TR100

Mining Truck
Maintenance Manual

TECHNICAL PUBLICATIONS DEPARTMENT

TEREX EQUIPMENT LIMITED,
MOTHERWELL, SCOTLAND, ML1 5RY
REF. NO. SM755/783

SM 1616 Rev 1 11-00

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 IMPORTANT SAFETY NOTICE

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

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

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

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

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

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

SM 222 Rev 1 9-93

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 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

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 TABLE OF CONTENTS
Section No. Description SM No.

000 GENERAL INFORMATION

0000 TR100 Off-Highway Truck 1618 Rev 1

100 CHASSIS
0010 Chassis, Hood and Fenders - Pre January 2000 Production 1622
0010 Chassis, Hood and Fenders - From January 2000 Production 1898

110 ENGINE
0030 Engine and Mounting 1655 Rev 1
0050 Air Cleaner 1246
0130 Power Takeoff 1656

120 TRANSMISSION
0010 Transmission and Mounting - Pre March 1999 Production 1623
0010 Transmission and Mounting - From March 1999 Production 1899
0070 Commercial Electronic Control (CEC) Shift System 1619 Rev 1
0090 Power Takeoff 1178
0100 Transmission Oil Filter 1624

130 DRIVELINE
0010 Front Driveline 1657
0020 Rear Driveline 1658

140 FRONT AXLE

0040 Wheel, Rim and Tyre 1625 Rev 1

160 REAR AXLE

0020 Differential 1626 Rev 1
0020 Differential (Optional) 1907
0030 Axle Group 1627 Rev 1
0050 Wheel, Rim and Tyre 1628 Rev 1

165 BRAKE PARTS

0020 Brake Parts - Front Axle 1629
` 0030 Brake Parts - Rear Axle 1630

180 SUSPENSION SYSTEM

0030 Ride Cylinder - Front 1631
0050 Ride Cylinder - Rear 1632

190 CIRCUIT DIAGRAMS

0000 Circuit Diagrams 1585
0270 Switches and Sensors - Pre March 2000 Production 1633 Rev 1
0270 Switches and Sensors - From March 2000 Production 2046

200 FUEL SYSTEM

0010 Fuel Tank and Mounting 1634

210 COOLING SYSTEM

0000 Cooling System 1263
0040 Radiator, Header Tank and Mounting - Pre September 1999 Production 1635
0040 Radiator, Header Tank and Mounting - From September 1999 Production 1900
0050 Disc Brake Oil Cooler 1636
0060 Transmission Oil Cooler 1637

SM 1617 Rev 1 11-00 1

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 TABLE OF CONTENTS
Section No. Description SM No.

220 STEERING SYSTEM

0000 Steering System Schematic 1661
0040 Steering and Brake Control Tank 1638
0050 Steering Pump 1639
0080 Accumulator 1205
0090 Steering Valve 1640 Rev 1
0110 Double Relief Valve 1208
0120 Steering Cylinder and Linkage - Pre August 2000 Production 1641
0120 Steering Cylinder and Linkage - From August 2000 Production 2047
0130 Accumulator Valve 1642
0150 Steering Filter 1593

230 BODY SYSTEM

0000 Body System Schematic 1646 Rev 1
0040 Body and Disc Brake Cooling Tank 1643
0050 Main Hydraulic Pump 1644
0060 Body Control Valve 1659 Rev 1
0081 Body Control Joystick 1277
0100 Manifold Relief Valve 1645
0121 Pilot Supply Valve 1599
0130 Body Cylinder 1279

250 BRAKING SYSTEM

0000 Braking System Schematic 1660 Rev 1
0050 Brake Manifold Valve 1647
0055 Tandem Pump 1648
0060 Accumulator 1600
0070 Treadle Valve 1649
0090 Directional Control Valve 1226
0100 Monoblock Brake Valve 1227 Rev 2
0110 Pressure Reducing Valve 2045
0130 Retarder Control Valve 1650 Rev 1
0140 Shuttle Valve 1229
0151 Parking Brake Valve 1651
0152 Brake Dump Valve 1652

260 OPERATORS COMPARTMENT

0010 Cab and Mounting 1602 Rev 1
0090 Driver Seat and Mounting 1901
0110 Passenger Seat and Mounting - Pre November 1999 Production 1603
0110 Passenger Seat and Mounting - From November 1999 Production 1902
0130 Air Conditioning 1903

270 BODY
0010 Body and Mounting 1653 Rev 1

300 MISCELLANEOUS
0020 Lubrication System 1654 Rev 1
0070 Service Tools 1662 Rev 1
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239

* * * *

2 SM 1617 Rev 1 11-00

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 GENERAL INFORMATION - TR100 Mining Truck
Section 000-0000

SM - 2034

Max
Body 1 635
Depth (5-4) 5 150
(16-11)

4 730
(15-6)

1 220 755
(4-0) (2-7)
1 755 (5-9)
8 960
3 420 (11-3) Vehicle Clearance Diameter (SAE) 24.5 m (80 ft) (29-5)

5 080 (16-8)

8 640
(28-4)
5 935 (19-6) 6 880
(22-7)
4 825 (15-10) 275
Optional (0-11) 6 080
Spillguard (19-11)
510
(1-8)
58˚

5 235
(17-2)
4 850
(15-11)
4 700 15˚
(15-5) 4 575 4 445
(15-0) (14-7)

660 (2-2)
815 (2-8)

2 945 (9-8) 3 150 (10-4) 4 570 (15-0) 3 100 (10-2)

3 760 (12-4) 10 820 (35-6)
4 570 (15-0)
Dimensions in mm (ft-in)

Fig. 1 - Machine Dimensions

ENGINE TRANSMISSION
Make/Model .................................. Cummins KTA-38-C1050 Make/Model ........................................ Allison DP-8963 CEC
Type .............................. 4 Cycle, Turbocharged/Aftercooled Automatic electronic control with soft shift feature.
Gross Power Remote mounted in the frame with integral TC 890 torque
at 2 100 rev/min .................. 783 kW (1 050 hp, 1 094 PS) converter and planetary gearing. Six speeds forward, one
Net Power at 2 100 rev/min .......... 727 kW (975 hp, 988 PS) reverse. Automatic converter lockup action in all speed
ranges. Downshift inhibitor. Hydraulic retarder.
Note: Power ratings to SAE J1995 June 1990. Net Power
is after deductions for fan and alternator. Engine requires Speeds With Standard Planetary
no derating up to 3 050 m (10 000 ft) altitude. Forward
Maximum Torque .............................. 4 631 Nm (3 415 lbf ft) Gear 1 2 3 4 5 6
at 1 300 rev/min Ratio 4.24 2.32 1.69 1.31 1.00 0.73
Number of Cylinders/Configuration ................................ 12V km/h 8.2 15.0 20.6 26.5 34.8 47.6
Bore x Stroke ........................ 159 x 159 mm (6.25 x 6.25 in) mile/h 5.1 9.3 12.8 16.5 21.6 29.6
Total Displacement .............................. 37.7 litres (2 300 in³)
Starting ...................................................................... Electric Reverse
Maximum Speed, Full Load ............................ 2 100 rev/min Ratio 5.75
Maximum Speed, No Load ............................. 2 400 rev/min km/h 6.0
Idle Speed .......................................................... 750 rev/min
Safe Operating Angle .................................. 30°/60% Grade mile/h 3.8

SM 1618 Rev 1 11-00 1

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General Information - TR100 Mining Truck
Section 000-0000
DRIVE AXLE Parking
Heavy duty axle with full floating axle shafts, single Application of rear brakes by springs in brake disc pack.
reduction spiral bevel gear differential and planetary Hydraulically released.
reduction at each wheel. Hold-off Pressure .................................. 83 bar (1 200 lbf/in²)

Ratios: Standard Optional Retardation

Differential ............................................. 2.16:1 2.16:1 Modulated lever control of rear disc pack.
Planetary ............................................. 13.75:1 10.50:1 Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in²)
Total Reduction ................................... 29.70:1 22.68:1
Emergency
SUSPENSION Push button solenoid control applies service and parking
brakes. Automatically applies when engine is switched off.
Front: King pin strut type independent front wheel Parking brake applies should system pressure fall below a
suspension by self-contained, variable rate, nitrogen/oil predetermined level.
cylinders.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
Rear: Variable rate nitrogen/oil cylinders with A-frame
linkage and lateral stabilizer bar.
STEERING SYSTEM
Maximum Strut Stroke
Front ....................................................... 235 mm (9.25 in) Independent hydrostatic steering with closed-centre
Rear .......................................................... 175 mm (6.9 in) steering valve, accumulator and pressure compensating
Maximum Rear Axle Oscillation ..................... ± 7.0 Degrees piston pump.

Accumulator provides uniform steering regardless of engine

WHEELS AND TYRES speed. In the event of loss of engine power it provides
steering of approximately two lock-to-lock turns.
Wheel Rim Width ....................................................... 19.5 in A low pressure indicator light warns of system pressure
Tyres (Front & Rear) below 83 bar (1 200 lbf/in²). Steering conforms to ISO 5010,
Standard ............................................. 27.00 R 49** Radial SAE J53.
Optional ........................................... 27.00-49 (48 PR) E-4
System Pressure ................................ 159 bar (2 300 lbf/in²)
Note: It is recommended that for tyres both listed and Relief Pressure ................................... 207 bar (3 000 lbf/in²)
unlisted, the user should consult the tyre manufacturer and Steering Cylinders ................... Double Acting, Single Stage
evaluate all job conditions in order to make the proper Accumulator:
selection. Oil Capacity ................................. 16.4 litres (4.33 US gal)
Nitrogen Precharge Pressure ............... 55 bar (800 lbf/in²)
Steering Angle (Left and Right) ....................................... 39°
BRAKES Pump:
Service Type ......................................................................... Piston
All hydraulic brake system. Transmission mounted pressure Capacity at 2 100 rev/min ....... 2.0 litres/s (32 US gal/min)
compensating pump provides hydraulic pressure for brakes
and steering. Independent circuits front and rear. Each
circuit incorporates a nitrogen accumulator which stores BODY HYDRAULICS
energy to provide consistent braking response. Two body hoist cylinders are mounted between the frame
rails. Cylinders are two-stage with power down in the
Front Brake Circuit Pressure ............. 159 bar (2 300 lbf/in²) second stage.
Rear Brake Circuit Pressure .................... 52 bar (750 lbf/in²)
Accumulators: System Relief Pressure ..................... 190 bar (2 750 lbf/in²)
Nitrogen Precharge Pressure ............... 55 bar (800 lbf/in²) Pump:
Type ........................................................................... Gear
Front: Capacity at 2 100 rev/min ....... 6.1 litres/s (97 US gal/min)
Type .............................. Dry Disc with 1 calliper per wheel Control Valve ...................... Servo Controlled, Open Centre
Disc Diameter ............................................ 965 mm (38 in) Body Raise Time ............................................. 16.3 Seconds
Pad Area, Total .................................... 2 015 cm² (320 in²) Body Lower Time ............................................... 18 Seconds

Rear:
Type ............................... Oil cooled, multiple friction discs, ELECTRICAL
completely sealed from dirt and water. Type ............................................. 24 Volt, Negative Ground
Braking Surface, Total .................. 87 567 cm² (13 573 in²) Battery ......... Four, 12 Volt, 210 Ah each, Maintenance Free
Accessories ................................................................ 24 Volt
Alternator .................................................................. 70 Amp
Starter ............................................................... Two, 8.9 kW

2 SM 1618 Rev 1 11-00

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 General Information - TR100 Mining Truck
Section 000-0000
BODY SERVICE CAPACITIES
Longitudinal 'V' type floor with integral transverse box- Engine Crankcase and Filters .......... 134 litres (35.4 US gal)
section stiffeners. The body is exhaust heated and rests on Transmission and Filters ..................... 100 litres (26 US gal)
resilient impact absorption pads. Cooling System ................................ 304 litres (80.3 US gal)
Fuel Tank ....................................... 1 090 litres (288 US gal)
Body wear surfaces are high hardness (360-440 BHN) Steering Hydraulic Tank .................... 61 litres (16.1 US gal)
abrasion resistant steel. Yield strength of plates 1 000 MPa Steering System .................................... 72 litres (19 US gal)
(145 000 lbf/in²). Body and Brake Cooling Tank ......... 297 litres (78.5 US gal)
Body and Brake Cooling System ...... 564 litres (149 US gal)
Plate Thicknesses: Planetaries (Total) ............................. 57 litres (15.1 US gal)
Floor ......................................................... 19 mm (0.75 in) Differential .......................................... 61 litres (16.1 US gal)
Side .......................................................... 10 mm (0.39 in) Front Ride Strut (Each) ........................ 27 litres (7.1 US gal)
Front, lower ............................................... 10 mm (0.39 in) Rear Ride Strut (Each) ......................... 18 litres (4.8 US gal)
Power Takeoff ........................................ 4 litres (1.1 US gal)
ROPS Cabguard SAE J1040 Feb 86. ISO 3471 Air Conditioning Compressor ...... 0.135 litres (0.036 US gal)

Volumes:
Struck (SAE) ......................................... 41.6 m³ (54.4 yd³) VEHICLE WEIGHTS (MASS)
Heaped 2:1 (SAE) ................................ 57.0 m³ (74.5 yd³) kg lb
Chassis, with hoists 53 240 117 380
Body, standard 15 380 33 900
TYPICAL NOISE LEVELS
Net Weight 68 620 151 280
OPERATOR EAR (ISO 6394) .................................... 83 dbA
PAYLOAD, maximum 90 720 200 000
*EXTERIOR SOUND RATING Maximum Gross Weight* 159 340 351 280
(SAE J88 JUN 86) ...................................................... 93 dbA FOR UNIT EQUIPPED WITH OPTIONAL BODY LINER
PLATES:
*The above result is for the mode giving the highest exterior Chassis, with hoists 53 240 117 380
sound level when measured and operated as per the Body, with wear plates 20 910 46 100
prescribed procedures of the standard. Results shown are Net Weight 74 150 163 480
for the unit in base configuration.
PAYLOAD, maximum 85 190 187 800
Note: Noise Level Exposure to the operator and bystander Maximum Gross Weight* 159 340 351 280
personnel may be higher depending upon proximity to * Maximum permissible gross vehicle weight with options,
buildings, rock piles, machinery etc.. The actual job site attachments, full fuel tank and payload.
Noise Level Exposure must be measured and applicable
WEIGHT DISTRIBUTION Front Axle Rear Axle
regulations complied with in respect to Employee Hearing
Protection. Empty % 49 51
Loaded % 34 66

* * * *

SM 1618 Rev 1 11-00 3

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 CHASSIS - Chassis, Hood and Fenders
Section 100-0010

SM - 1585

10
7
6
13
12
10
11
8 6
5
5

4
13
12
11
8
7 6 6
9 3 9

1 - Frame Assembly
2 - Bushing 5 - Nut 8 - Hardened Washer 11 - Spring Disc
3 - Engine Guard 6 - Hardened Washer 9 - Bolt 12 - Hardened Washer
4 - Transmission Guard 7 - Bolt 10 - Nut 13 - Hardened Spacer

Fig. 1 - Exploded View of Chassis and Guards

REMOVAL 3. Attach a suitable lifting device to the component

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

To remove any of the components shown in

Figs. 1 through 6 (or similar components) the WARNING
following procedures should be carried out. To prevent personal injury and property
damage, be sure wheel chocks, blocking
1. Position the vehicle in a level work area, apply the materials and lifting equipment are properly
parking brake and switch off the engine. secured and of adequate capacity to do the job
safely.
2. Turn steering wheel several times to relieve
pressure in the steering circuit. Block all road Using a suitable lifting device, align the component to
wheels. be installed in position on the chassis. Secure the
component securely to the chassis with mounting
hardware removed during removal.

SM 1622 12-98 1

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Chassis - Chassis, Hood and Fenders
Section 100-00100

SM - 1586
13
4 7
7

4
7

11

15

7
4 12
12
7 7
9

2 10 13
7
7 6 7
14

4 7
1
13 10
7 7
7 7 8
5 5 14
7
5
6
7
3
7
5

1 - Hood Assembly 5 - Bolt 9 - Baffle Assembly

2 - Bracket - LH 6 - Locknut 10 - Bracket 13 - Bolt
3 - Bracket - RH 7 - Hardened Washer 11 - Plate Assembly - Top 14 - Nut
4 - Bolt 8 - Plate Assembly - Base 12 - Bolt 15 - Beading

Fig. 2 - Exploded View of Hood and Mounting

MAINTENANCE
WARNING
Inspection Welding and flame cutting cadmium plated
Inspect the frame and attached parts at intervals not metals produce odourless fumes which are
exceeding 250 hours for cracked or broken welds and toxic. Recommended industrial hygiene
bending/twisting of the frame. Any defects found practice for protection of the welding operator
should be repaired before they progress into major from the cadmium fumes and metallic oxides
failures. Contact your dealer for recommended weld requires enclosure ventilation specifically
and repair instructions. designed for the welding process. A
respiratory protective device such as the
M.S.A. 'Gasfoe' respirator with G.M.A.
Welding cartridge will provide protection against
Note: It is important that the electrical connections cadmium, fumes and metallic oxides. The
are disconnected in the following order to prevent 'Gasfoe' respirator has been approved by the
damage to the electrical components: U.S. Bureau of Mines: Approval number
23B-10, and is designed to protect against
a. Disconnect battery equalizer ground cables. gases, vapours, and/or metal fumes.
b. Disconnect battery cables from terminal posts
(ground cable first). Electric arc welding is recommended for all chassis
c. Disconnect battery equalizer positive cables. welding. Since the nature and extent of damage to the
d. Disconnect electrical connections at the ECU. frame cannot be predetermined, no definite repair
procedure can be established. As a general rule
After welding, reconnect all of the above in the however, if parts are twisted, bent or pulled apart, or
reverse order. a frame is bent or twisted, no welding should be done

2 SM 1622 12-98

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 Chassis - Chassis, Hood and Fenders
Section 100-0010

SM - 2035
4 SECT 'B-B'

13 6 46
26
21 47
40 39 26 40
43 50
21 33 39 27 44 35
40 7 37 20
14 30 47
22 45 46
40 49 48
27 47
11
40
19
36 32 47
48
18
17
9 4
33 40
42 41 'B' 28
6
8
'B'
21
33 'A' 40
39 17
23 5
10
'A'
3 41

33 2
29 12 43 40
21
38
23
15 39 39 31 33
16 1
38 39
34 23 21 25
SECT 'A-A' 40 33 33 40 21
40 24
1 - Fender Extension 14 - Mirror
2 - Fender Assembly - LH 15 - Block 27 - Bolt 39 - Hardened Washer
3 - Fender Assembly - RH 16 - Spacer 28 - Bolt 40 - Hardened Washer
4 - Platform Assembly - RH 17 - Spacer 29 - Bolt 41 - Plug
5 - Front Crossmember 18 - Spacer 30 - Bolt 42 - Mirror
6 - Rear Crossmember 19 - Bolt 31 - Bolt 43 - Nut
7 - Cover Plate 20 - Hardened Washer 32 - Nut 44 - Bracket
8 - Mudguard 21 - Bolt 33 - Locknut 45 - Bracket
9 - Mudguard 22 - Bolt 34 - Nut 46 - Nut
10 - Handrail - LH 23 - Bolt 35 - Nut 47 - Washer
11 - Handrail - RH 24 - Bolt 36 - Washer 48 - Nut
12 - Plate Assembly 25 - Bolt 37 - Hardened Washer 49 - Plate Cover
13 - Arm 26 - Bolt 38 - Hardened Washer 50 - Bolt
Fig. 3 - Exploded View of Fenders and Mounting

until the parts are straightened or realigned. thoroughly clean the areas to be painted. Apply a
primer coat of red oxide and then a finish coat of
Successfully welded repairs will depend to a great polyurethane enamel.
extent upon the use of the proper equipment,
materials and the ability of the welder. The Service To keep rust and corrosion to a minimum, periodic
Department can be consulted regarding the feasibility painting of abrasions and other exposed metal areas
of welding repairs. on the frame is highly recommended.

Painting SPECIAL TOOLS

A check of the condition of the paint should be made There are no special tools required for procedures
approximately twice a year and chassis repainted if outlined in this section. Refer to Section 300-0070,
necessary. SERVICE TOOLS for part numbers of general
service tools required. These tools are available from
If painting of the actual frame of the unit is required, your dealer.

SM 1622 12-98 3

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Chassis - Chassis, Hood and Fenders
Section 100-00100

SM - 2036

28
29
7 27
21 11
11 7 26 2 1
1 7
11
28 1
29
27 12
1
25
17 20

19 12
11 7 1 2
1
24
26
18

1
12 7 11
10
12 7
1 5
8 16
23 8
6 22

15
15 7 12
3
7
9
12 4
1 13
13 14 14
22 - Bumper Extension - LH
1 - Bolt 8 - Hardened Washer 15 - Cable Assembly 23 - Bumper Assembly - RH
2 - 'U' Bolt 9 - Washer 16 - Step Assembly - LH 24 - Bracket
3 - Bolt 10 - Spacer 17 - Step Assembly - RH 25 - Bracket
4 - Bolt 11 - Hardened Washer 18 - Hoodside - LH 26 - Nut
5 - Bolt 12 - Hardened Washer 19 - Hoodside - RH 27 - Bolt
6 - Nut 13 - Rung 20 - Panel Assembly - LH 28 - Nut
7 - Locknut 14 - Step Assembly 21 - Panel Assembly - RH 29 - Hardened Washer
Fig. 4 - Exploded View of Ladders and Handrails

4 SM 1622 12-98

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 Chassis - Chassis, Hood and Fenders
Section 100-0010

SM - 1589

6
1
3

11

4
5
9
8

9
10

1 - Radiator Guard 4 - Clamp 7 - Bolt

2 - Grille - Bottom 5 - Clip 8 - Bolt 10 - Bolt
3 - Grille - Top 6 - Button Plug 9 - Hardened Washer 11 - Hardened Washer

Fig. 5 - Exploded View of Radiator Guard and Mounting

SM 1622 12-98 5

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Chassis - Chassis, Hood and Fenders
Section 100-00100

SM - 2037

A D B

8 A
8 B

13
9 D

9 1 11 2
5,6
5,6,7 C
10

4 3 9 6,7 STEERING
C TANK - REF.
8 VIEW CC 1
VIEW AA ENLARGED
VIEW BB
LEFT FRONT - ENLARGED TYP. 35 PLACES
ENLARGED
LEFT REAR - SHOWN
5,6,7 RIGHT REAR - OPPOSITE HAND
4
14
4 5,15
8
8
5,6 FUEL TANK
12 REF. VIEW DD
ENLARGED
13 9
13
VIEW AA RIGHT FRONT - ENLARGED

1 - Mudguard 5 - Bolt 9 - Mudflap - LH

2 - Bolt 6 - Lockwasher 10 - Support Bar 13 - Mudguard
3 - Bar 7 - Nut 11 - Angle Support 14 - Bracket
4 - Bar 8 - Flap 12 - Bar 15 - Hardened Washer

Fig. 6 - Mudguards

* * * *

6 SM 1622 12-98

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 CHASSIS - Chassis, Hood and Fenders
Section 100-0010

SM - 2387

7 10
6
13

12
10
11
8 6
5
5

4
13
12
11
8
7 6 6
9 3 9

1 - Frame Assembly
2 - Bushing 5 - Nut 8 - Hardened Washer 11 - Spring Disc
3 - Engine Guard 6 - Hardened Washer 9 - Bolt 12 - Hardened Washer
4 - Transmission Guard 7 - Bolt 10 - Nut 13 - Hardened Spacer

Fig. 1 - Exploded View of Chassis and Guards

REMOVAL 3. Attach a suitable lifting device to the component

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

To remove any of the components shown in

Figs. 1 through 6 (or similar components) the WARNING
following procedures should be carried out. To prevent personal injury and property
damage, be sure wheel chocks, blocking
1. Position the vehicle in a level work area, apply the materials and lifting equipment are properly
parking brake and switch off the engine. secured and of adequate capacity to do the job
safely.
2. Turn steering wheel several times to relieve
pressure in the steering circuit. Block all road Using a suitable lifting device, align the component to
wheels. be installed in position on the chassis. Secure the
component securely to the chassis with mounting
hardware removed during removal.

SM 1898 11-00 1

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Chassis - Chassis, Hood and Fenders
Section 100-00100

SM - 1586
13
4 7
7

4
7

11

15

7
4 12
12
7 7
9

2 10 13
7
7 6 7
14

4 7
1
13 10
7 7
7 7 8
5 5 14
7
5
6
7
3
7
5

1 - Hood Assembly 5 - Bolt 9 - Baffle Assembly

2 - Bracket - LH 6 - Locknut 10 - Bracket 13 - Bolt
3 - Bracket - RH 7 - Hardened Washer 11 - Plate Assembly - Top 14 - Nut
4 - Bolt 8 - Plate Assembly - Base 12 - Bolt 15 - Beading

Fig. 2 - Exploded View of Hood and Mounting

MAINTENANCE
WARNING
Inspection Welding and flame cutting cadmium plated
Inspect the frame and attached parts at intervals not metals produce odourless fumes which are
exceeding 250 hours for cracked or broken welds and toxic. Recommended industrial hygiene
bending/twisting of the frame. Any defects found practice for protection of the welding operator
should be repaired before they progress into major from the cadmium fumes and metallic oxides
failures. Contact your dealer for recommended weld requires enclosure ventilation specifically
and repair instructions. designed for the welding process. A
respiratory protective device such as the
M.S.A. 'Gasfoe' respirator with G.M.A.
Welding cartridge will provide protection against
Note: It is important that the electrical connections cadmium, fumes and metallic oxides. The
are disconnected in the following order to prevent 'Gasfoe' respirator has been approved by the
damage to the electrical components: U.S. Bureau of Mines: Approval number
23B-10, and is designed to protect against
a. Disconnect battery equalizer ground cables. gases, vapours, and/or metal fumes.
b. Disconnect battery cables from terminal posts
(ground cable first). Electric arc welding is recommended for all chassis
c. Disconnect battery equalizer positive cables. welding. Since the nature and extent of damage to the
d. Disconnect electrical connections at the ECU. frame cannot be predetermined, no definite repair
procedure can be established. As a general rule
After welding, reconnect all of the above in the however, if parts are twisted, bent or pulled apart, or
reverse order. a frame is bent or twisted, no welding should be done

2 SM 1898 11-00

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 Chassis - Chassis, Hood and Fenders
Section 100-0010

SM - 2035
4 SECT 'B-B'

13 6 46
26
21 47
40 39 26 40
43 50
21 33 39 27 44 35
40 7 37 20
14 30 47
22 45 46
40 49 48
27 47
11
40
19
36 32 47
48
18
17
9 4
33 40
42 41 'B' 28
6
8
'B'
21
33 'A' 40
39 17
23 5
10
'A'
3 41

33 2
29 12 43 40
21
38
23
15 39 39 31 33
16 1
38 39
34 23 21 25
SECT 'A-A' 40 33 33 40 21
40 24
1 - Fender Extension 14 - Mirror
2 - Fender Assembly - LH 15 - Block 27 - Bolt 39 - Hardened Washer
3 - Fender Assembly - RH 16 - Spacer 28 - Bolt 40 - Hardened Washer
4 - Platform Assembly - RH 17 - Spacer 29 - Bolt 41 - Plug
5 - Front Crossmember 18 - Spacer 30 - Bolt 42 - Mirror
6 - Rear Crossmember 19 - Bolt 31 - Bolt 43 - Nut
7 - Cover Plate 20 - Hardened Washer 32 - Nut 44 - Bracket
8 - Mudguard 21 - Bolt 33 - Locknut 45 - Bracket
9 - Mudguard 22 - Bolt 34 - Nut 46 - Nut
10 - Handrail - LH 23 - Bolt 35 - Nut 47 - Washer
11 - Handrail - RH 24 - Bolt 36 - Washer 48 - Nut
12 - Plate Assembly 25 - Bolt 37 - Hardened Washer 49 - Plate Cover
13 - Arm 26 - Bolt 38 - Hardened Washer 50 - Bolt
Fig. 3 - Exploded View of Fenders and Mounting

until the parts are straightened or realigned. thoroughly clean the areas to be painted. Apply a
primer coat of red oxide and then a finish coat of
Successfully welded repairs will depend to a great polyurethane enamel.
extent upon the use of the proper equipment,
materials and the ability of the welder. The Service To keep rust and corrosion to a minimum, periodic
Department can be consulted regarding the feasibility painting of abrasions and other exposed metal areas
of welding repairs. on the frame is highly recommended.

Painting SPECIAL TOOLS

A check of the condition of the paint should be made There are no special tools required for procedures
approximately twice a year and chassis repainted if outlined in this section. Refer to Section 300-0070,
necessary. SERVICE TOOLS for part numbers of general
service tools required. These tools are available from
If painting of the actual frame of the unit is required, your dealer.

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Chassis - Chassis, Hood and Fenders
Section 100-00100

SM - 2386

7 11 28
29
11 7 27
1 21 1
26 26 7 11
2
28
29 12
27 1

25
20
17

12
1
19 26
11 7 24
1 18 26

1
11
7
35
37 22 16
36 13
23
A 7 12
33,34 3
8 A
32
A 9 36 13
5 30
8 8
8 8
6 7 37 31
14 35
14
15

28 - Nut
1 - Bolt 10 - Rung 19 - Hoodside - RH 29 - Hardened Washer
2 - Bolt 11 - Hardened Washer 20 - Panel Assembly - LH 30 - Locknut
3 - Bolt 12 - Hardened Washer 21 - Panel Assembly - RH 31 - Bolt
4 - Hardened Washer 13 - Rubber Strip 22 - Bumper Extension - LH 32 - Bolt
5 - Bolt 14 - Hardened Washer 23 - Bumper Assembly - RH 33 - Chain Assembly
6 - Nut 15 - Bolt 24 - Bracket 34 - 'U' Bolt
7 - Locknut 16 - Step Assembly - LH 25 - Bracket 35 - Locknut
8 - Hardened Washer 17 - Step Assembly - RH 26 - 'U' Bolt & Nut 36 - Nut
9 - Step Assembly 18 - Hoodside - LH 27 - Bolt 37 - Hardened Washer
Fig. 4 - Exploded View of Ladders and Handrails

4 SM 1898 11-00

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 Chassis - Chassis, Hood and Fenders
Section 100-0010

SM - 1589

6
1
3

11

4
5
9
8

9
10

1 - Radiator Guard 4 - Clamp 7 - Bolt

2 - Grille - Bottom 5 - Clip 8 - Bolt 10 - Bolt
3 - Grille - Top 6 - Button Plug 9 - Hardened Washer 11 - Hardened Washer

Fig. 5 - Exploded View of Radiator Guard and Mounting

SM 1898 11-00 5

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Chassis - Chassis, Hood and Fenders
Section 100-00100

SM - 2388

15
5 17
2
6 4 3
7 7
6
5 1
6
5
6 7
10
11

9 5
16 6
7

3 4
7 8
6 18
2
1 5
5
6
14

13

1 - Mudguard 6 - Lockwasher
2 - Bar 7 - Nut 11 - Angle Support 15 - Bar
3 - Bar 8 - Hardened Washer 12 - Angle Support 16 - Bar
4 - Bolt 9 - Mudflap - LH 13 - Mudflap - RH 17 - Flap
5 - Bolt 10 - Angle Support 14 - Angle Support 18 - Flap

Fig. 6 - Mudguards

* * * *

6 SM 1898 11-00

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 ENGINE - Engine and Mounting
Section 110-0030

SM - 1592
19,20,16 44 21
18
20,19,17 22
21,22
48 26,3 LHS 38
29 35
2,3 RHS 1 36
47

37 39,40,41
46
45
32 43
33 34 42
24

38 31
35

27
28
30
6 5 4
7
50 49
8
10 12 52 51
23 53

11 55
12 54
7 14
8
12 15
13 9
9 13

1 - Engine 15 - Rear Mount 29 - Coolant Filter

2 - Reducer Bush 16 - Clamp 30 - Lube Oil Filter 43 - Clip
3 - Drain Cock 17 - Latch 31 - Hand Hole Cover 44 - Dipstick
4 - Bolt 18 - Latch 32 - Plate Assembly 45 - Bolt
5 - Support 19 - Bolt 33 - Bolt 46 - Lockwasher
6 - Crossmember 20 - Locknut 34 - Hardened Washer 47 - Spacer
7 - Bolt 21 - Lock 35 - Clamp 48 - Fan
8 - Hardened Washer 22 - Key 36 - Dipstick Hose 49 - Bolt
9 - Shock Mount 23 - Bolt 37 - Filler Hose 50 - Adaptor
10 - Bolt 24 - Tube Assembly 38 - T-bar Clamp 51 - Bolt
11 - Hardened Washer 25 - Tube Assembly 39 - Twisted Bracket 52 - Hardened Washer
12 - Hardened Washer 26 - Reducer Bushing 40 - Bolt 53 - Drive Coupling
13 - Locknut 27 - Lube Oil Bypass Filter 41 - Nut 54 - Bolt
14 - Bolt 28 - Fuel Filter 42 - Clip 55 - Flange Coupling

Fig. 1 - Exploded View of Engine Mounting

DESCRIPTION There are four full flow lube oil filters (30), two lube oil
Numbers in parentheses refer to Fig. 1. bypass filters (27) two fuel filters (28) and four coolant
filters (29) installed on engine (1). Mounted at the front
For engine make, model and specification, refer to left hand side of the engine is the fuel pump and at the
Section 000-0000, GENERAL INFORMATION. For front right hand side of the engine is the alternator.
detailed engine servicing and repair data refer to the There are two starter motors mounted at the rear right
engine manufacturers service manual. hand side of the engine, one of which is a prelube
starter motor.

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Engine - Engine and Mounting
Section 110-0030

REMOVAL 6. If the vehicle is equipped with an air conditioning

Numbers in parentheses refer to Fig. 1. system, evacuate refrigerant from the system and
disconnect lines at the compressor. Refer to Section
260-0130, AIR CONDITIONING.
WARNINGS
To prevent personal injury and property 7. Place a suitable container under the engine drain
damage, ensure wheel blocks, blocking port, remove drain plug and drain the oil. After
materials and lifting equipment are properly draining, reinstall drain plug in the engine sump and
secured and of adequate capacity to do the job tighten securely.
safely.
8. With suitable containers in position, open drain
High electrical current. Disconnect cocks and drain coolant from the radiator assembly
battery equalizer and battery cables at the and engine (1) assembly. Close all drain cocks after
batteries before removing engine attachments. draining.
High electrical current can cause sparks and
personal injury from burns. 9. Identify all cooling lines for ease of installation and
with suitable containers in position, disconnect all
Note: Tag and identify all lines, hoses, cables and cooling lines from engine (1).
linkages disconnected to remove the engine.
10. Using suitable lifting equipment, carefully remove
1. Position the vehicle in a level work area, ensure the the radiator, shroud and screen assemblies from the
body is fully lowered, apply the parking brake and vehicle. Refer to Section 210-0040, RADIATOR,
switch off the engine. HEADER TANK AND MOUNTING.

2. Turn steering wheel several times to relieve 11. Disconnect and remove air cleaner intake pipes
pressure in the steering circuit. Block all road wheels. from the engine turbochargers and air cleaner plenum
chamber. Refer to Section 110-0050, AIR CLEANER.
3. Disconnect electrical connections as follows:
a. Disconnect battery equalizer ground cables. 12. Disconnect and remove exhaust tubes from the
b. Disconnect battery cables from terminal posts engine turbochargers.
(ground cable first).
c. Disconnect battery equalizer positive cables. 13. Disconnect throttle control linkage from engine (1).
d. Disconnect electrical connections at the ECU.
14. Identify heater lines for ease of installation and,
4. Remove mounting hardware securing the hood and with a suitable container in position, disconnect heater
hoodsides on the vehicle. Remove hood and hood lines from engine (1).
side assemblies from the vehicle. Refer to Section
100-0010, CHASSIS, HOOD AND FENDERS. 15. Close fuel shutoff valve at filter head, identify fuel
lines for ease of installation and, with a suitable
5. Disconnect electrical connections from the radiator container in position, disconnect fuel lines from
guard and remove mounting hardware securing the engine (1).
radiator guard on the vehicle. Remove radiator guard
from the vehicle. Refer to Section 100-0010, 16. Slacken T-bar clamp (38) and clamp (35) securing
CHASSIS, HOOD AND FENDERS. filler hose (37) and dipstick hose (36) respectively to
hand hole cover (31) on left hand side of engine (1).
Remove hose assemblies (36 & 37) from hand hole
WARNING cover (31) and cover hose ends and fittings to prevent
Harmful gas. Before disconnecting any air entry of dirt.
conditioner lines refer to Section 260-0130, AIR
CONDITIONING. Refrigerant will rapidly freeze 17. Remove bolt (40), nut (41) and clips (42 & 43)
all objects with which it comes into contact, from twisted bracket (39). Tie hose assemblies (36 & 37)
and it can cause serious damage to the skin away from engine (1) to prevent fouling during engine
and eyes. removal.

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 Engine - Engine and Mounting
Section 110-0030
18. Identify all electrical harnesses and cables the chassis, remove disc brake oil cooler and
attached to engine (1) assembly for ease of installation transmission oil cooler from crossmember (6) first.
and disconnect from engine (1) assembly. Refer to Section 210-0050, DISC BRAKE OIL
COOLER, and, Section 210-0060, TRANSMISSION
19. Disconnect front driveline from engine coupling OIL COOLER.
and secure clear of engine (1). Refer to Section
130-0010, FRONT DRIVELINE. 28. With oil coolers removed, remove locknuts (13),
hardened washers (12), bolts (10) and hardened
20. Using suitable lifting equipment, remove tandem washers (11). Remove front crossmember (6) from
pump assembly from the left hand side of the engine chassis mounts.
power takeoff. Refer to Section 250-0055, TANDEM
PUMP. The hydraulic lines can be left attached to the 29. If necessary, adaptor (50) can be removed from
tandem pump. the flywheel housing after the power takeoff and yoke
assembly is removed. Refer to Section 110-0130,
21. Using suitable lifting equipment, remove main POWER TAKEOFF.
hydraulic pump assembly from theright hand side of
the engine power takeoff. Refer to Section 230-0050, 30. With the power takeoff and yoke assembly
MAIN HYDRAULIC PUMP. The hydraulic lines can be removed, remove bolts (49) and adapter (50) from the
left attached to the main hydraulic pump. flywheel housing.

31. Remove bolts (51), hardened washers (52) and

WARNING drive coupling (53) assembly from the flywheel.
Heavy assembly. To prevent personal injury
and property damage, be sure lifting device is 32. Remove bolts (54) securing flange coupling (55) in
properly secured and of adequate capacity to drive coupling (53) and remove flange coupling (55)
do the job safely. from drive coupling (53).

22. Attach suitable lifting equipment to engine (1) lifting 33. If necessary, support fan (48) assembly with suitable
brackets and raise lifting equipment to take up the slack. lifting equipment and remove bolts (45) and lockwashers
(46) securing fan (48) and spacer (47) on engine (1) fan
23. Remove bolts (7) and hardened washers (8) hub. Remove fan (48) and spacer (47).
securing support (5) assembly to crossmember (6).
Remove locknuts (13), bolts (7) and hardened
washers (8) securing rear mounts (15) to the chassis. INSPECTION
Numbers in parentheses refer to Fig. 1.
24. Check to make certain that all necessary line and
electrical disconnections have been made before lifting 1. Inspect shock mounts (9) for damage and replace if
engine (1) assembly. damaged.

25. Carefully lift engine (1) assembly clear of the 2. Check all mounting components for cracks and
chassis and move to a clean work area. Securely excessive wear. Repair or replace as required.
mount engine (1) assembly to a work stand.
3. Inspect drive coupling (53) and flange coupling (55)
26. If necessary, remove shock mounts (9) from for wear or damage and replace if necessary.
support (5) assembly and rear mounts (15). Rear
mounts (15) can be removed from engine (1) by 4. Replace all filters (27, 28, 29 & 30). Check all drive
removing bolts (14 & 23) and hardened washers (12). belts for tension and wear, as described under
Support (5) assembly can be removed by removing 'Maintenance'.
bolts (4).
5. Refer to the Engine Service Manual for additional
27. If it is necessary to remove crossmember (6) from engine disassembly/assembly, repair, adjustment and
tune-up procedures.

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Engine - Engine and Mounting
Section 110-0030

INSTALLATION SM - 1593

Numbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners without special torques

specified to standard torques listed in Section Install coupling with
300-0080, STANDARD BOLT AND NUT TORQUE Part No. this side
SPECIFICATIONS.
54
55
WARNING
To prevent personal injury and property
damage, be sure lifting device is properly
secured and of adequate capacity to do the job
safely.

1. Position spacer (47) and fan (48) on engine (1) fan

hub and secure with bolts (45) and lockwashers (46).
PTO Housing
2. Thoroughly clean and dry threads on bolts (54) and
drive coupling (53) and apply Loctite Activator 'T' to the 53
threads. Apply Loctite 638 to the threads of bolts (54)
and drive coupling (53). Position flange coupling (55)
to drive coupling (53) and secure with bolts (54). 51,52
50
Note: The flange coupling must be installed on the 49
drive coupling side opposite the side that has the part Flywheel Flywheel
number on it. See Fig. 2. Housing

52 - Hardened Washer
3. Thoroughly clean and dry threads on bolts (51) and 49 - Bolt 53 - Drive Coupling
engine flywheel and apply Loctite Activator 'T' to the 50 - Adaptor 54 - Bolt
threads. Apply Loctite 638 to the threads of bolts (51) 51 - Bolt 55 - Flange Coupling
and engine flywheel. Position drive coupling (53) Fig. 2 - Sectional View of Engine Coupling Installation
assembly to engine flywheel and secure with bolts (51)
and hardened washers (52). The part number must be
facing out. See Fig. 2. 7. Install front crossmember (6) on the chassis
mounts and secure with bolts (10), hardened washers
Note: Incorrect assembly of drive coupling (53) (11 & 12) and locknuts (13).
assembly to the engine flywheel can cause engine
and/or power takeoff damage. 8. Install disc brake oil cooler and transmission oil
cooler on front crossmember (6). Refer to Section
4. Position adaptor (50) to the engine flywheel housing 210-0050, DISC BRAKE OIL COOLER and, Section
and secure with bolts (49). Install the power takeoff 210-0060, TRANSMISSION OIL COOLER.
and yoke assembly to adaptor (50). Refer to Section
110-0130, POWER TAKEOFF.
WARNING
5. Install new shock mounts (9) in support (5) Heavy assembly. To prevent personal injury
assembly and rear mounts (15). Lubricate shock and property damage, be sure lifting device is
mounts (9) with water and press in using a driver of properly secured and of adequate capacity to
same diameter as internal metal sleeve in the shock do the job safely.
mount to protect the rubber from damage.
9. Attach suitable lifting equipment to engine (1) lifting
6. Secure support (5) assembly to engine (1) with bolts brackets and carefully position engine (1) assembly in
(4). Secure rear mounts (15) to engine (1) with bolts the frame.
(14 & 23) and hardened washers (12).

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 Engine - Engine and Mounting
Section 110-0030
10. Secure support (5) assembly to crossmember (6) 23. Connect throttle control linkage to engine (1) assembly.
with bolts (7) and hardened washers (8). Secure rear
mounts (15) to chassis mounts with bolts (7), 24. If the vehicle is equipped with an air conditioning
hardened washers (8) and locknuts (13). system, connect the lines at the compressor as
identified at removal.
11. Connect front driveline to power takeoff and yoke
assembly. Refer to Section 130-0010, FRONT Note: On completion of engine installation the air
DRIVELINE. conditioning system will require to be charged. Refer
to Section 260-0130, AIR CONDITIONING.
12. Install tandem pump to the left hand side of the
engine power takeoff assembly and secure with 25. Using suitable lifting equipment, install radiator guard
mounting hardware removed at removal. Refer to assembly to the chassis and secure with mounting
Section 250-0055, TANDEM PUMP. hardware removed at removal. Refer to Section
100-0010, CHASSIS, HOOD AND FENDERS. Connect
13. Install main hydraulic pump to the right hand side electrical connections removed at removal.
of the engine power takeoff assembly and secure with
mounting hardware removed at removal. Refer to 26. Connect electrical connections as follows:
Section 230-0050, MAIN HYDRAULIC PUMP. a. Connect electrical connections at the ECU.
b. Connect battery equalizer positive cables.
14. Using suitable lifting equipment, install the radiator, c. Connect battery cables to terminal posts (ground
shroud and screen assemblies and secure with cables last).
mounting hardware removed at removal. Refer to d. Connect battery equalizer ground cables.
Section 210-0040, RADIATOR, HEADER TANK AND
MOUNTING. 27. Check that all electrical connections and cables, all
lines and components removed or disconnected at
15. Remove blanking caps from all cooling lines and removal have been reinstalled correctly. Ensure all
connect lines to the radiator assembly and engine (1) drain plugs and drain cocks are tightly secured.
assembly as identified at removal.
28. Fill the cooling system with coolant specified in
16. Remove caps from heater lines and connect Section 300-0020, LUBRICATION SYSTEM. Check
heater lines to engine (1) as identified at removal. the coolant level as described in Section 210-0000,
COOLING SYSTEM.
17. Remove caps from fuel lines and connect fuel lines
to engine (1) as identified at removal. Open fuel 29. Fill engine (1) with lube oil specified in Section
shutoff valve at filter head. 300-0020, LUBRICATION SYSTEM. Check oil level as
described under 'Maintenance'.
18. Remove covers and connect dipstick hose (36)
and filler hose (37) to hand hole cover (31) fittings. 30. Start the engine and bring the engine oil to
Secure dipstick hose (36) with clamp (35) and filler operating temperature. Check all lines and fittings for
hose (37) with T-bar clamp (38). leaks and tighten as required. Switch off the engine.

19. Secure hose assemblies (36 & 37) to twisted 31. Using suitable lifting equipment, install hood
bracket (39) with bolt (40), clips (42 & 43) and nut (41). assembly into position on the vehicle. Secure hood
assembly with mounting hardware removed at
20. Connect all electrical harnesses and cables to removal. Refer to Section 100-0010, CHASSIS,
engine (1) assembly as identified at removal. Do not HOOD AND FENDERS.
connect battery and battery equalizer connections at
this time. 32. Install hood side assemblies on the vehicle and
secure with mounting hardware removed at removal.
21. Install air cleaner intake pipes to the engine Refer to Section 100-0010, CHASSIS, HOOD AND
turbocharger and air cleaner plenum chamber. Tighten FENDERS.
mounting clamps securely.
33. Ensure the parking brake is applied and remove
22. Install exhaust tubes on the engine turbochargers wheel blocks from road wheels.
and tighten mounting clamps securely.

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Engine - Engine and Mounting
Section 110-0030

MAINTENANCE by hand until the gasket contacts the filter head

Numbers in parentheses refer to Fig. 1, unless surface. Tighten fuel filters (28) per the filter
otherwise specified. manufacturer's instructions.

Every 10 Hours (Daily) Note: Mechanical tightening of the filters is not

General - Visually check the engine for leaks, loose or recommended, and may result in seal and/or cartridge
damaged parts, worn or damaged belts or any change in damage. Tighten filters by hand only.
engine appearance. Listen for any unusual engine noise
which can indicate that a service is required. Open the shut off valve, start the engine and check for
leaks. If leaks are noted, have them corrected.
Oil Level Check - Position the vehicle in a level work
area, apply the parking brake, shut off the engine and Engine Oil and Oil Filters (27 & 30) - Replace the
wait at least five minutes (to allow oil to drain to the oil lubricating oil and oil filters.
pan) before checking the oil level. Oil level should be
between the low (L) and high (H) marks on dipstick
(44). Add oil through filler hose (37) if low. WARNING
Avoid direct contact of hot oil with your skin.
Note: Never operate the engine with oil level below Hot oil can cause serious personal injury.
the low (L) or above the high (H) mark on the dipstick.
Operate the engine until the water temperature
Fuel Filter/Water Separators - Drain the water and reaches 60° C (140° F). Shut off the engine. Position a
sediment from the separators daily. suitable container under the engine oil drain plug and
drain the oil immediately to make sure all the oil and
Position the vehicle in a level work area, apply the parking suspended contaminants are removed from the
brake, shut off the engine and, with a suitable container engine.
below the drain valve to catch spillage, open the drain
valve by hand. Turn the valve anticlockwise approximately Note: The external appearance of full flow lube oil
1.5 - 2 turns until draining occurs. Drain the filter sump filters (30) and lube oil bypass filters (27) are the
until clear fuel is visible. Turn the valve clockwise same. However, the full flow filters have 1.5 x 16 in
approximately 1.5 - 2 turns to close the drain valve. threads and the bypass filters have 1.375 x 16 in
Repeat for second separator. threads.

Note: Do not overtighten the drain valves as Position the vehicle on a level work area, apply the
overtightening can damage the threads. parking brake and switch off the engine. Using strap
type filter wrench, remove lube oil bypass filters (27)
and full flow lube oil filters (30). Discard the filters if
Every 250 Hours or 6 Months they are not required for a failure analysis.
Fuel Filters (28) - Clean the area around the fuel filter
head and replace the fuel filters. Note: Cut all the way around the top of lube oil filter
(30) using a pipe cutter or hacksaw. Inspect the
Note: There is a fuel system shut off valve at the filter pleated paper element for debris. Metal debris in the
head. Closing this valve will prevent loss of fuel prime filter can reveal impending engine failure. If debris is
at time of filter replacement. found, find the reason for the debris and make the
necessary repairs.
Position the vehicle on a level work area, apply the
parking brake and switch off the engine. Close fuel Clean the area around the oil filter head and gasket
system shut off valve and, using strap type filter sealing surface of the filter head.
wrench, remove and discard fuel filters (28).
Note: The 'O' ring can stick on the filter head. Make
Apply a thin film of clean engine oil to the gasket sure the 'O' ring is removed and discarded.
surface of new fuel filters (28) and fill fuel filters (28)
with clean fuel specified in Section 300-0020, Note: Fill the filters with clean lubricating oil prior to
LUBRICATION SYSTEM. installation. The lack of lubrication during the delay
until the filters are pumped full of oil is harmful to the
Install new fuel filters (28) on the filter head and tighten engine.

6 SM 1655 Rev 1 11-00

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 Engine - Engine and Mounting
Section 110-0030
Apply a thin film of clean lubricating oil to the gasket Crankcase Breather - Check and clean the
surface of the new filters and fill the filters with clean crankcase breather hose. Remove the breather hose
lubricating oil specified in Section 300-0020, and check internally for obstructions or sludge buildup.
LUBRICATION SYSTEM. Clean or replace breather hose as necessary, to
prevent excess crankcase pressure buildup.
Install the filters on the filter head as specified by the
filter manufacturer. The tightening instructions are Cooling Fan (48) - Visually check fan (48) for cracks,
normally printed on the outside of the filter. loose rivets, and bent or loose blades. Check fan
mounting bolts (45) and tighten if required. Replace
Note: Mechanical tightening of the filters is not fan (48) if damaged.
recommended, and may result in seal and/or cartridge
damage. Tighten filters by hand only. Note: The fan belt is maintained to the correct belt
tension by a spring loaded idler arm, therefore, there is
Check and clean the engine oil drain plug threads and no need to check or adjust belt tension.
the seal surface. Install and tighten the drain plug to a
torque of 100 Nm (75 lbf ft). Fill the engine with clean Alternator Drive Belt - Visually check alternator belt
lubricating oil specified in Section 300-0020, and replace if it is cracked or frayed. Adjust belt if it
LUBRICATION SYSTEM. The oil level should be has a glazed or shiny surface which indicates belt
between the low (L) and high (H) marks on dipstick (44). slippage. A correctly installed and tensioned belt will
show even pulley and belt wear. Check belt tension
Note: The engine is fitted with a prelube starter motor and adjust if necessary, as described in the engine
which will prelube the engine until the oil pressure manufacturers service manual.
reaches 0.34 - 0.48 bar (5 - 7 lbf/in2), before the
cranking procedure begins.
SERVICE TOOLS
Start the engine and operate at idle speed to inspect Refer to Section 300-0070, SERVICE TOOLS, for part
for leaks at the filters and oil drain plug. Shut off the numbers of tools referenced in this section, general
engine, wait approximately five minutes to let the oil service tools required, and service tools which should
drain back to the sump and check the oil level again. be used in conjunction with procedures outlined in the
Add oil as necessary to bring the level to the high (H) engine manufacturers service manual. These tools are
mark on dipstick (44). available from your dealer.

* * * *

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 ENGINE - Air Cleaner
Section 110-0050

SM - 1532

1 - Air Cleaner Body 3

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

DESCRIPTION SM - 1898

Numbers in parentheses refer to Fig. 1, unless

otherwise specified.

There are three, dual dry element type air cleaner

assemblies mounted on the platform to the right hand STOP

side of the cab. Air cleaner assemblies prolong engine

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

A rubber vacuator valve (6) attached to cover

assembly (4) in a downward position, ejects grit, dust
Fig. 2 - Air Cleaner Restriction Indicator Light
and water while the engine is running. Vacuator valve
(6) minimizes the need for daily servicing. Even
though vacuator valve (6) is normally under a slight the circuit closes and a restriction indicator light located
vacuum when the engine is running, pulsing of the on the dash panel (Fig. 2) illuminates. This light shows
vacuum opens and closes vacuator valve (6) expelling at a glance when the system air flow is being restricted
grit, dust and water as they collect. When the engine is indicating that primary element (2) should be serviced.
stopped, vacuator valve (6) opens and expels any Air restriction gauge (18, Fig. 3) automatically resets
accumulated grit, dust or water. after each air cleaner assembly is serviced.

An electrical air restriction gauge (18, Fig. 3) indicates While the indicator light indicates the need for
when air restriction levels reach the maximum servicing, it does not give as precise a measurement
allowable limit. When air restriction levels are reached, as a water manometer or vacuum gauge. Refer to

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Engine - Air Cleaner
Section 110-0050

SM - 1693

6
6
6
18,19
10
17
8
11 16

1
12

14 11
10 8 9

11 11
7 2
10 12

8 14
11
11 9
11
4 9
11
15 11
13
5
20

9 11
3

1 - Plenum Chamber 6 - Cap Assembly 11 - Clamp 16 - Nipple

2 - LH Tube 7 - Mounting Band 12 - Bolt 17 - Elbow
3 - RH Tube 8 - Hump Hose 13 - Nut 18 - Air Restriction Gauge
4 - Bracket 9 - Hump Hose 14 - Washer 19 - Protective Cap
5 - Hardened Washer 10 - Clamp 15 - Washer 20 - Bolt

Fig. 3 - Exploded View of Air Cleaner Mounting

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

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 Engine - Air Cleaner
Section 110-0050
Check condition of clamps (10 & 11, Fig. 3), hump however, it should perform satisfactorily through
hoses (8 & 9, Fig. 3) and plenum chamber (1, Fig. 3). approximately six cleanings, providing it does not rupture.
Tighten/replace as necessary.
Visually determine the condition of primary element
(2) and choose either the compressed air or washing
Air Cleaner Assembly method.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified. 1. Release latches (5) on cover assembly (4) and
remove cover assembly from air cleaner body (1).
Note: Air cleaner body (1) should be thoroughly
cleaned twice a year. Do not apply heat in any form to 2. Remove primary element (2) from air cleaner body (1).
air cleaner body (1).
3. Using a damp cloth and a suitable solvent, wipe out
1. Release latches (5) on cover assembly (4) and all excess dust from air cleaner body (1) and allow to
remove cover assembly from air cleaner body (1). dry.

2. Remove primary element (2) and safety element (3) 4. If the major contaminant on primary element (2) is light
from air cleaner body (1). dust, direct a jet of compressed air, not exceeding
6.9 bar (100 lbf/in2), against the pleats of the element.
3. Slacken clamps (10 & 11, Fig. 3) and disconnect The air jet should be directed in the opposite direction of
hump hose (8, Fig. 3) from air cleaner body (1). normal operating air flow. Move the air jet up and down
the pleats, holding the air nozzle 25 mm (1.0 in) away
4. Remove bolts (12, Fig. 3) and washers (14, Fig. 3) from the pleats, to prevent rupturing the element with
securing the air cleaner assembly to the platform. either the nozzle or air jet.

5. Remove the air cleaner assembly from the platform 5. In cases where the dust cake on primary element
for cleaning. (2) contains oil or carbon, air will not clean effectively.
Using manufacturers recommended solution and
6. Open mounting bands (7) and remove from aircleaner warm water, not exceeding 48° C (120° F), soak
body (1). Open clamp on cap assembly (6, Fig. 3) and primary element (2) for fifteen minutes. Element
remove cap assembly from air cleaner body (1). should be gently agitated to assist cleaning process.

7. Blank off air cleaner body (1) outlets with tape or Note: It is possible to modify an old agitator type
cardboard. Reach inside body with a compressed air washing machine for primary element (2) cleaning. Do
nozzle or brush and remove dust from the body. not soak or agitate primary element (2) in the solution
for more than fifteen minutes. Prolonged exposure
8. Remove all loose dust from air cleaner body (1) and softens vertical seams in the element.
remove tape or cardboard from body outlets.
6. Rinse washed element thoroughly with a low
Note: Assembly and installation of the air cleaner pressure stream of water, not exceeding 0.7 bar
assembly is the reverse of disassembly and removal. (10 lbf/in2), opposite from the normal air flow, until
rinse water runs clear.

Primary Element 7. Air dry primary element (2) thoroughly before

Numbers in parentheses refer to Fig. 1. returning it to service. Drying is a slow process which
may be hastened by exposing element to slowly
Although a paper primary element (2) is used, it is circulating heated air. Heated air temperature should
possible to clean it so that it can be reused. The not exceed 46o C (115o F). Drying time can be reduced
number of times one element can be reused depends to about three hours with heated air. DO NOT use a
on the type of dirt on the element and the care light bulb for drying. DO NOT use compressed air on a
exercised in cleaning. wet element.

The life of a properly cleaned element will be Note: Replace paper elements after six cleanings or
approximately as long as that of a new element for the two years in service, whichever comes first. Mark each
first one or two cleanings. After that, the life of the cleaned element to show total cleanings to date.
element will gradually decrease with each cleaning;

SM 1246 2-98 3

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Engine - Air Cleaner
Section 110-0050

8. After primary element (2) is thoroughly dried, MEASURING AIR RESTRICTION

inspect for damage or ruptures, especially close to the Numbers in parentheses refer to Fig. 3.
end caps. To detect paper ruptures, place a bright light
bulb inside the element and rotate element slowly. As a dry air cleaner element becomes loaded with
Inspection of element on the outside will disclose any dust, the vacuum on the engine side of the air cleaner
holes where concentrated light shines through. Even (air cleaner outlet) increases. This vacuum is generally
the smallest hole will pass dust to the engine and may measured as 'restriction in mm (inches) of water'.
result in costly engine repairs.
The recommended maximum allowable intake
9. Install primary element (2) in air cleaner body (1). restrictions at rated speed and load are as follows:
a. 380 mm-H2O (15 in-H 2O) with clean filter elements.
10. Install cover assembly (4) on air cleaner body (1) b. 635 mm-H2O (25 in-H 2O) with dirty filter elements.
and secure with latches (5).
While the air restriction gauge sends a signal to
indicate the need for servicing, it does not give as
Secondary Element precise a measurement as a water manometer or
Numbers in parentheses refer to Fig. 1. vacuum gauge.

Since safety element (3) is protected from Water Manometer

contamination by primary element (2), it needs no a. Remove protective cap (19) and disconnect
periodic cleaning and should be replaced only after harness at air restriction gauge (18). Remove air
every third primary element (2) service. restriction gauge (18) from elbow (17).

1. With primary element (2) removed from air cleaner b. Hold water manometer vertically and fill both legs
body (1), remove safety element (3). approximately half full of water. Connect one of the
upper ends to elbow (17) by means of a flexible hose.
2. Remove any dust dislodged into air cleaner body (1)
outlet and, using a damp cloth and a suitable solvent, c. With the manometer held vertically and the engine
wipe out all excess dust from air cleaner body (1) and drawing maximum air, the difference in height of the
allow to dry. water columns in the two legs is measured as the air
cleaner restriction.
3. Install new safety element (3) followed by primary
element (2) in air cleaner body (1) d. If the restriction exceeds the levels indicated,
engine performance will be affected. Primary filter
4. Install cover assembly (4) on air cleaner body (1) element should be cleaned or replaced.
and secure with latches (5).
Vacuum Gauge
a. Remove protective cap (19) and disconnect
Recommendations harness at air restriction gauge (18). Remove air
Numbers in parentheses refer to Fig. 3. restriction gauge (18) from elbow (17).

1. Under no condition should the vehicle be operated b. Connect the hose from the vacuum gauge to
without both filter elements in each air cleaner elbow (17) and, with the engine drawing maximum air,
assembly. take a note of the reading on the gauge.

2. It is very important that hump hoses (8), tube c. If the restriction exceeds the levels indicated, engine
assembly (12) and elbow (11) from the air cleaner performance will be affected. Primary filter element
assembly to the engine be airtight or the purpose of should be cleaned or replaced.
the air cleaner will be completely defeated. All clamps
(9 & 10) should be checked frequently and tightened to
prevent leaks. SERVICE TOOLS
Refer to Section 300-0070, SERVICE TOOLS for part
3. Keep new or cleaned filter elements on hand for numbers of service tools referenced in this section and
replacement to prevent unnecessary downtime of the general service tools required. These tools are
vehicle. available from your dealer.
* * * *
4 SM 1246 2-98

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 ENGINE - Power Takeoff
Section 110-0130

DESCRIPTION AND OPERATION SM - 2042

Numbers in parentheses refer to Fig. 1.

1 12
The function of the power takeoff (PTO), as the name
implies, is to provide the means of mounting and 16
driving auxiliary components.
11 11
The tandem gear pump for the disc brake cooling
system is mounted on the left hand side of the PTO
cover (6) and its input shaft is meshed with the 5
internal splines in the hub of driven gear (12). Refer 15
10
to Section 250-0055, TANDEM PUMP.

The main hydraulic pump for the body hoist system is 9

mounted on the right hand side of the PTO cover (6)
and its input shaft is meshed with the internal splines 16
in the hub of driven gear (17). Refer to 14
Section 230-0050, MAIN HYDRAULIC PUMP. 16
The major components of the PTO assembly are; 11 11
flywheel cover case (1), PTO cover (6), driveshaft (15),
17
drive gear (14) and driven gear (12). 6

As driveshaft (15) is driven by the engine crankcase, 13

drive gear (14) turns to drive driven gears (12 & 17).
1 - Flywheel Cover Case 12 - Driven Gear
The main hydraulic pump and tandem pump 5 - Oil Seal 13 - Gasket
driveshafts, meshed in the hub of driven gears (12 & 6 - PTO Cover 14 - Drive Gear
17), turn with driven gears (12 & 17) to operate the 9 - Oil Seal 15 - Driveshaft
main hydraulic pump and tandem pump which, in 10 - Bearing 16 - Snap Ring
11 - Bearing 17 - Driven Gear
turn, supplies hydraulic oil to the body hoist system
and steering system and disc brake assemblies. Fig. 1 - Cutaway View of Power Takeoff Assembly
Refer to Section 230-0050, MAIN HYDRAULIC PUMP
and Section 250-0055, TANDEM PUMP. assembly (1). Refer to Section 130-0010, FRONT
DRIVELINE.
REMOVAL 4. Drain oil from power takeoff housing by removing
Numbers in parentheses refer to Fig. 2, unless drain plug (14) from flywheel cover case (1, Fig. 1).
otherwise specified. Reinstall drain plug (14) securely.

5. Match mark main hydraulic pump mounting flange

WARNING and PTO cover (6, Fig. 1) so that the pump can be
To prevent personal injury and property installed in the same position at installation.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 6. With suitable blocking or lifting equipment, support
secured and of adequate capacity to do the job the main hydraulic pump before loosening attaching
safely. nuts. Remove nuts and lockwashers from main
hydraulic pump mounting studs and secure pump
1. Position the vehicle in a level work area, apply the clear of PTO assembly (1).
parking brake and switch off the engine.
7. Match mark tandem pump mounting flange and
2. Turn steering wheel in both directions several PTO cover (6, Fig. 1) so that the pump can be
times to relieve pressure in accumulator and steering installed in the same position at installation.
system. Block all road wheels.
8. With suitable blocking or lifting equipment, support
3. Disconnect driveline from yoke (5) at PTO the tandem pump before loosening attaching nuts.

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Engine - Power Takeoff
Section 110-0130

SM - 2043

8
2,4 2,4
9
1 10
11

3,4

7
6
5

12,13

1
14
14 3,4 15 12,13 3,4
FLYWHEEL HOUSING
ADAPTOR
4 - Lockwasher 8 - Breather Cap 12 - Elbow
1 - PTO Assembly 5 - Yoke 9 - Pipe Coupling 13 - Plug
2 - Bolt 6 - Hardened Washer 10 - Breather Assembly 14 - Plug
3 - Bolt 7 - Locknut 11 - Reducer Bush 15 - Plug
Fig. 2 - Power Takeoff Installation

Remove nuts and lockwashers from tandem pump 2. Remove bolts (3 & 7) and lockwashers (4 & 8) from
mounting studs and secure pump clear of PTO PTO cover (6). Pull PTO cover (6) and gasket (13) from
assembly (1). flywheel cover case (1). Discard gasket (13).

9. Match mark engine flywheel housing and flywheel 3. Place PTO cover (6) yoke side up on a work bench.
cover case (1, Fig. 1) so that PTO assembly (1) can Pry oil seal (9) from PTO cover (6) and discard.
be installed in the same position at installation.
4. Remove snap rings (16) from pump and driveshaft
10. Attach a suitable lifting device to PTO assembly bores. Drive bearings (10 & 11) from PTO cover (6)
(1) and remove bolts (2 & 3) and lockwashers (4) with a sleeve or soft steel drift. Drive on the outer
securing PTO assembly (1) to the engine flywheel race of bearings (10 & 11) taking care not to damage
housing. Carefully lower PTO assembly (1) from the the bearings.
flywheel housing and move to a clean work area for
disassembly. 5. Slide drive gear (14) from driveshaft (15) and pull
driven gears (12 & 17) from flywheel cover case (1).

DISASSEMBLY 6. Pull driveshaft (15) from flywheel cover case (1). Pry
Numbers in parentheses refer to Fig. 3, unless oil seal (5) from flywheel cover case (1) and discard.
otherwise specified.
7. Pull bearings (10 & 11) from flywheel cover case
1. Remove locknut (7, Fig. 2) and hardened washer (1) with a suitable bearing puller.
(6, Fig. 2) from driveshaft (15). Pull yoke (5, Fig. 2)
from driveshaft (15). 8. If required, note locations and remove dowel pins
(2) from flywheel cover case (1).

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 Engine - Power Takeoff
Section 110-0130

SM - 2044
6
2
13

4 3

16
12 11

1
11 9

16
10
15
7
8

10 14
16
11

5 17
11

13 - Gasket
1 - Flywheel Cover Case 5 - Oil Seal 9 - Oil Seal 14 - Drive Gear
2 - Dowel Pin 6 - PTO Cover 10 - Bearing 15 - Driveshaft
3 - Bolt 7 - Bolt 11 - Bearing 16 - Snap Ring
4 - Lockwasher 8 - Lockwasher 12 - Driven Gear 17 - Driven Gear
Fig. 3 - Exploded View of Power Takeoff Assembly

9. If required, remove breather assembly (10, Fig. 2) 5. Visually check oil seal lip contact surfaces on driveshaft
from PTO cover (6). (15) and yoke (5, Fig. 2) for nicks, dents, scratches,
wear, or corrosion. Replace as necessary.

INSPECTION
Numbers in parentheses refer to Fig. 3, unless ASSEMBLY
otherwise specified. Numbers in parentheses refer to Figs. 3, unless
otherwise specified.
1. Wash all parts thoroughly in a suitable solvent and
dry all but bearings (10 & 11) with compressed air. Note: Prior to assembly, lubricate all seal lips and
Dry bearings (10 & 11) with a clean lint free cloth. surfaces with lubricant specified in Section 300-0020,
LUBRICATION SYSTEM.
2. Check the condition of splines and teeth on gears
(12, 14 & 17), driveshaft (15) and yoke (5, Fig. 2) for Note: Tighten all fasteners without special torques
burrs or signs of wear. specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE
3. Lubricate bearings (10 & 11) with oil and check SPECIFICATIONS.
operation by spinning bearings by hand. DO NOT spin
bearings with compressed air. Inspect bearing bores for
out of roundness. Replace bearings, if required. WARNING
To prevent personal injury and property
4. Inspect flywheel cover case (1) and PTO cover (6) damage, be sure lifting device is properly
for cracks. If either flywheel cover case (1) or PTO secured and of adequate capacity to do the job
cover (6) are damaged, both parts must be replaced safely.
as an assembly.

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Engine - Power Takeoff
Section 110-0130

1. If removed, install dowel pins (2) in flywheel cover 1. Using suitable lifting equipment, position PTO
case (1), as noted at disassembly. assembly (1) on engine flywheel housing. Secure
PTO assembly (1) to the engine flywheel housing
2. If removed, install breather assembly (10, Fig. 2) with bolts (2 & 3) and lockwashers (4).
in PTO cover (6).
2. Using suitable lifting equipment, position main
3. Install new oil seal (5) in centre bore of flywheel hydraulic pump over its mounting studs and secure
cover case (1) so that it is flush with flywheel cover with nuts and lockwashers removed during removal.
case (1) face. See Fig. 1.
3. Using suitable lifting equipment, position tandem
Note: When installing new oil seals, install them with pump over its mounting studs and secure with nuts
the oil lip (larger of the two lips with the spring behind and lockwashers removed during removal.
it) facing inward. Care should be taken to prevent
damage to seal lips during assembly. 4. Reconnect driveline to yoke (5). Refer to Section
130-0010, FRONT DRIVELINE.
4. Press bearings (10 & 11) into their bores in
flywheel cover case (1). 5. Remove oil level plug (13) from elbow (12) in the
front of PTO cover (6, Fig. 1). Fill PTO assembly (1)
5. Press bearings (10 & 11) into their respective with lubricant specified in Section 300-0020,
bores in PTO cover (6). Turn PTO cover (6) over and LUBRICATION SYSTEM, until oil flows from the oil
install snap rings (16). level port. Install oil level plug (13) in elbow (12) and
tighten securely.
6. Install new oil seal (9) into centre bore in PTO
cover (6) so that it is flush with PTO cover (6) face. 6. Start the engine and bring oil to correct operating
See Fig. 1. temperature. Check for leaks and correct as
necessary.
7. Install driven gears (12 & 17) and driveshaft (15)
into flywheel cover case (1). Slide drive gear (14) 7. Remove wheel blocks from all road wheels.
over driveshaft (15) to its proper location.

8. Install new gasket (13) on PTO cover (6) and MAINTENANCE

assemble PTO cover (6) to flywheel cover case (1). Numbers in parentheses refer to Fig. 2, unless
Secure PTO cover (6) to flywheel cover case (1) with otherwise specified.
bolts (3 & 7) and lockwashers (4 & 8).
Note: Refer to Section 300-0020, LUBRICATION
9. Install yoke (5, Fig. 2) on driveshaft (15) end and SYSTEM for recommended check and drain intervals
secure with hardened washer (6, Fig. 2) and locknut and lubricant specifications.
(7, Fig. 2). Tighten locknut (7, Fig. 2) to a torque of
950 - 1 085 Nm (700 - 800 lbf ft).
Oil Level Check
Remove oil level plug (13) from elbow (12) and, if oil
INSTALLATION is not showing in elbow (12), add lubricant until oil is
Numbers in parentheses refer to Fig. 2, unless to the level of elbow (12). Reinstall oil level plug (13)
otherwise specified. and tighten securely.

Note: When reassembling PTO assembly (1) to the

engine flywheel housing, and main hydraulic and Drain and Refill
tandem pumps to PTO assembly (1), be sure to align To drain: Remove drain plug (14) from flywheel
match marks inscribed during disassembly. cover case (1, Fig. 1) and drain oil into a suitable
container. Reinstall drain plug (14) securely when
Note: Tighten all fasteners to standard torques listed draining is complete.
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.

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