIS CHART

Air continually blows Unloader valve held open by foreign Disassemble and clean unloader
out of drain port while particles on the valve seat valve assembly.
compressor is pumping Faulty unloader valve Disconnect pilot line from the air drier
to compressor. If leak stops and air is
being expelled from the unloader valve
line, unloader valve is the problem.
Repair or replace unloader valve.
Leakage occurs while air
compressor is unloaded:
A - Continuous leakage Faulty check valve at air drier Clean or replace check valve.
B - Pulsating leakage Faulty unloader valve Clean, rebuild or replace unloader
valve.
Continuous on-off purge cycle No/Faulty check valve at air drier Install or replace check valve.
Primary tank drain cock open Close drain cock
Unloader valve malfunction If cycling occurred when air compressor
was unloaded, check unloader valve for
by-pass leakage. Check unloader valve
high-low limits.
Safety valve blowing - air drier Check system pressure when safety If pressure is below 9 bar (130 lbf/in)
not unloading valve blows off check safety valve.
If pressure is above 9 bar (130 lbf/in)
check unloader valve.
Large amount of water in Desiccant cartridge plugged Replace desiccant cartridge.
primary tank Desiccant saturated with water Not enough cooling of air. Check for
air line too near engine exhaust, etc.
Excessive duty cycle. Check for leakage
in air system.
SM 1985 Rev 1 11-00 7

Section 250-0200

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ins
5 1 Bolt 5.1 - 6.2 45 - 55
* * * *
8 SM 1985 Rev 1 11-00

BRAKING SYSTEM - Pressure Converter
Section 250-0260
SM - 821
1 - Air Cylinder Body 9 - Air Piston 17 - Contact Assembly 25 - Hydraulic Piston

2 - Nut 10 - Return Spring 18 - Shim (if used) 26 - Valve Insert
3 - Washer 11 - Push Rod 19 - Nut 27 - Valve
4 - Piston Follower 12 - End Cap 20 - Lockwasher 28 - Retainer Ring
5 - Felt Wiper 13 - Seal Ring 21 - Hydraulic Cylinder Body 29 - 'V' Seal
6 - Expander Spring 14 - 'O' Ring 22 - Retainer Ring (if used) 30 - 'O' Ring
7 - Leather Cup 15 - Indicator Rod 23 - 'V' Seal 31 - Bushing
8 - 'O' Ring 16 - Bleeder Screw 24 - Back-up Ring (if used) 32 - 'V' Seal
Fig. 1 - Cutaway View of Pressure Converter
There are two pressure converters used in the air Numbers in parentheses refer to Figs. 1 and 2.
system one for the front brake tank and the other for
the rear. The front pressure converter is mounted off When the operator depresses the brake treadle valve,
of a bracket on the front left hand cab leg. The rear air from the treadle valve enters inlet port 'A' of air
pressure converter is mounted alongside the rear cylinder body (1), via the relay emergency valves. The
brake tank in the trailer frame. air then forces piston follower (4), air piston (9) and
push rod (11) to stroke hydraulic cylinder (21) and
The pressure converters are used to convert air compress return spring (10). Piston follower (4)
pressure to hydraulic pressure. Air pressure applied to contains a leather cup (7) and a felt wiper (5) that
one end of the pressure converter results in hydraulic cleans and lubricates air cylinder body (1) housing. Air
pressure at the other end. The pressure converter displaced on the atmospheric side of air piston (9)
consists of an air cylinder group and a hydraulic group. passes through port 'B' in hydraulic cylinder body (21)
to the air breather. Refer to Section 250-0270, AIR
There are 4 line connections to each pressure BREATHER.
converter as follows:
When air is released, return spring (10) forces push
Port 'A' - Supply air line from relay emergency valve rod (11), air piston (9) and piston follower (4) back to
Port 'B' - Air line to air breather the static position. In the static position, valve (27) is
Port 'C' - Hydraulic line to brake fluid reservoir open, allowing fluid in hydraulic cylinder body (21) to
Port 'D' - Supply line to hydraulic brake lines pass through hydraulic piston (25) and port 'C' to the
remote brake fluid reservoir to compensate the closed
SM 1508 9-98 1
Braking System - Pressure Converter
Section 250-0260
SM - 822
8 - 'O' Ring
9 - Air Piston
10 - Return Spring
11 - Push Rod
12 - End Cap
13 - Seal Ring
14 - 'O' Ring
15 - Indicator Rod
16 - Bleeder Screw
17 - Contact Assembly
18 - Shim (if used)
19 - Nut
20 - Lockwasher
21 - Hydraulic Cylinder
22 - Retainer Ring (if used)
23 - 'V' Seal
24 - Back-up Ring (if used)
25 - Hydraulic Piston
1 - Air Cylinder 26 - Valve Insert
2 - Nut 27 - Valve
3 - Washer 28 - Retainer Ring
4 - Piston Follower 29 - 'V' Seal
5 - Felt Wiper 30 - 'O' Ring
6 - Expander Spring 31 - Bushing
7 - Leather Cup 32 - 'V' Seal
Fig. 2 - Exploded View of Pressure Converter
hydraulic system for temperature expansion and switch in contact assembly (17) causing converter
contraction or seepage. During an application, initial overstroke warning light to illuminate. This will continue
push rod (11) movement seats valve (27) against until switch is reset by manually pushing indicator rod
hydraulic piston (25) and seals passage to port 'C', (15) into hydraulic cylinder body (21) until flush.
then the stroke displaces fluid into the brake system.
Pressure builds when this fluid movement ceases. 'V'
seal (23) on hydraulic piston (25) seals the pressure REMOVAL
system and hydraulic pressure is directed to the Numbers in parentheses refer to Figs. 1 and 2.
brakes through outlet port 'D'.
Note: When removing rear pressure converter from
Upon release, return spring (10) forces push rod (11) the machine, it is advisable to raise the body and
to unseat valve (27) and return hydraulic piston (25) to secure in place with the body safety prop.
its stop. Displaced fluid passes through hydraulic
piston (25) to equalize hydraulic pressure and the
system returns to the static position. WARNING
To prevent personal injury, be sure body prop
When the pressure converter stroke has been exceeded, is in place before working under a raised body.
because of a loss of hydraulic pressure in the brake
system, air piston (9) strokes indicator rod (15), closing
2 SM 1508 9-98
Section 250-0260
1. If required, to remove the rear pressure converter, 3. Remove contact assembly (17) and shim (18), if
raise body and secure in place with the body safety used, from hydraulic cylinder body (21).
prop.
4. Remove bleeder screw (16), end cap (12) and seal
2. Switch off the engine, install steering lock bar in the ring (13) from hydraulic cylinder body (21). Discard
'locked' position and drain the air tanks. Close air tank seal ring (13).
drain cocks when air has exhausted from the air tanks.
5. Match mark air cylinder body (1) and hydraulic
3. If required, to remove the front pressure converter, cylinder body (21) and remove nuts (19) and
open the hood to gain access. lockwashers (20). Remove air cylinder body (1).
4. Remove electrical wire from contact assembly (17) on 6. Remove retainer ring (22), if used, indicator rod (15)
hydraulic cylinder body (21) of pressure converter. and 'O' ring (14). Discard 'O' ring (14) and retainer ring
(22), if used.
5. Remove breather hose assembly from port 'B' of
hydraulic cylinder body (21).
WARNING
6. Remove air supply line from port 'A' of air cylinder Return spring (10) is under tension. Remove
body (1). nut (2) slowly, being careful to control
expansion of return spring (10) to avoid
7. Remove hydraulic line from port 'D'. property damage or personal injury.
8. Using a suitable container to catch brake fluid, 7. Remove nut (2), washer (3), piston follower (4),
remove brake fluid reservoir line from port 'C' of leather cup (7), 'O' ring (8), air piston (9) and return
hydraulic cylinder body (21). spring (10) from air cylinder body (1). Discard leather
cup (7), 'O' ring (8) and return spring (10).
9. Remove mounting hardware securing pressure
converter to its mounting on the machine. Remove 8. Remove expander spring (6) and felt wiper (5).
pressure converter assembly to a clean work area for Discard felt wiper (5).
'Disassembly'.
9. Unscrew bushing (31), push rod (11) and hydraulic
piston (25) as an assembly from hydraulic cylinder
DISASSEMBLY body (21). Do not remove bushing (31) from push rod
Numbers in parentheses refer to Figs. 1 and 2. (11) at this time.
Note: When it is necessary to clamp the pressure 10. Disconnect retainer ring (28). Remove hydraulic
converter in a vice or equivalent mechanism, do not piston (25), valve (27), valve insert (26) and retainer
clamp on air cylinder body (1) or on the cylindrical ring (28). Discard retainer ring (28) and seal (26).
portion of hydraulic cylinder body (21).
11. Slide bushing (31) off push rod (11) end. Remove
and discard 'V' seals (29 & 32) and 'O' ring (30) from
WARNING bushing (31).
Use care to prevent damaging seal grooves,
push rod and cylinder bores. Defects on these 12. Remove and discard 'V' seal (23) from hydraulic
surfaces will cause leakage. One mark could piston (25). Back-up ring (24), if used, should not be
mean loss of pressure and brake failure which removed
could cause personal injury and property
damage.
INSPECTION
1. Using a suitable solvent, clean pressure converter Numbers in parentheses refer to Figs. 1 and 2.
assembly thoroughly.
1. Using mineral spirits, clean air cylinder body (1),
2. Drain hydraulic fluid from pressure converter into a piston follower (4), expander spring (6), air piston (9),
suitable container. push rod (11), hydraulic cylinder body (21), hydraulic
piston (25), valve (27) and bushing (31).
SM 1508 9-98 3
Section 250-0260
2. Inspect cleaned parts for nicks, scratches, grooves, 9. Screw bushing (31) into hydraulic cylinder body (21).
wear, pits, corrosion or foreign material which could Torque tighten bushing (31) to 7 - 40 Nm (5 - 30 lbf ft).
cause leaks. Damaged parts should be replaced.
10. Install new seal ring (13) on end cap (12). Install
end cap (12) assembly on hydraulic cylinder body
ASSEMBLY (21). Torque tighten end cap (12) to 80 - 105 Nm
Numbers in parentheses refer to Figs. 1 and 2. (60 - 80 lbf ft).
Note: When it is necessary to clamp the pressure 11. Install new return spring (10), air piston (9) and
converter in a vice or equivalent mechanism, do not new 'O' ring (8) on push rod (11).
clamp on air cylinder body (1) or on the cylindrical
portion of hydraulic cylinder body (21). 12. Install expander spring (6) and new leather cup (7)
on piston follower (4). Install piston follower (4) washer
(3) and nut (2) on push rod (11). Extra help may be
WARNING required to overcome the spring load. Torque tighten
Use care to prevent damaging seal grooves, nut (2) to 7 - 14 Nm (5 - 10 lbf ft).
push rod and cylinder bores. Defects on these
surfaces will cause leakage. One mark could 13. Apply a coating of grease to new felt wiper (5) and
mean loss of pressure and brake failure which install felt wiper on piston follower (4).
could cause personal injury and property
damage. 14. Install new 'O' ring (14) on indicator rod (15) and
install in hydraulic cylinder body (21). Install new
1. Lubricate 'V' seals (23, 29 & 32) with hydraulic fluid retainer ring (22), if used.
used in brake system. Refer to Section 300-0020,
LUBRICATION SYSTEM. 15. Install contact assembly (17) and shim (18), if
used, in hydraulic cylinder body (21). Torque tighten
2. Install new 'V' seal (23) on hydraulic piston (25). contact assembly (17) to 5 - 10 Nm (4 - 8 lbf ft).
Make sure 'V' seal (23) is installed in the direction as
shown in Fig. 1. 16. Apply a coating of grease to leather cup (7), air
piston (9), piston follower (4) and air cylinder body (1)
3. Install new 'V' seals (29 & 32) into bushing (31). bore. Slide air piston assembly into air cylinder body
Make sure 'V' seal (29 & 32) lips face opposite (1). Push air cylinder body (1) in place, with the six
directions, as shown in Fig. 1. Exercise care as these studs extending through hydraulic cylinder body (21).
seals are difficult to insert. Make sure match marks are aligned.
4. Install new 'O' ring (30) on bushing (31). 17. Secure air cylinder body (1) to hydraulic cylinder
body (21) with lockwashers (20) and nuts (19).
5. Install new valve insert (26) into valve (27). Make Alternately torque tighten nuts (19) to 8 - 16 Nm
sure valve insert (26) is installed as shown in Fig. 1. (6 - 12 lbf ft).
6. Lubricate push rod (11) and valve (27) with 18. Install bleeder screw (16) into hydraulic cylinder
hydraulic fluid used in brake system. Refer to Section body (21). Torque tighten bleeder screw (16) to
300-0020, LUBRICATION SYSTEM. Slide bushing 14 - 28 Nm (10 - 20 lbf ft).
(31) over hydraulic end of push rod (11), as shown in
Fig. 1. Be careful to avoid damage to 'V' seals
(29 & 32). INSTALLATION
Numbers in parentheses refer to Figs. 1 and 2.
7. Slip new retainer ring (28) over hydraulic end of
push rod (11). Attach valve (27) and then slide Note: Tighten all fasteners to standard torques listed
hydraulic piston (25) over the valve. Install retainer in Section 300-0080, STANDARD BOLT AND NUT
ring (28) to secure hydraulic piston (25) to push rod (11). TORQUE SPECIFICATIONS.
8. Lubricate hydraulic piston (25) with hydraulic fluid 1. Install pressure converter in machine and secure
used in brake system. Refer to Section 300-0020, with mounting hardware, as removed at 'Removal'.
LUBRICATION SYSTEM. Carefully insert hydraulic
piston (25) into bore of hydraulic cylinder body (21). 2. Install brake fluid reservoir line in port 'C' of
4 SM 1508 9-98
Section 250-0260
hydraulic cylinder body (21). MAINTENANCE

Note: Maintenance and adjustment of the brake
3. Install hydraulic line in port 'D' of end cap (12). system is contained in Section 165-0010, BRAKE
PARTS.
4. Install breather hose assembly in port 'B' of
hydraulic cylinder body (21). Every 10 hours/Daily
Inspect brake fluid level in remote mounted brake fluid
5. Install air supply line in port 'A' of air cylinder body (1). reservoirs and add if low. Refer to Section 300-0020,
LUBRICATION SYSTEM, for fluid specification.
6. Install electrical wire on contact assembly (17) in
hydraulic cylinder body (21). Check air and hydraulic lines to the pressure
converters for leaks and/or wear. Tighten line fittings
7. Fill remote mounted brake fluid reservoir with fluid, or replace as required.
as specified in Section 300-0020, LUBRICATION
SYSTEM. Bleed brakes as described in
PRESSURE CONVERTER DIAGNOSIS

Air cylinder leak, other than at Worn leather cup Replace cup.
inlet fitting Dent or corrosion in cylinder Repair or replace cylinder body.
body
Loose piston on push rod Replace piston and push rod assembly.
Internal pressure leak in Pitted cylinder, worn valve Replace cylinder assembly if pitted. Replace
hydraulic cylinder. This is seal or worn hydraulic piston worn seals.
indicated by creep or stroke seal
travel during extended holding
application at low pressure.
Fluid leak at rear of hydraulic Cylinder pitting Replace cylinder.
cylinder
Worn end cap seal Replace seal.
Hydraulic pressure builds and Hydraulic piston passage Clean or replace hydraulic piston.
fails to release (brakes lock up) blocked by dirt or corrosion
Swollen valve insert which Replace valve insert.
expands over hydraulic piston
passage. Caused by improper Drain and flush brake hydraulic system. Fill
or contaminated brake fluid. with clean brake fluid, as specified in
Bleed brake system, as specified in
Stroke too long Air in hydraulic lines Bleed brake system, as specified in
SM 1508 9-98 5
Section 250-0260

TORQUE
1&2 2 Nut 7 - 14 5 - 10
1&2 12 End Cap 80 - 105 60 - 80
1&2 16 Bleeder Screw 14 - 28 10 - 20
1&2 17 Contact Assembly 5 - 10 4-8
1&2 19 Nut 8 - 16 6 - 12
1&2 31 Bushing 7 - 40 5 - 30
* * * *
6 SM 1508 9-98
BRAKING SYSTEM - Air Breather
Section 250-0270
DESCRIPTION AND OPERATION SM - 823
There are two non-pressurised air breathers used in

the air system, one on each of the brake pressure
converters. Air displaced on the atmospheric side of
the air piston in the pressure converter exhausts
through the air breather. Refer to Section 250-0000,
AIR BRAKING SYSTEM SCHEMATIC, for
relationship of breathers to pressure converters.
MAINTENANCE
The air breather is manufactured in glass-filled nylon
and glass-coupled polypropylene, ensuring the
product does not corrode even in the most arduous
Fig. 1 - Typical Air Breather Assembly
applications.
Note: An air system maintained to proper Every 500 Hours

specification can lead to prolonged component life. Inspect air breather assembly and check for correct
Refer to Section 250-0200, AIR DRIER, for correct operation. It may be necessary to clean or replace
air filtration service procedures. the air breather if excessive oil vapour has been
present.
* * * *
SM 1509 9-98 1
BRAKING SYSTEM - Relay Emergency Valve
Section 250-0280
SM - 2258
1
2 24
23
4 17
18
5
19
6
7
10
11 22
12 21
20
13
14
15 16
1 - Valve Body - Upper 7 - Inlet/Exhaust Valve 13 - 'O' Ring 19 - Valve Rubber
2 - 'O' Ring 8 - 'O' Ring 14 - Circlip 20 - Rivet
3 - Piston - Upper 9 - Valve Body - Lower 15 - Valve Guide 21 - Part Number Label
4 - 'O' Ring 10 - Spring Seat 16 - Exhaust Check Valve 22 - Bolt
5 - Distance Piece 11 - Spring 17 - Circlip 23 - Lockwasher
6 - Piston - Lower 12 - 'O' Ring 18 - Valve Ring 24 - Nut
Fig. 1 - Cutaway View of Relay Emergency Valve
The relay emergency valve can be identified as

41 42
item 11 in Section 250-0000, AIR BRAKING SYSTEM
SCHEMATIC. 9
c
1
The relay emergency valve speeds the application and 8
release of air pressure to and from the rear pressure
converter. The relay emergency valve is also used as b
a means of preventing the force from the spring brake

and service diaphragm being applied to the foundation
brake at the same time. a
2
OPERATION
1 2
3
Pressure from the park/emergency control valve is

7 6 5 4
supplied via port '42' to chamber 'C' where it acts upon
piston (1). Under the action of the pressure in chamber 5 - Spring
'C', piston (1) moves down and contacts the back of 1 - Piston 6 - Inlet Seat
2 - Piston 7 - Exhaust Seat
piston (2); they then move down together and close
3 - Chamber A 8 - Chamber B
the exhaust seat (7). The application of further 4 - Inlet/Exhaust Valve 9 - Chamber C
pressure causes pistons (1 & 2) to move the inlet/
Fig. 2 - Operational View of Relay Emergency Valve
SM 1945 4-00 1
Braking System - Relay Emergency Valve
Section 250-0280
SM - 2457 supplied from the treadle valve to both the service

diaphragm of the spring brake chamber and to
chamber 'B' of relay emergency valve via port '41'.
2 This forces piston (2) down to close exhaust seat (7)
3 and open inlet seat (6) thereby reinstating air pressure
4
to the pressure converters to compress the power
spring and prevent its force compounding that from the
41
service brake diaphragm. If the service brake pressure
from the treadle valve is released then the pressure in
4
the spring brake will be exhausted through the relay
42 valves and the parking brake will be reapplied.
6
REMOVAL/INSTALLATION
1 2

1
4 TORQUE SPECIFICATIONS.
5
WARNING
1 - Relay Emergency Valve
4 - Adaptor
2 - Locknut 5 - Elbow - 90 damage, be sure wheel chocks, blocking
3 - Washer 6 - Plug materials and lifting equipment are properly
Fig. 3 - Relay Emergency Valve Installation safely.
exhaust valve (4) down again and open the inlet seat 1. Position the vehicle in a level work area, apply the
(6) thereby permitting air to flow from the supply port parking brake and switch off the engine. Block all road
'1' into chamber 'A' and out through delivery port '2' to wheels and place the battery master switch in the 'Off'
the pressure converters. The pressure in chamber 'A' position.
acts on the underside of piston (2) and forces the
pistons up until the inlet/exhaust valve (4), under the 2. Open drain cocks on air tanks and drain air from all
action of spring (5), is in a lapped condition (both the three air tanks. Close drain cocks on air tanks when
inlet (6) and exhaust (7) seats closed). air is exhausted.
When the pressure from the park/emergency control 3. Clean relay emergency valve (1) and surrounding
valve is reduced the pressure in chamber 'C' falls and area with a suitable solvent. Ensure all lines connected
the pressure in chamber 'A' forces pistons (1 & 2) up to relay emergency valve (1) are identified for ease of
and the exhaust seat (7) is opened allowing air from installation and disconnect lines. Fit blanking caps to
the delivery port and the pressure converters to flow all open lines and ports.
out of the exhaust port. The pressure in chamber 'A'
continues to fall until the pressure in chamber 'C' is 4. Support valve body and remove locknuts (2) and
sufficient to close the exhaust seat (7). washers (3) securing relay emergency valve (1) to its
mounting. Remove relay emergency valve (1) from the
When the vehicle is running the power spring in the vehicle.
pressure converter is held compressed by air pressure
from the relay emergency valve and, when the vehicle 5. Note location of adaptors (4), elbow (5) and plug (6)
is required to be parked, the park/emergency control and remove from relay emergency valve (1) for use on
valve delivery is vented and pressure in the spring the new valve.
brake is exhausted through the relay emergency valve
allowing the force from the power spring to apply the 6. Replace all 'O' rings and install adaptors (4), elbow
vehicle foundation brakes. Should the service brake (5) and plug (6) in new relay emergency valve (1)
be applied in this condition then air pressure is ports as removed from the old valve.
2 SM 1945 4-00
Braking System - Relay Emergency Valve
Section 250-0280
7. Secure relay emergency valve (1) to its mounting Note: Limited repair of the relay emergency valve is
using locknuts (2) and washers (3). by replacement of parts only. Refer to vehicle Parts
Book for part numbers of kits.
8. Remove blanking caps from air lines and
install lines to relay emergency valve (1) as identified
during removal. Leak Checking
Block all road wheels, ensure air tanks are fully
9. Place master switch in the 'On' position, start the charged and apply the parking brake. Apply a soap
engine and allow air pressure in the tanks to build up solution to the valve housing and pipe joints and check
to correct operating pressure. Check for leaks at air for leakage. No leakage is permitted from the valve
lines and tighten as required. housing or joints.

SPECIAL TOOLS
There are no special tools required for procedures
MAINTENANCE outlined in this section. Refer to Section 300-0070,
Inspect the relay emergency valve regularly for any SERVICE TOOLS, for part numbers of general service
signs of leakage or damage and repair/replace as tools required. These tools are available from your
required. dealer.
* * * *
SM 1945 4-00 3
BRAKING SYSTEM - Air Pressure Protection Valve
Section 250-0290
SM - 2447 SM - 2448
5
4
3
2 1
Rear
Brake
18 1 Tank and Front
15 Rear
Treadle Front
Brake
6 Tank
Valve Tank
Tank
17 16 14
7 22 21
13
8
9
11,12
10
24 23
1 - Pressure Protection Valve 7 - Tee Piece Primary
Primary Auxiliary
Park/Emergency
2 - Mounting Bracket 8 - Pressure Switch TankTank Brake Control
3 - Lockwasher 9 - Adaptor
4 - Nut 10 - Elbow - 90
5 - Elbow - 90 11 - Adaptor
6 - Adaptor 12 - Tee Piece
13 - Pressure Switch
Fig. 1 - Pressure Protection Valve Installation Fig. 2 - Pressure Protection Valve Schematic
The 4 way pressure protection valve can be identified Numbers in parenthesis refer to Fig. 2.
as item 9 in Section 250-0000, AIR BRAKING
SYSTEM SCHEMATIC. The pressure protection valve takes air from the
compressor and supplies it to the separate circuits of
Mounted off the front left hand side of the tractor the vehicle's brake and auxiliary systems.
frame, adjacent to the primary air tank, the pressure
protection valve is located in the air compressor and The valve has elements which feed circuits '21' and
air drier delivery line, immediately prior to the air tanks. '22' which, when the vehicle system is being charged,
are designed to remain closed until the supply
The pressure protection valve supplies air to all three pressure to them reaches 6.0 to 6.3 bar, after which
tanks for the service brakes, secondary braking and they open to supply the appropriate circuit and then
accessory air devices. If a pressure drop or failure is remain in the open state allowing air to flow back
experienced in one circuit of the air system, the valve through the element ('Feedback') thereby equalising
closes, isolating the circuit, enabling the compressor to the pressures in circuits '21' and '22'.
continue to recharge the unfailed circuits.
This feedback will continue unless the supply pressure
The pressure protection valve also has a built in safety falls to 4 bar minimum at which point the valve element
function which does not allow the spring brakes to be will close preventing any further feedback ('Limited
released, unless there is sufficient pressure in the Feedback').
service brake system to at least provide the prescribed
residual braking performance of the laden vehicle by Air flows from circuits '21' and '22' through non-return
application of the service brakes. valves to the elements feeding circuits '23' and '24',
both designed to open at 6.0 to 6.3 bar. Circuit '24' is
fed through a feedback element the same as circuits
SM 1938 4-00 1
Braking System - Air Pressure Protection Valve
Section 250-0290
SM - 2449 SM - 2450
B B
C C
M M
D D
E E
Z Z
A A
Y Y
X X
A - Piston A - Piston
B - Spring Retainer M - Valve Body B - Spring Retainer M - Valve Body
C - Circlip X - Connection Point C - Circlip X - Connection Point
D - Spring Y - Hole D - Spring Y - Hole
E - 'O' ring Z - Hole E - 'O' ring Z - Hole
Fig. 3 - Safety Function - Disengaged Fig. 4 - Safety Function - Engaged
'21' and '22', while circuit '23' is fed through an element However, if while the vehicle is stationary there is a
which incorporates a non-return valve (Non-Feedback leak in the service reservoirs which is sufficient to
Element). Should there be a failure in either of circuits deplete the pressure in those reservoirs to below
'21' or '22' then the pressures in circuits '23' and '24' 3.5 bar 0.5 bar, then piston (A) will move down
will be unaffected as their supply comes through non- under the force of spring (D) and hole (Z) will move
return valves. Similarly if there is a failure in circuit '24' below 'O' ring (E) (refer to Fig. 4). In this condition,
and circuit '23' will be unaffected because of its Non- holes (Y & Z) will be connected allowing air to pass
feedback element (i.e. it is protected to a minimum of from circuit '23' to atmosphere through the hole in
6 bar). However, if there is a failure in circuit '23' then spring retainer (B). The rate of air loss through is
the pressure in circuit '24' will fall to 4 bar minimum at 16 to 35 Nl/min at 8 bar.
which its element will close protecting it from any
further drop. As with circuits '21' and '22', the element It is this action of the safety function which will drop the
feeding the failed circuit will tend to remain closed pressure in the spring brake reservoir, thereby
allowing the non-failed circuit to recharge. preventing release of the spring brakes until the
pressure in the service reservoirs has built up
sufficiently to move up piston (A) to close off hole (Z).
Safety Function Operation
Letters in parenthesis refer to Fig. 3 & 4.
REMOVAL AND INSTALLATION
Under normal running conditions with all circuits Numbers in parentheses refer to Fig. 1.
pressurised there is pressure on piston (A), fed from
circuit '21', which is sufficient to lift piston (A) and The pressure protection valve is a non-serviceable
compress spring (D) (refer to Fig. 3). In this condition, item and should be replaced completely, if damaged,
hole (Z) in piston (A) is above 'O' ring (E) thereby as follows:
sealing off connection (Y), therefore the operation of
the pressure protection valve is unaffected by the Note: Tighten all fasteners to standard torques listed
safety function. in Section 300-0080, STANDARD BOLT AND NUT
2 SM 1938 4-00
Braking System - Air Pressure Protection Valve
Section 250-0290
(8 & 13) from pressure protection valve (1) ports.

WARNING
To prevent personal injury and property 6. If removed, replace all 'O' rings and install elbows
damage, be sure wheel blocks are properly (5 & 10), adaptors (6, 9 & 11), tee pieces (7 & 12) and
secured and of adequate capacity to do the job pressure switches (8 & 13) to pressure protection
safely. valve (1) ports.
1. Position the vehicle in a level work area, apply the 7. Secure pressure protection valve (1) to mounting
parking brake and switch off the engine. bracket (2) using nuts (4) and lockwashers (3).
2. Block all road wheels and place the battery master 8. Install air lines and electrical connection to pressure
switch in the 'Off' position. Open drain cocks on air protection valve (1), as tagged at 'Removal'.
tanks and drain air from all three air tanks. Close drain
cocks on air tanks when air is exhausted. 9. Start engine and allow air pressure in the tanks to
build up to correct operating pressure. Check for leaks
3. Tag and disconnect air lines and electrical at air lines and tighten as required.
connections from pressure protection valve (1), to aid
in installation. 10. Remove wheel blocks.
4. Support valve body and remove nuts (4) and

lockwashers (3) securing pressure protection valve (1) SPECIAL TOOLS
to mounting bracket (2). Remove pressure protection There are no special tools required for procedures
valve (1) from vehicle. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
5. If required, remove elbow (5 & 10), adaptors tools required. These tools are available from your
(6, 9 & 11), tee pieces (7 & 12) and pressure switches dealer.
* * * *
SM 1938 4-00 3
OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010
SM - 2471
14,16,17 15,16,17
18,19,20
11
12
21
13
26
1
27
28
4
8
7
6
25
2
23 3
3
22 24 2
5 4
FRONT MOUNTING REAR MOUNTING
1 - Cab Assembly 8 - Ball Bearing 15 - Hinge 22 - Spring

2 - Isolation Mount 9 - Hardened Washer 16 - Bolt 23 - Hardened Washer
3 - Washer 10 - Locknut 17 - Locknut 24 - Locknut
4 - Locknut 11 - Mirror Arm 18 - Bolt 25 - Firewall Barrier Mat
5 - Bolt 12 - Mirror 19 - Lockwasher 26 - Plate
6 - Bolt 13 - Mirror - Wide Angle 20 - Washer 27 - Lockwasher
7 - Hardened Washer 14 - Hinge 21 - Rear Window Guard 28 - Screw
Fig. 1 - Cab and Mounting
DESCRIPTION Cab assembly (1) is spacious and offers outstanding

Numbers in parentheses refer to Fig. 1. visibility through large areas of tinted safety glass.
Access to cab assembly (1) is from the left hand side
The cab is fully insulated and mounted on rubber with open tread steps, platform and handrail.
isolation mounts (2) to damp structure-borne noise
and vibration. It conforms with ISO/SAE, ROPS (Roll The cab interior, trimmed with noise-absorbent
Over Protective Structure) and FOPS (Falling Object material, is extensively thermally insulated and a
Protective Structure) requirements as standard. heater/filter/pressurizer and demisting unit keeps
internal air fresh and dust free. Sliding windows
ROPS - ISO 3471, SAE J1040 APR 88 provide additional ventilation. A side mounted air
FOPS - ISO 3449, SAE J231 conditioner is also fitted. Refer to Section 260-0130,
AIR CONDITIONING.
WARNING Note: Access from the cab, in the case of an emergency,

The protection offered by the roll over and can be gained by breaking any of the windows using the
falling object protective structure may be hammer provided (mounted on the right hand cab pillar).
impaired if it has been subjected to any
modification or damage.
SM 1957 4-00 1
Operators Compartment - Cab and Mounting
Section 260-0010
REMOVAL
Numbers in parentheses refer to Fig. 1. WARNING
Before disconnecting any air conditioner lines,
Note: Identify and tag all cables, harnesses, lines and refer to Section 260-0130, AIR CONDITIONING.
linkages disconnected from cab assembly (1) during Refrigerant will rapidly freeze all objects with
removal to aid in installation. which it comes into contact. It can cause
serious and permanent damage to the eyes
and skin.
WARNINGS
To prevent personal injury and property 5. Evacuate the refrigerant from the air conditioning
damage, be sure wheel chocks, blocking system and disconnect the lines. Refer to Section
materials and lifting equipment are properly 260-0130, AIR CONDITIONING. Fit blanking caps to
secured and of adequate capacity to do the job all open lines and fittings.
safely.
6. Ensure heater lines are identified for ease of
Hydraulic fluid pressure will remain within installation and with suitable containers available to
the body hoist system after engine shutdown. catch leakage, disconnect heater lines. Fit blanking
To prevent personal injury and property caps to open line ends and fittings.
damage, press and hold down body hoist
bleed down switch and operate the body 7. Remove the front right hand tyre and rim assembly
control joystick continually to relieve pressure for access. Refer to Section 160-0050, WHEEL RIM
in the system before disconnecting any hoses. AND TYRE.
High electrical current. Turn the battery 8. Disconnect electrical harnesses from cab bulkhead.
master switch 'Off' before disconnecting any
electrical components. Disconnect electrical 9. Loosen the steering coupling attaching the upper
connections in the correct order given to column to the lower column. Remove mounting
prevent damage to the electrical components. hardware securing the steering valve mounting plate to
the cab floor and lower the assembly from the cab.
parking brake and switch off the engine. 10. Remove mounting hardware securing the treadle
valve and accelerator pedal mounting plate to the cab
2. Press and hold down body hoist bleed down switch floor and lower the assembly from the cab.
relieve pressure in the body hoist system. 11. Tag and disconnect the harnesses and hoses at
the underside of the manifold on the right-hand side of
3. Block all road wheels, except the front right hand, the cab. Disconnect earth strap at rear right hand cab
and place the battery master switch in the 'Off' leg.
position.
12. With a suitable container in position, drain the
4. Disconnect the electrical cables in the following cooling system. Refer to Section 210-0000, COOLING
order to prevent damage to the electrical components. SYSTEM.
a. Disconnect battery ground cables from terminal 13. Pull on handle (inside cab) to release hood catch
posts. and lift up hood assembly.
b. Disconnect battery supply cables from terminal
posts. 14. Disconnect ball joint and clips securing hood
c. Disconnect alternator ground cables. release cable to lock mechanism.
d. Disconnect alternator supply cables.
e. Disconnect electrical connections at the ECU. 15. Release rear screen guard from its retainers on
the hydraulic tank and disconnect the linkage between
5. Open drain cocks on air tanks and drain air from all the guard and the tank.
three air tanks. Close drain cocks on air tanks when
air is exhausted.
2 SM 1957 4-00
Section 260-0010
16. Attach suitable slings to the cab lifting points and 5. Reconnect ball joint to lock mechanism and secure
raise lifting equipment to take up the slack. hood release cable using clips removed during
removal.
17. Remove locknuts (4), washers (3), hardened
washers (7) and bolts (5 & 6) securing the cab 6. Connect the linkage between the rear screen guard
assembly (1) to isolation mounts (2) and cab mounting and the hydraulic tank. Secure the guard to its
brackets on the tractor frame. retainers.
18. Check to make certain that all necessary 7. Install treadle valve and accelerator pedal mounting
disconnections have been made, before lifting cab plate assembly and secure to cab floor with mounting
assembly (1). Taking care to prevent damaging the hardware removed during removal.
insulating material, lift cab assembly (1) from the frame
and place on suitable stands. 8. Install steering valve assembly and secure to cab
floor with mounting hardware removed during removal.
Secure the steering coupling to the lower steering
INSTALLATION column with mounting hardware removed during
Numbers in parentheses refer to Fig. 1. removal.
Note: Tighten all fasteners without special torques 9. Pass the heater hoses up through the cutout in cab
specified to standard torques listed in floor and connect them to the heater as identified at
Section 300-0080, STANDARD BOLT AND NUT removal.
10. Connect air conditioning lines and charge air
conditioning system. Refer to Section 260-0130, AIR
WARNING CONDITIONING.
damage, be sure blocking materials and lifting 11. Connect the harnesses and hoses at the
equipment are properly secured and of underside of the manifold on the right-hand side of the
adequate capacity to do the job safely. cab as noted on removal. Connect earth strap at rear
right hand cab leg.
1. Inspect isolation mounts (2) for damage and replace
if necessary. If installing rubber mounts, lubricate them 12. Connect electrical harnesses at cab bulkhead.
with water or a suitable rubber lubricant and install
them from above into the cab mounting brackets on 13. Install front right hand tyre and rim assembly.
frame. Use a driver of the same diameter as the Refer to Section 160-0050, WHEEL RIM AND TYRE.
internal metal sleeve in the mount to drive the mounts
fully home. 14. Fill the cooling system with coolant specified in
2. Attach suitable slings to the cab lifting points and
raise and position cab on frame. 15. Connect cables to battery terminal posts (ground
cable last).
3. Secure front of cab assembly (1) to cab mounts with
bolts (5), washers (3), hardened washers (7) and 16. Place the battery master switch in the 'On' position,
locknuts (4), as shown in Fig. 1. Tighten locknuts (4) to start the engine and check for leaks. Tighten fittings if
a torque of 380 Nm (280 lbf ft). necessary. Allow engine to warm up and recheck all
connections for leaks. Ensure electrical systems and
4. Secure rear of cab assembly (1) to cab mounts gear shift are functioning properly.
with bolts (6), washers (3) and locknuts (4), as shown
in Fig. 1. Tighten locknuts (4) to a torque of 380 Nm 17. Ensure parking brake is applied and remove wheel
(280 lbf ft). blocks from all road wheels.
SM 1957 4-00 3
Section 260-0010
MIRROR ARMS 4. Repeat steps 1, 2 and 3 for other mirror arm bracket
(11).
Removal
REPLACING GLASS
Note: When replacing broken glass, it is the users
WARNING responsibility to ensure that the replacement glass
To prevent personal injury and property meets the required specifications. Replacement glass
damage, be sure blocking materials and lifting can be purchased from your dealer.
adequate capacity to do the job safely. The rear glass, left and right hand side glasses and
front windscreen are held in place by a bonding
1. Support mirror arm bracket (11) and remove adhesive. The rear glass and right hand side glass
locknuts (24), hardened washers (23) and springs (22) also have two mounting blocks to support the glass.
securing mirror arm assembly to mounting brackets.
To replace a glass assembly, proceed as follows:
2. Remove mirror arm bracket (11) and ball bearings
(8) from mounting brackets. Note: Ensure the glass is supported adequately
before starting to cut the adhesive seal.
3. Repeat steps 1 and 2 for other mirror arm bracket
(11). 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
MIRROR ARMS the wire through the opening. Pierce a second hole in
the adhesive on the side directly opposite the first.
Installation
Numbers in parentheses refer to Fig. 1. 2. From inside the cab pull the wire through and feed it
back out through the second hole.
specified to standard torques listed in 3. Re-fit the handle on the special tool. Pull both
Section 300-0080, STANDARD BOLT AND NUT handles outwards until wire is taut.
4. Manouver the special tool around the edge of the
glass, keeping the wire taut, to cut the adhesive seal.
WARNING Ensure the glass is supported adequately before
To prevent personal injury and property completing the cut.
damage, be sure blocking materials and lifting
equipment are properly secured and of 5. If fitted, loosen mounting blocks to allow the glass to
adequate capacity to do the job safely. be removed from window aperture. Remove the
mounting blocks if necessary.
1. Coat ball bearings (8) with grease and locate in
mounting brackets. 6. Clean the remains of the adhesive from the edge of
the panel opening using a suitable solvent.
2. Locate mirror arm bracket (11) to mounting brackets
and install hardened washers (23), springs (22) and 7. If removed, re-fit window mounting blocks, do not
locknuts (24) as shown in Fig. 1. tighten.
3. Set mirror bracket spring (22) pressure as follows; 8. Coat the edge of the replacement glass with primer
a. rotate mirror arm (11) until ball bearings (8) are and apply adhesive around the lip of the window
out of their detent. aperture, as per the manufacturers recommendations.
b. tighten locknut (24) until spring (22) is almost
completely compressed (typical two places).
c. swing arm until it seats in detent.
d. check the other two detent positions
4 SM 1957 4-00
Section 260-0010
9. Position glass onto panel opening, pressing firmly leakage inside the cab. Care should be taken to note
so that adhesive bonds sufficiently to allow the glass to whether the leak is between adhesive and glass. Then
be moved or straightened up as required. apply a sealing compound from the outside. Start from
a point near the leak and continue applying the sealer
10. Ensuring the glass is adequately supported, allow until well beyond the suspected point of entry.
the sealing adhesive to set properly.
This should stop the leak immediately, but since some
11. Clean off any excess adhesive using a suitable sealing compounds should be allowed to set before
solvent. getting wet, wait a few minutes before testing.
12. If necessary, tighten window mounting blocks.

SERVICE TOOLS
Water Leaks numbers of the glass removal tool, adhesive bonding
Test for leaks by directing a stream of water along the kit and other general service tools required. These
adhesive seal, while an assistant marks the spot of tools are available from your dealer.

TORQUE
1 4 Locknut 380 280
* * * *
SM 1957 4-00 5
OPERATORS COMPARTMENT - Driver Seat and Mounting
Section 260-0090
SM - 2486
1 - Seat Frame 30 - Air Spring

2 - Backrest Cushion 31 - Pop-out Button
3 - Seat Cushion 12 - Bushing 21 - Compressor 32 - Suspension Skirt
4 - Screw 13 - Plug 22 - Connecting Cable 33 - Allen Screw
5 - Screw 14 - Slide Adjuster Rail 23 - Air Hose 34 - Seat Base
6 - Backrest 15 - Shock Absorber - Horizontal 24 - Lever 35 - Bolt
7 - Cover 16 - Locking Lever 25 - Bowden Cable 36 - Washer
8 - Cover 17 - Bowden Cable 26 - Shock Absorber - Vertical 37 - Bolt
9 - Lap Belt 18 - Adjuster Control Unit 27 - Cover 38 - Washer
10 - Nut 19 - Handle 28 - Level Controller 39 - Lockwasher
11 - Spacer 20 - Horizontal Isolator Unit 29 - Swing Arm 40 - Nut
Fig. 1 - Exploded View of Driver Seat
DESCRIPTION The driver seat is secured to the cab wall with bolts
Numbers in parentheses refer to Fig. 1. (35) and washers (36). The seat assembly consists of
a seat cushion (3) and backrest cushion (2) mounted
to seat frame (1). Seat frame (1) is attached to seat
WARNING base (34) by means of a suspension assembly. The
By Law, seat belts must be provided. Always air seat only reacts when the driver sits on the seat.
wear seat belts when travelling in the vehicle.
SM 1981 4-00 1
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
When unoccupied, the seat sinks to the lowest position 7. Set damper adjustment (G) position to suit driving
to allow easier access. conditions, (4 positions; forward position - hardest
setting, rearmost position - softest setting).
A retractable lap belt (9) is secured to the seat
assembly using nuts and spacers. A push button 8. Set fore/aft isolator (C) position to suit driving
allows quick release of lap belt (9). conditions, (forward position - unlocked, rearmost
position - locked).
The following is the list of controls to adjust the seat:
A. Height and weight adjustment. 9. Engage seat belt (D).
B. Horizontal adjustment (sliderails).
C. Fore/aft isolator (forward position - unlocked,
rearmost position - locked). REMOVAL
D. Seat belt. Numbers in parentheses refer to Fig. 1.
E. Backrest angle adjustment.
F. Backrest height adjustment.
G. Damper adjustment (4 positions; forward position - WARNINGS
hardest setting, rearmost position - softest setting). To prevent personal injury and property
WARNING secured and of adequate capacity to do the job
Do not attempt to adjust the seat or seat belt safely.
while the machine is moving. Loss of control
may result. Stop the machine; apply the 1. Position the vehicle in a level work area, apply the
brakes; then adjust. parking brake and switch off the engine.

OPERATION switch in the 'Off' position.
To achieve the most comfortable driving position,
adjust the seat as follows; 3. Disconnect harness connector at the rear of the
seat.
1. Sit in seat.
4. Push down height and weight adjustment (A) handle
2. Pull up and release height and weight adjustment to release the air from the seat air suspension system.
(A) handle - this will reset the seat to the
predetermined height setting - 'bounce' lightly until a 6. Using suitable lifting equipment, support seat and
'click' is heard, the seat position in now engaged remove bolts (35) and washers (36) securing complete
properly. seat assembly to the cab wall. Remove seat assembly
from vehicle.
3. Pull up horizontal adjustment handle (B) and move
seat forwards or backwards, release handle when
required position is achieved. DISASSEMBLY
4. Pull up (or push down) height and weight adjustment
(A) handle and hold until the require height position is Note: The disassembly and assembly procedures will
achieved, release handle - 'bounce' lightly until a 'click' cover only basic subassemblies due to the multitude of
is heard, the seat position in now engaged properly. parts. If a subassembly must be disassembled, use
the exploded view in Fig. 1 for reference.
5. Pull up handle (E) and adjust backrest to the
required angle, release handle when required position 1. Remove bolts (37), washers (39), lockwashers (39)
is achieved. and nuts (40) securing seat base (34) to seat
assembly. Remove seat base (34) from seat
6. Pull up (or push down) backrest (F) to the required assembly.
height.
2. Remove covers (7 & 8) from seat assembly.
Remove nuts and spacers securing lap belt (9) to seat
assembly. Remove lap belt (9).
2 SM 1981 4-00
Section 260-0090
3. Pull up and remove backrest (6) from seat frame (1). Vertical Shock Absorber
4. Remove screws (5) securing backrest cushion (2) to
seat frame (1). Remove backrest cushion (2). Note: Remove seat assembly as described in
'Disassembly'
5. Remove screws (4) securing seat cushion (3) to
seat frame (1). Remove seat cushion (3). 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly.
6. Pull up horizontal adjustment (B) lever and slide
seat assembly rearwards. Hold captive nuts using a 2. Unhook Bowden wire (5) and damper adjuster (6)
suitable spanner and remove front allen screws (33). assembly from the top of shock absorber (7).
7. Pull up horizontal adjustment (B) lever and slide 3. Remove circlips (3) and lever out shock absorber
seat assembly forwards. Hold captive nuts using a (7) from mounting pins (4).
suitable spanner and remove rear allen screws (33).
4. Remove spacers (8) from lower mounting pin (4).
8. Remove seat assembly from suspension base.
5. Reassembly is done in the reverse order.
Horizontal Shock Absorber Note: Inscription must face upwards when assembling
Numbers in parentheses refer to Fig. 2. shock absorber (7).
Note: Remove seat assembly as described in SM - 2488
'Disassembly'
1. Remove pop-out buttons (1) and remove access

2. Unclip hooked end of shock absorber (4) from

horizontal spring assembly.
3. Remove circlip (3) and lever out shock absorber (4)

from rocker shaft and slide off of mounting pin.
4. Remove spacer (5) from mounting pin.
SM - 2487
Fig. 3 - Exploded View of Vertical Shock Absorber
Compressor
Note: Remove seat assembly as described in

'Disassembly'

2. Remove pop-out buttons (3) and push down

suspension skirt (4) to allow further access to
suspension assembly.
Fig. 2 - Exploded View of Horizontal Shock Absorber 3. Remove pressurised airline (5) from compressor (6).
SM 1981 4-00 3
Section 260-0090
4. Identify and tag and disconnect electrical plug 3. Pull suspension assembly up to its highest position
connections (7 & 8). Unfasten cable tie on the rocker. and block securely.
5. Pull suspension assembly up to its highest position 4. Unhook bowden wires (5 & 6) from level controller (7).
and block securely.
5. Identify and tag and disconnect electrical plug
6. Unscrew lower nut (9) and remove micro connections (8 & 9).
encapsulated cylinder screw (10) and retaining clamp
(11). 6. Identify and tag and disconnect pressurised airlines
(10) from air suspension unit (11). Unfasten cable tie on
7. Remove compressor (6) and felt mat (12) from the rocker.
suspension base.
7. Remove screw (12), push out pin (13) and release
8. Reassembly is done in the reverse order. roll up belt (17).
Note: Replace micro encapsulated cylinder screw (10). 8. Remove nuts (14) and manoeuvre level controller
(7) until studs are free from mounting holes.
Note: Centralise compressor (6) and felt mat (12)
between rocker arms. 9. Remove screws (15) and remove bowden wire (16)
retainer from level controller (7).
SM - 2489
10. Remove level controller (7) from suspension base.
Note: Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).
SM - 2490
Fig. 4 - Exploded View of Compressor and Mounting
Level Controller
Note: Remove seat assembly as described in

'Disassembly'
Fig. 5 - Exploded View of Level Controller and Mounting

2. Remove pop-out buttons (3) and push down

suspension skirt (4) to allow further access to
suspension assembly.
4 SM 1981 4-00
Section 260-0090
INSPECTION INSTALLATION
1. Inspect air lines, shock absorbers (15 & 26), Note: Tighten all fasteners without special torques
compressor (21), level controller (28) and air spring specified to torques listed in Section 300-0080,
(30) for leaks and damage and replace if required. STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
2. Check all brackets and frame for cracks and/or
damage. Repair or replace as necessary.
WARNINGS
3. Check springs for fatigue or damage and replace as To prevent personal injury and property
required. damage, be sure wheel chocks, blocking
ASSEMBLY safely.
1. Using suitable lifting equipment, position seat
Note: Tighten all fasteners without special torques assembly on the cab wall and secure with bolts (35)
specified to torques listed in Section 300-0080, and washers (36).
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 2. Reconnect harness at the rear of the seat.
1. Position seat assembly onto suspension base. Hold 3. Place battery master switch in the 'On' position,
captive nuts using a suitable spanner and install rear start the engine and charge the air system. Check seat
allen screws (33). Tighten allen screws (33) to a for proper operation, refer to 'Operation'.
4. Remove wheel chocks from road wheels.
2. Pull up horizontal adjustment (B) lever and slide
seat assembly rearwards. Hold captive nuts using a
suitable spanner and install front allen screws (33). MAINTENANCE
Tighten allen screws (33) to a torque of 25 Nm Numbers in parentheses refer to Fig. 1.
(18 lbf ft).
The care of the upholstery on seat cushion (3) and
3. Install seat cushion (3) to seat frame (1) and secure backrest cushion (2) is a relatively simple, but
using screws (4). important matter. Accumulation of dirt on the surface
eventually turns into a hard gritty substance which cuts
4. Install backrest cushion (2) to seat frame (1) and into the surface of the upholstery.
secure using screws (5).
To clean seat cushion (3) and backrest cushion (2),
5. Refit backrest (6) to seat frame (1). use warm water and a mild soap, such as Castile.
Work up thin soap suds on a piece of soft cloth and
6. Position lap belt (9) to seat assembly and secure rub the upholstery briskly. Remove the suds with a
using nuts (10) and spacers (11) as removed at damp cloth, using no soap, and finish by wiping the
'Disassembly'. Tighten nuts (10) to a torque of 50 Nm upholstery dry with a soft, dry cloth.
(36 lbf ft). Refit covers (7 & 8).
Lap belt (9) assembly should be inspected by the user
7. Position seat assembly onto seat base (34) and on a regular basis. Replace lap belt (9) immediately if
secure using bolts (37), washers (38), lockwashers hardware is worn or damage, straps are nicked or
(39) and nuts (40). frayed, buckle is not functioning correctly, loose
stitching is found, or if the strap material has lost
strength due to the effects of ultraviolet rays.
Note: Regardless of appearance, lap belt (9) must be

removed and replaced at least once every three years.
SM 1981 4-00 5
Section 260-0090

TORQUE
1 10 Nut 50 36
1 33 Allen Screw 25 18
5 14 Nut 25 18
* * * *
6 SM 1981 4-00
OPERATORS COMPARTMENT - Air Conditioning
Section 260-0130
SM - 2430
1 3 IN
D
S OUT
4
5
1 - Compressor 3 - Receiver Drier 5 - Evaporator

2 - Condenser 4 - Expansion Valve
Fig. 1 - Typical Air Conditioning Flow Diagram
DESCRIPTION Compressor Drive Clutch

The R-134a compressor systems use an electronically
Temperature Control Switch actuated clutch to engage and disengage drive to the
A thermostat switch senses the temperature of the compressor. The 'V' belt pulley is mounted on a bearing
evaporator and engages or disengages the and is free to rotate without turning the compressor
compressor clutch. The control for this switch is crankshaft any time electrical power is disconnected.
located in the cab. The compressor is not operating when the pulley is
freewheeling. The field coil is energized by supplying
electrical current to the exposed wire. The other end of
Compressor the coil winding is grounded to the compressor and
The compressor is designed to compress vapour and equipment frame. Energizing the coil creates a magnetic
can be damaged by non-compressibles such as dirt, force that locks the driven disk to the pulley and drives
moisture, liquid refrigerant (R-134a), etc. The the compressor.
compressor draws vaporized R-134a from the
evaporator (which maintains the low pressure
necessary for proper evaporation) and compresses Condenser
the vapour to a high pressure, which is necessary for The purpose of the condenser is to radiate enough
condensation. The high pressure vapour then moves heat energy from the compressed high pressure
into the condenser where heat can be radiated to vaporized R-134a so that the R-134a changes from
change the R-134a back to liquid. vapour to liquid. During normal operation all the high
pressure section of the system will be warm or hot,
Note: R-134a designates the type of refrigerant used but large quantities of heat should be radiating from
in heavy duty vehicle air conditioning systems. the condenser. Nothing should be permitted to stop or
SM 1966 4-00 1
Operators Compartment - Air Conditioning
Section 260-0130
slow down this radiation of heat. Cooling fins are A filter screen is located in the receiver drier to stop
located on the condenser tubes and fans are used to solid contaminates from leaving the unit. Blockage of
circulate cool air around the condenser tubes. Keep the filter will result in a drop in pressure that will be
all leaves, paper, dirt, etc. clear from the condenser indicated by a drop in temperature. Connections of
and condenser filter. The cooling fins should be the new receiver drier should be securely capped
straight to permit free flow of air. The condenser is before installation to prevent the entrance of moisture
sometimes located ahead of the engine radiator and (air) while in storage.
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 Thermostatic Expansion Valve
that lessens the amount of cool air circulated through An expansion valve is installed in the system to lower
the condenser, should be corrected. The oil, dirt, or the pressure before the R-134a enters the
antifreeze will act as an insulator that will inhibit the evaporator. The reduction in pressure is done by
radiation of heat. passing the R-134a through a small hole (orifice).
The size of the orifice must be controlled to
Since the purpose of the condenser is to radiate heat compensate for changes in pressure and
energy, anything that prevents or inhibits this action temperature. The temperature of R-134a leaving the
may affect cooling, but the temperature and pressure evaporator is sensed by a thermostatic sensor that
of the R-134a raise and lower together. Heat energy moves the valve seat via a diaphragm and actuating
that has not been radiated will remain in the R-134a pin.
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 Evaporator - Heat/Cool
safety switches may be activated by the high The evaporator is the low pressure, low temperature
pressure caused by the condenser not radiating component where liquid R-134a absorbs heat from
enough heat. 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
Receiver Drier temperature is quickly reduced. The R-134a absorbs
The high pressure liquid R-134a moves from the heat from the air when the blower fan circulates air
condenser to the receiver drier, where the R-134a is over the evaporator coil fins. The exchange of heat
stored and filtered. Moisture is the major enemy of from the air to the R-134a depends upon the
the air conditioning system and the desiccant inside difference in temperature. During high heat load, such
the receiver drier will absorb only a small amount. as usually encountered when the system is first
The container of desiccant inside the receiver drier turned on, the temperature difference is great and the
may break open and contaminate the system if any R-134a will absorb heat quickly. The blower fan can
attempt is made to dry the desiccant, or, if more be set at its highest setting to circulate large
moisture is inside the system than the desiccant can quantities of warm air around the evaporator. After
absorb. the cab has cooled, the fan speed should be reduced
so that the already cool air will have a longer time to
Every effort should be made to remove all moisture yield heat to the R-134a as it passes the evaporator
from the system and install a new receiver drier if its coils. The heater circuits utilize engine coolant at
condition is questionable. Installation of a new approximately 82 C (180 F).
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 High Pressure and Low Pressure Switches
receiver drier during the charging procedure. 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.
2 SM 1966 4-00
Section 260-0130
REMOVAL 6. When satisfied that the system is completely

Numbers in parentheses refer to Fig. 2, unless discharged, tag refrigerant hoses (5 & 6) to aid in
otherwise stated. installation and carefully disconnect hoses from air
conditioner (1). Cap air conditioner (1) fittings and
refrigerant hoses (5 & 6) to prevent foreign matter
WARNINGS from entering the system.
Always wear goggles or glasses to protect
your eyes when working around R-134a. 7. Remove bolts (47, Fig. 3) and lockwashers
R-134a boils at sea level temperatures of (48, Fig. 3) securing front cover and filter assemblies
-29.8 C (-21.6 F), which means that direct on air conditioner (1) outer box.
contact with your skin will produce frostbite.
Exercise extreme care when handling R-134a. 8. Disconnect harness (4, Fig. 3) and unhook control
cable (49, Fig. 3) from water valve (50, Fig. 3).
If you get the slightest trace of R-134a in
your eye, flood the eye immediately with cool 9. Remove bolts (42, Fig. 3), lockwashers (43, Fig. 3)
water; then treat with mineral oil or clear and washers (44, Fig. 3) securing air conditioner (1)
petroleum jelly followed by boric acid rinse. outer box to cab assembly and withdraw box.
Report to a hospital or doctor as soon as
possible. 10. Tag refrigerant hoses (5 & 9) to aid in installation
and carefully disconnect hoses from receiver/drier
The chemicals of R-134a change when (16). Cap receiver/drier (16) fittings and refrigerant
burned and become a poison phosgene gas hoses (5 & 9) to prevent foreign matter from entering
that will damage the respiratory system if the system.
inhaled. NEVER SMOKE in an area where
R-134a is used or stored. Use hot water or an 11. Support receiver/drier (16) and remove bolts (38)
approved heated charge cylinder as a heat and nuts (39) securing receiver/drier (16) to mounting
source if required to force R-134a into the bracket (17). If necessary, remove bolts (21),
system. If using water, do not exceed 52 C lockwashers (22), nuts (25) and mounting bracket
(125 F). Never use direct flame or electric (17) from bracket (20).
heaters in direct contact with the R-134a
container. High temperatures may result in 12. Tag refrigerant hoses (7, 8, 9 & 10) to aid in
raising the pressure to a dangerous level. installation and carefully disconnect hoses at radiator
cowl and condenser (11). Cap condenser (11) fittings
To prevent personal injury and property and refrigerant hoses to prevent ingress of foreign
damage, be sure wheel blocks, blocking matter.
secured and of adequate capacity to do the job 13. If required, support air conditioner condenser (11)
safely. and remove bolts (13), lockwashers (14) and
washers (15) securing condenser (11) to radiator
1. Position the vehicle in a level work area, apply the assembly. Remove condenser (11) from vehicle.
14. Tag refrigerant hoses (6 & 7) to aid in installation
2. Block all road wheels and place the battery master and carefully disconnect hoses from compressor
switch in the 'Off' position. (12). Cap compressor (12) fittings and refrigerant
hoses (6 & 7) to prevent foreign matter from entering
3. Pull on handle (inside cab) to release hood catch the system.
and raise the hood.
15. Disconnect electrical connection from
4. Discharge the air conditioning system as compressor (12) clutch.
described under 'Discharging The System'.
16. Slacken nut (26) and bolt (24). Adjust bolt (24) to
5. Remove screws (2) and lockwashers (3) securing release tension on 'V' belt (18).
cover on air conditioner (1) outer box to gain access
to refrigerent hosing. 17. 'V' belt (18) should now be free to slide off the
groove in compressor (12).
SM 1966 4-00 3
Section 260-0130
SM - 2481B
AIR CONDITIONER
OUTER BOX
3 1
2
7 6
12
34 33
11
33
32
15
14
13 31
30
29
36
37 35
24 21
22 17
18 26 38
39
19
8 23 5
27 20
28
25
7
10 9 16
20 - Adjuster Bracket 30 - Lockwasher

1 - Air Conditioner 11 - Condenser 21 - Bolt 31 - Bolt
2 - Screw 12 - Compressor 22 - Lockwasher 32 - Bolt
3 - Lockwasher 13 - Bolt 23 - Washer 33 - Washer
5 - Refrigerant Hose 14 - Lockwasher 24 - Bolt 34 - Locknut
6 - Refrigerant Hose 15 - Washer 25 - Nut 35 - Bracket
7 - Refrigerant Hose 16 - Receiver/Drier 26 - Nut 36 - Bolt
8 - Refrigerant Hose 17 - Bracket 27 - Lockwasher 37 - Lockwasher
9 - Refrigerant Hose 18 - 'V' Belt 28 - Bolt 38 - Bolt
10 - Refrigerant Hose 19 - Bracket 29 - Washer 39 - Nut
Fig. 2 - Air Conditioner Lines and Mounting
4 SM 1966 4-00
Section 260-0130
SM - 2481A
44 43 42
MOUNTING
A-A
46
DETAIL INSIDE CAB

41
45
A
40
50
49
EXPLODED VIEW ON FRONT 4

OF AIR CONDITIONER BOX
48
47
4 - Harness 45 - Cover
40 - Harness 46 - Blower Unit
41 - Harness 47 - Bolt
42 - Bolt 48 - Lockwasher
43 - Lockwasher 49 - Control Cable
44 - Washer 50 - Water Valve
Fig. 3 - Air Conditioner Lines and Mounting
SM 1966 4-00 5
Section 260-0130
18. Support compressor (12) and remove bolts (32), 2. Connect harness (4, Fig. 3) and attach control
washers (33) and locknuts (34) securing compressor cable (49, Fig. 3) to water valve (50, Fig. 3).
(12) to bracket (19). Remove compressor (12) from
the vehicle. 3. Position front cover and filter assemblies on air
conditioner (1) outer box and secure using bolts
Note: If 'V' belt (18) does not require replacement do (47, Fig. 3) and lockwashers (48, Fig. 3).
not remove from engine fan pulley. If 'V' belt (18)
requires replacement, proceed with steps 19 and 20. 4. Remove caps from end of refrigerant hoses (5 & 6)
and ports on air conditioner (1) and connect hoses to
19. If required, remove mounting hardware securing ports as tagged at removal.
fan guard assembly to radiator shroud assembly.
Refer to SECTION 210-0040, RADIATOR AND 5. Route refrigerant hoses (5 & 6) behind the engine
MOUNTING. and along the LH side of the engine securing with
clamps removed during removal.
20. Release tension on Poly 'V' fan belt and remove
from fan pulley. Remove compressor 'V' belt (18) 6. If removed, install receiver/drier (16) to mounting
from the rear groove of the fan pulley. Refer to bracket (17) and secure with bolts (38) and nuts (39).
Section 110-0030, ENGINE AND MOUNTING. Secure assembly to bracket assembly (20) with bolts
(21), lockwashers (22) and nuts (25).
21. If required, remove bolts (31), lockwashers (30),
washers (29) and bracket (19) from engine. 7. Remove caps from end of refrigerant hoses (5 & 9)
and ports on receiver/drier (16) and connect hoses to
22. If required, disconnect all clamps and clips ports as tagged at removal.
securing refrigerant hoses and harnesses to the
vehicle. Remove hoses and harnesses from the 8. If removed, install condenser unit (11) to radiator
vehicle. assembly and secure with bolts (13), washers (15)
and lockwashers (14).
23. If necessary to gain access to blower unit (46,
Fig. 3), disconnect harnesses (40 & 41, Fig. 3) and 9. Remove caps and connect refridgerant hoses
air ducting tubes from air conditioning unit (located in (7, 8, 9 & 10) to radiator cowl and condenser unit (11)
the right hand side of the cab). Remove bolts (42, ports as tagged at removal.
Fig. 3), lockwashers (43, Fig. 3), washers (44, Fig. 3)
and slide cover (45, Fig. 3) from air conditioning unit. 10. If removed, install mounting bracket (19) to
engine and secure using bolts (31), washers (29) and
lockwashers (30) as shown in Fig. 2.
INSTALLATION
Numbers in parentheses refer to Fig. 2, unless 11. Fit compressor (12) to mounting bracket (19) and
otherwise stated. secure with bolts (32), washers (33) and locknuts
(34). Do not fully tighten at this stage.
Note: Tighten all fasteners to standard torques
specified in Section 300-0080, STANDARD BOLT Note: If fan guard, Poly 'V' fan belt and compressor
AND NUT TORQUE SPECIFICATIONS. 'V' belt (18) were removed, proceed with steps 12 & 13.
12. Install new 'V' belt (18) onto rear groove on engine
WARNING fan pulley and fit to rear groove on compressor (12).
damage, be sure wheel blocks, blocking 13. Refit Poly 'V' fan belt and adjust tension. Refer to
materials and lifting equipment are properly Section 110-0030, ENGINE AND MOUNTING. Refit
secured and of adequate capacity to do the job fan guard and secure with mounting hardware as
safely. removed during removal. Refer to Section 210-0040,
RADIATOR AND MOUNTING.
1. If removed, connect harnesses (40 & 41, Fig. 3)
and air ducting tubes. Slide air conditioner cover (45, 14. Adjust tension of compressor 'V' belt with nuts
Fig. 3) into position inside the cab and secure cover (26) on adjuster bolt (24) until there is approximately
(45, Fig. 3) with bolts (42, Fig. 3), lockwashers (43, an inward deflection of 10 mm (0.4 in) at the centre of
Fig. 3) and washers (44, Fig. 3) 'V' belt (18). Fully tighten all mounting hardware.
6 SM 1966 4-00
Section 260-0130
15. Remove caps from end of refrigerant hoses (6 & 7) 1. Periodically clean the condenser coil of debris and
and ports on compressor (12) and connect hoses to dirt using water or air pressure. A partially blocked
ports as tagged at removal. condenser coil can reduce the life of the compressor
belt and/or clutch.
16. Connect electrical connection to compressor (12)
clutch. 2. If the system has a heater in the same location as
the air conditioning evaporator core, heater valves
17. Secure all lines with clips and clamps as should be closed.
removed during removal. Ensure no lines are chaffing
on sharp edges or resting against areas where heat 3. To check the refrigerant level, run the engine at
will be evident. 1 200 rev/min with fans on high speed and thermostat
fully open for a minimum of five minutes. If the clutch
18. Charge the air conditioning system as described is engaged in this situation, there should be very few
under 'Charging Procedure'. bubbles visible in the receiver-drier sight glass.
19. Switch the battery master switch to the 'On' Note: Unit can operate with some bubbles visible, but
position, start up the engine and check for correct not milky looking.
operation of the air conditioning system.
4. Ensure all hoses and hose clamps are free from
20. Secure cover to air conditioner (1) outer box contact with sharp metal, moving parts or near to
using screws (2) and lockwashers (3). Lower hood manifolds.
assembly and remove wheel chocks.
5. Inspect condensation drain lines for debris, sharp
bends or breaks.
MAINTENANCE
6. Inspect the clutch wire from the thermostat for
bare spots.
WARNINGS
Always wear goggles or glasses to protect 7. Inspect bolts and nuts on the compressor and
your eyes when working around R-134a. mounting bracket for proper tightness.
R-134a boils at sea level temperatures of
-29.8 C (-21.6 F), which means that direct 8. Inspect and clean outside and inside cab air filters
contact with your skin will produce frostbite. periodically, depending on dust conditions. Replace
Exercise extreme care when handling R-134a. the outside filter when it becomes saturated to the
point it won't come clean.
If you get the slightest trace of R-134a in
your eye, flood the eye immediately with cool
water; then treat with mineral oil or clear Maintenance of 'V' belt Drives
petroleum jelly followed by boric acid rinse. 1. Listen for 'ticking' sound - they mean interference
Report to a hospital or doctor as soon as with the belts. Visually inspect for bent or damaged
possible. belt guards.
The chemicals of R-134a change when 2. Replace all belts in a mismatched set at one time
burned and become a poison phosgene gas to ensure even load distribution.
that will damage the respiratory system if
inhaled. NEVER SMOKE in an area where 3. Periodically check tension and keep belts tight.
R-134a is used or stored. Use hot water or an
approved heated charge cylinder as a heat - The ideal tension is the lowest tension at which the
source if required to force R-134a into the belt will not slip under peak load conditions.
system. If using water, do not exceed 52 C - Check belt tension frequently during the first 24 - 48
(125 F). Never use direct flame or electric hours of run-in operation.
heaters in direct contact with the R-134a - Initial belt tension should be 445 N (100 lbf)
container. High temperatures may result in dropping to 334 N (75 lbf) after the first 48 hours.
raising the pressure to a dangerous level. - There should be a freeplay of 10 mm in the 'V' belt.
SM 1966 4-00 7
Section 260-0130
- Do not over tension belts. being used. The quantity added should be calculated
- Keep belts free from foreign material that may using the following equation:
cause slippage.
- Inspect the V-drive periodically. Re-tension belts if Amount of oil to add in fl oz. =
they are slipping. (0.47 x total length of hoses in m) - 2.15
- Maintain sheave alignment with a strong straight
edge tool while tensioning belts. If any component is replaced the following amount of
oil should be added to the system;
4. Never attempt to correct belt slippage by using a
belt dressing. The dressing may cause softening and Condenser add 1 fl oz (28.4 ml)
deterioration. Drier add 1 fl oz (28.4 ml)
Evaporator add 3 fl oz (85.2 ml)
5. If belt slips, even when properly tensioned, check Compressor add 4.4 fl oz (125 ml)
for overload, worn sheave grooves or oil or grease on
the belts. The oil should be added to the oil filling port of the
compressor before the evacuation procedure is
6. Never pry a 'V' belt or force it into the sheave started or by using an oil injector when the system is
groove. Loosen the 'V' belt tightener prior to being charged, observing the following good
installation. practises:
7. A belt that has operated while rolled over in the a. Only pour the amount required from the container
sheave groove may be damaged - replace it. straight into a CLEAN measuring jug and
immediately pour the oil into the compressor.
8. Store belts in a cool, dry place. If stored on a b. Re-cap container tightly as soon as the required
machine, relieve all belt tension by loosening the amount has been taken (never leave an oil
'V' belt tightener. container open).
c. Do not mix different oils.
9. Never attempt to check or adjust belts while they
are running. Only new oil should be used, because oil that has
been exposed to the air will have absorbed water
(hygroscopic).
Refrigerant Oil
Use only refrigerant oil as specified in Section
300-0020, LUBRICATION SYSTEM.
WARNINGS
To prevent personal injury always wear rubber
gloves when handling refrigerant oils. System Leak Testing
Recommended Equipment Required:
Too much refrigerant oil will dampen the Electronic Leak Detector
cooling effect and too little refrigerant oil may
lead to compressor failure. If in doubt flush Switch off the engine and check all connections
the system. throughout the system for leaks. A large leak point
will have an oily or greasy appearance. The
Oil is required to lubricate the compressor. The oil refrigerant carries compressor oil with it and deposits
mixes with the refrigerant and is carried around the it around the leak area. Check all such points for
system. The compressor is supplied with an oil loose connections and tighten.
charge. However, additional oil is required, the
amount depending on the length of refrigerant hose 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.
8 SM 1966 4-00
Section 260-0130
DISCHARGING THE SYSTEM 1. Position the vehicle in a level work area, apply the
Note: Refer to all WARNINGS listed under parking brake and switch off the engine.
'Maintenance' prior to discharging the system.
Recommended Equipment Required: switch in the 'Off' position.
Portable High Vacuum Charging Station
Suitable Canister 3. Pull on handle to release hood catch and raise the
or Standard Service Manifold (Refer to Fig. 4) hood.
To eliminate system contaminants from an air 4. Connect the service hose (yellow) to the centre
conditioning system requires discharging the entire access port on the manifold gauge and to the vacuum
system. This means removing all of the refrigerant connection (6) on vacuum pump. Ensure that the
and cleansing all contamination (air and moisture) system is empty before connecting the vacuum so
from the system components. If any of the major that refrigerant does not enter the pump.
system components are to be repaired or replaced,
the system must also be completely discharged. 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
WARNING ports on the compressor.
The vehicle must not be running during this
procedure. Be sure to have adequate 6. Connect both service hoses from the two fittings (2
ventilation during this operation. Do not & 3) in the bottom of the manifold to the two service
discharge refrigerant near an open flame. ports on the compressor. High side (red) to
compressor discharge valve, low side (blue) to
Numbers and letters in parentheses refer to Fig. 4. compressor suction valve.
7. Switch vacuum pump on, open vacuum pressure

SM - 2424 valve (1) until less than 6 mb is reached on vacuum
B C D gauge (A). The vacuum gauge (A) should remain at
this value when vacuum pressure valve (1) is closed
to indicate that there are no leaks.
4
2 3 8. Open the low side hand valve on the manifold and
SUC DIS
vacuum pressure valve (1) and watch that the
R
E gauges start to register that a vacuum is being
ACCESS
PORT
F drawn. If the gauges do not register the vacuum
R
I thena blockage is present. Open the high side and
G pump down until a vacuum of 10 mb is achieved.
E
A R
A 9. After 10 - 15 minutes close vacuum pressure valve
N
T (1) and allow the system to settle, vacuum gauge (A)
should not alter. If the vacuum is held, no leaks or
refrigerant contaminated oil is present. If not, open
VACUUM PUMP the vacuum pressure valve (1) and continue
pumping, checking at regular intervals. If there is a
6 leak, check all fittings and tighten if necessary.
1 5
10. Tighten down (turn clockwise) both high and low

Gauges: Valves:
A - Vacuum Gauge 1 - Vacuum Pressure
side valves on the gauge manifold to the closed
B - Low Pressure Gauge 2 - Suction Line position, remove the service hose (yellow) from the
C - High Pressure Gauge 3 - Discharge Line vacuum connection (6) on vacuum pump and switch
D - Charging Cylinder 4 - Refrigerant Gas the pump 'Off'.
Pressure Gauge 5 - Refrigerant Liquid
Port:
6 - Vacuum Connection
Fig. 4 - Standard Service Manifold
SM 1966 4-00 9
Section 260-0130
11. Connect the service hose (yellow) to the R-134a 2. Pull on handle to release hood catch and raise the
cylinder. Open the cylinder valve and then purge air hood.
from the hose at the manifold connection.
3. Remove protective caps from 'quick coupler'
12. Open the low side hand valve on the manifold valves on rear of compressor.
slowly, until low pressure gauge (B) is at bottle
pressure. Watch the high side manifold gauge (C) 4. Connect low pressure gauge hose (blue hose and
rise to ensure that no blockage is present. Close the gauge) to suction side or low side fitting on
manifold valve and cylinder, then disconnect the hose compressor. The suction side can be identified by the
from the cylinder. size of the hose connected to the fitting. This will be
the largest diameter hose of the system.
13. Connect the service hose (yellow) to the Nitrogen
cylinder. Open the neck valve on the cylinder and set 5. Connect the high pressure gauge hose (red hose
the regulator pressure such that it is higher than the and gauge) to discharge or high side fitting on
system pressure then purge the hose. Open the low compressor.
side hand valve on the manifold, as the pressure
rises open the high side hand valve on the manifold 6. Connect yellow supply hose to suction port on
and allow a system pressure of 10 bar (150 psig) to vacuum pump.
be reached. Close all the valves. Using a suitable
electronic leak detector, check all joints in the air 7. Open both sides of gauges, low and high, completely.
conditioning system for leaks. Tighten any loose
joints and re-test if necessary. 8. Start vacuum pump to evacuate the complete air
conditioning system.
14. Vent the refrigerant mix to atmosphere by
removing the service hose (yellow) from the Nitrogen 9. Run vacuum pump for approximately 30 minutes.
cylinder and opening the low side hand valve on the Ideal gauge readings should be 29.92 inches of
manifold. Re-evacuate the system to below 6 mb mercury. The pressure will vary with altitude; it will
(steps 7 to 10). be approximately 0.03 bar (0.5 lbf/in) less for each
305 m (1 000 ft) of elevation.
15. Lower hood assembly and remove wheel blocks.
10. Before disconnecting power supply from vacuum
pump, close both high and low side gauges. Remove
CHARGING THE SYSTEM yellow hose from vacuum pump and connect to
Note: Refer to all WARNINGS listed under R-134a source.
'Maintenance' prior to charging the system.
11. Open R-134a source. Loosen, but do not remove,
Recommended Equipment Required: yellow supply hose at manifold on gauges to remove
Portable High Vacuum Charging Station all air in the yellow supply hose, replacing the air with
Electronic Leak Detector R-134a. This is done in a few seconds. Tighten
or Standard Service Manifold (Refer to Fig. 4) yellow supply hose.
12. Open low side of R-134a gauges slowly. When

For New Or Completely Empty System gauge reads zero open both sides completely.
Note: The charging procedure must be done in Vacuum in the system will draw R-134a gas into the
ambient temperatures above 15.5 C (60 F) with the system. Hold until both gauge readings equalize.
R-134a canister temperature equal to the outside
ambient temperature. Note: Never charge with liquid R-134a. Charge on
the low pressure side only.
1. Shut off engine and block all road wheels.
10 SM 1966 4-00
Section 260-0130
Final Charging Of The System remove the yellow supply hose. Remove both the low
1. Start the engine and run at engine idle speed. pressure (blue) hose and high pressure (red) hose
from the filling ports on the compressor.
2. Turn the air conditioning system on with the
thermostat set on maximum cooling and fan on high Note: Some R-134a will escape as the hoses are
speed. being removed.
3. At this point a visual inspection must be made of The system is completely charged when;
the sight glass on top of the receiver-drier. As
charging continues, the sight glass will appear milky a. the sight glass is free from bubbles.
coloured as the bubbles in the system circulate. As b. the suction pressure on the gauge is approx.
the system continues the charging process, the 20 - 30 psig at 25 C ambient.
regularity of the bubbles in the sight glass will c. the correct weight of refrigerant has been added
gradually diminish. When no bubbles are seen in the (3.75 lbs.)
sight glass, close the low pressure valve (blue side) d. the correct superheat can be measured at the
completely. evaporator, approx. 3 - 6 C.
e. the correct sub-cooling can be measured at the
4. Increase the engine idle speed while observing the condenser, approx. 5 - 7 C.
sight glass. If many bubbles are seen resulting from
the increased engine speed, open the low pressure 6. Replace protective caps on hoses and valve
side valve. Allow the system to continue the charging fittings.
procedure until the sight glass is clear. If the sight
glass remains clear, with the increased engine 7. Lower hood assembly and remove wheel blocks.
speed, do not add any more R-134a.
Note: Occasionally bubbles are noticed during clutch SPECIAL TOOLS

cycling or system start-up. This is a normal condition. Refer to Section 300-0070, SERVICE TOOLS, for
part numbers of special tools referenced in this
5. With the system completely charged, shut off the section and general service tools and sealants
engine. Close the valve on the R-134a canister and required. These tools and sealants are available from
your dealer.
SM 1966 4-00 11
Section 260-0130
AIR CONDITIONING DIAGNOSIS

CONDITION PROBLEM REMEDY
1. Belt Trouble
Slipping Loose Adjust belt to 12 mm (0.5 in)

depression
Overcharge Correct the charge
Air in system Evacuate and re-charge
Excessive wear Pulley not aligned Align pulley
Belt too tight Adjust or replace
Bad idler bearing Replace idler bearing
Belt wrong width Replace with correct belt
2. Vibration/Noise in Compressor
area
Vibration/noise Stuck compressor or clutch Replace
Vibration Overcharge Correct the charge
Air in system Evacuate system and re-charge
Compressor mounting or belts loose Tighten
Drive pulley loose Tighten
Belt tension incorrect Correct tension
Faulty compressor Replace compressor
Noise with clutch engaged Faulty clutch bearing Replace bearing
Noise with clutch engaged or Clutch loose Tighten

disengaged
Noise Clutch rubbing field coil Align clutch
Faulty belt Replace belt
Compressor oil level low Add oil
Chatter/Knock Valve plate broken Repair or replace
12 SM 1966 4-00
Section 260-0130
AIR CONDITIONING DIAGNOSIS (CONTINUED)

3. Noise - Evaporator
Rubbing/scraping Fan blade or blower Repair or replace
Hissing Low charge/leak Correct charge/repair leak
Chatter/Knocking Expansion valve Replace
Noisy case Loose brackets/screws Tighten
Motor squeal Dry bearings Replace
4. Air Conditioning Inadequate

After Short Period Of Operation
Cooling quits Loss of refrigerant Charge system/check for leaks
Moisture in system Replace drier
Thermostat Replace thermostat
Clutch Check pull-in of clutch or replace
Cooling intermittent Moisture in system Replace drier
5. Electrical Trouble
Blower motor or condenser fan Defective circuit breaker or bad Replace. Clean and tighten
motor inoperable wiring connections connections
Tight motor bearing Repair or replace motor
Switch open or shorted Repair or replace switch
Slow running blower Shaft binding Replace motor - worn bearings
Wheel misaligned Replace
Bad blower switch Replace blower
Insufficient current Install larger alternator
Clutch inoperable Defective circuit breaker Replace
Loose connection Clean and tighten connection
Broken wire - ground Repair wire
Shorted or open field Replace field
SM 1966 4-00 13
Section 260-0130
AIR CONDITIONING DIAGNOSIS (CONTINUED)

6. Air Conditioning System
Trouble - Gauges must be
connected
High head pressure Overcharge of refrigerant Purge system as necessary
Air in system Evacuate and re-charge
Condenser clogged Clean condenser
Low head pressure Undercharge of refrigerant Complete charge
Bad compressor valve plate or Repair or replace

gasket
Restriction in drier Replace drier
Low suction pressure Restriction in lines Clean lines
Restriction in expansion valve Replace expansion valve and drier
Improper expansion valve in charge Replace expansion valve
Refrigerant leak Inspect lines and fittings. Tighten,

repair or replace
* * * *
14 SM 1966 4-00
BODY - Body and Mounting
Section 270-0010
SM - 1909
LIFTING
POINT
LIFTING
1 POINT
10
7
15
1
13
6
A
5
A
4
14
7 A
8 3
2
8
9
11
12
1 - Body 5 - Shim
2 - Bushing 6 - Shim 9 - Shim 12 - Plate
3 - Hinge Pin 7 - Washer 10 - Locknut 13 - Washer
4 - Body Pad 8 - Bolt 11 - Spacer 14 - Lube Fitting
Fig. 1 - Exploded View of Body and Mounting
The standard body is an all welded construction with The body control joystick, mounted on the right hand
all wear plates fabricated from high hardness dash panel, controls the hydraulic control valve
(min. 360 BHN) 1 000 MPa (145 000 lbf/in2) yield operation, by means of electrical signals to the
strength steel. Angled lower body sides reduce body pressure reducing valves, which in turn operates the
impacts when loading and a tailshute angle of 25 body hoist cylinders. The four operating positions of
provides good retention when travelling without a the joystick from front to rear are as follows:
tailgate. Refer to Section 000-0000, GENERAL
INFORMATION for body capacities. 'FLOAT' - The joystick should be moved to this
position while the body is lowering by gravity and
The body is pivoted at the rear of the trailer frame and should remain in this position until the body must be
is operated by two single stage, double acting hoist operated again. The control joystick should always be
cylinders which are cushioned at both ends of the kept in 'FLOAT' while the machine is in motion.
stroke to reduce impact shocks. The hoist cylinders
raise the body to a tipping angle of 65 in 'LOWER' - Pushing the joystick forward and holding it
12 seconds and powerdown the body in 7.5 seconds. in this position provides hydraulic force to power-down
the body. It is needed when the body cannot be
SM 1980 4-00 1
Body - Body and Mounting
Section 270-0010
started downward from the fully raised position by

gravity. When the body starts lowering by gravity, the WARNING
joystick can be released and internal valve springs will Exercise extreme caution when lowering
move the joystick to the 'HOLD' position. the cylinders from the body. The cylinders will
swing out sharply as they leave their
'HOLD' - Moving the joystick to this position while the mountings.
body is being raised or lowered traps the oil in the
body hoists to stop and hold the body at any desired 1. Position the vehicle in a level work area, ensure the
height. The joystick will remain in the 'HOLD' position body is fully lowered, apply the parking brake and
when released. switch off the engine.

'RAISE' - Pushing the joystick back and holding it in
this position directs oil to extend the body hoists and
raise the body. When released, the joystick will be
spring-returned to the 'HOLD' position. the lever fully
into the detented float position.
the 'Off' position.
Note: The body control lever must remain in the
'FLOAT' position until it is necessary to operate the
4. Remove upper pins securing the body cylinders to
body again. Failure to comply to this could result in
body (1) assembly and secure body cylinders clear of
overheating the hydraulic oil and failure of the
the body. Refer to Section 230-0130, BODY
hydraulic system components.
CYLINDER.
Note: A proximity sensor prevents the body being fully
powered down onto the chassis. At a predetermined Note: Body lifting lugs can be fabricated as shown in
height, the sensor automatically defaults the body Fig. 2.
control valve to the detented 'FLOAT' condition.
5. Secure lifting lugs to body (1) using suitable bolts.
Note: If an electrical failure occurs, the body control Using appropriate lifting equipment, sling body (1)
valve will automatically default to the 'HOLD' condition. assembly at the four lifting points and take an initial
The cause of the electrical fault must be investigated strain.
and corrected.
Note: Approximate weight of body (1) assembly is
4 000 kg (8 820 lb).
REMOVAL
Numbers in parentheses refer to Fig. 1. 6. Remove bolts (15) and washers (13) securing hinge
pins (3) in place. Remove hinge pins (3) and shims (9)
from body (1).
WARNINGS
To prevent personal injury and property 7. Remove body (1) assembly from the vehicle.
materials and lifting equipment are properly 8. Remove bushing (2) from body hinge bores.
safely.

in the system.
2 SM 1980 4-00
Section 270-0010
INSTALLATION BODY SHIMMING PROCEDURE

Note: Tighten all fasteners to standard torques listed Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. TORQUE SPECIFICATIONS.
Note: When it becomes necessary, body pads (4)

WARNING should be replaced as a set to maintain load
To prevent personal injury and property distribution along the frame. Existing body pads will
damage, be sure wheel blocks, blocking have taken a compression 'set' and a new pad,
materials and lifting equipment are properly shimmed to match existing pads, will not carry its
secured and of adequate capacity to do the job share of the load, resulting in uneven load distribution
safely. along the frame.
1. Inspect bushing (2) for damage and replace if 1. Raise body (1) clear of the trailer frame and lay
necessary. Install bushing (2) in body hinge bores. body pads (4) (metal face down) roughly in position on
the frame.
Note: Body lifting lugs can be fabricated as shown in
Fig. 2. 2. Lower body (1) assembly onto body pads (4).
2. Secure lifting lugs to body (1) using suitable bolts. 3. Centralise body (1) assembly to the frame and
Using appropriate lifting equipment, sling body (1) place shims (5 & 6) under the front two body pads (4)
assembly and position over the trailer frame. until all other pads are clear of body (1) assembly.
Note: Approximate weight of body (1) assembly is 4. Slide shims (5 & 6) under remaining body pads (4)
4 000 kg (8 820 lb). until they just make contact with body (1) assembly.
3. Align hinge pin bores in body (1) assembly with bores 5. Raise body (1) assembly and install body pads (4)
in the trailer frame. Install hinge pins (3) and shims (9) and and shim packs (5 & 6) to their relative brackets on
secure with bolts (15) and washers (17). body (1) assembly securing with bolts (8), washers (7)
and locknuts (10).
4. Secure body cylinders to body (1) assembly with
pins and mounting hardware removed during removal. 6. Lower body (1) assembly to the frame and check
Refer to Section 230-0130, BODY CYLINDER for the shimming.
instructions.
7. Install body guide plates (12) with spacers (11) to
5. Lubricate hinge pins (3) through lube fitting (14) mounting brackets on body (1) assembly. Set gap
with lubricant specified in Section 300-0020, between plates (12) and the frame at 5 - 10 mm
LUBRICATION SYSTEM. Lubricate slowly until (0.2 - 0.4 in). Secure plates (12) and spacers (11) to
excess lube is seen. mounting brackets with bolts (8).
6. Install body pads (4) and body guide plates (12) on

body (1) assembly as described under 'Body
Shimming Procedure'.
7. Remove lifting equipment from body (1) assembly

and blocks from all road wheels.
8. Place the battery master switch in the 'On' position,

start the engine and check for correct operation of
body (1) assembly.
SM 1980 4-00 3
Section 270-0010
MAINTENANCE SM - 1630
Lubricate the body hinge pins and body cylinder pins 64 DIA HOLE
at the intervals stated and with lubricant specified in BURN
Section 300-0020, LUBRICATION SYSTEM. Lubricate 8
R4
slowly until excess lube is seen.
SPECIAL TOOLS
Special tools can be fabricated as shown in Fig. 2.
96
19.5
numbers of the general service tools required. These 6 6
0
2 PLACES 2 PLACES
10
tools are available from your dealer.
40
114
R 20
71
31
48 16
1 HOLE DRILL THRO'

21 MM DIA
Fig. 2 - Body Lifting Lug
* * * *
4 SM 1980 4-00
MISCELLANEOUS - Lubrication System
Section 300-0020
LUBRICATION AND SERVICE

SAFETY PRECAUTIONS
Do not allow unauthorized personnel to service or
maintain this vehicle. Study the Operators Handbook WARNING
and Maintenance Manual before starting, operating or These vehicles are equipped with engine and
servicing this vehicle. Always follow procedures and transmission oil pans which permit operation
safety precautions detailed throughout this manual. at maximum gradeability as designated in the
'Performance Data' section of the relevant
Always attach a DO NOT OPERATE or similar Sales Specification Sheet.
warning sign to the ignition switch or a prominent
control before cleaning, lubricating or servicing the Lubrication is an essential part of preventive
vehicle. maintenance. It is important that the instructions
regarding lubricant specifications, and the frequency of
Never allow anyone to work on the vehicle while it is their application, be followed to prolong the useful life
moving. Make sure there is no one on the vehicle of the vehicle. Periodic lubrication of moving parts
before working on it. reduces to a minimum the possibility of mechanical
failures.
Do not work under or near an unblocked or
unsupported body. Always use the body prop. The All change periods are recommendations based on
body prop must only be used when the body is empty. average operating conditions. Lubricants showing
evidence of excessive heat, oxidation or dirt should be
Always install the steering lock bar before making changed more frequently to prevent these conditions.
adjustments or servicing the vehicle with the engine
running. Lubricant change and service periods must be
established on the basis of individual job conditions
Do not work under or near any unblocked or utilizing oil sampling and recommendations from
unsupported linkage, part or vehicle. lubricant suppliers.
Always relieve pressure before servicing any Thoroughly clean all fittings, caps, plugs etc., to
pressurized system. Follow the procedures and safety prevent dirt from entering any system while carrying
precautions detailed in the relevant Maintenance out servicing procedures. Lubricants must be at
Manual section. normal operating temperature when draining.
When changing oil in the engine, transmission and Note: Do not operate any system unless oil level is
hydraulic system, or removing hydraulic lines, within the recommended operating levels as indicated
remember that the oil may be hot and can cause burns on oil level dipstick, sight gauge or level plug.
to unprotected skin.
Small circles on the following illustration represent
When working on or around exhaust components, points at which lubrication and/or servicing must take
remember that the components may be hot and can place, at the intervals indicated on the left hand side of
cause burns to unprotected skin. the lubrication and service chart.
Always deflate the tyre before trying to remove any The numbered circles on the illustration contain
embedded objects or removing the tyre and rim reference numbers which correspond to the reference
assembly from the vehicle. numbers in the 'Ref. Points' column of the lubrication
and service chart.
Always use a self-attaching chuck with a long airline,
and stand to one side while inflating the tyre. Refer to
Section 160-0050, WHEEL RIM AND TYRE.
SM 1972 4-00 1
Miscellaneous - Lubrication System
Section 300-0020
SM - 2482
34 20 33 20 20
5 19 1 17 18 32 16 21 10 24 12 3 28 10 23 11 8 23 28 27 16 11 4 13 21 16 14
6 7 15 27 8 24 16 10 12 30 2 24 26 11 9 22 29 7 24 21 16 24 13 16 14
25 20 31 25 25 20 25 20
Fig. 1 - Lubrication and Servicing Points
LUBRICATION AND SERVICE CHART

Interval Ref. No. of
Hours Points Identification Service Instructions Points Lubricant Service/Quantities
1 Engine Check oil level. Add if low. 1 EO As Required
2 Transmission Check oil level. Add if low. 1 * As Required
3 Hydraulic Tank Check oil level. Add if low. 1 HO As Required
- Radiator Header Tank Check coolant level. Add if low. 1 - See Page 4
10 6 Fuel Filter/Water Separator Drain. 1 - -
(Daily) 7 Air Reservoirs Drain. 3 - -
8 Brake Fluid Reservoirs Check fluid level. Add if low. 2 HBF As Required
9 Oscillation Bushes Lube. 2 EP, NLGI See Note 1
34 Fuel Tank Check fuel level. Add if low. 1 - As Required
- Air Filter Restriction Gauge Check. Replace element if required. 1 - -
- Hydraulic Filter Warning Light Check. Replace element if required. 1 - -
- Tyres Check condition and pressure. 6 - Refer Sec 160-0050
- General Check for debris, leaks and damage. - - -
10 Steering Cylinder Pins Lube. 4 EP, NLGI See Note 1
11 Body Cylinder Pins Lube. 4 EP, NLGI See Note 1
12 Suspension Frame Spherical Bearings Lube. 2 EP, NLGI See Note 1
50 13 Suspension Beam Bushings Lube. 2 EP, NLGI See Note 1
(Weekly) 4 Panhard Rod Spherical Bearings Lube. 4 EP, NLGI See Note 1 & 2
14 Body Hinge Pins Lube. 2 EP, NLGI See Note 1
15 Battery Electrolyte Check level. Add if low. 2 - As Required
16 Wheel Rim Nuts Check torque. 72 - 590 Nm (435 lbf ft)
32 Cab Ventilation Filter Inspect and clean if required. 1 - -
2 SM 1972 4-00
Section 300-0020
LUBRICATION AND SERVICE CHART

Interval Ref. No. of
Hours Points Identification Service Instructions Points Lubricant Service/Quantities
1 Engine Drain oil and refill. 1 EO See Page 6
- Engine Crankcase Breather Clean. 1 - -
- Transmission Breather Clean. 1 - -
6 Fuel Filter/Water Separator Replace. 1 - -
17 Engine Oil Filter Replace. 1 - -
18 DCA4 Coolant Filter Replace. 1 - -
250 - DCA4 Coolant Additive Check DCA4 concentration. - - Ref Engine Manual
(Monthly) 19 Drive Belts Check tension. Adjust if required. - - Ref Engine Manual
20 Wheels Planetaries Check oil level. Add if low. 6 EPL As Required
21 Differentials Check oil level. Add if low. 3 EPL As Required
- Differential Breathers Clean if required. 3
22 Oscillation Pivot Check end float. Adjust if required. 1
23 Driveshaft Bearings Lube. 2 EP, NLGI Four Shots (each)
24 Driveline Universal Joints Lube. 10 EP, NLGI See Note 1
25 Driveline Slip Joints Lube. 4 EP, NLGI See Note 1
26 Pivot Pins Lube. 2 EP, NLGI See Note 1
28 Park Brake Slack Adjuster Adjust if required. 1 - -
29 Parking Brake Pads Check wear. Replace if required. 2 - See Page 5
- Service Brake Pads Check wear. Replace if required. 12 See Page 5
500 27 Pressure Convertor Clean. 2
(3 Monthly) 34 Fuel Tank Clean filler neck, screen & cap. 1
- Engine Air Cleaner Clean inlet screen. -
2 Transmission Drain oil and refill. 1 * See Page 6
20 Wheel Planetaries Drain oil and refill. 6 EPL See Page 6
21 Differentials Drain oil and refill. 3 EPL See Note 2
1 000 28 Park Brake Slack Adjuster Lube. 1 EP, NLGI See Note 1
(6 Monthly) 29 Parking Brake Pads Check wear. Replace if required. 2 - See Page 5
30 Transmission Oil Filter Replace. 1 - -
31 Transmission Internal Oil Filter Clean. 1 - -
32 Cab Ventilation Filter Replace. 1 - -
- Door Hinges Lube. 2 - See Note 1
34 Fuel Tank Replace cap filter/cartridge. 1 - -
1 Engine Steam clean. 1 - -
3 Hydraulic Tank Drain oil and refill. 1 HO See Page 6
8 Brake Fluid Reservoirs Drain fluid and refill. 2 HBF See Page 5
26 Articulation Pivot Nut Check torque. 1 - 1 425 Nm
2 000 (1 050 lbf ft)
(Annually) 33 Hydraulic Oil Filter Replace. 1 See Page 5
- Engine Mounting Bolts Check torque. 298 Nm (220 lbf ft)
- Transmission Mounting Bolts Check torque. Refer Sec 120-0010
- Turbocharger Mounting Bolts Check torque. 65 Nm (50 lbf ft)
- Drivelines (Low Maintenance) Check for leaks and damage. - See Page 5
- Air Drier Replace desiccant cartridge. 1
4 000 5 Cooling system Drain, flush and refill. See Page 6
- Air Conditioning Compressor Drain, flush and refill. 1 Pag Oil See Page 6
Note - Capacities given are approximate - work to HO - Hydraulic Transmission Oil. Refer to
dipstick, sight gauges or level plugs. 'Recommended Lubricants'.
Note 1 - Lubricate slowly until excess lube is seen. EPL - Extreme Pressure Gear Lubricant spec.
Note 2 - Capacity of front and rear differentials is MIL-L-2105 D.
11 litres (2.9 US gal). Capacity of centre HBF - Hydraulic Brake Fluid (heavy duty)
differential is 14 litres (3.7 US gal). This SAE J 1703.
includes 1 litre (2 pints) for priming the 3rd. EP, NLGI - Extreme Pressure Lithium No. 2 Grease
differential unit. (without 'Molybdenum')
EO - Engine Oil. Refer to 'Recommended PAG Oil - Polyalklene Glycol (PAG) Compressor
Lubricants'. Lubricating Oil - Low Viscosity (ISO46)
*- Refer to chart under 'Recommended
Lubricants'.
SM 1972 4-00 3
Section 300-0020
MISCELLANEOUS SERVICING AFTER FIRST 100 HOURS OF OPERATING NEW

OR REBUILT COMPONENTS
WHEN REQUIRED Transmission - Drain oil, replace filter, clean
Seat Belts - Inspect for damage and replace if internal filter and finger magnet. Refill transmission.
required.
Note: Replace seat belts at least once every three Differentials - Drain oil and refill to level plug.
years, regardless of appearance. Note: When refilling centre axle ensure that the 3rd.
differential unit is primed with 1 litre (2 pints) of oil
Windscreen Wipers and Washers - Inspect wiper before filling drivehead.
blades and replace if damaged. Top up washer
reservoir. Planetaries - Drain lubricant and refill to level plug.
Wheel Rim Nuts - After first 10 hours of operation

re-torque nuts to 590 Nm (435 lbf ft). Check torque EVERY 250 HOURS OF OPERATION (MONTHLY)
every 50 hours (weekly) thereafter. Oil Can Points - Oil brake treadle rollers and other
working parts with engine oil.
EVERY 10 HOURS OF OPERATION (DAILY) General Inspection - Check entire vehicle for leaks,
Walk Around Inspection - Inspect the machine as loose bolts and nuts or damaged parts. Examine the
described in Section 4 of the Operator's Handbook. vehicle, particularly the chassis, for cracks or broken
welds. Repair where necessary.
Engine - Visually check engine for damage, loose or
frayed belts and listen for any unusual noises. Engine Air Intake - Check air intake system for
wear points or damage to piping, loose clamps and
Engine Air Cleaners - Change air cleaner element leaks.
only when air restriction gauge locks up in the red.
Service vacuator valves daily. Inspect and remove Drive Belts - Visually check the belts and replace if
any obstructions from the vacuator valve lips which they are cracked or frayed. Adjust belts that have a
should be open and pliable with the engine stopped. glazed or shiny surface which indicates belt
Note: Service air cleaners more often when slippage. Correctly installed and tensioned belts will
operating under extremely dusty conditions. show even pulley and belt wear. Refer to 'Engine
Operation and Maintenance Manual' for drive belt
Engine Crankcase - Check oil level and add if low. tension and adjustment of new and used belts.
With the engine off, the oil should be between the
lower and upper marks on the dipstick, up to the Service Brakes - Check pads and discs for wear
upper mark is preferable. and adjust or replace where necessary. Test for
proper function.
Transmission - Check oil level and add if low. Refer Note: This service interval applies to normal driving.
to Section 120-0010, TRANSMISSION AND Check the pads more frequently under more severe
MOUNTING, for correct oil level check procedure. conditions. Thickness of pad friction material should
never be allowed to wear below 3 mm (0.12 in).
Hydraulic Tank - Check oil level and add if low.
With the engine off and the body down the oil should Parking Brake - Check pads and disc for wear.
be visible in the bottom of the top sight gauge. Adjust or replace if required. Test for proper function.
Friction material thickness should never be allowed
Radiator Header Tank - Check coolant level and to wear below 3 mm (0.12 in).
add if low. Fill the radiator header tank with coolant
until coolant reaches the bottom of the filler neck and Coolant Additive - Check and replenish DCA4
holds at that level. concentration as described in Engine 'Operation and
Note: Any time a significant amount of coolant is Maintenance Manual'.
added, the DCA4 concentration MUST be checked.
If the concentration is low, engine damage will result. Coolant Filter - Replace coolant filter if required.
Conversely, over-inhibiting antifreeze solutions can When testing the DCA4 concentration, depending on
result in silicate dropout. Refer to Section 210-0000, the level of DCA4 the coolant filter may not
COOLING SYSTEM.
4 SM 1972 4-00
Section 300-0020
Hydraulic Oil Filter - Clean filter housing and install
necessarily have to be changed. If concentration is:
new element when filter restriction indicator light
illuminates, or after 2 000 hours of operation,
Below 0.3 units per litre (1.2 units per US gallon)
whichever comes first.
- Add both the normal amount of DCA4 liquid as
specified in the respective 'Service Chart' and the
Brake Fluid Reservoirs - Drain brake fluid, refill
amount specified in the respective 'Precharge Chart'.
reservoirs and bleed the brakes. Refer to Section
Replace the DCA4 coolant filter.
165-0010, BRAKE PARTS.
Note: Each reservoir (2 off) has a capacity of
Between 0.3 and 0.8 units per litre (1.2 and 3
0.66 litres (0.17 US gal). System capacity, as listed
units per US gallon) - Add the normal amount of
in the 'Recommended Lubricants' table, takes into
DCA4 liquid as specified in the respective 'Service
account brake fluid contained in the brake lines.
Chart'. Replace the DCA4 coolant filter.
Above 0.8 units per litre (3 units per US gallon) - Drivelines - Visually check Low Maintenance
Do not replace the DCA4 filter or add liquid DCA4 drivelines for leaking or damaged seals.
until the concentration drops below 0.8 units per litre Note: Low Maintenance drivelines can be identified
(3 units per US gallon). The concentration must be by having plugs fitted to the spiders, not grease
tested at every subsequent 250 hour service interval nipples.
until the concentration decreases below 0.8 units per Note: When service is required, remove plug and fit
litre (3 units per US gallon). grease nipple. Grease spider and refit plug when
finished. Use Type K lubricating grease in
accordance to DIN 51825-KP2-K-40.
EVERY 1 000 HOURS OF OPERATION (6 MONTHS)
Differential - Drain oil and refill to level plug. ENGINES AND TRANSMISSIONS
Note: When refilling centre axle ensure that the 3rd.
differential unit is primed with 1 litre (2 pints) of oil All information contained in the 'Lubrication and
before filling drivehead. Service Chart' was extracted from the relevant
manufacturers Operators Manual and was correct at
Parking Brake - Check pads and disc for wear. time of publication. User should ensure that
Adjust or replace if required. Test for proper function. information contained in this chart, regarding
Friction material thickness should never be allowed engines and transmissions, reflects the information
to wear below 3 mm (0.12 in). shown in the relevant manufacturers Operators
Manuals supplied with the machine. Maintenance
procedures should be carried out in conjunction with
EVERY 2 000 HOURS OF OPERATION (ANNUALLY) any additional procedures contained in the relevant
Hydraulic Oil Tank - Drain oil, remove and clean manufacturers Operators Manuals at the intervals
filter screen assemblies. Reinstall filter screens and specified.
refill tank.
SM 1972 4-00 5
Section 300-0020
SERVICE CAPACITIES
Service Capacities
TA30
Identification Lubricant litres US gal
Engine Crankcase and Filters EO 40 10.5
Transmission and Filters (dry fill) EO 52 13.8
Transmission and Filters (wet fill) EO 26 6.9
Hydraulic System (Hoist & Steering) HO 200 52.8
Cooling System Coolant 59 15.6
Fuel Tank Diesel 330 87
Differential - Front and Rear (each) EPL 11 2.9
Differential - Centre EPL 14 3.7
Planetaries (each) EPL 3.5 0.9
Service Brakes HBF 3 0.79
Air Conditioning Compressor PAG Oil 0.125 0.033
Note: Capacities given are approximate, work to dipstick, sight gauges or level plugs. Use table in conjunction
with 'Recommended Lubricants' table.
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT SPECIFICATIONS API CODE SAE GRADE
Engine Crankcase and Engine Oil with 1.00% sulphated CG-4 or 15W-40
Filter ash is recommended. Sulphated CF-4 (See Note 1*)
ash must not exceed 1.85% limit
Transmission and Engine Oil with 1.85% max. MIL-L-2104 C/D/E CD, CE, CF, See Trans.
Filters sulphated ash limit MIL-L-46152 C/D/E SF & SG Oil Table
(See Note 2*)
Hydraulic System Hydraulic Transmission Oil See Hydraulic Oil Table
(Hoist and Steering) (See Note 3*)
Cooling System Antifreeze, Ethylene Glycol
Fuel Tank Diesel Fuel Oil with max. DIN EN590
Sulphur 0.5%
Differentials - Extreme Pressure Gear MIL-L-2105 D GL-5 80W-90 LS
Front & Rear Lubricant (See Note 4*)
Differentials - Centre Extreme Pressure Gear MIL-L-2105 D GL-5 80W-90 LS
Lubricant (See Note 4*)
Planetaries Extreme Pressure Gear MIL-L-2105 D GL-5 80W-90 LS
Lubricant (See Note 4*)
Service Brakes Hydraulic Brake Fluid Heavy Duty J1703
Grease Nipples Extreme Pressure Lithium No. 2
(No 'Molybdenum') Consistency
Air Conditioning Polyalklene Glycol (PAG) ISO46
Compressor Compressor Lubricating Oil - SP 10
Low Viscosity
6 SM 1972 4-00
Section 300-0020
Notes on Recommended Lubricants and

Lubricant Grade Selection Tables Note 3 - Hydraulic Transmission Oil meeting
Specification EMS19058 is suitable for use in the
Note 1 - The use of low viscosity oils, such as 10W or hydraulic system.
10W-30, can be used to aid in starting the engine and
providing sufficient oil flow at ambient temperatures Note 4 - Axles have limited slip differentials. If use of
below -5 C (23 F). Continuous use of low viscosity standard SAE 90 oil results in very loud noise and
oils can decrease engine life due to wear. jerking of wheels when driving slowly round sharp
corner, an Extreme Pressure Gear Lubricant with
Note 2 - Operation below the minimum temperatures limited slip additives should be used.
listed for the oil used without proper preheat or warm-
up results in greatly reduced transmission life. Proper Note 5 - Automatic Transmission Fluids (ATF) may
warm-up requires 20 minutes minimum operation in only be used when the ambient temperature is less
neutral (with engine at part throttle) before operating than -10 C (14 F). Should the temperature increase,
the transmission in gear. it is necessary to switch to engine oil.
LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) TEMPERATURE

SM - 803
HYDRAULIC OIL
API
SAE CODE MIL-SPEC
1 - - MIL-H-5606A
2 DEXRON Auto Trans. Fluid
3 10W CC/CD MIL-L-2104 B/C
4 20W/20 CC/CD MIL-L-2104 B/C
5 30 CC/CD MIL-L-2104 B/C
SM - 804
TRANSMISSION OIL
(See Note 5)
Note: Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.
* * * *
SM 1972 4-00 7
MISCELLANEOUS - Service Tools
Section 300-0070
INTRODUCTION 15270006 - Connecting Rod Checking Fixture

Contained in this section are recommended service 15269956 - Standard Puller
tools and equipment required for maintenance, 15269958 - Piston Ring Expander
overhaul and troubleshooting. In certain instances, 15270078 - Manometer
both Metric and Imperial equivalents of the same 15269959 - Main Bearing Cap Puller
tools are listed. 15270081 - Pressure Gauge
15269960 - Dial Gauge Attachment
Note: A tool may be of one piece construction or 15270009 - Threaded Insert Kit
consist of a number of parts. 15269962 - Dial Bore Gauge Kit
15270079 - Manometer Tool
General 15270042 - Pressure Gauge (0 - 160 lbf/in)
*15269784 - Multi-Gauge - Pressure range of 30 in of 15270010 - Crack Detection Kit
vacuum to 5 000 lbf/in 15270082 - Pressure Gauge (0 - 300 lbf/in)
15269785 - Non-contact Infrared Thermometer 15269971 - Connecting Rod Guide Pins
15268968 - Strap Type Filter Wrench 15269966 - Cylinder Liner Puller Plate
15268969 - Socket Type Filter Wrench 15269961 - Dial Indicator Gauge
15268970 - Universal Belt Tension Gauge 15269973 - Oil Seal Guide
15269858 - Digital Tachometer 15269974 - Oil Seal Guide
15269859 - Multimeter 15269975 - Pulley Installation Tool
15269813 - Water Manometer 15269980 - Regulator Retainer Plug Driver
15269802 - Dial Indicator Gauge - Metric 15269981 - Oil Seal Guide
15269803 - Dial Indicator Gauge - Imperial 15269982 - Torque Wrench - lb in
15269804 - Magnetic Base for Dial Indicator Gauge 15269985 - Flywheel Housing Alignment Plate
15269805 - Micrometer - 0 to 25 mm 15270070 - Coupling Puller
15269806 - Micrometer - 0 to 1 in 15270004 - Magnetic Base
15269860 - 92 Piece Heavy Equipment Tool Kit 15269994 - Cylinder Head Lifting Bracket
15269861 - Torque Wrench - 3/8 in drive, 15270084 - Blowby Check Tool
20 - 100 Nm (15 - 80 lbf ft) range 15269996 - Injector Puller
15269862 - Torque Wrench - 1/2 in drive, 15269997 - Piston Ring Compressor
60 - 330 Nm (45 - 250 lbf ft) range 15269999 - Gauge Block
15269863 - Torque Wrench - 3/8 in drive, 15270072 - Drive Gear Driver
4 - 20 Nm (40 - 180 lbf in) range 15270020 - Needle Bearing Kit
15269864 - Torque Wrench - 3/4 in drive, 15270021 - Bearing Installation Tool
300 - 1 000 Nm (200 - 750 lbf ft) range 15269984 - Engine Barring Tool
15269865 - Torque Wrench - 3/4 in drive, 15270003 - Cylinder Liner Clamping Tool
700 - 1 500 Nm (500 - 1 000 lbf ft) range 15274125 - Cooling System Test Kit
15269866 - Torque Multiplier - 1/2 in to 1 in drive, 15274126 - Refractometer
25:1 Ratio, 3 000 Nm (2 200 lbf ft) range 15274129 - Hose Adaptor
15274130 - Hose Adaptor
* - The following items should be added to the 15274127 - Belt Tension Gauge
multi-gauge to enable the gauge to be used on 15274128 - Hose Assembly Tools
diagnostic test points: 15274060 - Heavy Duty Cam Gear Puller Kit
15018226 - Diagnostic Coupling 15274131 - Wrench, Air Impact
00118748 - Connector (2 off) 15274138 - Installer, Valve Guide
15004085 - Hose Assembly (-4 HP, 84 in long) 15274146 - Adaptor, Fuel Restriction
15274141 - Lubriplate 105 Lubricant
Engine 15274136 - Kit, Torque Wrench
The following tools are recommended for Engine 15274139 - Pliers, Boot
Maintenance Procedures. These tools should be used 15274142 - Lamp, 100W Black Light Kit
in conjunction with procedures outlined in the engine 15274143 - Charger Set International
manufacturers service manual. 15274135 - Kit, Guide Pin
15274140 - Fixture, Pulley Alignment
15270076 - Vacuum Gauge 15274134 - Kit, Inline II Datalink Adaptor
15270075 - Dial Depth Gauge 15274059 - Liner Puller
SM 1973 4-00 1
Miscellaneous - Service Tools
Section 300-0070
15274061 - Injector Protrusion Comparator 15274109 - Torque Angle Gauge
15274062 - Tube, Fuel Line Sight #12 15274110 - Small Bushing Driver Set
15274063 - Pilot, Oil Seal Puller Drills 15274111 - Kit,CNG Wastegate Test
15274064 - Kit, Turbo Rebuild 15274112 - Fixture, Cam Follower Assy R/I
15274065 - Digital Tachometer Kit 15274113 - Validator, Torque Wrench
15274066 - Bent Wrench 15274114 - Kit, Cylinder Head Leak Test
15274067 - Adaptor, Fuel Line Sight #16 Hose 15274115 - Kit, Charge Air Cooler Tester
15274068 - Gear Puller, Jaw 15274116 - Module, Vacuum Pressure
15274069 - Guide, Valve Installation 15274117 - Meter, Automotive
15274070 - Expander, Fan Hub Seal 15274118 - Puller, STC Injector
15274071 - Capscrew, Pulley Puller 15274119 - Driver, Thermostat Seal
15274072 - Driver, Regulator Valve Seat 15274120 - Sensor Break-out Kit
15274073 - Gauge, Cylinder Liner Ring 15274121 - Counterbore Salvage Kit
15274074 - Tube, Fuel Line Sight 15274122 - Installer, Oil Capacitor
15274075 - Cam Guide Expander - Large Dia 15274123 - Kit, Wiring Repair, Basic
15274076 - Fluorescent Tracer 15274133 - Cable, Throttle Breakout
15274077 - Expander, Accessory Drive Shaft Seal
15274078 - Fuel Pump S Wrench Transmission
15274079 - Kit, Torque Wrench
The following tools are recommended for
15274080 - Fitting Quick Connect
Transmission Maintenance Procedures. These tools
15274081 - Fitting Quick Connect should be used in conjunction with procedures
15274082 - Tube, Cooling System Sight outlined in the transmission manufacturers service
15274083 - Tube, Cooling System Sight manual.
15274084 - Tube, Cooling System Sight
15274148 - Wrench, Dial Type Torque 15270087 - Straight Pin
15274144 - Wrench, Nylon Strap Filter 15270088 - Back-off Device
15274145 - Gauge, Torque Angle 15270089 - Puller Device
15274147 - Wrench, Crows Foot 13 mm 15270090 - Puller
15274124 - Set, Torx Plus Driver 15270091 - Puller
15274137 - Bit, Screw Driver 15270092 - Puller
15274085 - Engine Parts Rack 15270093 - Puller
15274086 - Gauge, Belt Tension 15270094 - Driver
15274087 - Socket, Engine Position Sensor 15270095 - Driver
15274088 - Kit, Combustion Gas Leak Test 15270096 - Driver
15274132 - Test Fluid 15270097 - Driver
15274089 - Thermocouple Wire Kit 15270098 - Driver
15274090 - Engine Coolant Analyser 15270099 - Driver
15274091 - Gauge, Belt Tension 15270100 - Driver
15274092 - Wrench, CELECT Torque 15270101 - Driver
15274093 - Screwdriver, CELECT 15270102 - Driver
15274094 - Puller, Water Pump Pulley 15270103 - Driver
15274095 - Adjuster, STC Tappet 15270104 - Driver
15274096 - Super Chip Vacuum Kit 15270105 - Driver
15274097 - Gauge, Cyl. Head Capscrew Length 15270106 - Driver
15274098 - Kit, Counterbore Ledge Cutter 15270107 - Driver
15274099 - Cutter Plate 15270108 - Driver
15274100 - Clamp On Current Probe 15270109 - Driver
15274101 - Injector Puller/driver 15270110 - Driver
15274102 - Kit, Hydraulic Actuator 15270111 - Pressure Piece
15274103 - Kit, Hydraulic Cylinder Support 15269948 - Straightedge
15274104 - Kit, Cam Bushing I/R 15270112 - Measuring Pin
15274105 - Kit, Rail Pressure Response 15269804 - Magnetic Base
15274106 - Kit, Pulley Installation Adaptor 15269802 - Dial Indicator
15274107 - Socket, Deep Flank Drive 15270113 - Gauge Blocks
15274108 - Template, Cylinder Head Capscrew
2 SM 1973 4-00
Section 300-0070
15270114 - Digital Depth Gauge Axles and Differentials

15270115 - Set of Eye Bolts 15269893 - Pin Spanner - M95 x 1.5
15270116 - Adjusting Screws - M8 15269894 - Wheel Bolt Puller - Basic Set
15270117 - Adjusting Screws - M5 15269895 - Insert - M22 x 1.5
15270118 - Adjusting Screws - M6 15269896 - Driver
15270119 - Adjusting Screws - M10 15269897 - Driver
15269899 - Hot Air Blower 220 V, 50 Hz 15269898 - Driver Handle
15269900 - Hot Air Blower 110 V, 60 Hz 15269899 - Hot Air Blower - 220 V, 50 Hz
15270120 - Clamping Yoke 15269900 - Hot Air Blower - 127 V, 60 Hz
15269942 - Handle 15269928 - Back-off Screw - M14
15270121 - Driver 15269929 - Lifting Pliers
15270122 - Backup Tool 15269930 - Grab Sleeve
15270123 - Internal Puller 15269931 - Sleeve
15270124 - Internal Puller 15269932 - Basic Set Rollex 1
15270125 - Internal Puller 15269933 - Grab Sleeve 'Super'
15270126 - Internal Puller 15269934 - Measuring Shaft
15270127 - Guide Plate 15269935 - Thrust Washer
15270128 - Assembly Jig 15269936 - Measuring Piston
15270129 - Assembly Aid 15269937 - Shims - 120 mm Diameter
15270130 - Expanding Ring 15270204 - Driver
15270131 - Pry Bar 15269939 - Measuring Ring
15270132 - Crow Bar 15269940 - Driver
15270133 - Profiled Bush 15269941 - Driver
15270134 - Drift 15269942 - Driver Handle
15270135 - Lifting Device 15269943 - Spanner
15270136 - Drift 15269944 - Hook Spanner
15270137 - Drift 15269945 - Insert
15270138 - Rubber Cap 15269946 - Puller Set
15270139 - Striker 15269947 - Shims
15270140 - Installer 15269948 - Straightedge - 600 mm
15270141 - Installer 15269949 - Pry Bars - Set of 2
15270142 - Pre-heating Sleeve 15269950 - Driver
15270143 - Brake Spring Pliers
15270144 - Clamping Pliers Nitrogen Charging/Inflation
15270145 - External Snap Ring Pliers 15269121 - Nitrogen Tyre Inflation Kit
15270146 - External Snap Ring Pliers 09359489 - Charging Assembly
15270147 - Circlip Pliers
15270148 - Circlip Pliers
Cooling and Air Conditioning
15270149 - Two Leg Puller
15270150 - Three Leg Puller 15269814 - DCA4 Test Kit - Metric Version
15270151 - PR-78A Tester 15269815 - DCA4 Test Kit - US gallon Version
15270152 - Harness 15269816 - Refractometer - C Scale
15270153 - Foil 15269817 - Refractometer - F Scale
15270154 - Test Box II 15269844 - Portable High Vacuum Charging
15270155 - Flowmeter Station - R-134a Gas
15270725 - PR-68 Tester 15269845 - Halogen Leak Tester
Cab
15271016 - Glass Removal Tool
15271017 - Bonding Kit (Quick Dry)
SM 1973 4-00 3
Section 300-0070
Adhesives and Sealants 15270244 - Loctite 592 - Pipe Sealer with Teflon
15269103 - Loctite 221 15023696 - Loctite 635
09362529 - Loctite 225 09371048 - Loctite 638
09029849 - Loctite 243 15269107 - Loctite 641
09244598 - Loctite 270 15269108 - Loctite Superclean Safety Solvent 706
09985300 - Loctite 271 15229541 - Loctite Activator 'N'
15269104 - Loctite 275 09243825 - Loctite Activator 'T'
15269245 - Loctite 277 09175039 - General Adhesive
15233715 - Loctite Prism 406 15269114 - Tectyl 280 Wax Based Rust Preventive
15269111 - Loctite Prism 410 09380475 - Hylosil RTV Silicone Compound
15269105 - Loctite 515
09007209 - Loctite 574 (50 ml)
09379518 - Loctite 574 (160 ml) Fabricated Tools
15269106 - Loctite 577 (Superflex) The service tools shown in Figs. 1 through 8 can be
fabricated as shown.
SM - 625
Fig. 1 - Centring Spring Installation Tool

(Section 220-0090, STEERING VALVE)
SM - 407
DRILL
RAD
DEEP
RAD TYP
BURN OUT
SQUARE
SECURE ALUMINIUM DRILL AND REAM THROUGH

COLLAR WITH (3) M8 AND FIT 12 (0.472)
CAP SCREWS HARDENED DOWEL
TORQUE PINS 2 PLACES
Fig. 2 - End Cap Torque Tool (Section 220-0120, STEERING CYLINDER)
4 SM 1973 4-00
Section 300-0070
SM - 633
SILVER STEEL
SQUARE
OUTER SHIELD TO BE SECURED DOM TUBE

TO INNER BODY WITH 2BA CAPSCREWS
Fig. 3 - Piston Torque Tool (Section 220-0120, STEERING CYLINDER)
SM - 2469
50 25
160 (6.299) (1.9680) (0.984)
90 (3.54) 10
DRILL 13 (0.51) (0.394) 11
RAD X 25 (0.984) (0.433)
DEEP
10 (0.394)
RAD TYP
150 (5.90) DIA
110 (4.33) DIA

120 (4.724)
(3.154 - 0.000 )
(4.724 - 0.005 )
+0.002
120.00 - 0.13
(1.9680)
80.10 - 0.00
+0.05
94 (3.7)
+
50
+
19 (0.75)
SQUARE
SECURE ALUMINIUM FIT 2 OFF B&T BUSH 12 (0.472) ID

COLLAR WITH (3) M8 25 65 18 (0.708) OD AND 2 OFF 12 DIA DOWEL
CAP SCREWS (0.984) (2.560) DRIVE FIT IN BUSH
110 (4.33)
Fig. 4 - End Cap Torque Tool (Section 230-0130, BODY CYLINDER)
SM 1973 4-00 5
Section 300-0070
SM - 2470
89 (3.5)
38.1 (1.5)
(0.375)
9.525
DIA
(0.470)
11.938
124.45 - 0.000 (4.899 - 0.000 )
+0.005
DIA
90 - 0.05 (3.543 - 0.002 )
SILVER STEEL
136 (5.35)
+
25.4 (1.0)
SQUARE
+0.13
+
(0.500)
12.7
EN3B
DIA
MILD STEEL
OUTER SHELL TO BE SECURED DOM TUBE

TO INNER BODY WITH 2BA CAP SCREWS 10.16 25.4
(0.4) (1.0)
Fig. 5 - Piston Torque Tool (Section 230-0130, BODY CYLINDER)
SM - 647
6 mm (0.25 in)
Drill Thru Hole SPECIAL SLEEVE TOOL DIMENSIONS
DIMENSION mm in
A 85.7 3.375
B 114.3 4.50
C Radius 14.3 0.56
D Diameter 34.9758 + 0.000 1.377 + 0.000
- 0.0508 - 0.002
E Diameter 31.75 + 0.050 1.250 + 0.002
- 0.000 - 0.000
F Chamfer 1.6 x 60 0.063 x 60
Fig. 6 - Special Sleeve Tool Dimensions (Section 230-0050 MAIN HYDRAULIC PUMP)
6 SM 1973 4-00
Section 300-0070
SM - 1953 SM - 1630
64 DIA HOLE
BURN
8
R4
Shank should be about 8 in long

and fitted with Tee handle
approx. 4 in long 96
0.218 in dia.
Machined
dia.
19.5
Length 6 6
0.343 in
0.480 in
0.475 in
0
1.00 in 2 PLACES 2 PLACES
10
0.75 in 40
0.5 in dia.
bar
114
R 20
0.938 in 71
Pins to be 0.072 in dia. 31
48 16
1 HOLE DRILL THRO'

21 MM DIA
Fig. 7 - Unloader Valve Adjusting Bush Installation Tool Fig. 8 - Body Lifting Lug Dimensions
(Section 250-0200, AIR DRIER) (Section 270-0010, BODY AND MOUNTING)
* * * *
SM 1973 4-00 7
MISCELLANEOUS - Axle Bolt and Nut Torque Specifications
Section 300-0080
TORQUE LIMITS IN Nm (lbf ft)

Friction coefficient total 0.125 for screws and nuts
without after treatment as well as for phosphated
nuts.
Tighten by hand!
If nothing special is indicated, select correct Torque

Limits from the following tabulations -
Metric ISO Thread DIN 13 TABLE161
6.9 8.8 10.9 12.9
Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)

M6 8 (5.9) 9.5 (7) 13 (9.6) 16 (11.8)
M8 19 (14) 23 (16.9) 32 (23.6) 39 (28.8)
M 10 39 (28.8) 46 (33.9) 64 (47.2) 77 (56.8)
M 12 67 (49.4) 80 (59) 110 (81.1) 135 (99.6)
M 14 105 (77) 125 (92) 180 (133) 215 (159)
M 16 165 (122) 195 (144) 275 (203) 330 (243)
M 18 225 (166) 270 (199) 390 (288) 455 (336)
M 20 325 (240) 385 (284) 540 (398) 650 (479)
M 22 435 (321) 510 (376) 720 (531) 870 (642)
M 24 560 (413) 660 (487) 930 (686) 1 100 (812)
M 27 830 (612) 980 (723) 1 400 (1 033) 1 650 (1 217)
M 30 1 100 (811) 1 350 (996) 1 850 (1 365) 2 250 (1 660
Metric ISO Fine Thread DIN 13 TABLE162
6.9 8.8 10.9 12.9

M8x2 21 (15.5) 25 (18.4) 35 (25.8) 42 (31)
M 10 x 1.25 41 (30.3) 49 (36.1) 68 (50.2) 82 (60.5)
M 12 x 1.25 74 (54.6) 88 (64.9) 125 (92.2) 150 (110.6)
M 12 x 1.5 70 (51.6) 83 (61.2) 115 (84.8) 140 (103.3)
M 14 x 1.5 115 (85) 140 (103) 195 (144) 235 (173)
M 16 x 1.5 175 (129) 210 (155) 295 (218) 340 (251)
M 18 x 1.5 255 (188) 305 (225) 425 (314) 510 (376)
M 20 x 1.5 360 (266) 425 (314) 600 (443) 720 (531)
M 22 x 1.5 480 (354) 570 (420) 800 (590) 960 (708)
M 24 x 2 610 (450) 720 (531) 1 000 (738) 1 200 (885)
M 27 x 2 890 (656) 1 050 (774) 1 500 (1 106) 1 800 (1 328)
M 30 x 2 1 250 (922) 1 450 (1 070) 2 050 (1 512) 2 500 (1 844)
SM 1521 10-98 1
Miscellaneous - Axle Bolt and Nut Torque Specifications
Section 300-0080
Friction coefficient total 0.14 for screws and nuts
without after treatment as well as for phosphated
nuts.
Tighten by hand!
If nothing special is indicated, select correct Torque

Limits from the following tabulations -
Metric ISO Thread DIN 13 TABLE163
6.9 8.8 10.9 12.9

M6 8.5 (6.3) 10 (7.4) 14 (10.3) 17 (12.5)
M8 21 (15.5) 25 (18.4) 35 (25.8) 41 (30.2)
M 10 41 (30.2) 49 (36.1) 69 (50.9) 83 (61.2)
M 12 72 (53.1) 86 (63.4) 120 (88.5) 145 (106.9)
M 14 115 (85) 135 (100) 190 (140) 230 (170)
M 16 180 (133) 210 (155) 295 (218) 355 (262)
M 18 245 (181) 290 (214) 400 (295) 485 (358)
M 20 345 (255) 410 (302) 580 (428) 690 (509)
M 22 465 (343) 550 (406) 780 (575) 930 (686)
M 24 600 (443) 710 (524) 1 000 (738) 1 200 (885)
M 27 890 (656) 1 050 (774) 1 500 (1 106) 1 800 (1 328)
M 30 1 200 (885) 1 450 (1 070) 2 000 (1 475) 2 400 (1 770)
Metric ISO Fine Thread DIN 13 TABLE164
6.9 8.8 10.9 12.9

M8x1 23 (17) 27 (19.9) 38 (28) 45 (33.2)
M 10 x 1.25 44 (32.5) 52 (38.4) 73 (53.8) 88 (65)
M 12 x 1.25 80 (59) 95 (70) 135 (99) 160 (118)
M 12 x 1.5 76 (56.1) 90 (66.4) 125 (92) 150 (111)
M 14 x 1.5 125 (92) 150 (111) 210 (155) 250 (184)
M 16 x 1.5 190 (140) 225 (166) 315 (232) 380 (280)
M 18 x 1.5 275 (203) 325 (240) 460 (339) 550 (406)
M 20 x 1.5 385 (284) 460 (339) 640 (472) 770 (568)
M 22 x 1.5 520 (384) 610 (450) 860 (634) 1 050 (774)
M 24 x 2 650 (479) 780 (575) 1 100 (811) 1 300 (959)
M 27 x 2 970 (715) 1 150 (848) 1 600 (1 180) 1 950 (1 438)
M 30 x 2 1 350 (997) 1 600 (1 180) 2 250 (1 660) 2 700 (1 991)
* * * *
2 SM 1521 10-98
MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
Section 300-0080
and to establish a uniform value to which these

WARNING fasteners can be safely tightened, the following torque
Some fasteners are important attaching parts tables have been compiled.
which could affect the performance of vital
components and systems, and/or, could result The torque values listed in the tables have been
in major repair expense. Fasteners should be established over a period of years and cover all
replaced with parts of the same part number, conditions of assembly. The maximum torque values
or with equivalent parts, if replacement for standard bolts and nuts are based on 75% of the
becomes necessary. Do not use replacement specified minimum proof strength of the bolt steel in
parts of lesser quality or substitute design. order to provide a safety factor to compensate for the
The torque values shown in the following variation in the accuracy of torque wrenches, skill of
tables should be used in all cases, unless the assembler, and variance in fractional conditions.
otherwise specified elsewhere in this manual, All torque values are for lubricated threads. The
in order to avoid possible personal injury or term 'lubricated' includes the application of thread
property damage. lubricants, cadmium plating or the use of hardened
washers.
The following torque specification tables are based on
GM Standard Materials for bolts, nuts, studs and self- To provide a quick method for determining the GM
locking fasteners based on SAE bolt steel material classification of a particular standard bolt or
classifications, or, prevailing torque specifications for nut, compare the bolt head markings to those in the
self-locking fasteners. appropriate tables, then locate the maximum torque
value for that bolt size in the column under that
To prevent the threaded bolts and nuts used on this marking.
equipment from being overstressed during assembly,
RECOMMENDED MAXIMUM TORQUES (IMPERIAL) 10% TABLE144
SAE Symbol SAE Symbol SAE Symbol SAE Symbol

GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel 12 Point Cap
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8) Screws
Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
0.25 - 20 5 4 8 6 11 8 12 9 14 10
0.25 - 28 7 5 10 7 12 9 14 10 15 11
0.31 - 18 11 8 18 13 22 16 24 18 27 20
0.31 - 24 12 9 19 14 24 18 27 20 30 22
0.38 - 16 20 15 31 23 38 28 43 32 49 36
0.38 - 24 23 17 34 25 43 32 49 36 56 41
0.44 - 14 33 24 47 35 59 43 68 50 75 55
0.44 - 20 37 27 54 40 68 50 79 58 87 64
0.50 - 13 50 37 75 55 94 69 106 78 119 88
0.50 - 20 56 41 88 65 106 78 122 90 134 99
0.56 - 12 75 55 108 80 136 100 156 115 171 126
0.56 - 18 81 60 122 90 149 110 176 130 191 141
0.62 - 11 102 75 149 110 190 140 217 160 237 175
0.62 - 18 115 85 169 125 210 155 244 180 270 199
0.75 - 10 176 130 271 200 332 245 380 280 420 310
0.75 - 16 203 150 298 220 366 270 420 310 472 348
0.88 - 9 169 125 434 320 536 395 610 450 679 501
0.88 - 14 190 140 488 360 590 435 678 500 751 554
1.00 - 8 258 190 651 480 800 590 915 675 1 021 753
1.00 - 12 285 210 719 530 881 650 1 003 740 1 119 825
1.00 - 14 285 210 732 540 902 665 1 030 760 1 148 847
SM 1238 2-98 1
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
RECOMMENDED MAXIMUM TORQUES (IMPERIAL) 10% TABLE145
SAE Symbol SAE Symbol SAE Symbol SAE Symbol

GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel 12 Point Cap
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8) Screws
Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
1.12 - 7 366 270 800 590 1 132 835 1 302 960 1 447 1 067
1.12 - 12 407 300 902 665 1 274 940 1 451 1 075 1 624 1 198
1.25 - 7 515 380 1 132 835 1 600 1 180 1 830 1 350 2 043 1 507
1.25 - 12 569 420 1 254 925 1 776 1 310 2 034 1 500 2 267 1 672
1.38 - 6 664 490 1 478 1 090 2 095 1 545 2 400 1 770 2 676 1 974
1.38 - 12 759 560 1 688 1 245 2 393 1 765 2 739 2 020 3 056 2 254
1.50 - 6 881 650 1 966 1 450 2 786 2 055 3 186 2 350 3 556 2 623
1.50 - 8 936 690 2 088 1 540 2 962 2 185 3 390 2 500 3 781 2 789
1.50 - 12 990 730 2 217 1 635 3 145 2 320 3 593 2 650 4 010 2 958
1.75 - 5 - - - - 4 393 3 240 5 016 3 700 5 604 4 133
1.75 - 12 - - - - 5 091 3 755 5 830 4 300 6 497 4 792
1.88 - 8 - - - - 6 006 4 430 6 874 5 070 7 664 5 653
1.88 - 12 - - - - 6 304 4 650 7 213 5 320 8 048 5 936
2.00 - 4.5 - - - - 6 623 4 885 7 565 5 580 8 448 6 231
2.00 - 8 - - - - 7 342 5 415 8 406 6 200 9 367 6 909
2.00 - 12 - - - - 7 687 5 670 8 786 6 480 9 811 7 236
2.25 - 4.5 - - - - 9 701 7 155 11 090 8 180 12 377 9 129
2.25 - 8 - - - - 10 629 7 840 12 148 8 960 13 566 10 006
2.25 - 12 - - - - 11 050 8 150 12 636 9 320 14 102 10 401
2.50 - 12 - - - - 15 280 11 270 17 463 12 880 19 500 14 383
Note: Where materials other than GM Standards are used, refer to the conversion table below.
Types of Steel Rockwell Hardness Range Applicable Torque Values SAE Bolt Head Symbols
Plain Low Carbon

(eg. SAE 1018 or 1020) Rockwell "B" 85-100 GM 260-M
Plain Medium Carbon
(eg. SAE 1035, 1038 & 1045) Rockwell "C" 19-30 GM 280-M
Medium Carbon Alloy
Medium Carbon Alloy
2 SM 1238 2-98
Section 300-0080
RECOMMENDED MAXIMUM TORQUES (METRIC) 10% TABLE146
Class 8.8 Class 9.8 Class 10.9 Class 12.9

Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
M 1.6 - 0.35 - - 0.20 0.15 - - 0.20 0.15
M 1.6 - 0.20 - - 0.25 0.20 - - 0.40 0.30
M 2.0 - 0.40 - - 0.25 0.20 - - 0.45 0.30
M 2.0 - 0.25 - - 0.45 0.30 - - 0.45 0.30
M 2.0 - 0.45 - - 0.25 0.20 - - 0.45 0.30
M 2.5 - 0.35 - - 1 0.75 - - 1 0.75
M 3.0 - 0.50 - - 1 0.75 - - 2 1.5
M 3.0 - 0.35 - - 1 0.75 - - 2 1.5
M 3.5 - 0.60 - - 2 1.5 - - 3 2
M 4.0 - 0.70 - - 3 2 - - 4 3
M 4.0 - 0.35 - - 3 2 - - 5 3
M 5.0 - 0.80 - - 5 4 - - 8 6
M 5.0 - 0.50 - - 6 4 - - 9 6
M 6.0 - 1.00 - - 9 6 - - 13 10
M 6.3 - 1.00 - - 10 8 13 10 16 11
M 6.0 - 0.75 - - 10 7 12 9 14 10
M 8.0 - 1.25 - - 21 15 27 20 32 23
M 8.0 - 1.00 - - 23 17 29 21 34 25
M 10.0 - 1.50 - - 42 31 54 39 63 46
M 10.0 - 1.25 - - 45 32 57 41 67 48
M 12.0 - 1.75 - - 74 53 94 68 110 80
M 12.0 - 1.25 - - 81 58 103 74 121 87
M 14.0 - 2.00 - - 118 85 151 109 176 127
M 14.0 - 1.50 - - 128 92 163 118 190 137
M 16.0 - 2.00 169 122 - - 234 169 274 197
M 16.0 - 1.50 181 130 - - 250 180 292 211
M 18.0 - 2.50 234 169 - - 323 234 378 273
M 18.0 - 1.50 263 190 - - 363 262 425 307
M 20.0 - 2.50 330 239 - - 457 330 531 386
M 20.0 - 1.50 367 265 - - 507 366 593 423
M 22.0 - 2.50 451 325 - - 623 450 728 526
M 22.0 - 1.50 495 357 - - 684 494 800 577
M 24.0 - 3.00 571 412 - - 790 570 923 667
M 24.0 - 2.00 623 450 - - 861 622 1 007 727
M 27.0 - 3.00 837 605 - - 1 158 836 1 354 977
M 27.0 - 2.00 903 652 - - 1 250 902 1 461 1 055
M 30.0 - 3.00 1 135 820 - - 1 570 1 134 1 835 1 325
M 30.0 - 2.00 1 258 908 - - 1 740 1 256 2 034 1 468
M 30.0 - 1.50 1 300 939 - - 1 799 1 299 2 102 1 516
M 36.0 - 4.00 1 985 1 433 - - 2 745 1 982 3 208 2 317
M 36.0 - 3.00 2 102 1 517 - - 2 907 2 099 3 398 2 453
SM 1238 2-98 3
Section 300-0080
SELF-LOCKING FASTENERS has been used. Do not use a self-locking fastener

Self-locking fasteners develop a measured gripping more than five times.
action or torque and provide a renewed locking action
after being removed and reinstalled to their original The following table shows the minimum torque
mating part. The self-locking fasteners used on this specifications allowed to remove self-locking fasteners
equipment meet specifications necessary to allow the after the initial break-away torque has been achieved.
fasteners to be reused up to five times. Whenever a Any self locking fastener that can be removed with
self-locking fastener is removed, the head of the less than the prevailing torque value shown in the
fastener should be deeply scribed or otherwise table should be discarded, even if the fastener has not
marked to record the number of times the fastener yet been reused five times.
MINIMUM PREVAILING TORQUE - REMOVAL TABLE537
Lockscrews Locknuts
SAE Grade 5 & 8
and ASTM A-574 SAE Grade 5 SAE Grade 8
Size Nm lbf in Nm lbf in Nm lbf in
0.25 - 20 0.3 3 0.4 3.5 0.5 4.5
0.25 - 28 0.3 3 0.4 3.5 0.5 4.5
0.31 - 18 0.6 5 0.6 5.5 0.9 7.5
0.31 - 24 0.6 5 0.6 5.5 0.9 7.5
0.38 - 16 1.0 9 1.0 8.5 1.3 11.5
0.38 - 24 1.0 9 1.0 8.5 1.3 11.5
0.44 - 14 1.4 12 1.4 12 1.8 16
0.44 - 20 1.4 12 1.4 12 1.8 16
0.50 - 13 1.8 16 1.7 15 2.3 20
0.50 - 20 1.8 16 1.7 15 2.3 20
0.56 - 12 2.5 22 2.4 21 3.2 28
0.56 - 18 2.5 22 2.4 21 3.2 28
0.62 - 11 3.4 30 3.1 27 4.1 36
0.62 - 18 3.4 30 3.1 27 4.1 36
0.75 - 10 5.1 45 4.6 41 6.1 54
0.75 - 16 5.1 45 4.6 41 6.1 54
0.88 - 9 7.3 65 7.0 62 9.3 82
0.88 - 14 7.3 65 7.0 62 9.3 82
1.00 - 8 9.6 85 9.5 84 12.7 112
1.00 - 12 9.6 85 9.5 84 12.7 112
1.00 - 14 - - 9.5 84 12.7 112
* * * *
4 SM 1238 2-98
MISCELLANEOUS - Unit Storage
Section 300-0090
GENERAL 8. ENGINE - Consult the relevant Engine Maintenance

The storage of machines for short periods of time or Manual for complete information on storing the engine
during the off-season is an important item if major for periods shorter than 30 days.
damage to components is to be avoided. Failure to
take the necessary steps to protect the various 9. TRANSMISSION - Fill transmission sumps to the
assemblies while the machine is being stored can proper level.
result in an expensive overhaul job and delay in
returning the machine to work.
EXTENDED STORAGE - Under Six Months
When storing a machine for periods of longer than 30
TEMPORARY STORAGE days, but under six months, the following procedure
When storing a machine for a period of 30 days or must be followed:
less, the following precautions must be taken:
1. INSPECTION AND REPAIR - Same as Step 1
1. INSPECTION AND REPAIR - Thoroughly inspect given under 'Temporary Storage'.
and test the machine and make any necessary repairs
or adjustments which may be necessary to prepare 2. LUBRICATION - Same as Step 2 given under
the machine for service. This will enable you to put the 'Temporary Storage'.
machine back into use immediately at the end of the
storage period. 3. PARKING - Same as Step 3 given under
'Temporary Storage'. Machines should be blocked up
2. LUBRICATION - Lubricate the machine completely so the tyres are off the ground or floor.
according to the instructions given in Section
300-0020, LUBRICATION SYSTEM of this manual. 4. BATTERIES - Remove batteries from the machine
and store them in a suitable place where they can be
3. PARKING - After thoroughly cleaning the entire inspected and charged at least every 30 days or
machine, park it on a hard, dry, level surface that is placed on a trickle charger.
free from grease and oil. The oil and grease would
cause tyre deterioration. Apply the parking brake. 5. RUST PREVENTION - Same as Step 5 given under
'Temporary Storage'.
4. BATTERIES - Where moderate temperatures are
expected, the batteries may be left in the machine. Up 6. SUPPLY TANKS - Same as Step 6 given under
to 30 days, the batteries may require a boost at the 'Temporary Storage'.
end of the storage period. Preferably place the
batteries in the shop where they can be inspected, 7. TYRES - With the machine on blocks, as called for
brought up to full charge and placed on a trickle in Step 3, deflate the tyres to 0.7 bar (10 lbf/in)
charge to keep them at full charge. In very cold or hot pressure. Remove all traces of grease and oil and
climates, store the batteries where they will be protect the tyres from direct sunlight and water with a
protected from temperature extremes. suitable cover.
5. RUST PREVENTION - Remove all evidence of rust 8. TRANSMISSION - Consult the relevant
from the machine and repaint. In addition, cover all Transmission Maintenance Manual for storage data
exposed machine surfaces with a good rust involving periods longer than 30 days.
preventive.
9. ENGINE - Consult the relevant Engine Maintenance
6. SUPPLY TANKS - Fill fuel and hydraulic tanks to Manual for storage data involving periods longer than
prevent moisture condensation within the tanks. 30 days.
7. TYRES - Inflate all tyres to correct pressure. During 10. VENTS AND BREATHERS - Remove all vents
storage, check inflation pressure approximately once and breathers and plug openings with pipe plugs. If it
every two weeks. is not possible to do this, seal vents and breathers with
waterproof tape.
SM 1239 2-98 1
Miscellaneous - Unit Storage
Section 300-0090
EXTENDED STORAGE - Over Six Months 2. BATTERIES - Install batteries and check for a full
When a machine is to be stored for a period over SIX charge. Charge batteries as required.
MONTHS, the following procedure must be followed:
3. TYRES - Inflate tyres to the proper pressures. Refer
Note: These steps are in addition to those given to Section 140-0040, WHEEL RIM AND TYRE, of this
previously under 'Extended Storage - Under Six manual.
Months'.
4. FUEL AND HYDRAULIC TANKS - Drain off
1. LUBRICATION - Completely lubricate the machine condensation and fill tanks to proper level, remove
according to the instructions contained in Section breather covers and install air breathers. Be sure
300-0020, LUBRICATION SYSTEM of this manual. breathers are clean before installation.
2. WHEEL BEARING - Remove, clean, inspect and 5. VENTS AND BREATHERS - Remove seals and
repack all wheel bearings. plugs from all breather openings, then install all
breathers and vents.
Note: The above steps must be repeated for every Six
Month period the machine is in storage. 6. ENGINES - Consult the relevant Engine
Maintenance Manual for instructions on removing an
engine from storage.
REMOVAL FROM EXTENDED STORAGE
7. PAINT - Check machine for rust. Remove all rust
General spots and repaint rusted areas.
1. LUBRICATION - Completely lubricate the machine
according to the instructions in Section 300-0020, 8. TRANSMISSION - Consult the relevant
LUBRICATION SYSTEM of this manual. Transmission Maintenance Manual for instructions on
removing from storage.
* * * *
2 SM 1239 2-98

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TECHNICAL PUBLICATIONS DEPARTMENT

SM 1936 Rev 1 11-00

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

To advise potentially hazardous condition.

b. If this is affirmed - Do Not Touch

TEREX SERVICE DEPARTMENT

SMF 222 Rev 1 9-93

Section No. Description SM No.

SM 1935 Rev 1 11-00 1

Section No. Description SM No.

Fig. 1 - Machine Dimensions

ENGINE overspeed. Blocked filter indicator and filter bypass system

SM 1937 Rev 1 11-00 1

2 SM 1937 Rev 1 11-00

SM 1937 Rev 1 11-00 3

Fig. 1 - General Arrangement of Frame Assemblies

DESCRIPTION frame, secures the coupling in position. Wear on the

The rear frame is fabricated to form a rigid structure

Welding clamp is attached to the rear frame when welding is

Successfully welded repairs will depend to a great

DESCRIPTION AND OPERATION

Note: It is not necessary to separate the frames in

WARNING 7. Slacken adjuster (14, Fig. 3) until brake pads

Transmission - Pivot Pivot - Centre Axle

1 - Bolt 9 - Rear Wedge Plate

Fig. 3 - Parking Brake Assembly

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

ARTICULATION BEARINGS 7. Remove bolt (53) and hardened washer (54)

9. Remove pin (32), tapping pin upwards to ease

Note: Retainers (5, 11, 17 & 21) are not

13. Remove bolts (13), lockwashers (14), retainers

14. Remove and discard 'O' rings (4, 10 & 18).

Fig. 7 - Section Through Articulation Bearing

Note: Two bearings are installed on EACH articulation

Note: Never interchange cups or cones between

8. Install spacer (52) in upper bearing as noted on OSCILLATION BUSHES

9. Install 'O' rings (18) for lower bearing (6).

15. Using special tool, which can be fabricated as WARNING

6. Attach suitable lifting equipment to the front of the SM - 011

rear frame and take up slack.

8. Install new pre-greased rear 'V' ring (41). Refer to

FRONT 'V' RING REAR 'V' RING

Fig. 10 - Pivot Housing 'V' Ring Installation

Lubricate the oscillation bushes, articulation bearings/

4. Position levelling jack under centre front portion of

SPECIAL TORQUE SPECIFICATIONS

ARTICULATION AND OSCILLATION felt throughout the frame.

ARTICULATION AND OSCILLATION PIVOT DIAGNOSIS

53 2,3,50 38 LUBRICATION POINT

1 - Pivot 17 - Retainer 33 - Bolt

DESCRIPTION AND OPERATION

SM 1988 Rev 1 11-00 1

Note: It is not necessary to separate the frames in

WARNING 7. Slacken adjuster (14, Fig. 3) until brake pads

Transmission - Pivot Pivot - Centre Axle

2 SM 1988 Rev 1 11-00

1 - Bolt 9 - Rear Wedge Plate