2010 TEREX TA350-TA400 Dump Truck Service Repair Manual

Terex Equipment Limited Maintenance Manual
TA350 - TA400
MAINTENANCE MANUAL
15504580
CLICK HERE FOR TABLE OF CONTENTS
SM975/972/982
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Terex Equipment Limited Maintenance Manual - Introduction
For further information on the subject matter detailed within this Maintenance Manual,
please refer to Terex Equipment Limited Operator Handbooks and Product Parts
Books.
Alternatively, please contact;

TA350 - TA400
Customer Support Department

Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210
The illustrations, technical information, data and descriptive text in this manual, to the
MAINTENANCE MANUAL
best of our knowledge, were correct at the time of print. The right to change
specifications, equipment and maintenance instructions at any time without notice, is
reserved as part of the Terex Equipment Limited policy of continuous development
and improvement of the product.
No part of this publication may be reproduced, transmitted in any form - electronic,

mechanical, photocopying, recording, translating or by any other means without prior
permission of Customer Support Department - Terex Equipment Limited.
Please refer to TEREX Specification Sheets or consult Factory Representatives to

ensure that information is current.
15504580
SM975/972/982
Terex Equipment Limited Maintenance Manual Re-order
Issued by;
Customer Support Department
Terex Equipment Limited
TA350 - TA400
Newhouse Industrial Estate

Motherwell, ML1 5RY
Scotland
Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210
www.terex.com
MAINTENANCE MANUAL
Technical Assistance:
http://constructionsupport.terex.com
SM975/972/982
Re-order Part Number

15504580
Revision: April 2010
15504580
SM975/972/982
TABLE OF CONTENTS
Section No. Description SM No.

000 GENERAL INFORMATION
0000 Technical Data - TA350 (972) 2577 Rev1
0010 Welding Procedure 2172
100 CHASSIS
0010 Frames 2403
0020 Articulation and Oscillation Pivot 2580
0040 Hood and Mounting 2581
110 ENGINE
0030 Engine and Mounting 2582
0050 Air Cleaner 2583
120 TRANSMISSION
0010 Transmission and Mounting 2584 Rev1
0090 Transmission PTO 2371
125 DROPBOX
0010 Dropbox and Mounting 2585 Rev1
0020 Emergency Steering Pump 2586
0035 Dropbox Pump Assembly 2587 Rev1
0045 Dropbox Pressure Filter (new style) 2571
0050 Dropbox Suction Filter 2568
130 DRIVELINES
0010 Front Drivelines 2588
0020 Rear Drivelines 2589
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 2590
160 REAR AXLE GROUP
0020 Differential Drive Head 2591
0030 Axle Group (Hub) 2592
0050 Wheel Rim and Tyre 2593
165 BRAKE ASSEMBLY
0015 Oil Cooled Disc Brakes 2594
170 PARKING BRAKE
0010 Parking Brake and Mounting 2428 Rev1
180 SUSPENSION SYSTEM

0020 Front Suspension 2595
0040 Rear Suspension 2392
SM 2628 Rev1 04-10 1

TABLE OF CONTENTS
190 ELECTRICAL SYSTEM

0000 Circuit Diagrams (DDEC V, 4000 Series transmission) 2596 Rev1
0085 Hydraulic System ECU 2597 Rev1
0270 Switches and Sensors 2598
200 FUEL SYSTEM

0040 Fuel System 2599
0051 Electronic Foot Pedal 2395
210 COOLING SYSTEM
0000 Cooling System (Series 60 Engine) 2374
0005 Brake Cooling System Schematic 2600
0010 Cooling Fan and Motor 2601
0040 Radiator and Mounting 2602
0044 Fan Disconnect Valve 2603
0050 Disc Brake Oil Cooler (later version) 2604
0060 Transmission Oil Cooler (later version) 2563
0065 Dropbox Oil Cooler 2605
0100 Hydraulic Oil Cooler 2606
215 MAIN HYDRAULIC VALVE

0050 Main Hydraulic Valve Assembly 2607
220 STEERING SYSTEM

0000 Steering System Schematic 2608 Rev1
0090 Steering Valve 2609
0120 Steering Cylinder 2610
230 BODY SYSTEM

0000 Body System Schematic 2611 Rev1
0040 Hydraulic Tank (Refer to Section 250-0026) -
0050 Main Hydraulic Pump 2612 Rev1
0081 Body Control Lever 2613
0130 Body Cylinder 2614
0135 Load Sense Control Valve 2615 Rev1
250 BRAKING SYSTEM

0000 Braking System Schematic 2616 Rev1
0026 Brake Coolant/Hydraulic Tank 2617
0045 Motor/Triple Pump Assembly 2618
0050 Brake Manifold Valve 2619
0060 Accumulator 2620
0070 Treadle Valve 2621 Rev1
0075 OCDB Relief Unloader Valve 2622
2 SM 2628 Rev1 04-10

TABLE OF CONTENTS

260 OPERATORS COMPARTMENT
0010 Cab and Mounting 2623
0090 Driver Seat and Mounting 2624
0110 Instructor Seat and Mounting 2572
0130 Air Conditioning 2625
270 BODY
0010 Body and Mounting 2626
300 MISCELLANEOUS
0020 Lubrication System 2627
0070 Service Tools 2567
0080 Standard Bolt and Nut Torque Specifications 1238 Rev 1
0090 Unit Storage 2629
SM 2628 Rev1 04-10 3

4 SM 2628 Rev4 01-10

IMPORTANT SAFETY NOTICE
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.
It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the possible
hazardous consequences of each way. Consequently, no such broad evaluation has been undertaken.
Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must first satisfy
themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the service
method he/she selects.
Safety Alert Symbol

The safety alert symbol is used to alert you to a potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
Hazard Classification
A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following
signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard. Signal
words used without the safety alert symbol relate to property damage and protection only. All are used as
attention getting devices throughout this manual as well as on deals and labels fixed to the machinery to assist in
potential hazard recognition and prevention.
DANGER indicates an imminently hazardous situation which, if not avoided, will

DANGER result in death or serious injury.
WARNING indicates an potentially hazardous situation which, if not avoided, could

WARNING result in death or serious injury.
CAUTION indicates an potentially hazardous situation which, if not avoided, may

CAUTION result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous
CAUTION
situation which, if not avoided, may result in property damage.
WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardise
the integrity of the machine and could result in property damage or serious personal injury.
SM 2495 01-10
General Information - Technical Data TA350 (A972)
Section 000-0000
SM - 4004
3 315
(10-11)
Max 1 380
Body (4-6) 3 130
Depth (10-3)
6 872
(22-7)
66˚
3 888
(12-9)
3 686 2 967
(12-1) (9-9)
3 494 2 414
(11-5) (7-11)
851
553 (2-7)
(1-10)
1 837 2 914 1 310 2 990 1 950 1 780
(6-0) (9-7) (4-4) (9-10) (6-5) (5-10)
2 520
(8-3) 10 944
3 206 (35-11)
(10-6)
Dimensions in mm (ft-in)
Fig. 1 - Machine Dimensions
ENGINE Main ................................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

Make/Model ................................... Detroit Diesel Series 60 Temperatures:
Type ... 6 Cylinder, in line , Four cycle diesel, water cooled, Normal ............................ 60 °C - 135 °C (140 °F - 275 °F)
turbocharged with air to air cooling, electronic engine Maximum .................................................. 165 °C (329 °F)
management. Ratios:
Transmission ..................................... Refer to table below
Gross power at 2110 rev/min ....... 298 kW (400 hp, 405 PS)
Net power at 2110 rev/min ........... 289 kW (388 hp, 393 PS) Low Range
Note: Gross power rated to SAE J1995 Jun 90. Engine Forward
emission meets USA EPA Tier 3 /CARB MOH 40 CFR 89 Gear 1 2 3 4 5 6
Tier 3 and proposed EU NRMM (non-road mobile km/h 5.2 11.0 15.9 24.3 31.0 35.2
machinery) Tier 3 directive.
mile/h 3.2 6.8 9.9 15.1 19.3 21.9
Maximum Torque ...... 2000 Nm (1475 lbf ft) at 1200 rev/min Reverse
Number of cylinders/configuration .......................... 6, in line Gear 1
Bore x Stroke ........................ 133 x 168 mm (5.24 x 6.61 in)
Piston Displacement ........................................ 14 l (855 in³) km/h 4.6
Air cleaner .................................... Dry type, double element mile/h 2.9
Starting ..................................................................... Electric
Maximum Speed (No load) ............................. 2300 rev/min
Maximum Speed (Full load) ............................ 2200 rev/min High Range
Idle Speed ........................................................ 700 rev/min Forward
Gear 1 2 3 4 5 6
km/h 7.9 16.8 24.3 37.1 47.7 53.9
TRANSMISSION
mile/h 4.9 10.4 15.1 23.1 29.6 33.5
Make/Model ................................... Allison 4500 ORS with
integral retarder mounted directly to the engine, fully Reverse
automatic transmission with planetary gearing, lock-up in all Gear 1
gear ranges. Electronic control with six forward and one km/h 7.0
reverse gear.
mile/h 4.3
SM 2577 Rev1 04-10 1

Section 000-0000
DROPBOX HYDRAULIC SYSTEM
Remote mounted transfer gearbox taking drive from the Braking, steering and body hoist systems are controlled by
transmission and feeding it via a lockable differential to the a main hydraulic valve mounted on frame. Systems are
front and rear wheels. supplied with oil from a common tank by the main hydraulic
pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
AXLES line.
Three axles in permanent all-wheel drive (6 X 6) with Pump:
differential coupling between each axle to prevent driveline Type ......................................................................... Piston
wind-up. Heavy duty axles with fully-floating axle shafts and Capacity at 2700 rev/min ........... 5.4 l/s (85.6 US gal/min)
outboard planetary reduction gearing.
Brakes
Automatic limited slip differentials in each axle. Centre axle Full hydraulic braking system with enclosed, forced oil-
incorporates a through-drive differential to transmit drive to cooled multiple discs on each wheel. Independent circuits
the rear axle. This differential and the dropbox output for front and rear brake systems. Warning lights and
differential are locked simultaneously using one switch audible alarm indicate low brake system pressure. Brake
selected by the operator. system conforms to ISO 3450, SAE J1473.
Ratios: Actuating Pressure ................ 58 ± 2.4 bar (845 ± 35 lbf/in²)
Differential ............................................................... 3.70:1 Pump Type ............................................... Triple stage gear
Planetary ................................................................. 6.35:1 Capacity at 1 685 rev/min .............. 8.9 l/s (2.35 US gal/min)
Total Reduction ..................................................... 23.50:1
SUSPENSION Braking surface (tractor) ....... 590240 mm2 (914.9 in2)/brake

Front: Four trailing links and a Panhard rod locate the front Braking surface (trailer) ........ 590240 mm2 (914.9 in2)/brake
axle giving a high roll centre. The optimised front axle
position along with the wide spaced main and rebound Parking: Spring-applied, hydraulic-released disc on
mounts, mounted directly above the axle and long rear driveline.
suspension travel, combine with two heavy duty dampers
each side to give excellent handling and ride. Emergency: Automatic application of driveline brake
should pressure fall in main brake hydraulic
Rear: Each axle is coupled to the frame by three system. Service brakes may also be applied
rubber- bushed links with lateral restraint by a transverse using the parking-emergency brake control.
link. Pivoting inter-axle balance beams equalize load on
each axle. Suspension movement is cushioned by Retardation: Hydraulic retarder integral with transmission.
rubber/metal laminated compression units between
each axle and underside of balance beam ends. Pivot
points on rear suspension linkages are rubber-bushed Steering
and maintenance-free.
Hydrostatic power steering by two single-stage, double-
WHEELS AND TYRES acting, cushioned steering cylinders. Emergency steering
Wheels: ........... 5-piece earthmover rims with 12 stud fixing pressure is provided by a ground driven pump mounted on
the rear of the transmission. An audible alarm and warning
Size:
light indicates should the emergency system activate.
Standard ....................... 25 x 22.00 in for 26.5 R25** tyres
Conforms to ISO 5010, SAE J53.
Tyres:
System Pressure ................................ 240 bar (3500 lbf/in²)
Standard .......................................................... 26.5 R25**
Steering Angle to either side .......................................... 45°
Lock to Lock Turns, steering wheel .................................... 4
Inflation Pressures (Bridgestone):
Body Hoist
Front Centre/Rear
Two single-stage, double-acting hoist rams, cushioned at
26.5 R25** ...... 3.73 bar (54 lbf/in²) 4.97 bar (72 lbf/in²)
both ends of stroke. Electro servo assisted hoist control.
Inflation Pressures (Michelin):
System Pressure ................................ 240 bar (3500 lbf/in²)
Front Centre/Rear
Control Valve ....................... Pilot Operated, Closed Centre
Body Raise Time (loaded) ...................................... 12.5 sec
Body Lower Time (power down) .................................. 8 sec
Inflation Pressures (GoodYear):
Front Centre/Rear
26.5 R25** ...... 4.75 bar (69 lbf/in²) 4.75 bar (69 lbf/in²) ELECTRICAL SYSTEM
Type ................................................. 24 V, Negative Ground
Note: Tyre pressures should be regarded as nominal only. Battery ............................................. Two, 12 V, 175 Ah each
It is recommended that for tyres both listed and unlisted, Accessories ................................................................... 24 V
the user should consult the tyre manufacturer and evaluate Alternator ................................................................ 100 Amp
all job conditions in order to make the proper selection.
2 SM 2577 Rev1 04-10

Section 000-0000
BODY
Of all welded construction, fabricated from high hardness
Vehicle Weights 29.5 R25 Tyres
(min. 360 BHN) 1000 MPa (145000 lbf/in²) yield strength Standard Vehicle kg lb
steel. 25° tail chute angle provides good load retention Net Distribution
without tailgate.
Front Axle 15086 32258
Centre Axle 7125 15707
Plate Thicknesses:
Floor and Tailchute .................................. 15 mm (0.58 in) Rear Axle 7068 15582
Sides ........................................................ 12 mm (0.47 in) Vehicle, Net 29279 64547
Front ........................................................... 8 mm (0.39 in) Payload 34000 74956
Volume: Gross Distribution
Struck (SAE) .......................................... 15.5 m³ (20.3 yd³) Front Axle 17279 38094
Heaped 2:1 (SAE) ................................. 21.0 m³ (27.5 yd³) Centre Axle 23000 50705
Rear Axle 23000 50705
SERVICE CAPACITIES Vehicle, Gross 63279 139506
Fuel tank ................................................. 481 l (127 US gal) Bare Chassis 23669 52177
Hydraulic System .................................... 330 l (87.2 US gal) Body 4950 10915
Cooling System ........................................ 80 l (21.1 US gal) Body Hoists (Pair) 660 1455
Engine Crankcase (with filters) .................. 37 l (9.8 US gal)
Transmission (with filters) ......................... 61 l (14.8 US gal)
Differentials - Front & Rear ......................... 33 l (8.9 US gal)
Differential - Centre .................................... 34 l (8.7 US gal)
Planetaries (each) ........................................ 9 l (2.4 US gal)
Driveshaft Bearings ................................... 1.5 l (0.4 US gal)
Air Conditioning Compressor ........... 0.125 l (0.033 US gal)
TYPICAL NOISE LEVELS

Operator Ear (ISO 6394) ........................................... 76 dbA
*Exterior Sound Rating (ISO 6395) ......................... 109 dbA

* - 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
are for the vehicle in base configuration.
Note: Noise Level Exposure to the operator and bystander

personnel may be higher depending upon proximity to
buildings, rock piles, machinery, etc. The actual job site
Noise Level Exposure must be measured and applicable
regulations complied with in respect to Employee Hearing
Protection.
* * * *
SM 2577 Rev1 04-10 3

Section 000-0000
4 SM 2577 Rev1 04-10

Section 000-0000
SM - 4004
3 315
(10-11)
Max 1 380
Body (4-6) 3 130
Depth (10-3)
6 872
(22-7)
66˚
3 888
(12-9)
3 686 2 967
(12-1) (9-9)
3 494 2 414
(11-5) (7-11)
851
553 (2-7)
(1-10)
1 837 2 914 1 310 2 990 1 950 1 780
(6-0) (9-7) (4-4) (9-10) (6-5) (5-10)
2 520
(8-3) 10 944
3 206 (35-11)
(10-6)
ENGINE Main Pressure ................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

Type … 6 Cylinder, in line , Four cycle diesel, water cooled, Normal ............................ 60 °C - 135 °C (140 °F - 275 °F)
management. Ratios:
Net power at 2110 rev/min ............ 326 kW (437hp, 433 PS) Low Range
mile/h 3.4 7.3 10.5 16.0 20.5 23.3
Maximum Torque ..... 2100 Nm (1548 lbf ft) at 1 350 rev/min Reverse
Piston Displacement ........................................ 14 l (855 in³) km/h 4.8
Gear 1 2 3 4 5 6
km/h 8.4 17.8 25.8 39.5 50.4 60.0
TRANSMISSION
mile/h 5.2 11.0 16.0 24.5 31.3 37.3
reverse gear.
mile/h 4.6
SM 2578 Rev1 04-10 1

Section 000-0000
DROPBOX Inflation Pressures (Michelin):

Remote mounted transfer gearbox taking drive from the Front Centre/Rear
transmission and feeding it via a lockable differential to the 26.5 R25** ........ 3.2 bar (47 lbf/in²) 4.5 bar (65 lbf/in²)
front and rear wheels.
Inflation Pressures (Double Coin):
Ratios: Front Centre/Rear
Low...........................................................................1.129:1 26.5 R25** ........ 4.5 bar (65 lbf/in²) 5.5 bar (80 lbf/in²)
High..........................................................................0.738:1
Inflation Pressures (Triangle):
Front Centre/Rear
Pressure: 26.5 R25** ........... 4 bar (58 lbf/in²) 5.9 bar (86 lbf/in²)
High/Low Actuation........................................15 ±0.2 bar
Differential Lock Actuation...............................42 ±8 bar Note: Tyre pressures should be regarded as nominal
Lubrication...........................................................2 ± 1 bar only. It is recommended that for tyres both listed and
unlisted, the user should consult the tyre manufacturer
Temperature:
and evaluate all job conditions in order to make the
Maximum.................................................100 °C (212 °F)
proper selection.
AXLES
HYDRAULIC SYSTEM
Three axles in permanent all-wheel drive (6 X 6) with a
Braking, steering and body hoist systems are controlled by
differential coupling between each axle, to prevent driveline
a main hydraulic valve mounted on the frame. Systems are
wind-up. Heavy duty axles with fully-floating axle shafts and
supplied with oil from a common tank by the main hydraulic
pump, driven from a power take-off on the transmission.
System components are protected by full flow filtration on
Automatic limited slip differentials in each axle. Centre axle
the return line.
incorporates a through-drive differential to transmit drive to
Pump:
the rear axle. This differential and the dropbox output
Type ......................................................................... Piston
differential are locked simultaneously using one switch
Capacity at 2700 rev/min ........... 5.4 l/s (85.6 US gal/min)
selected by the operator.
Ratios: Brakes
Differential ............................................................... 3.70:1 Full hydraulic braking system with enclosed, forced oil-
Planetary ................................................................. 6.35:1 cooled multiple discs on each wheel. Independent circuits
Total Reduction ..................................................... 23.50:1 for front and rear brake systems. Warning lights and
audible alarm indicate low brake system pressure. Brake
SUSPENSION system conforms to ISO 3450, SAE J1473.
Front: Four trailing links and a Panhard rod locate the front
axle giving a high roll centre. The optimized front axle Actuating Pressure ................ 58 ± 2.4 bar (850 ± 35 lbf/in²)
position, along with the wide spaced main and rebound Pump Type ............................................... Triple stage gear
mounts, mounted directly above the axle, and long Capacity at 1685 rev/min ........... 8.9 l/s (2.35 US gal/min)
each side to give excellent handling and ride.
Braking surface (tractor) ....... 590240 mm2 (914.9 in2)/brake
Rear: Each axle is coupled to the frame by three rubber- Braking surface (trailer) ........ 590240 mm2 (914.9 in2)/brake
bushed links with lateral restraint by a transverse link.
Pivoting inter-axle balance beams equalize the load on Parking: Spring-applied, hydraulically-released disc
each axle. Suspension movement is cushioned by on rear driveline.
rubber/metal laminated compression units between each
axle and underside of balance beam ends. Pivot points Emergency: Automatic application of driveline brake
on rear suspension linkages are rubber-bushed and should pressure fall in main brake hydraulic
maintenance-free. system. Service brakes may also be applied
using the parking-emergency brake control.
WHEELS AND TYRES
Wheels: ............ 3-piece earthmover rims with 19 stud fixing Retardation: Hydraulic retarder integral with transmission.
Size:
Standard ....................... 25 x 22.00 in for 26.5 R25** tyres
Steering
Tyres:
Standard .......................................................... 26.5 R25**
acting, cushioned steering cylinders. Emergency steering
pressure is provided by a ground driven pump mounted on
the rear of the transmission. An audible alarm and warning
Inflation Pressures (Bridgestone): light indicates should the emergency system activate.
Front Centre/Rear Conforms to ISO 5010, SAE J53.
26.5 R25** ........ 4.5 bar (65 lbf/in²) 5.7 bar (82 lbf/in²)
2 SM 2578 Rev1 04-10

Section 000-0000
System Pressure ............................... 240 bar (3 500 lbf/in²) Vehicle Weights 29.5 R25 Tyres
Steering Angle to either side .......................................... 45° Standard Vehicle kg lb
Lock to Lock Turns, steering wheel .................................... 4
Net Distribution
Body Hoist Front Axle 15086 32258
Two single-stage, double-acting hoist rams, cushioned at Centre Axle 7125 15707
both ends of stroke. Electro servo assisted hoist control. Rear Axle 7068 15582
Vehicle, Net 29279 64547
System Pressure ................................ 240 bar (3500 lbf/in²) Payload 34000 74956
Body Raise Time (loaded) ...................................... 12.5 sec Gross Distribution
Body Lower Time (power down) .................................. 8 sec Front Axle 17279 38 094
Centre Axle 23000 50 705
Rear Axle 23000 50705
ELECTRICAL SYSTEM
Vehicle, Gross 63279 139506
Type ................................................. 24 V, Negative Ground
Battery ............................................. Two, 12 V, 175 Ah each Bare Chassis 23669 52177
Accessories ................................................................... 24 V Body 4950 10915
Alternator ................................................................ 100 Amp Body Hoists (Pair) 660 1 455
BODY
(min. 360 BHN) 1 000 MPa (145 000 lbf/in²) yield strength
steel. 25° tail chute angle provides good load retention
without tailgate.
Plate Thicknesses:
Floor and Tailchute .................................. 15 mm (0.58 in)
Sides ........................................................ 12 mm (0.47 in)
Front ........................................................... 8 mm (0.39 in)
Volume:
Struck (SAE) .......................................... 15.5 m³ (20.3 yd³)
Heaped 2:1 (SAE) ................................. 21.0 m³ (27.5 yd³)
SERVICE CAPACITIES
Fuel tank ................................................. 481 l (127 US gal)
Hydraulic System .................................... 330 l (87.2 US gal)
Cooling System ........................................ 80 l (21.1 US gal)
Engine Crankcase (with filters) .................. 37 l (9.8 US gal)
Transmission (with filters) ......................... 61 l (14.8 US gal)
Differentials - Front & Rear ......................... 33 l (8.9 US gal)
Differentials - Centre .................................. 34 l (8.7 US gal)
Planetaries (each) ........................................ 9 l (2.4 US gal)
Driveshaft Bearings ................................... 1.5 l (0.4 US gal)
Air Conditioning Compressor ........... 0.125 l (0.033 US gal)



buildings, rock piles, machinery etc.. The actual job site
Protection.
* * * *
SM 2578 Rev1 04-10 3

Section 000-0000
4 SM 2578 Rev1 04-10

General Information - Technical Data TA400 (982)
Section 000-0000
SM - 4003
3 315
Max 1 495 (10-11)
Body (4-11)
Depth 3 130
(10-3)
6 930
(22-9)
66˚
3 945
(12-11)
3 740 3 140
(12-3) (10-4)
3 550 2 470
(11-8) (8-1)
905
605 (2-9)
(2-0)
1 840 3 025 1 310 2 990 1 950 1 780
(6-0) (9-11) (4-4) (9-10) (6-5) (5-10)
2 595
(8-6) 11 055
3 360 (36-3)
(11-3)
ENGINE Main ................................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

Type 6 .... Cylinder, in line , Four cycle diesel, water cooled, Normal ............................ 60 °C - 135 °C (140 °F - 275 °F)
management. Ratios:
Net power at 2110 rev/min ........... 326 kW (437 hp, 443 PS) Low Range
mile/h 3.4 7.3 10.5 16.0 20.5 23.3
Maximum Torque ...... 2100 Nm (1548 lbf ft) at 1350 rev/min Reverse
Piston Displacement ................................. 14 litres (855 in³) km/h 4.8
Gear 1 2 3 4 5 6
km/h 8.4 17.8 25.8 39.5 50.4 60.0
TRANSMISSION
mile/h 5.2 11.0 16.0 24.5 31.3 37.3
reverse gear.
mile/h 4.6
SM 2579 Rev1 04-10 1

Section 000-0000
DROPBOX HYDRAULIC SYSTEM
Remote mounted transfer gearbox taking drive from the Braking, steering and body hoist systems are controlled by
transmission and feeding it via a lockable differential to the a main hydraulic valve mounted on frame. Systems are
front and rear wheels. supplied with oil from a common tank by the main hydraulic
pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
AXLES line.
Three axles in permanent all-wheel drive (6 X 6) with Pump:
differential coupling between each axle to prevent driveline Type ......................................................................... Piston
wind-up. Heavy duty axles with fully-floating axle shafts and Capacity at 2700 rev/min ........... 5.4 l/s (85.6 US gal/min)
Brakes
Automatic limited slip differentials in each axle. Centre axle Full hydraulic braking system with enclosed, forced oil-
incorporates a through-drive differential to transmit drive to cooled multiple discs on each wheel. Independent circuits
the rear axle. This differential and the dropbox output for front and rear brake systems. Warning lights and audible
differential are locked simultaneously using one switch alarm indicate low brake system pressure. Brake system
selected by the operator. conforms to ISO 3450, SAE J1473.
Ratios: Actuating Pressure ................ 58 ± 2.4 bar (845 ± 35 lbf/in²)
Differential ............................................................... 3.70:1 Pump Type ............................................... Triple stage gear
Planetary ................................................................. 6.35:1 Capacity at 1 685 rev/min ...... 8.9 litre/s (2.35 US gal/min)
Total Reduction ..................................................... 23.50:1
SUSPENSION Braking surface (tractor) ........ 590240 mm2 (914.9 in2)/brake

Front: Four trailing links and a panhard rod locate the front Braking surface (trailer) ......... 590240 mm2 (914.9 in2)/brake
axle giving a high roll centre. The optimised front axle
position along with the wide spaced main and rebound Parking: Spring-applied, hydraulic-released disc on
mounts, mounted directly above the axle and long rear driveline.
each side to give excellent handling and ride. Emergency: Automatic application of driveline brake
should pressure fall in main brake hydraulic
Rear: Each axle is coupled to the frame by three rubber- system. Service brakes may also be applied
bushed links with lateral restraint by a transverse link. using the parking-emergency brake control.
Pivoting inter-axle balance beams equalise load on each
axle. Suspension movement is cushioned by rubber/metal
laminated compression units between each axle and Steering
underside of balance beam ends. Pivot points on rear
suspension linkages are rubber-bushed and maintenance-
acting, cushioned steering cylinders. Emergency steering
free. pressure is provided by a ground driven pump mounted on
WHEELS AND TYRES the rear of the transmission. An audible alarm and warning
light indicates should the emergency system activate.
Wheels: ............ 5-piece earthmover rims with 12 stud fixing Conforms to ISO 5010, SAE J53.
Size:
Standard ....................... 25 x 25.00 in for 29.5 R25** tyres System Pressure ................................ 240 bar (3500 lbf/in²)
Steering Angle to either side .......................................... 45°
Tyres: Lock to Lock Turns, steering wheel .................................... 4
Standard ........................................................... 29.5 R25**
Body Hoist
Two single-stage, double-acting hoist rams, cushioned at
Inflation Pressures (Bridgestone): both ends of stroke. Electro servo assisted hoist control.
Front Centre/Rear
29.5 R25** ........ 4.0 bar (76 lbf/in²) 5.0 bar (73 lbf/in²) System Pressure ................................ 240 bar (3500 lbf/in²)
Inflation Pressures (Michelin): Body Raise Time (loaded) ......................................... 13 sec
Front Centre/Rear Body Lower Time (power down) ............................... 7.5 sec
Inflation Pressures (Good Year): ELECTRICAL SYSTEM

Front Centre/Rear Type ................................................. 24 V, Negative Ground
29.5 R25** ...... 3.24 bar (47 lbf/in²) 4.6 bar (66 lbf/in²) Battery ............................................. Two, 12 V, 175 Ah each
Accessories ................................................................... 24 V
Note: Tyre pressures should be regarded as nominal only. It Alternator ................................................................ 100 Amp
is recommended that for tyres both listed and unlisted, the
user should consult the tyre manufacturer and evaluate all
job conditions in order to make the proper selection.
2 SM 2579 Rev1 04-10

Section 000-0000
BODY
Vehicle Weights 29.5 R25 Tyres
(min. 360 BHN) 1000 MPa (145000 lbf/in²) yield strength Standard Vehicle kg lb
steel. 25° tail chute angle provides good load retention Net Distribution
without tailgate.
Plate Thicknesses:
Rear Axle 7440 16368
Floor and Tailchute ................................... 15 mm (0.58 in)
Sides ......................................................... 12 mm (0.47 in) Vehicle, Net 30820 67804
Front ......................................................... 10 mm (0.39 in) Payload 38000 83775
Gross Distribution
Volume:
Struck (SAE) .......................................... 17.4 m³ (22.8 yd³)
Heaped 2:1 (SAE) ................................. 23.3 m³ (30.3 yd³)
Rear Axle 25000 55000
Vehicle, Gross 68320 151500
SERVICE CAPACITIES
Bare Chassis 24760 54444
Fuel tank .................................................. 481 l (127 US gal)
Hydraulic System .................................... 330 l (87.2 US gal) Body 5400 11905
Engine Crankcase and filters ..................... 32 l (8.4 US gal) Body Hoists (Pair) 660 1455
Cooling System ........................................ 67 l (17.7 US gal)
Transmission (including cooler) ................. 61 l (2.6 US gal)
Dropbox ......................................................... 13 l (8.7 US g
Differentials - Front & Rear (each) ............. 33 l (8.7 US gal)
Differential - Centre .................................... 34 l (8.9 US gal)
Planetaries (each) ...................................... 9 l (2.37 US gal)
Hand Pump Tank ........................................ 1 l (0.26 US gal)
Air Conditioning Compressor ............ 0.125 l (0.033 US gal)



buildings, rock piles, machinery etc.. The actual job site
Protection.
* * * *
SM 2579 Rev1 04-10 3

Section 000-0000
THIS PAGE IS INTENTIONALLY LEFT BLANK
4 SM 2579 Rev1 04-10

GENERAL INFORMATION - Welding Procedure
Section 000-0010
Welding
WARNING
Welding and flame cutting cadmium plated
WARNINGS metals produce odourless fumes which are
Before any welding is done on a machine toxic. Recommended industrial hygiene
equipped with any electronic systems, practice for protection of the welding operator
disconnect the following (if applicable) in this from the cadmium fumes and metallic oxides
order: Battery earth cable, battery supply requires enclosure ventilation specifically
cable, alternator earth cables, alternator supply designed for the welding process. A
cables and electrical connections at the engine respiratory protective device such as the
ECM, transmission ECU, body control lever, M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
hydraulics ECU and cab bulkhead to avoid will provide protection against cadmium,
damage to electrical components. Turn off fumes and metallic oxides. The 'Gasfoe'
battery master switch to isolate the batteries respirator has been approved by the U.S.
before disconnecting any components. Bureau of Mines: Approval number 23B-10,
After welding connect all of the above in the and is designed to protect against gases,
reverse order. vapours, and/or metal fumes.
Note: The current from the welding rod always follows

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

frame repairs. Since the nature and extent of damage General Welding Procedure
to the frame cannot be predetermined, no definite The following general procedure should be used for
repair procedure can be established. As a general rule the repair of defects outwith the vicinity of alloy steel
however, if parts are twisted, bent or pulled apart, or a castings.
frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned. 1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
Successfully welded repairs will depend to a great employed, pre-heat area to 100° C (212° F), measure
extent upon the use of the proper equipment, materials 3 - 4" either side of repair prior to gouging. On
and the ability of the welder. The Customer Support completion of gouging grind to remove thin carbon
Department can be consulted regarding the feasibility layer.
of welding repairs.
2. Apply dye-penetrant check to ensure crack has
been completely removed.
SM 2172 01-10 1
General Information - Welding Procedure
Section 000-0010
3. Pre-heat area to 100° C (212° F), measured 3 - 4" 3 - 4" either side of repair prior to gouging. On
either side of repair. Avoid local overheating. completion of gouging grind to remove thin carbon
layer.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from 2. Apply dye-penetrant check to ensure crack has
moisture pick-ups at all times. been completely removed.
5. Allow repair weld to cool slowly. 3. Pre-heat area to 200° C (392° F), measured 3 - 4"
either side of repair. Avoid local overheating.
6. Grind and blend repair to original contour. Paint
heat damaged areas. 4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the 5. On completion of welding, post-heat repair area to
welds joining steel castings. 400° C (752° F), measure 3 - 4" either side of repair.
1. Completely ARC-AIR gouge or grind out the crack 6. If welding has to be interrupted for any reason, e.g.
until sound metal is reached. If ARC-AIR method is overnight, post-heat immediately as in Step 5.
employed, pre-heat area to 200° C (392° F), measure
* * * *
2 SM 2172 01-10
CHASSIS - Frames
Section 100-0010
SM - 3413
Fig. 1 - General Arrangement of Frame Assemblies
DESCRIPTION
The front and rear frames are all-welded high grade Note: For details on the articulation and oscillation
steel fabrications, with rectangular box section beams pivot and procedures for separating the front and rear
forming the main side and cross-members. These frames, refer to Section 100-0020, ARTICULATION
heavy duty structures are designed to withstand the AND OSCILLATION PIVOT.
severe loadings incurred when operating over rough
terrain.
MAINTENANCE
The front frame houses engine, transmission, Note: This section covers maintenance of the front
hydraulic and fuel tanks and carries the cab, front and rear frames only.
suspension and front drive axle. The rear frame
carries the body, body cylinders, rear suspension
system and the rear drive axles. Inspection
Inspect the frames and attached parts at intervals not
Inter-frame oscillation is provided by a robust exceeding 250 hours for cracked or broken welds and
cylindrical coupling, carried on large nylon bushes. bending of the frame. Any defects found should be
Steering is by frame articulation to 45 degrees either repaired before they progress into major failures.
side by two widely spaced vertical pivot pins in taper
roller bearings.
SM 2403 12-09 1
Chassis - Frames
Section 100-0010
Straightening d- Battery supply cables

If the frame is not too badly sprung or twisted, e- Alternator earth cables
hydraulic straightening and aligning equipment can be f- Alternator supply cables
used to straighten the frame without dismantling the g- ECM Vehicle (both 68 pin connectors)
machine. However, if the frame is severely damaged, h- Transmission TCM (80 pin connector)
it will be necessary to disassemble the machine in i- Transmission (4th Gen) connector
order to repair or replace the frame assembly. j- Hydraulic ECU Electronic Controller
k- Body hydraulics joystick
All straightening operations should be performed l- VDU panel CPU (all connectors)
without application of heat if possible. If heat must be
applied, do not heat the metal beyond a dull cherry red After welding, connect all of the above in the reverse
colour, as it will result in serious weakening of the order.
frame by decreasing the tensile strength of the steel.
When it is necessary to apply heat, apply it uniformly Note: Always fasten the welding machines ground
over the area to be straightened until the metal cable to the piece/frame being welded if possible.
reaches a uniform colour. Protect the heated surface
from drafts to prevent sudden cooling of the metal. If Electric arc welding is recommended for all welded
the frame or frame parts cannot be straightened they frame repairs. Since the nature and extent of damage
must be replaced. to the frame cannot be predetermined, no definite
repair procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
Welding frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned.
WARNINGS Successfully welded repairs will depend to a great

Before any welding is done on a machine extent upon the use of the proper equipment, materials
equipped with the DDEC system, disconnect and the ability of the welder. The Service Department
wiring harnesses at the ECM, connections at can be consulted regarding the feasibility of welding
body hydraulics joystick, all battery repairs.
connections at both positive and negative
terminals and ground cable to alternator to
avoid damage to electrical components. Turn Reinforcement
battery master switch to the 'Off' position Frame reinforcement can be made with channel, angle
before disconnecting any components. or flat structural stock. Whenever possible, the
Remove battery ground cable first, and reinforcement should extend well beyond the bent,
reconnect last, to avoid damaging electrical broken or cracked area. The reinforcement stock
components. thickness should not exceed that of the frame stock
and the material should be of the same tensile
strength.
Before any welding is done ensure all paint
has been removed from the area to be welded.
Failure to do so may result in hazardous fumes Painting
being given off from the paint. To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
Note: Prior to welding, switch off/disconnect the on the frames is highly recommended.
following in the order given. Failure to do so may
seriously damage the machines electrical If painting of a frame is required, thoroughly clean the
components. areas to be painted. Apply a primer coat of synthetic
red oxide and then a finish coat of synthetic enamel.
a - Turn keyswitch off
b - Turn battery master switch off
c - Battery earth cables
* * * *
2 SM 2403 12-09
CHASSIS - Frames
Section 100-0010
SM - 3413
Fig. 1 - General Arrangement of Frame Assemblies
DESCRIPTION
The front and rear frames are all-welded high grade Note: For details on the articulation and oscillation
steel fabrications, with rectangular box section beams pivot and procedures for separating the front and rear
forming the main side and cross-members. These frames, refer to Section 100-0020, ARTICULATION
heavy duty structures are designed to withstand the AND OSCILLATION PIVOT.
severe loadings incurred when operating over rough
terrain.
MAINTENANCE
The front frame houses engine, transmission, Note: This section covers maintenance of the front
hydraulic and fuel tanks and carries the cab, front and rear frames only.
suspension and front drive axle. The rear frame
carries the body, body cylinders, rear suspension
system and the rear drive axles. Inspection
Inspect the frames and attached parts at intervals not
Inter-frame oscillation is provided by a robust exceeding 250 hours for cracked or broken welds and
cylindrical coupling, carried on large nylon bushes. bending of the frame. Any defects found should be
Steering is by frame articulation to 45 degrees either repaired before they progress into major failures.
side by two widely spaced vertical pivot pins in taper
roller bearings.
SM 2403 12-09 1
Chassis - Frames
Section 100-0010
Straightening d- Battery supply cables

If the frame is not too badly sprung or twisted, e- Alternator earth cables
hydraulic straightening and aligning equipment can be f- Alternator supply cables
used to straighten the frame without dismantling the g- ECM Vehicle (both 68 pin connectors)
machine. However, if the frame is severely damaged, h- Transmission TCM (80 pin connector)
it will be necessary to disassemble the machine in i- Transmission (4th Gen) connector
order to repair or replace the frame assembly. j- Hydraulic ECU Electronic Controller
k- Body hydraulics joystick
All straightening operations should be performed l- VDU panel CPU (all connectors)
without application of heat if possible. If heat must be
applied, do not heat the metal beyond a dull cherry red After welding, connect all of the above in the reverse
colour, as it will result in serious weakening of the order.
frame by decreasing the tensile strength of the steel.
When it is necessary to apply heat, apply it uniformly Note: Always fasten the welding machines ground
over the area to be straightened until the metal cable to the piece/frame being welded if possible.
reaches a uniform colour. Protect the heated surface
from drafts to prevent sudden cooling of the metal. If Electric arc welding is recommended for all welded
the frame or frame parts cannot be straightened they frame repairs. Since the nature and extent of damage
must be replaced. to the frame cannot be predetermined, no definite
repair procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
Welding frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned.
WARNINGS Successfully welded repairs will depend to a great

Before any welding is done on a machine extent upon the use of the proper equipment, materials
equipped with the DDEC system, disconnect and the ability of the welder. The Service Department
wiring harnesses at the ECM, connections at can be consulted regarding the feasibility of welding
body hydraulics joystick, all battery repairs.
connections at both positive and negative
terminals and ground cable to alternator to
avoid damage to electrical components. Turn Reinforcement
battery master switch to the 'Off' position Frame reinforcement can be made with channel, angle
before disconnecting any components. or flat structural stock. Whenever possible, the
Remove battery ground cable first, and reinforcement should extend well beyond the bent,
reconnect last, to avoid damaging electrical broken or cracked area. The reinforcement stock
components. thickness should not exceed that of the frame stock
and the material should be of the same tensile
strength.
Before any welding is done ensure all paint
has been removed from the area to be welded.
Failure to do so may result in hazardous fumes Painting
being given off from the paint. To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
Note: Prior to welding, switch off/disconnect the on the frames is highly recommended.
following in the order given. Failure to do so may
seriously damage the machines electrical If painting of a frame is required, thoroughly clean the
components. areas to be painted. Apply a primer coat of synthetic
red oxide and then a finish coat of synthetic enamel.
a - Turn keyswitch off
b - Turn battery master switch off
c - Battery earth cables
* * * *
2 SM 2403 12-09
CHASSIS - Articulation and Oscillation Pivot
Section 100-0020
SM - 3933
25 52 56
50 51 29 56
16 64-69 5,6 55
19 7
20
27 53 54
14 8,9 56
17
DETAIL A 25
42
41 39
45,46,49 36,49
45,47,49
1
32
26,56 26,53
30
52,55 54,55 10,26
23
56
38 11
2,3,4 2,3,4
33 60
57,58,59
49,61,62 36,49 40 28
A 51 18
13
15 8,9
51
31 63
17
50 16
19
64-69
44,48,49 43 19
37,49
16 29
31
35 14 24 8,9
29 15
38
30,23 21,22
34 12
25
10,26
45,46,49 37,49 45,47,49
1 - Pivot Assembly 16 - Lockplate 28 - Plug 43 - Lower Pin 58 - Connector

2 - Nylon Bush 17 - Front Yoke 29 - 'O' Ring 44 - Hardened Washer 59 - Elbow
3 - Loctite 648 18 - Brake Yoke 30 - Bearing Assembly 45 - Washer 60 - Pipe Assembly
4 - Loc Quick Primer 19 - Bolt 31 - Retaining Ring 46 - Bolt 61 - Washer
5 - Gasket 20 - Washer 32 - Seal Housing 47 - Bolt 62 - Bolt
6 - Cover Plate 21 - Lockwasher 33 - Seal Housing 48 - Bolt 63 - Thrust Collar-Rear
7 - Bolt 22 - Bolt 34 - Seal Housing 49 - Loctite 243 64 - Shim
8 - Bearing Assy - Cup 23 - Extreme Pressure 35 - Seal Housing 50 - Thrustcollar-Front 65 - Shim
9 - Bearing Assy - Cone Lithium No.2 Grease 36 - Seal 51 - 'O' Ring 66 - Shim
10 - 'V' Ring Seal 24 - SAE 80W-90 EP 37 - Seal 52 - Hose Assembly 67 - Shim
11 - Thrust Nut Gear Oil 38 - Shim 53 - Hose Assembly 68 - Shim
12 - Locking Plate 25 - Plug 39 - Spacer 54 - Connector 69 - Shim
13 - Antiseize Comp 26 - Extreme Pressure 40 - Upper Pin 55 - Lube Fitting
14 - Driveshaft Multipurpose Grease 41 - Washer 56 - Elbow
15 - Seal 27 - Lube Fitting 42 - Nut 57 - Adaptor
Fig. 1 - Articulation and Oscillation Pivot
DESCRIPTION AND OPERATION connecting the drive between the front and rear frames.
The articulation and oscillation pivot allows the front
and rear frames to rotate horizontally (articulation) and Articulation bearings, oscillation bushes, pivot
tilt laterally (oscillation) with respect to each other. It is driveshaft bearing and associated parts can be
also the main load bearing coupling between the two removed, inspected and replaced or renewed by
frames. The pivot assembly houses the driveshaft following the procedures outlined in this section.
SM 2580 01-10 1
Chassis - Articulation and Oscillation Pivot
Section 100-0020
THRU-DRIVE DRIVESHAFT 9. Disconnect mounting hardware securing protective

Numbers in parentheses refer to Fig. 1, unless guard (if fitted), from beneath the parking brake disc, to
otherwise specified. the rear frame.
Note: The following procedures assume that only 10. Release the parking brake by turning the hex-head
thru-drive components require repair. on the parking brake actuator fully anticlockwise.
Note: Tighten all fasteners without special torques

WARNING
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE Tensioned spring on adjuster.
SPECIFICATIONS.
11. Remove mounting hardware securing parking
brake assembly to mounting bracket on frame, then
WARNINGS secure parking brake assembly clear of brake disc.
To prevent personal injury and property
damage, be sure wheel blocks are properly 12. Identify the relationship of the driveline caps to
secured and of adequate capacity to do the job brake yoke (18). Remove capscrews, disconnect
safely. driveline and secure clear of brake yoke.
When necessary to drive out or drive on 13. Withdraw driveshaft assembly (14) from housing
components during disassembly/assembly, be by pulling rearwards on parking brake disc/brake
sure to use a soft drift to prevent property yoke assembly (18). If necessary, tap front end of
damage and personal injury. driveshaft (14) to ease removal, take care to avoid
damaging threads. Place driveshaft (14) assembly on
work bench for further disassembly.
Removal and Disassembly
1. Position the vehicle on a level work area and apply 14. Prise out and discard seal (15) from front of the
parking brake. housing.
2. Raise body and install body safety prop to secure 15. Lift out front bearing assembly cup (8) from front
body in partially raised position. of the housing.
3. Shut down engine and block all wheels securely. 16. If bearing replacement is required, use a suitable
puller to remove front and rear bearing assembly
4. Identify the relationship of the driveline caps to the cups (8) from the housing.
transmission yoke and front yoke (17). Remove
capscrews and remove driveline from vehicle. Note: If either bearing assembly cup or cone (8 or 9)
need replacing, they must be replaced as a set.
Note: Take extra care when handling drivelines as
any deformity on a rotating mass creates vibration 17. If retaining rings (31) need replacing, use a
and excessive wear during any operation. suitable drift or puller to remove them from the housing.
5. Remove wheel blocks, start engine and steer 18.Temporarily install front yoke (17) fully onto front of
vehicle into a full left-hand lock. Shut down engine driveshaft (14) and suitably restrain to resist rotation.
and block all wheels securely.
19. Remove mounting hardware securing parking
6. Remove Lockplate (16) , 2 0ff Front bolts (19), brake disc to brake yoke (18) and remove brake disc.
Shims (64 - 69), Front thrust collar (50) & Front yoke
(17) from the drive shaft (14). 20. Remove Lockplate (16) , 2 off Rear bolts (19) ,
Rear Thrust collar (63) & Brake yoke (18) from
7. Remove and discard 'O' rings (29 & 51) from Thrust driveshaft (14). Identify front and rear ends of
collar (50). driveshaft (14).
8. Place a suitable container under the front of the 21. Remove and discard 'O' rings (29 & 51) from Rear
pivot and pull front yoke (17) from driveshaft (14). Thrust collar (63).
2 SM 2580 01-10
Section 100-0020
22. Remove and discard seal (15) from driveshaft (14). 9 SM - 3143
14
23. If bearing replacement is required, use a suitable

puller or drift to remove rear bearing assembly cone (9)
from driveshaft (14).
Inspection
1. Clean all parts with a suitable solvent and let dry.

DO NOT spin bearings with compressed air. Place
bearings on a clean surface, cover with a lint free 55mm
cloth and allow to dry.
Fig. 2 - Pre assembly of bearing
2. Check bearing assemblies cups and cones (8 & 9)
for wear or damage. Renew as necessary. 6. Refer to Fig. 2, Maintain end face of cone approximately
55mm from end of spline face.
Note: If either bearing assembly cup or cone (8 or 9)
need replacing, they must be replaced as a set. 7. Insert driveshaft (14) into truck end of pivot casing
until bearing assembly cone (9) seats firmly in the
3. Inspect splines of driveshaft (14) and yokes bearing assembly cup (8).
(17 & 18) for nicks, burrs or excessive wear. Replace
if wear is excessive or splines are nicked. Burrs may 8. Apply loctite (3) to new seal (15) and fit over the
be removed with a fine file or medium India stone. driveshaft (14) with seal 'Lip' to bearing side.Press seal
home using a mandrel.
4. Check yokes (17 & 18) for damage in region
polished by oil seal lip; even slight damage in this 9. Apply grease to splines of Rear thrust collar (63) and
area can cause leakage. Very slight marks may be slide onto the drive shaft (14).
polished out with fine emery cloth but it is essential
that polishing marks are parallel to the seal lip. 10. Fit new 'O'-rings ( 29 & 51) to Rear thrust collar (63)
and fit collar over stub end of driveshaft (14) (align
5. Replace all seals and 'O' rings with new parts. mating holes). Fit 2 off front bolts (19).
11. Tighten Rear bolts (19) ; alternately 1/4 - 1/2 turns,

Assembly and Installation drawing driveshaft (14) hard against the inner face of
1. If removed, use a suitable driver and install retaining Rear thrust collar (63). Shaft will be visible through
rings (31) into housing, ensuring that they butt hard inspection hole on the collar.
against abutment shoulders.
12. Lock Rear yoke (18) from rotation by a suitable
2. Using a suitable driver, install front bearing cup (8) method / bar acting on the ground. Torque Front bolts
into tractor end of pivot casing. Ensure it is firmly (19) to 54Nm/39 Ibf ft.
seated & that a 0.05mm (0.002") feeler gauge cannot
be inserted between cup and mating face. 13. Using special mandrel (15270104) home locking
plate (16) onto Bolts (19). Remove the clamping bar.
3. Check rear bearing cup (8) is firmly seated in the
body end of the pivot casing, again ensuring 0.05mm 14. Slide Front bearing asembly cone (9) onto rear end
(0.002") feeler gauge cannot be inserted between cup of drive shaft (14) until it seats in bearing assembly cup
and mating face. (8).
4. Lightly oil both bearing assembly cones (9) with SAE 15. Position clamping bar assembly and screw central
80W - 90 E. P. gear oil (24). bolt hard against bolts (19) of Rear thrust collar (63),
enabling body end bearing to be fully seated home.
5. Support driveshaft (14) in a suitable fixture & tap one
Bearing assembly cone (9) onto driveshaft (14) using a 16. Using mandrel and heavy hammer, drive Rear
tubular mandrel. bearing assembly cone, fully into cup. Now remove
clamp bar assembly from front end.
SM 2580 01-10 3
Section 100-0020
MOT00048
'A' 'D'
'C' DEPTH
MICROMETER SHAFT - FRONT
SHIM
AREA
'B' 'E' (D - C)
Fig. 3 - Measurements / various
17. Take remaining seal (15), apply loctite (3) and fit 22. The actual free air space 'E' to be shimmed
over drive shaft with seal 'Lip' to bearing side. Press between end of drive shaft (14) and compression face of
seal home using a mandrel. Front Thrust collar (50) equals:
18. Apply grease to splines of Front yoke (17) and slide E='D' - 'C'.
onto drive shaft (14). Ensure milled slots of driving
flanges are aligned with those of brake yoke. 23. Now add 0.6mm (0.024") to dimension 'E' to allow
for oversize shims. This value is dimension 'F'
Note : For Measurment letters- refer to fig. 3, unless (End float will be determined by subtraction).
otherwise stated.
24. Remove Front bolts (19) and Front thrust collar (50)
19. Before fitting of Front Thrust collar (50) record from pivot body end and chap drive shaft (14) to free
Measurements as stated: bearing.
i) Measure total width 'A' of Rear thrust collar (63) 25. Calculate the nominal combination of minimum
number if shims (64-69) to achieve the size nearest to
ii) Using Depth micrometer, measure inner bore depth dimension 'F'. Record the appropriate part numbers and
'B' of Front thrust collar (50) and record value. total nominal thickness value.
iii) Subtract 'B' from 'A' to determine recess dimension 26. Select the shims (64-69) and measure the total
'C'. actual thickness of the combination. Record this value.
20. Fit Front thrust collar (50) without 'O'-rings onto 27. Place the shim pack (64-69) in the front thrust
Drive shaft (14) and tighten Rear bolts (19) to a nominal collar (50) , lock off the front yoke (17) from rotation by
torque of 15Nm/11Ibf ft. suitable method / bar on ground. Torque bolts (19) to
full torque.
Note : a gap should be visible between end of shaft
and inner face of collar. 28. Remove the clamp and spin the front yoke (17) to
ensure driveshaft (14) free rotation.
21. Using a Depth micrometer, measure distance 'D'
from front thrust collar (50) outer face to end face of 29. Take a magnetic clock gauge located on the flange
drive shaft (14) via the hole in the collar and record the
value.
4 SM 2580 01-10
Section 100-0020
of pivot casing, needle acting on front thrust collar (50) the bottom of filler/level hole.
end face. Check Front yoke (17) float movement.
43. Remove plug (25) from underside of oscillation hub
30. Take reading obtained and subtract a figure sufficient to drain the cavity between the oscillation hub and pivot
to give an end float in the range 0.05mm - 0.15mm assembly (1) of any oil that entered while filling the
(0.002" - 0.006"), reduce shim pack (64-69) accordingly. driveshaft bearing housing.
31. Remove Front thrust collar (50) and shims (64-69) 44. Install plug (25) into filler/level hole on pivot
and re-assemble with the apporpriate shims. Ensure assembly (1). Install gasket (5) and cover plate (6) on
'O'-rings (29 & 51) are now fitted. side of oscillation hub, secure with bolts (7) and
washers (20).
32. Lock Front yoke (17) flange as before ,applying
alternate 1/4 -1/2 turns on bolts (19). Torque to 54 Nm 45. Install plug (25) into cavity drain port on underside
(39 Ibf ft). of oscillation hub.
33. Remove the locking bar and confirm that the driveshaft 46. Install parking brake disc protective guard (if fitted)
(14) end float is in the range 0.05mm -0.15mm and secure with bolts, washers and nuts. Tighten nuts
(0.002" - 0.006") by moving the front yoke (17) for and aft to a torque of 73 Nm (54 lbf ft).
against the clock gauge.
47. Start engine, raise body, lower body safety prop
34. Adjust and refit the shim pack (64-69) as and lower body.
necessary.
48. Remove wheel blocks.
35. Float set correctly; Drive home locking plate (16)
using a mandrel (15270104) . Re-check the end float.
ARTICULATION COMPONENTS
36. Install parking brake disc on front yoke (17) and Numbers in parentheses refer to Fig. 1, unless
secure with bolts and washers. Tighten bolts to a otherwise specified.
torque of 73 Nm (54 lbf ft).
Note: The following procedures assume that only
37. Install parking brake assembly to mounting components associated with articulation require repair.
brackets and secure with bolts, washers and nuts.
Refer to Section 170-0010, PARKING BRAKE AND Note: It is essential that the grease used for articulation
MOUNTING. components is Extreme Pressure Lithium Complex No. 2
(23), as specified in Section 300-0020, LUBRICATION
38. Apply parking brake by turning the hex-head on the SYSTEM.
parking brake actuator fully clockwise.
39. Apply Loctite 638 to the threads of capscrews used specified to torques listed in Section 300-0080,
to mount driveline to front yoke (17). Align match STANDARD BOLT AND NUT TORQUE
marks and install driveline. Tighten capscrews to a SPECIFICATIONS.
40. Apply Loctite 638 to the threads of capscrews used WARNINGS

to mount driveline between transmission yoke and front To prevent personal injury and property
yoke (17). Align match marks and install driveline. damage, be sure wheel blocks, blocking
Tighten capscrews to a torque of 153 Nm (113 lbf ft). materials and lifting equipment are properly
secured and of adequate capacity to do the job
41. Remove bolts (7), washers (20), gasket (5) and safely.
cover plate (6) from side of oscillation hub to gain
access to filler/level hole plug (25) on pivot assembly When necessary to drive out or drive on
(1). Remove filler/level plug (25). components during disassembly/assembly, be
sure to use a soft drift to prevent property
42. Add SAE 80W - 90 E. P. gear oil (24) through filler/ damage and personal injury.
level hole in pivot assembly (1) until the oil is level with
SM 2580 01-10 5
Section 100-0020
SM - 008 lifting equipment to support pivot/rear frame assembly.
9. Remove bolt (62), washer (61), large nut (42) and

washer (41) securing upper pin (40).
10. Remove upper pin (40). If necessary tap upper pin

(40) to ease removal taking care to avoid damaging the
threads.
Note: It may be necessary to relieve binding between

the pin and pin bores by raising or lowering the pivot/
rear frame assembly.
11. Remove bolt (48) and hardened washer (44)

Fig. 4 - Determining Shim Thickness securing lower pin (43).
12. Remove lower pin (43). If necessary tap lower pin

Disconnecting Front and Rear Frames (43) to ease removal taking care to avoid damaging the
pin.
Note: The front and rear frames can be separated
sufficiently to permit disassembly/assembly of the Note: Only separate the frames sufficiently to permit
articulation components without disconnecting removal of the articulation bearings or damage to
hydraulic lines or electrical wiring. hydraulic and electrical connections could result.
1. Position the vehicle on a level work area and apply 13. Remove blocks from rear wheels and use lifting
parking brake. equipment to pull pivot/rear frame assembly clear of
the front frame. After moving, block pivot/rear frame
2. Raise body and install body safety prop to secure assembly and block the wheels.
body in partially raised position.
14. Remove spacer (39) noting orientation to ensure
3. Shut down engine and block all wheels securely. correct installation.
4. Identify the relationship of the driveline caps to the
transmission yoke and front yoke (17). Remove Disassembly
capscrews and remove driveline from vehicle. 1. Identify seal housings (32, 33, 34 & 35) to ensure
correct location on assembly/installation.
5. Support tractor frame at front and rear with suitably
placed stands or timbers so the frame will remain level Note: Seal housings (32, 33, 34 & 35) are not
during and after pin removal. interchangeable.
6. Remove bolts, washers and pins securing steering 2. Remove bolts (46 & 47), washers (45), seal housings
cylinders to pivot. Secure steering cylinders clear of (32, 33, 34 & 35) and upper and lower shims (38).
pivot.
3. Prise out and discard seals (36 & 37) from the
7. Release the parking brake by turning the hex-head housings.
on the parking brake actuator fully anticlockwise.
4. Remove and tag all bearing assemblies (30) with
spacers to ensure correct assembly/installation.
WARNING
Tensioned spring on adjuster. Note: Bearing assemblies (30) and spacers are a
matched set, never interchange cups, cones or
8. Attach suitable lifting equipment to pivot/rear frame spacers between sets.
assembly. Lifting equipment must prevent pivot from
oscillating after separation, and, be capable of pulling Inspection
pivot/rear frame assembly clear of front frame. Raise 1. Clean all parts with a suitable solvent and let dry.
DO NOT spin bearings with compressed air. Place
6 SM 2580 01-10
Section 100-0020
bearings on a clean surface, cover with a lint free cloth 94 Nm (68 lbf ft).
and allow to dry.
Connecting Front and Rear Frames
2. Check bearing assemblies (30) and spacers, and 1. Install spacer (39) in upper outer seal housing (32),
pins (40 & 43) for wear or damage. Renew as as noted on removal.
necessary.
2. Smear bearing and pin bores with Extreme Pressure
Note: Bearing assemblies (30) and spacers must be Lithium Complex No. 2 grease (23).
renewed as a matched set.
3. Attach suitable lifting equipment to pivot/rear frame
3. Replace all seals with new parts. assembly. Lifting equipment must prevent pivot from
oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame
Assembly pin bores. Raise lifting equipment to support pivot/rear
1. Apply Loctite 243 (49) sparingly to bore of seal frame assembly.
housings (32, 33, 34 & 35).
4. Remove blocks from rear wheels and blocking from
2. Using a suitable driver, install seals (36 & 37) into pivot/rear frame assembly. Using lifting equipment, pull
seal housings (32, 33, 34 & 35) ensuring that the metal pivot/rear frame assembly to align pivot bearing bores
ring on inside of the seals are not disturbed, and, that and front frame pin bores. Block wheels and block
they are located towards the inside of seal housing. pivot/rear frame assembly to remain level and
stationary.
3. Apply Loctite 243 (49) to threads of outer seal
housing bolts (46). 5. Freeze upper and lower pins (40 & 43) to ease
installation.
4. Place outer seal housings (32 & 34) in position
ensuring that grease relief hole in seal housings are 6. Smear lower pin (43) with Extreme Pressure Lithium
directly opposite bearing grease port on pivot. Secure Complex No. 2 grease (23) and install through front
with bolts (46) and washers (45). Tighten bolts (46) to a frame and bearing bores.
Note: Bearing assemblies (30) and spacers are a the pin and pin bores by raising or lowering pivot/rear
matched set, never interchange cups, cones or frame assembly.
spacers between sets.
7. Apply Loctite 243 (49) to threads of bolt (48) and
5. Using Extreme Pressure Lithium Complex No. 2 secure lower pin (43) with bolt (48) and hardened
grease (23), pack bearing assemblies (30), including washer (44). Tighten bolt (48) to a torque of 73 Nm
end faces, and install bearings. (54 lbf ft).
6. Place inner seal housings (33 & 35) temporarily in 8. Smear upper pin (40) with Extreme Pressure Lithium
position and secure with bolts (47) and washers (45). Complex No. 2 grease (23) and install through front
Tighten bolts (47) to a torque of 16 Nm (12 lbf ft). frame and bearing bores.
7. Using feeler gauges, as shown in Fig. 4, measure 9. Apply Loctite 243 (49) to threads of bolt (62). Secure
the dimension between the inner pivot faces and seal upper pin (40) with bolt (62), washer (61), large nut (42)
housings (33 & 35). Measure at 3 positions equally and washer (41). Tighten nut (42) to a torque of 1 425
spaced around seal housings and determine average Nm (1 050 lbf ft).
dimension, this is the size of shims (38) required.
8. Remove bolts (47), washers (45) and inner seal Final Assembly
housings (33 & 35). 1. Apply parking brake by turning the hex-head on the
9. Install shims (38) as calculated at Step 7, reinstall
inner seal housings (33 & 35) and secure with bolts 2. Remove lifting equipment from pivot/rear frame
(47) and washers (45). Tighten bolts (47) to a torque of assembly.
SM 2580 01-10 7
Section 100-0020
3. Remove stands or timbers from front frame. SM - 038
4. Apply Loctite 270 to the threads of capscrews used

to mount driveline between transmission yoke and front
yoke (17). Align match marks and install driveline.
Tighten capscrews to a torque of 153 Nm (113 lbf ft).
5. Align steering cylinder bores and mounting pin bores

on pivot, install pins and secure with bolts and
washers. Tighten bolts to a torque of 73 Nm (54 lbf ft).
6. Remove plugs (28) from articulation bearing, grease

ports and replace with lube fittings (27).
Note: Lube fittings (27) are stored on pad on side of Fig. 5 - Preventing Pivot Assembly From Oscillating
pivot assembly (1).
be sure wheel blocks, blocking materials and
7. Fill bearing housings with Extreme Pressure Lithium
lifting equipment are properly secured and of
Complex No. 2 grease (23), through lube fittings (27),
adequate capacity to do the job safely.
until excess grease starts to escape from seal
housings (32 & 34).
When necessary to drive out or drive on
components during disassembly/assembly, be
8. Remove lube fittings (27) and reinstall plugs (28).
sure to use a soft drift to prevent property
Store lube fittings (27) on pad on side of pivot
damage and personal injury.
assembly (1).
Hydraulic fluid pressure will remain
9. Start engine, raise body, lower body safety prop and
within the braking system after engine shut
lower body.
down. Operate the treadle pedal continuously
until the pressure has dissipated before
carrying out any work on the braking system
or serious injury could result.
OSCILLATION COMPONENTS
Disconnecting Front and Rear Frames
Numbers in parentheses refer to Fig. 1.
1. Position the vehicle on a level work area and apply
Note: The following procedure assumes that only parking brake.
components associated with oscillation require repair.
2. Raise body and install body safety prop to secure
Note: It is necessary to disconnect the front and rear body in partially raised position.
frames at the articulation point to service the
oscillation components. 3. Shut down engine and block all wheels securely.
Note: It is essential that the grease used for 4. Depress and release brake pedal continuously to
oscillation components is Extreme Pressure relieve the pressure in the braking system.
Multipurpose Grease (26), as specified in
Section 300-0020, LUBRICATION SYSTEM. 5. Carefully loosen brake lines at base of both
accumulators to check that the pressure has
Note: Tighten all fasteners without special torques released. Re-tighten brake lines.
STANDARD BOLT AND NUT TORQUE 6. Tag all hydraulic lines and electrical wiring between
SPECIFICATIONS. front and rear frames to ensure correct assembly/
installation. Disconnect all hydraulic lines and plug
openings to prevent ingress of dirt. Disconnect
WARNINGS electrical wiring and any other attachments which could
To prevent personal injury and property damage, be damaged on separation of front and rear frames.
8 SM 2580 01-10
Section 100-0020
7. Identify the relationship of the driveline caps to the to the rear frame. Refer to Section 170-0010, PARKING
transmission yoke and front yoke (17). Remove BRAKE AND MOUNTING.
capscrews and remove driveline from the vehicle.
2. Remove mounting hardware securing parking brake
8. Support tractor frame at front and rear with suitably assembly to mounting bracket on frame. Remove and
placed stands or timbers to keep the frame level during secure parking brake assembly clear of brake disc.
and after pin removal.
3. Identify the relationship of the driveline caps to
9. Remove bolts, washers and pins securing steering brake yoke (18). Remove capscrews, disconnect
cylinders to pivot. Secure steering cylinders clear of driveline and secure clear of brake yoke (18).
pivot.
4. Remove mounting hardware securing parking brake
10. Release the parking brake by turning the hex- disc to brake yoke (18) and remove brake disc.
head on the parking brake actuator fully anticlockwise.
5. Place a suitable container under rear brake yoke (18)
to catch oil released when pulling brake yoke (18) from
WARNING driveshaft (14).
Tensioned spring on adjuster.
6. Remove Rear bolts (19), Lockplate (16) & Rear
11. Attach suitable lifting equipment to pivot/rear frame thrust collar (63). Pull brake yoke (18) from driveshaft
assembly. Lifting equipment must prevent pivot from (14) .
oscillating after separation, and, be capable of pulling
pivot/rear assembly clear of front frame. Raise lifting 7. Remove adaptor (57), connector (58), elbow (59)
equipment to support pivot/rear frame assembly. and pipe assembly (60) from oscillation hub.
12. Remove bolt, washer, large nut (42) and washer 8. Remove bolts (22) and washers (21) securing locking
(41) securing upper pin (40). plate (12). Remove locking plate (12).
13. Remove upper pin (40). If necessary tap upper pin 9. Restrain pivot assembly (1) to prevent it oscillating,
(40) to ease removal taking care to avoid damaging by placing a heavy bar between the steering cylinder
the threads. mountings. Lock the bar in position using suitable
trestles or stands. See Fig. 5.
the pin and pin bores by raising or lowering the pivot/ 10. Using a suitable tool, remove thrust nut (11). If
rear frame assembly. wear area of thrust nut (11) is damaged, replace thrust
nut (11).
14. Remove bolt (48) and hardened washer (44) 11. Insert an M20 eyebolt into tapped pad provided on
securing lower pin (43). top of pivot assembly (1) and attach suitable lifting
equipment.
15. Remove lower pin (43). If necessary tap lower pin 12. Remove pivot restraining bar.
(43) to ease removal taking care to avoid damaging the
pin. 13. Using lifting equipment, carefully pull pivot
assembly (1) clear of oscillation hub. Place pivot
16. Remove blocks from rear wheels and use lifting assembly (1) in a suitable work area for further
equipment to pull pivot/rear frame assembly clear of disassembly.
the front frame. After moving, block pivot/rear frame
assembly and block the wheels. 14. Note position of front 'V' ring (10) to aid in Installation'.
Remove and discard 'V' ring (10).
17. Remove spacer (39) noting orientation to ensure
correct installation. Cover articulation bearings to 15. Inspect nylon oscillation bushes (2) as described in
prevent ingress of dirt. 'Inspection'. If bushes are to be renewed, proceed with
step 16.
Disassembly 16. Remove nylon oscillation bushes (2) with hammer
1. Remove protective guard (if fitted) from beneath parking and chisel.
brake disc by removing mounting hardware securing guard
SM 2580 01-10 9
Section 100-0020
SM - 011 3. Install plug (25) in filler/level hole on pivot assembly

(1). Install gasket (5) and cover plate (6) on side of
PAINT DOT oscillation hub and secure with bolts (7) and washers
(20).
4. Install plug (25) in cavity drain port on underside of

oscillation hub.
5. Install plugs (28) into oscillation bearing grease

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

pivot with Extreme Pressure Multipurpose Grease (26)
and, install 'V' ring (10), with lip towards rear, on front of
Fig. 6 - Installing Oscillation Bushes
oscillation hub.
Note: The suggested method is to make an axial cut 7. Using suitable lifting equipment, and taking care to
along the bush then to lever the bush in order to prevent damaging bushes (2) or pivot threads, install
collapse it upon itself. pivot assembly (1) into rear frame.
Inspection 8. Lightly coat 'V' ring (10) and machined surfaces of

pivot with Extreme Pressure Multipurpose Grease (26)
1. Clean nylon oscillation bushes with a suitable and, install 'V' ring (10), with lip towards front, on rear of
solvent and allow to dry. oscillation hub.
2. Inspect nylon oscillation bushes for wear, scoring, 9 . a) Restrain pivot assembly (1) to prevent it
erosion and 'out of round'. Pay particular attention to oscillating, by placing a heavy bar between the steering
the thrust faces of the bushes which should also be cylinder mountings. Lock the bar in position using
inspected for cracking/splitting. Renew if required. suitable trestles or stands. See Fig. 5.
3. Replace all seals with new parts. b) Secure a suitable tool to pivot thrust nut (11) and
tighten thrust nut (11) until there is no end float/
Assembly clearance at thrust face of either bush. Slacken thrust
nut (11) until pin of the locking plate (12) can be
Numbers in parentheses refer to Fig. 1. inserted in the first available hole in the thrust nut (11).
Note: Tighten all fasteners without special torques c) Secure locking plate (12) with bolts (22) and
specified to torques listed in Section 300-0080, lockwashers (21). Torque tighten bolts (22) to 94 Nm
STANDARD BOLT AND NUT TORQUE (69 lbf ft).
SPECIFICATIONS.
10. Install adaptor (57), connector (58), elbow (59) and
pipe assembly (60) to oscillation hub.
WARNING
To prevent personal injury and property 11. Install front yoke (17) on driveshaft (14) until it butts
damage, be sure wheel blocks are properly against bearing assembly cup and cone (8 & 9).
safely. 12. Install parking brake disc on front yoke (17) and
secure with bolts, washers and nuts. Tighten bolts to a
1. Wipe bush housing clean using a suitable solvent torque of 73 Nm (54 lbf ft).
and allow to dry.
13. Install front of driveshaft (14).
2. Apply Loctite 648 (3) and Loc Quick Primer (4) and
align new bushes (2) to housing with grease holes 14. install front yoke (17) , Front thrust collar (50)
aligned vertically and identification 'PAINT DOT' at Top ensuring 'O'-rings (29 & 51) are in place , shim
Dead Centre. Refer to Fig. 6. Drift bushes (2) into pack (64-69) and bolts (19).
housing using hammer with soft packing for protection.
10 SM 2580 01-10
Section 100-0020
(54 lbf ft).
15. Lock off front yoke flange as before (18) with
suitable clamping method. Torque bolts (19) to 73 Nm 8. Smear upper pin (40) with Extreme Pressure Lithium
(Ibf ft) Complex No. 2 grease (23) and install through front
frame and bearing bores.
16. Take a magnetic clock gauge located on the flange 9. Apply Loctite 243 (49) to threads of bolt (62). Secure
of pivot casing , needle acting on Rear thrust collar (63) upper pin (40) with bolt (62), washer (61), washer (41)
end face. Check Front yoke (17) float movement. and large nut (42). Tighten nut (42) to a torque of 1 425
Ensure still within range 0.05mm - 0.15mm (0.002" - Nm (1 050 lbf ft).
0.006").
17. If float is incorrect, alter arrangement of shim pack Final Assembly

(64-69) to bring within size. 1. Install parking brake assembly to mounting
brackets and secure with bolts, washers and nuts.
18. Using special mandrel (15270104) home locking Refer to Section 170-0010, PARKING BRAKE AND
plate (16) onto bolts (19). Remove clamping bar. MOUNTING.
2. Apply parking brake by turning the hex-head on the

Connecting Front and Rear Frames
1. Install spacer (39) in upper bearing assembly (30) as
noted on removal. WARNING
Tensioned spring on adjuster.
2. Smear bearing assembly (30) and pin bores with
Extreme Pressure Lithium Complex No. 2 grease (23). 3. Remove lifting equipment from pivot/rear frame
assembly.
3. Attach suitable lifting equipment to pivot/rear frame
assembly. Lifting equipment must prevent pivot from 4. Remove stands or timbers from front frame.
oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame 5. Apply Loctite 270 to threads of capscrews used to
pin bores. Raise lifting equipment to support pivot/rear mount driveline between transmission yoke and front
frame assembly. yoke (17). Align match marks and install driveline.
Tighten capscrews to a torque of 153 Nm (113 lbf ft).
4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull 6. Align match marks and reconnect driveline to brake
pivot/rear frame assembly to align pivot bearing bores yoke (18). Tighten capscrews to a torque of
and front frame pin bores. Block wheels and block 153 Nm (113 lbf ft).
pivot/rear frame assembly to remain level and
stationary. Note: Take extra care when handling drivelines as
chips, dents, burrs or deformity on any rotating mass
5. Freeze upper and lower pins (40 & 43) to ease creates vibration and excessive wear during any
installation. operation.
Note: It may be necessary to relieve binding between 7. Align steering cylinder bores and mounting pin bores
the pin and pin bores by raising or lowering pivot/rear on pivot. Install pins and secure with bolts and washers.
frame assembly. Tighten bolts to a torque of 73 Nm (54 lbf ft).
6. Smear lower pin (43) with Extreme Pressure Lithium 8. Connect hydraulic lines and electrical wiring as
Complex No. 2 grease (23) and install through front noted on disassembly.
frame and bearing bores.
9. Remove bolts (7), washers (20), gasket (5) and
7. Apply Loctite 243 (49) to threads of bolt (48). Secure cover plate (6) from side of oscillation hub to gain
lower pin (43) with bolt (48) and hardened washer (44). access to filler/level plug (25) on pivot assembly (1).
Tighten bolt (48) to a torque of 73 Nm
SM 2580 01-10 11
Section 100-0020
Remove filler/level plug (25). oscillation bushing lube fittings (55) on top of oscillation
10. Add SAE 80W - 90 E. P. gear oil (24) through filler/ hub. Lube until excess grease in seen.
the bottom of filler/level hole.
WARNING
11. Remove plug (25) from underside of oscillation hub To prevent personal injury and property
to drain the cavity between the oscillation hub and damage, be sure wheel blocks are properly
pivot assembly (1) of any oil that entered while filling secured and of adequate capacity to do the job
the driveshaft bearing housing. safely.
12. Install plug (25) in filler/level hole on pivot Every 250 hours, check the end float/clearance at the
assembly (1). Install gasket (5) and cover plate (6) on thrust face of the oscillation bushes. Any clearance
side of oscillation hub, secure with bolts (7) and found must be removed by adjustment of the thrust
washers (20). nut, as described in step 9 of 'Assembly' procedure.
13. Install plug (25) in cavity drain port on underside of Note: A practical method of establishing the effective
oscillation hub. adjustment of the thrust nut is to use movement of the
machines body in the raised position. Move the body
14. Remove plugs (28) from articulation bearing grease from fully raised to almost fully raised while watching
ports and replace with lube fittings (27). the effect of this action on the frame and pivot
arrangement. Any slackness between the thrust nut
Note: Lube fittings (27) are stored on pad on side of and thrust faces will be clearly visible movement of the
pivot assembly (1). frame.
15. Fill bearing housings with Extreme Pressure Every 1 000 hours (6 months), follow the procedure
Lithium Complex No. 2 grease (23) through lube fittings given below to check the oil level in the driveshaft
(27) until excess grease starts to escape from seal bearing housing, and, lubricate the articulation and
housings (32 & 34). oscillation bearings.
16. Remove lube fittings (27) and reinstall plugs (28). Note: It is essential that the grease used for
Store grease fittings (27) on pad on side of pivot articulation components is Extreme Pressure Lithium
assembly (1). Complex No. 2 grease (23), as specified in Section
300-0020, LUBRICATION SYSTEM.
17. Add Extreme Pressure Multipurpose grease (26) to
oscillation bushing lube fittings (55) on top of oscillation 1. Position the vehicle on a level work area and apply
hub. Lube until excess grease in seen. parking brake.
18. Install parking brake disc protective guard (if fitted) 2. Raise body and install body safety prop to secure
and secure with bolts, washers and nuts. Tighten nuts body in partially raised position.
to a torque of 73 Nm (54 lbf ft).
3. Shut down engine and block all wheels securely.
19. Start engine to charge hydraulic systems, raise
body, lower body safety prop and lower the body. 4. Remove protective guard (if fitted) from beneath
parking brake disc by removing nuts, washers and
20. Bleed the braking system as described in Section bolts securing guard to rear frame.
165-0010, BRAKE PARTS.
5. Remove bolts (7), washers (20), gasket (5) and
21. Remove wheel blocks. cover plate (6) from side of oscillation hub to gain
access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).
MAINTENANCE
Numbers in parentheses refer to Fig. 1. 6. Add SAE 80W - 90 E. P. gear oil (24) through filler/
Every 250 hours, oscillation bushes must be lubricated. the bottom of filler/level hole.
Add Extreme Pressure Multipurpose grease (26) to
7. Remove plug (25) from underside of oscillation hub to
12 SM 2580 01-10
Section 100-0020
drain the cavity between the oscillation hub and pivot SPECIAL TOOLS
assembly (1) of any oil that entered while filling the Refer to Section 300-0070, SERVICE TOOLS, for part
driveshaft bearing housing. numbers of the thrust nut tool and general service tools
and adhesives required for procedures outlined in this
8. Install plug (25) into filler/level hole on pivot section. These tools and adhesives are available from
assembly (1). Install gasket (5) and cover plate (6) on your dealer.
side of oscillation hub, secure with bolts (7) and
washers (20).
9. Install plug (25) into cavity drain port on underside of

oscillation hub.
10. Remove plugs (28) from articulation bearing grease

ports and replace with lube fittings (27).
Note: Lube fittings (27) are stored on pad on side of

pivot assembly (1).
11. Fill bearing housings with Extreme Pressure

Lithium Complex No. 2 grease (23) through lube fittings
(27) until excess grease starts to escape from seal
housings (32 & 34).
12. Remove lube fittings (27) and reinstall plugs (28).

Store grease fittings (27) on pad on side of pivot
assembly (1).
13. Add Extreme Pressure Multipurpose grease (26) to

oscillation bushing lube fittings (55) on top of oscillation
hub. Lube until excess grease in seen.
14. Install parking brake disc protective guard (if fitted)

and secure with bolts, washers and nuts. Torque
tighten nuts to 73 Nm (54 lbf ft).
15. Start engine, raise body, lower body safety prop

and lower body.
SM 2580 01-10 13
Section 100-0020
SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. No. ITEM No. ITEM NAME Nm lbf ft
1 19 Nut (to seat bearing only) 250 180
1 22 Bolt 94 69
1 42 Nut 1 425 1 050
1 46 & 47 Bolt 94 68
1 48 Bolt 73 54
- - Parking Brake Disc Bolts 73 54
- - Parking Brake Brkt Mounting Nuts 680 490
- - Driveline Mounting Capscrews 153 113
- - Protective Guard Mounting Nuts 73 54
- - Steering Cylinder Pin Bolts 73 54
* * * *
14 SM 2580 01-10
Chassis - Hood and Mounting
Section 100-0040
SM - 3965
23
22
24 1
25
11 12
21
28 26 13 20
27
14 19
15
16
2
18
17
11 12
7 13
5 14
6 15
7
10
3 4 9
8
1 - Hood Assembly 12 - Bolt 23 - R Clip

2 - Grille 13 - Washer 24 - Actuator
3 - Bolt 14 - Lock Washer 25 - Spacer
4 - Washer 15 - Nut 26 - Bolt
5 - Adjustment Rod 16 - Cone 27 - Washer
6 - Hardened Washer 17 - Bolt 28 - Nut
7 - Nut 18 - Washer
8 - Bolt 19 - Rubber Cup
9 - Washer 20 - Hardened Washer
10 - Nut 21 - Nut
11 - Retaining Strap 22 - Clevis Pin
Fig 1 - Hood and Mounting
HOOD
SM - 3673
DESCRIPTION AND OPERATION
Numbers in parentheses refer to Fig 1 & 2.
The vehicle is fitted with a electrically powered hood.

The hood is activated from the hood control switch.
The hood control switch is located in the cab on the
under the passenger seat. It is a three position switch;
Centre:off; Up:raise; Down:lower. Operating the hood
control switch will send an electrical signal to the motor
fitted to the actuator. As the motor is powered the
actuator extends outwards to raise the hood or retracts
inwards to lower the hood. Fig 2 - Hood Switch
SM 2581 01-10 1
Section 100-0040
Removal Retaining Strap (11). The Hood assembly (1) should

now be free to be removed from the Vechicle.
10. Using suitable lifting equipment, remove the hood
assembly (1) from the vehicle.
WARNING
damage, be sure blocking materials and lifting Installation
equipment are properly secured and of
Note: Tighten all fasteners to torques listed in
1. Position the machine on a level surface, apply the
Section 300-0080, STANDARD BOLT AND NUT
parking brake.
TORQUE SPECIFICATIONS.
2. Remove bolts (3) and washers (4) securing grille (2)
to Hood Assembly (1). Remove grille (2) clear of hood
WARNING
(1).
damage, be sure blocking materials and lifting
3. Raise the hood enough to insert suitable sling / strap
for securing; by activating the appropriate request
button in the cab. This will cause the electric actuator
(24) to extend outward, raising the hood.
1. If removed, replace hood strap (11), to hood (1),
using bolts (12), washers (13), lockwashers (14) and
4. Once elevated secure the hood using suitable lifting
nuts (15).
equipment and sling, ensure the sling is secured the
full length of the hood from front to back. before
2. Using suitable lifting equipment, lift and position
removing the hood from the actuator (24).
hood assembly (1) on the machine and align holes in
hinges with mounting holes on hood assembly (1).
Secure hood assembly (1) to hinges using washers
5. Block all road wheels, switch off the engine. and
(18 and 20), Rubber cup (19), Bolts (17) and nuts (21).
place the battery master switch in the 'Off' position.
3. Instal Rod adjustment (5), Nuts (7 and 10), Washers
6. Remove engine sump guard from the front chassis
(6 and 9) and Bolts (8).
frame, to allow access to the electric actuator (24).
4. Taking the actuator (24), in the fully extended
Note: If for any reason, electrical power is disabled
position, locate and secure the base end of the
from the electric actuator (24) , the actuator can be
actuator to the mating holes on the front chassis
raised manually. Taking a suitable ball end allen key
bracket. Secure using bolt (28), washer (29) and nut
(6mm) with extension, remove the cap covering the
(30).
hand wind socket from the base end of the actuator
(24) (refer to Fig. 3)
4. Locate and secure the rod end of actuator (24) to
mating holes on rear sub-frame (4) lugs. Secure using
Using allen key, turning clockwise, screw the actuator
bolt (28), washers (29) and nut (30).
out manually, till sufficiently extended to allow access
to the inside of the hood.
5. Wire the electrical connections of the actuator (24)
to the correct system components to allow the actuator
7. Remove bolt (28), washer (29) and nut (30) securing
to screw down, lower the hood assembly (1) onto the
the base end of actuator (24) to the front chassis
vehicle frame bed.
bracket lugs.
6. Once fully lowered. Install grille (2) to the Hood
8. Remove bolt (28), washer (29) and nut (30) securing
mounting (1). Secure using bolts (3) and washers (4).
the rod end of the actuator (24) to the Hood Assembly
(1).
7. Lower hood assembly and check for correct
alignment between hood (1) and vehicle frame, ensure
9. Remove 2-off nuts (7). Remove Bolts (12), Washers
no interference occurs between elements contained
(13), Lock Washer (14) and Nuts (15). Remove Hood
under the hood and the hood assembly.
2 SM 2581 01-10
Section 100-0040
MAINTENANCE
Periodically check bolts (8), washers (9) and nuts (10)
and tighten when necessary.
Periodically check actuator (24) mechanism ensuring it

is secure and in working order.
Refer to Fig. 1. unless otherwise stated.
If for any reason the electric actuator (24) does not 1 - Rear Adaptor 6 - Rod
work, suitable investigation as to the cause of the 2 - Clutch 7 - Front Adaptor
failure should be carried out. 3 - Brake 8 - Electrical wires
4 - Screw 9 - Motor
5 - Nut 10 - Gear
If the motor (9, Fig. 4) or sealing elements within the
actuator need replacement, these can be replaced Fig 4 - Typical Actuator Assembly
using the applicable service kits. For details of service
kit number, refer to the relevant TEREX Parts book
manual.
SPECIAL TOOLS
For all other detail specific to the electric actuator,
There are no special tools required for procedures
consult the relevant manufacturer for detail.
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
SM - 3410
tools and adhesives required. These tools and
adhesives are available from your dealer.
Manual
Wind
View on Bottom
of Actuator
Fig 3 - Actuator End Detail
* * * *
SM 2581 01-10 3
Section 100-0040
4 SM 2581 01-10
Engine - Engine and Mounting
Section 110-0030
SM - 3513
FUEL FILTERS - ENGINE LHS
1 15
11
12
3 4
6
13
7
17
14
FRONT
FRAME REF.
TOP OF ENGINE
16
14
2
8
5 10
18
1 - Engine 6 - Alternator Pulley 11 - Bolt

2 - Oil Filter 7 - Adaptor Plate 12 - Washer
3 - Primary Fuel Filter 8 - Snubbing Washer 13 - Washer
4 - Secondary Fuel Filter 9 - Bolt 14 - Isolation Mount
5 - Coolant Filter 10 - Nut 15 - Alternator/ Air con Belt
16 - Engine Oil Fill
17 - Engine Oil Dipstick
18 - Quick drain
Fig. 1 - Engine and Mounting
washer (8) to the isolator mounting and the entire

DESCRIPTION assembly is secured in place by bolt (9) and nut (10).
Numbers in parentheses refer to Fig. 1. Rubber isolation mounts (14) provide sufficient
flexibility to absorb varying engine vibration and
For engine make, model and specification, refer to torsional loads.
Section 000-0000, GENERAL INFORMATION. For
engine servicing and repair data refer to the engine At its rear, the engine is coupled to the transmission,
manufacturers service manual. which in turn is secured to the frame rails at dedicated
mounting brackets located on either side of the
The engine is mounted to the front of the tractor frame transmission. Refer to section 120-0010,
at the engine isolator mounting point, which is integral TRANSMISSION AND MOUNTING.
to the front frame assembly. Through this, the engine
is secured from its bracket to the adaptor plate (7), via There are two full-flow oil filters (2) mounted on the
bolts and washers (11 & 12). This arrangement right hand side of engine (1) in a downward position.
sandwiches the isolation mounts (14) and snubbing The filters are of the throw away, spin-on type. Oil
supplied by the engine oil pump passes through oil
SM 2582 01-10 1
Section 110-0030
filters (2) before reaching the various moving parts of The DDEC V system also takes action to prevent
engine (1). The oil is forced by pump pressure through damage to the engine and, provides the serviceman
a passage in the filter adaptor and into the elements. with diagnostic capabilities so that problems can be
Impurities are filtered out as the oil passes through the corrected quickly and easily.
elements and out through another passage in the filter
adaptor. 1. Electronic Control Module (ECM) - Receives
electronic inputs from the driver as well as from
Engine coolant filter (5) and conditioner is a compact mounted sensors that provide information
bypass type unit with a replaceable spin-on type electronically, such as oil pressure and temperature
element mounted on the gear case cover at the front and intake manifold pressure. This information is used
right hand side of engine (1). Refer to Section to control both the quantity of fuel injected and injection
210-0000, COOLING SYSTEM. timing.
There are two spin-on type fuel filters mounted on the 2. Programmable Read Only Memory (PROM) -
left hand side of engine (1). Primary fuel filter (3) is in Located in the ECM and encoded with the operating
the fuel flow and acts as a strainer and secondary fuel software. Additional information is programmed into the
filter (4) filters the fuel after having passed through EEPROM. This information controls the horsepower
primary fuel filter (3). The word 'Primary' or 'Secondary rating, torque curve, maximum engine speed and
is cast into the top of the respective adaptor to prevent engine protection devices. The ECM processes this
mismatching. information and sends electronic signals to the
Electronic Unit Injectors (EUI) where the precise
amount of fuel is injected into the engine.
DETROIT DIESEL ELECTRONIC
CONTROL (DDEC V) 3. 'N3' Electronic Unit Injectors (EUI) - The EUI is a
lightweight, compact unit that injects diesel fuel directly
Description into the combustion chamber. The amount of fuel
Refer to Fig. 2. injected and the beginning of injection timing is
determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.
WARNING
Before any welding is done on a machine The EUI performs four functions:
equipped with the DDEC V system, disconnect
the following in this order: a - Creates the high fuel pressure required for efficient
Battery earth cable, battery supply cable, injection.
alternator earth cables, alternator supply b - Meters and injects the exact amount of fuel required
cables, body hydraulics joystick, hydraulic to handle the load.
ECU, Transmission TCM, Dash Panel (VDU) c - Atomizes the fuel for mixing with the air in the
CPU, ECM engine harness connector (68-pin combustion chamber.
LHS), ECM vehicle interface harness connector d - Permits continuous fuel flow for component cooling.
(68-pin RHS). Turn off battery master switch
before disconnecting any components. Electronic unit injectors are self compensating and
virtually eliminate engine tune-ups.
After welding connect all of the above in the
reverse order. Note: Never apply 12 V directly to terminals on the
injector or engine sensors as they will burn out. Before
removing injectors, the fuel passages must be blown
out to prevent fuel flow from entering the cylinder head.
The engine is equipped with DDEC V which controls
the timing and amount of fuel injection by the electronic 4. Electronic Foot Pedal - The electronic foot pedal
unit injectors (EUI). The system also monitors several provides an electrical signal to the engine's fuel control
engine functions using electrical sensors which send system in proportion to the degree of pedal actuation.
electrical signals to the electronic control module
(ECM). The ECM then computes the incoming data
and determines the correct fuel output and timing for
optimum power, fuel economy and emissions.
2 SM 2582 01-10
Section 110-0030
SM - 3934
5 6
3 2 STOP P
1
7
8
L
1,2
9
1 - Electronic Control Module (ECM) 6 - 'Check' Engine Light

2 - Programmable Read Only Memory (PROM) 7 - Diagnostic Switch
3 - 'N3' Electronic Unit Injectors (EUI) 8 - Diagnostic Test Point
4 - Electronic Foot Pedal 9 - Batteries
5 - 'Stop' Engine Light
Fig. 2 - DDEC components
Note: The DDEC V controlled engine will override the Pressing and releasing the switch will flash out the
electronic foot pedal position until the engine is warmed engine codes. Pressing the switch a second time will
up to the correct operating temperature. The engine stop the engine codes flashing.
MUST be started with foot 'OFF' the electronic foot
pedal. Note: Inactive codes are displayed on Check Engine
Light and active codes are displayed on Stop Engine
5. Stop Engine Light - When the 'Stop Engine' light Light. Code 25 means no codes present.
comes on, the computer has detected a major
malfunction in the engine that requires immediate Operates as a Stop Engine Override Switch when the
attention. It is the operators responsibility to shut down engine is in a rampdown protection mode for any of the
the engine to avoid serious damage. following:
6. Check Engine Light - When the 'Check Engine' light Low Coolant Level WARNING
comes on, the computer has detected a fault in the High Coolant Temperature Overide function only
engine. The fault should be diagnosed and corrected at Low Oil Pressure to be used in a safety
the earliest opportunity. High Oil Temperature critical condition.
7. Diagnostic Switch - Operates as a diagnostic 8. Diagnostic Test Point - Plug in connector for
request switch when: diagnostic data reader (DDR).
a - the engine is not running and ignition is 'On'. 9. Batteries - Two 12 volt maintenance free batteries
b - the engine is idling and not in an engine protection supply the machine with electrical power to operate all
condition. electrical components.
SM 2582 01-10 3
Section 110-0030
Operation can be plugged into the engine computer memory to

extract information related to the cause of the problem.
Once the malfunction has been corrected, the DDEC
system will return the engine to normal operation. The
The machine is equipped with the DDEC V engine
DDR and DDDL can distinguish between active codes
protection system, which records the stop engine
and those stored in the historic code memory. The
malfunction in ECM (1). The stop engine and check
malfunction code recorded in ECM (1) memory will
engine lights illuminate when the engine protection
remain until it is erased by a technician.
system is initiated. The engine will immediately reduce
to 70% of the available torque. Rampdown then
commences over a 30 second period and reduces the
WARNINGS
engine to 40% of the available torque.
The operator of a DDEC V-equipped vehicle
must not attempt to use or read a DDR of any
To allow for the possibility of the engine protection
kind while the vehicle is operating. Doing so
system being activated while the machine is operating
can result in loss of control, which may cause
in a critical situation, a stop engine override switch (7)
vehicle damage and may result in personal
is provided. If the switch is pressed and released
injury.
during rampdown, the 30 second timer will reset,
restoring torque to the level immediately following
When engine or electronics system
illumination of stop engine (5) and check engine (6)
diagnosis is required on a DDEC-V equipped
lights. The switch must be pressed and released again
vehicle, this must be done by a person other
to obtain a subsequent override.
than the operator. The operator must maintain
control of the moving vehicle while the
Note: The operator must continue to reset the
assistant performs the diagnosis.
automatic engine protection system by pressing and
releasing stop engine override switch (7) at intervals of
When the engine is not running and the ignition is on,
approximately 15 to 20 seconds.
or, the engine is idling and not in an engine protection
condition, engine faults can be diagnosed by the
Note: ECM (1) will record the number of times the
operator. Pressing and releasing diagnostic request
override is activated after the fault occurs. Available
switch (7) will cause check engine light (6) or stop
Torque is the actual torque available from the engine
engine light (5) to flash a code number indicating the
when the fault occurred based on the actual rev/min
fault, e.g. flash twice - pause - flash five times - pause
when the fault occurred.
indicates a code 25. Code 25 indicates all systems are
operating correctly. Pressing the switch a second time
The engine should not be restarted after it has been
will stop the engine codes flashing. Refer to 'DDEC V'
shut down after activation of the engine protection
Diagnostic Codes' table for other code descriptions.
system unless the problem has been diagnosed and
corrected. SM - 3935
Conditions that will cause the Stop Engine Light to H

come on are; Low Coolant Level, High Coolant
Temperature, Low Oil Pressure and High Oil
Temperature.
Whenever check engine light (6) or stop engine light (5)

comes on, the DDEC computer will determine where
the problem is and will store this information in its
memory. If the malfunction is intermittent, the lights
will come on and go off as the computer senses the
changing engine condition. Fig. 3 - Diagnostic Request/ Override Switch
A special diagnostic data reader (DDR) or laptop based

Detroit Diesel Diagnostic Link (DDDL) are available that
4 SM 2582 01-10
Section 110-0030
DDEC V DIAGNOSTIC CODES

DDEC Code
# (Flashed) PID SID FMI DDEC Description
- 240 - 2 Fram checksum incorrect
- 251 - 10 Clock module abnormal rate
- 251 - 13 Clock module fault/failure
- - 253 13 Incompatible calibration version
- - 254 0 External failed RAM
- - 254 1 Internal failed RAM
- - 254 6 Entered boot via switches
11 187 - 4 VSG sensor voltage low
11 187 - 7 VSG switch system not responding
12 187 - 3 VSG sensor high
13 111 - 4 Coolant level sensor input voltage low
13 111 - 6 Add coolant level sensor input voltage low
14 110 - 3 Coolant temperature sensor input voltage high
14 175 - 3 Oil temperature sensor input voltage high
15 110 - 4 Coolant temperature sensor input voltage low
15 175 - 4 Oil temperature sensor input voltage low
16 111 - 3 Coolant level sensor input voltage high
16 111 - 5 Add coolant level sensor input voltage high
21 91 - 3 TPS input voltage high
22 91 - 4 TPS input voltage low
23 174 - 3 Fuel temperature sensor input voltage high
24 174 - 4 Fuel temperature sensor input voltage low
25 - - - Reserved for 'No Codes'
26 - 25 1 Auxiliary shutdown #1 active
26 - 61 11 Auxiliary shutdown #2 active
27 171 - 3 Ambient air temperature sensor input voltage
high (Release 2.00 or later only)
27 172 - 3 Air temperature sensor input voltage high
27 105 - 3 Intake manifold temperature sensor input voltage
high
28 171 - 4 Ambient air temperature circuit failed low
(Release 2.00 or later only)
28 172 - 4 Air temperature sensor input voltage low
28 105 - 4 Intake manifold temperature sensor input voltage
low
31 - 51 3 Aux. output #3 open circuit (high side) (E-49)
31 - 51 4 Aux. output #3 short to ground (high side)
(E-49)
31 - 51 7 Aux. output #3 mechanical system fail (E-49)
31 - 52 4 Aux. output #4 short to ground (high side) (E-48)
SM 2582 01-10 5
Section 110-0030

DDEC Code
32 - 238 4 SEL open circuit
32 - 238 3 SEL short to battery (+)
32 - 239 3 CEL short to battery (+)
32 - 239 4 CEL open circuit
33 102 - 3 Turbo boost pressure sensor input voltage high
34 102 - 4 Turbo boost pressure sensor input voltage low
35 100 - 3 Oil pressure sensor input voltage high
36 100 - 4 Oil pressure sensor input voltage low
37 94 - 3 Fuel pressure sensor input voltage high
37 95 - 3 Fuel restriction sensor input voltage high
38 94 4 Fuel pressure sensor input voltage low
38 95 - 4 Fuel restriction sensor input voltage low
41 - 21 0 Too many SRS (missing TRS)
42 - 21 1 Too few SRS (missing SRS)
43 111 - 1 Coolant level low
44 110 - 0 Coolant temperature high
44 172 - 0 Air inlet temperature high
44 175 - 0 Oil temperature high
27 105 - 3 Intake manifold temperature sensor input voltage high
28 171 - 4 Ambient air temperature circuit failed low
(Release 2.00 or later only)
28 172 - 4 Air temperature sensor input voltage low
28 105 - 4 Intake manifold temperature sensor input voltage low
32 - 238 4 SEL open circuit
32 - 238 3 SEL short to battery (+)
32 - 239 3 CEL short to battery (+)
32 - 239 4 CEL open circuit
33 102 - 3 Turbo boost pressure sensor input voltage high
34 102 - 4 Turbo boost pressure sensor input voltage low
35 100 - 3 Oil pressure sensor input voltage high
36 100 - 4 Oil pressure sensor input voltage low
37 94 - 3 Fuel pressure sensor input voltage high
37 95 - 3 Fuel restriction sensor input voltage high
38 94 4 Fuel pressure sensor input voltage low
38 95 - 4 Fuel restriction sensor input voltage low
41 - 21 0 Too many SRS (missing TRS)
6 SM 2582 01-10
Section 110-0030

DDEC Code
42 - 21 1 Too few SRS (missing SRS)
43 111 - 1 Coolant level low
44 110 - 0 Coolant temperature high
44 172 - 0 Air inlet temperature high
44 175 - 0 Oil temperature high
44 105 - 0 Intake manifold temperature high
45 100 - 1 Oil pressure low
46 - 155 4 Injector Vreg voltage failed low
46 168 - 1 ECM battery voltage low
46 - 211 1 Vehicle sensor supply voltage low (V-11, V-12)
46 - 212 4 Injector Vslope voltage failed low
46 - 214 1 RTC backup battery voltage low
46 - 221 4 Injector Ipullin voltage failed low
46 - 232 1 Engine sensor supply voltage low (E-12, E-26)
47 94 - 0 Fuel pressure high
47 102 - 0 Turbo boost pressure high
47 106 - 0 Air inlet pressure high
48 94 - 1 Fuel pressure low
48 106 - 1 Air inlet pressure low
52 - 254 12 A/D conversion fail
53 - 253 2 Memory check failed on startup
53 - 253 12 Memory write error - single location
53 - 253 13 Calibration memory error
53 - 253 14 Memory write error - all locations
54 84 - 12 Vehicle speed sensor fault
55 - 216 14 Missing other ECU information
55 - 231 12 J1939 data link fault
56 - 250 12 J1587 data link fault
58 92 - 0 Torque overload
61 - xxx 0 Injector xxx response time long
61 - xxx 6 Injector xxx circuit short to ground
62 - 26 3 Aux. output #1 short to battery (+) (V-04)
62 - 26 4 Aux. output #1 open circuit (V-04)
SM 2582 01-10 7
Section 110-0030

DDEC Code
62 - 259 3 Aux. output #11 short to battery (+) (E-13)
62 - 259 4 Aux. output #11 open circuit (E-13)
62 - 26 7 Aux. output #1 mechanical system failure (V-04)
62 - 258 7 Aux. output #10 mechanical system failure (V-
55)
62 - 259 7 Aux. output #11 mechanical system failure (E-
13)
63 - 57 3 PWM #1 short to battery (+) (V-52)
63 - 57 4 PWM #1 open circuit (V-52)
63 - 58 3 PWM #2 short to battery (+) (V-46)
63 - 58 4 PWM #2 open circuit (V-46)
63 - 59 3 PWM #3 short to battery (+) (E-01)
63 - 59 4 PWM #3 open circuit (E-01)
63 - 60 3 PWM #4 short to battery (+) (E-04)
63 - 60 4 PWM #4 open circuit (E-04)
64 103 - 8 Turbo speed sensor input failure
64 103 - 0 Turbo overspeed
65 107 - 3 Air filter restriction sensor voltage high
65 107 - 4 Air filter restriction sensor voltage low
66 - 99 3 Oil filter restriction sensor voltage high
66 - 99 4 Oil filter restriction sensor voltage low
67 109 - 3 Coolant pressure sensor input voltage high
67 109 - 4 Coolant pressure sensor input voltage low
67 106 - 3 Air inlet pressure sensor input voltage high
67 106 - 4 Air inlet pressure sensor input voltage low
68 - 230 6 TPS idle validation circuit fault (short to ground)
68 - 230 5 TPS idle validation circuit fault (open circuit)
71 - xxx 1 Injector xxx response time short
72 84 - 0 Vehicle overspeed
72 84 - 11 Vehicle overspeed (absolute)
73 107 - 0 Air filter restriction high
8 SM 2582 01-10
Section 110-0030

DDEC Code
74 99 - 0 Oil filter restriction high
75 - 155 3 Injector Vreg voltage failed high
75 168 - 0 ECM battery voltage high
75 - 211 0 Vehicle sensor supply voltage failed high (V-11, V-12)
75 - 212 3 Injector Vslope voltage failed high
75 - 214 0 RTC backup battery voltage high
75 - 221 3 Injector Ipullin voltage failed high
75 - 232 0 Engine sensor supply voltage high (E-12, E-26)
76 121 - 0 Engine overspeed with engine brake
77 21 - 0 ECU temperature above range
77 21 - 1 ECU temperature below range
77 21 - 3 ECU temperature failed high
77 21 - 4 ECU temperature failed low
77 100 - 0 Oil pressure high
77 102 - 1 Turbo boost pressure low
77 108 - 0 Barometric pressure high
77 108 - 1 Barometric pressure low
77 171 - 0 Ambient air temperature high
77 171 - 1 Ambient air temperature low
77 174 - 0 Fuel temp high
77 251 - 10 Clock incorrect
77 251 - 13 Clock failure
77 252 - 10 Date incorrect
77 252 - 13 Clock/Date failure
81 98 - 3 Oil level sensor input voltage high
81 173 - 3 Exhaust temperature sensor input voltage high
82 98 - 4 Oil level sensor input voltage low
82 173 - 4 Exhaust temperature sensor input voltage low
83 173 - 0 Exhaust temperature high
83 173 - 4 Exhaust temperature sensor input voltage low
83 73 - 0 Pump pressure high
84 98 - 1 Oil level low
85 190 - 0 Engine overspeed
86 73 - 3 Pump pressure sensor input voltage high
86 108 - 3 Barometric pressure sensor input voltage high
87 73 - 4 Pump pressure sensor input voltage low
87 108 - 4 Barometric pressure sensor input voltage low
88 109 - 1 Coolant pressure low
89 95 - 0 Fuel restriction high
89 111 - 12 Maintenance alert coolant level fault
SM 2582 01-10 9
Section 110-0030
Note: Only one light will be flashing at any one time. Note: Radiator header tank will be removed as part of
When code flashing is initiated, the active codes (or the goalpost assembly.
code 25) will be flashed on stop engine light (7), then
the inactive codes (or code 25) will be flashed on 8. Support engine sump guard with suitable blocking
check engine light (6). When all of the inactive codes and remove mounting hardware securing sump guard to
have been flashed, the process of flashing the codes the frame. Remove sump guard from the frame.
will repeat until the conditions for code flashing are no
longer satisfied. 9. Support guard plate under the engine at the front of
the frame with suitable blocking and remove mounting
REMOVAL hardware securing guard plate to the frame. Remove
Numbers in parentheses refer to Fig. 1. guard plate from the frame.
Note: Tag all cables, harnesses, lines and pipes 10. Place a suitable container under the engine drain
disconnected during removal to aid in installation. port, remove drain plug on no drip drain plug (18) and
drain the oil. After draining, reinstall drain plug in engine
sump and tighten securely.
WARNINGS
damage, be sure wheel blocks, blocking WARNING
materials and lifting equipment are properly Before disconnecting any air conditioner lines,
secured and of adequate capacity to do the job refer to Section 260-0130, AIR CONDITIONING.
safely. Refrigerant will rapidly freeze all objects with
which it comes into contact. It can cause
High electrical current can cause sparks serious and permanent damage to the eyes and
and personal injury from burns. Turn battery skin.
master switch to the 'Off' position before
removing any components. Remove battery 11. Evacuate air conditioning system and disconnect
ground cable first, and reconnect last, to avoid air conditioner lines at the engine compressor. Refer to
damaging electrical components. Section 260-0130, AIR CONDITIONING.
1. Position the vehicle in a level work area, ensure the 12. Remove the radiator assembly from the vehicle.
body is fully lowered, apply the parking brake Refer to Section 210-0040, RADIATOR AND
MOUNTING.
2. Remove hood . Refer to Section 100-0040, HOOD
AND MOUNTING. 13. With a suitable container in position, remove drain
cock on the transmission oil cooler flanges and drain
3. Switch off the engine. Turn steering wheel several the coolant. Remove coolant pipes from the engine
times to relieve any pressure in the steering circuit. water pump and engine oil cooler. Refer to Section 210-
0060, TRANSMISSION OIL COOLER.
4. Block all road wheels and place the battery master
switch in the 'Off' position. 14. Remove charge air cooler pipes from engine
turbocharger and engine inlet manifold.
5. Disconnect battery cables from terminal posts (earth
cable first). 15. Disconnect exhaust piping from the engine
turbocharger.
6. Remove mounting hardware securing air cleaner
assembly to right hand fender. Slacken mounting clamp 16. Disconnect air cleaner intake pipe from engine
at air cleaner intake pipe and draw air cleaner, complete turbocharger and remove from the engine.
with rubber hose, away from intake pipe. Cover open ends
to prevent entry of dirt. 17. Identify heater lines for ease of installation and with a
suitable container in position, disconnect heater lines
7. With a suitable container in position, open shut-off from the engine. Cap open line ends and fittings.
valve on the radiator assembly and drain the coolant.
18. Identify fuel lines for ease of installation and with a
suitable container in position, disconnect fuel lines
from the engine. Cap open line ends and fittings.
10 SM 2582 01-10
Section 110-0030
SM - 3570
1 - Engine (Flywheel Housing)

2 - Transmission
3 - Flexplate Adapter
4 - Wear Plate
5 - Flexplate Assembly
6 - Starter Ring Gear
7 - Crankshaft Hub Adapter
8 - Bolt (8)
9 - Bolt (12)
10 - Bolt (12)
Fig. 4 - Engine and Transmission Coupling Components
19. Identify all electrical harnesses and cables for ease DISASSEMBLY
of installation and disconnect from the engine.
Numbers in parentheses refer to Fig. 4 & 5 unless
otherwise stated.
20. Disconnect clips securing items to the engine and
transmission that cannot be removed with the engine /
1. Remove plug from rear rhs of engine, using a 3/4"
transmission sub-assembly.
square drive.
21. Disconnect transmission hoses and lines. Refer to
Section 120-0010 TRANSMISSION AND MOUNTING.
SM - 3569
22. Disconnect all relevant electrical transmission

harness connections necessary prior to removal of
engine / transmission sub-assembly. Refer to Section
120-0010 TRANSMISSION AND MOUNTING.
23. Disconnect driveline from transmission to dropbox.

Refer to Sections 130-0010 DRIVELINES and 125-
0010 DROPBOX AND MOUNTING.
23. Attach suitable lifting equipment to the lifting

brackets on the engine and transmission units and
raise lifting equipment to take up the slack.
24. Carefully support weight of transmission and

remove transmission and engine from the mated
position.
25. Remove engine and transmission to side for further

disassembly as required.
Fig. 5 - Plug On Engine Removed
SM 2582 01-10 11
Section 110-0030
2. Turn crankshaft clockwise until one bolt (10) is Note: Alternator belt tension adjustment is made after
accessible for removal. Remove 1-off bolt (10). installation of engine (1) and the radiator assembly.
3. Continue cranking clockwise until next bolt (10) in 8. Install air conditioner compressor and drive belt to
concession is accessible for removal. Remove bolt engine (1). Refer to Section 260-0130, AIR
(10). CONDITIONING.
4. Repeat step 3 until all 12 bolts (10) have been Note: Position rubber isolation mount (14) to their
removed. mounts as shown in Fig. 1.
5. Remove 12-off bolts (9) and washers securing Numbers in parentheses refer to Fig. 1,4 & 5. unless
transmission outer housing to engine housing. otherwise stated
6. Remove and discard filters (2, 3, 4 & 5) from engine Sub-assembly: Engine & Transmission
(1), as described in 'Maintenance'. Cover engine inlet
ports to prevent entry of dirt. 1. Bolt flexplate assembly (5) onto the engine. Torque
12-off bolts (8) to a value of 68Nm (50Ibf ft), then turn
7. Refer to 'Engine Manufacturers Service Manual' if an additional 120degrees.
engine service or repair is required.
2. If not removed already, remove plug from rear RHS
of engine allowing access as shown in Fig. 5.
INSPECTION
Numbers in parentheses refer to Fig. 1. 2. Align one of the flexplates bolt holses around the
flexplate circumference with the access opening in the
Note: As the engine is installed with the transmission engine flywheel housing.
already assembled to it, it will be necessary to check
for damage on all related transmission mounts and 2. Lubricate the centre pilot boss with molybdenum
brackets. disulfide grease. (molycote G or equivalent).
1. Inspect rubber isolation mounts (14) for damage and 3. Install a headless guide bolt into one of the flexplate
replace if required. bolt holes in the flexplate adapter or torque converter
mounting lug. Align the guide bolt with the flexplate
2. Inspect engine flywheel housing for any damage. hole at the access opening.
3. Inspect crankshaft hub adapter for damage or 4. Push the transmission towards the engine while
cracks. Replace as necessary. guiding the pilot boss on the torque converter into the
flexplate hub adapter and guide the bolt into the hole on
the flexplate (5).
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 5. Seat the transmission squarely against the engine
flywheel housing. Note: no force is required. If
Note: Tighten all fasteners without special torques interference is encountered, move the transmission
specified to standard torques listed in Section away from the engine and investigate the cause.
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 6. Align the bolt holes in the converter housing with
those in the engine flywheel housing.
1. Remove covers from engine filter ports and install
new filters (2, 3, 4 & 5) on engine (1), as described in 7. Install all transmission to engine bolts finger tight.
'Maintenance'.
8. Tighten four bolts at equally spaced intervals around
the convertor housing bolt circle. Use the torque
Note: Replace all belts in a set when one is broken or specified by the engine manufacturer.
replaced.
9. Remove flexplate guide bolt through the engine
7. Install 'V' belts (15) in the grooves of alternator and flywheel housing access opening. Replace with self
accessory drive pulley. locking bolt. Tighten bolt finger tight.
12 SM 2582 01-10
Section 110-0030
10. Install remaining 8-off bolts (9) and washers to the
outer housing. Tighten bolts (9) to 80Nm. 7. Install air cleaner intake pipe and exhaust piping to
engine turbocharger.
11. Rotate the engine crankshaft to install the
remaining self-locking bolts into the flexplate adapter. 8. Remove caps from heater lines and fittings and
After all bolts have been installed finger tight. Tighten connect heater lines to engine (1) as identified at
12-off bolts (10) to 36Nm. (Rotate engine crankshaft as removal.
necessary to access bolts).
9. Remove caps from fuel lines and fittings and
Installation connect fuel lines to engine (1) as identified at removal.
10. Connect all electrical harnesses and cables to
Note: Tighten all fasteners without special torques engine (1) (with the exception of battery connections)
specified to standard torques listed in Section as identified at removal.
SPECIFICATIONS. 11. Connect air conditioner lines at the compressor as
identified at removal. On completion of engine
installation the air conditioning system will require to be
charged. Refer to Section 260-0130, AIR
WARNING
CONDITIONING.
damage, be sure lifting device is properly
12. Install the goalpost and radiator header tank
assembly on the vehicle. Refer to Section 100-0040,
safely.
HOOD AND MOUNTING.
1. Attach suitable lifting equipment to engine (1) and
13. Ensure all cooling lines to radiator assembly,
transmission sub assembly lifting brackets and
engine (1) and radiator header tank are correctly
carefully position assembly over tractor frame.
connected. Refer to Section 210-0040, RADIATOR
AND MOUNTING.
2. As required, assemble mounting for transmission
brackets on either side of the transmission. Refer to
14. Remove covers from air cleaner intake pipe and
Section 120-0010 TRANSMISSION AND MOUNTING.
rubber hose on the air cleaner inlet then slide air
cleaner assembly towards the hood locating the rubber
3. Secure isolation mounts (14) and adaptor plate in place
hose to the inlet pipe.
to front frame location, by means of washer (13), washer
(13), bolt (9) and nut (10). Torque nut (10) to a value of 921
15. Secure air cleaner assembly to the right hand
Nm (680 Ibf ft).
fender and rubber hose to the inlet pipe with mounting
hardware removed during removal.
4.Secure engine (1) to the front frame at adaptor plate (7),
by means of washers (12) and bolts (11). Torque bolts (11)
16. Connect battery positive connections to battery
to a value of 330 Nm (239 Ibf ft).
terminals. Connect battery earth connections to battery
terminals.
3. Connect driveline to the transmission coupling and
Refer to Section 130-0010, FRONT DRIVELINES.
17. Ensure all lines, harnesses and cables are secured
with clips and clamps as removed during removal.
4. Install transmission oil cooler on vehicle. Refer to
Ensure no lines are chaffing on sharp edges or resting
Section 210-0060, TRANSMISSION OIL COOLER.
against areas where heat will be evident.
5. Install radiator assembly on the vehicle. Refer to
18. Ensure shut-off valve at the bottom of the radiator
Section 210-0040, RADIATOR AND MOUNTING.
assembly, drain plugs in transmission oil cooler flanges
and drain cocks on engine (1) water jacket are securely
6. Install air cooler pipes from engine turbocharger and
closed. Ensure shut off cocks at coolant filter (3) are
engine inlet manifold to charge air cooler integral to the
open to allow flow through the filter.
rh combination cooler; radiator assembly. Refer to
19. Fill the cooling system with coolant. Refer to
Section 210-0040, RADIATOR AND MOUNTING.
Section 210-0000, COOLING SYSTEM.
SM 2582 01-10 13
Section 110-0030
20. Fill the engine with lubricant through oil filler to the top Every 500 Hours
mark on dipstick (6). Refer to Section 300-0020,
Engine (1): Drain engine oil and refill. Refer to Section
LUBRICATION SYSTEM for oil specification.
300-0020, LUBRICATION SYSTEM for oil
specification.
21. Check all line and pipe connections for leaks prior
to starting the vehicle. Tighten as required.
Engine Oil Filters (2): Replace oil filters as follows:
22. Switch the battery master switch to the 'On'
1. Using filter wrench, remove and discard both oil
position, start up the engine and check for leaks.
filters (2) from engine (1). Inspect the sealing surface
Tighten lines, pipes and fittings and top up all systems
of the filter to ensure that the seal ring stayed with the
as required.
filter. If not, remove it from the filter adaptor.
23. Install hood assembly on the vehicle. Refer to
2. Clean the filter adaptor with a clean, lint free cloth.
Section 100-0040, HOOD AND MOUNTING.
3. Lightly coat new oil filter (2) seal with clean engine
Note: Check that gap between hood and cowl is correct
oil as specified in Section 300-0020, LUBRICATION
(12 mm (0.5 in) maximum).
SYSTEM.
24. Using suitable lifting equipment position front guard
4. Start a new oil filter (2) on the filter adaptor and
plate under the engine and secure to the frame with
tighten it by hand until the seal touches the adaptor
mounting hardware removed during removal.
filter head. Tighten an additional 2/3 of a turn after
contact.
25. Using suitable lifting equipment position engine
sump guard under the engine and secure to the frame
Note: Mechanical tightening of oil filters (2) is not
with mounting hardware removed during removal.
necessary and will distort or crack the adaptor. Tighten
oil filters by hand only.
26. Remove wheel blocks from all road wheels.
5. Repeat steps 3 and 4 for second oil filter (2).
MAINTENANCE
6. Start and run the engine for a short period and check
for oil leaks. If any leaks are noted, have them
corrected.
Note: Carry out the following maintenance procedures
in conjunction with additional procedures listed in
7. After the engine has been stopped long enough
Section 300-0020, LUBRICATION SYSTEM.
(approximately 20 minutes) for the oil from various
parts of engine (1) to drain back to the crankcase,
Every 10 Hours (Daily) check oil level and add oil to bring it to the proper level
on the dipstick. Refer to Section 300-0020,
Engine (1): Visually check engine for damage, loose or
frayed belts and listen for any unusual noises. Check
the turbocharger for leaks.
Fuel Filters (4 & 5): Replace primary fuel filter (4) and
secondary fuel filter (5) as follows:
Engine (1) Oil Level: Check engine oil level and add
Note: There is a fuel system shut off valve on the
oil if low.The dipstick is provided with a 'MIN' and
discharge side of secondary fuel filter (5). Closing this
'MAX' level band which the oil level should be within.
valve will prevent loss of fuel prime at time of filter
replacement.
Note: If checking the oil level after the vehicle has bee
running for any period, ensure the vehicle is parked on
1. Close shut off valve at secondary fuel filter (5) and,
level ground and has been stopped for a minimum of 3
using filter wrench, remove and discard both fuel filters
minutes to allow oil to drain into the sump.
(4 & 5) from engine (1).
2. Fill the replacement filters and coat the gaskets
Every 150 Hours slightly with clean fuel oil as specified in Section
Engine Air cleaner: Visual Check of inlet screen.
Clean. Refer to Section 110-0050, AIR CLEANER for
detail.
14 SM 2582 01-10
Section 110-0030
3. Start new primary fuel filter (4) on the filter adaptor 3. Lightly coat new coolant filter (3) seal with clean
and tighten it by hand until the gasket contacts the engine oil as specified in Section 300-0020,
adaptor fully with no side movement of the filter LUBRICATION SYSTEM.
evident. Tighten an additional 1/2 of a turn.
Note: Mechanical tightening of fuel filters (4 & 5) is not 4. Start coolant filter (3) on the filter adaptor and tighten
recommended, and may result in seal and/or cartridge it by hand until the seal touches the adaptor filter head.
damage. Tighten fuel filters by hand only. Tighten an additional 2/3 of a turn after contact.
4. Repeat step 3 for secondary fuel filter (5). Note: Mechanical tightening of coolant filter (3) is not
necessary and will distort or crack the adaptor. Tighten
5. Start the engine and check for leaks. If any leaks coolant filter by hand only.
are noted, have them corrected.
5. Open shut off valves at coolant filter (3) inlet and
Engine Air Cleaner : Visual Check of inlet screen. outlet lines.
Clean. Refer to Section 110-0050, AIR CLEANER for 6. Start the engine and check for leaks. If any leaks are
detail. noted, have them corrected. Add coolant as required.
Refer to Section 210-0000, COOLING SYSTEM.
Every 1000 Hours
Coolant Filter (3): Check condition of coolant inhibitor Engine Air Cleaner : Replace element. Refer to
as described in Section 210-0000, COOLING Section 110-0050, AIR CLEANER for detail.
SYSTEM. Replace coolant filter (3) as follows:
Note: There is a shut off valve at the coolant inlet and Every 2000 Hours
outlet lines of coolant filter (3). Closing these valves Engine (1) Steam Clean: clean engine to help
will enable coolant filter (3) to be replaced without an maintain proper working order.
excessive loss of coolant.
Engine Mounting Bolts (X): Check torque. (Torque
1. Close shut off valves at coolant filter (3) inlet and seal). Torque value should be 330Nm (239 Ibf ft).
outlet lines and, using filter wrench, remove and
discard coolant filter (3) from engine (1). Every 3000 Hours
Engine Water Pump: Inspect water pump drain hole
2. Clean the filter adaptor with a clean, lint free cloth. and clean if required.
SM 2582 01-10 15
Section 110-0030
TES295 APPROVED OILS

Approval Number Approved Maker Product Brand Name
AN-011001 Castrol Heavy Duty Lubricants Transynd
AN-031002 BP Autran Syn 295
AN-031003 Cognis Corporation Emgard 2805
AN-031004 International Truck & Engine Co. Fleetrite Synthetic ATF
AN-031005 Exxon Mobile Lubricants Mobile Delvac Synthetic ATF
and Petroleum Specialities Co.
* - When determining whether a fluid is TES 295 approved or not look and/or ask for one of two things - The
Allison TES 295 approval number or the Allison approved logo { }. TES 295 approved fluids are listed on the
following page. If uncertain if a fluid is approved, consult Allison Transmission for confirmation.
Drive Belt Adjustments Note: A belt is considered 'Used' if it has been in

Every 50 Hours: Check all drive belt tensions and service for 10 minutes or longer. If the used belt tension
adjust if required. If vehicle is equipped with air is less than the minimum value, tighten the belt to the
conditioning, compressor belts should be checked and maximum value.
adjusted as described in Section 260-0130, AIR
CONDITIONING. Belts should be neither too tight nor too loose. Belts
that are too tight impose excess loads on the alternator
Every 2 000 Hours: Replace all drive belts. bearings, shortening both belt and bearing life. A loose
belt will slip and may cause damage to accessory
Note: Replace all belts in a set when one is worn. components.
Single belts of similar size should not be used as a
substitute for a matched belt set as premature belt SPECIAL TOOLS
wear can result due to belt length variation. All belts in Refer to Section 300-0070, SERVICE TOOLS, for part
a matched belt set are within 0.81 mm (0.032 in) of numbers of service tools which should be used in
their specified centre distances. conjunction with procedures outlined in the engine
Using belt tension gauge, adjust the belt tension to the manufacturers service manual, and, general service
following values: tools required. These tools are available from your
dealer.

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Locknut 921 680
1 11 Bolt 330 239
1 38 Bolt 81 - 95 60 - 70
1 41 Locknut 165 122
4 8 Bolt 68 50
4 9 Bolt 80 59
4 10 Bolt 36 26.5
* * * *
16 SM 2582 01-10
ENGINE - Air Cleaner
Section 110-0050
SM - 3415
8 AIR CLEANER RESTRICTION GAUGE

AND WARNING PRESSURE SWITCH
(behind).
5
1 - Air Cleaner Body 5 - Mounting Band

2 - Primary Element 6 - Cover Assembly
3 - Safety Element 7 - Rain Cap
4 - Vacuator Valve 8 - Clamp
Fig. 1 - Exploded View of Typical Air Cleaner
DESCRIPTION AND OPERATION An air restriction pressure switch is located in the

Numbers in parentheses refer to Fig. 1. primary filter element, this senses when system air
flow is being restricted, a signal is then sent to the cab
The dual dry element air cleaner is remotely mounted mounted Visual display unit displaying a symbol to
horizontally on the right-hand side of the tractor frame. indicate to the operator that the filter element should be
The air cleaner prolongs engine life by removing grit, checked and changed if necessary.
dust and water from the air as it enters the engine. Grit
and dust, combined with engine oil, forms a highly While air restriction warning gauge indicates the need
abrasive compound which can destroy the engine in a for servicing, it does not give as precise a
comparatively short period of time. measurement as a water manometer or vacuum gauge.
Refer to 'Measuring Air Restriction'.
A rubber vacuator valve (4) attached to end cover (6) in
a downward position, ejects grit, dust and water while A secondary (safety) element (3) is installed in the air
the engine is running. Vacuator valve (4) minimizes the cleaner body (1) inside the primary element (2). This
need for daily servicing. Even though vacuator valve element increases the reliability of the air cleaner’s
(4) is normally under a slight vacuum when the engine protection of the engine from airborne dirt. It protects
is running, pulsing of the vacuum opens and closes the the engine from dirt admitted by a damaged primary
rubber valve, expelling dust and water as they collect. element (2), or dirt that might be dropped into the air
When the engine is stopped, vacuator valve (4) opens cleaner assembly while changing the primary element
and expels any accumulated grit, dust or water. (2).
SM 2583 01-10 1
Engine - Air Cleaner
Section 110-0050
SM - 3936
21
15 AIR FILTER ELEMENT

WARNING SYMBOL
18 17
12 20 19
11 9
10
8
14 16 13
7
6
1
2 5
4
3
5
22
23
24
1 - Air Intake Tube 9 - Lockwasher 17 - Bolt

2 - Hose 10 - Washer 18 - Washer
3 - Clamp 11 - Nut 19 - Spring Washer
4 - Elbow 12 - Platform 20 - Nut
5 - Clamp 13 - Bolt 21 - Air filter / element warning.
6 - Reducer 14 - Washer 22 - Support Bracket
7 - Clamp 15 - Bolt 23 - Clamp
8 - Bolt 16 - Lockwasher 24 - Hardened Washer
Fig. 2 - Exploded View of Typical Air Cleaner Mounting
4. Remove the bolts (15) and the lockwashers (16)

AIR CLEANER securing the platform (12) to the top of the right-hand
fender.
Removal
Numbers in parentheses refer to Fig. 2. 5. Remove the bolts (13) and washers (14) securing the
platform (12) to the chassis frame brackets.
1. Position the vehicle in a level work area, apply the
parking brake. 6. Using suitable lifting equipment, lift the platform (12)
assembly clear of the air cleaner body (1, Figure 1).
2.Raise the hood by activating the appropriate request
button in the cab. 7. Slacken the clamps (3,5 and 7) securing the hose
(2), air intake tube (1), elbow (4) and reducer (6).
3. Block all road wheels, switch off the engine, place
the steering lock bar in the 'Locked' position and the 8. Loosen nuts on the Clamp (23) and remove nuts,
battery master switch in the 'Off' position. washers (24) and Clamp (23) from Support Bracket
(22) securing Air Intake Tube (1).
2 SM 2583 01-10
Section 110-0050
9. Remove the bolts (8), nuts (11), lockwashers (9) and is the reverse of disassembly and removal. Reset the
washers (10) securing the air cleaner to the right-hand air restriction gauge (17).
fender brackets.
Following installation, but before starting the engine,
10. Using suitable lifting equipment, support the air the following system checks should be carried out:
cleaner assembly and draw the air cleaner away from
the elbow (2). a. Check the air intake tube (1), elbow (4) and hose (2)
for defects, and check that the clamps (3,5 and 7) (and
11. Blank off all open ends with tape or cardboard to those supplied with the engine) are securely tightened
prevent the ingress of contaminants. to ensure that there are no leaks in the system.
12. If required, remove the clamps ( 5 and 7), securing b. Check that the air cleaner is mounted securely to
the hose (2), air intake tube (1), elbow (4) and reducer the right-hand fender support brackets.
(6). Remove all components from the vehicle.
MAINTENANCE
Disassembly Numbers in parentheses refer to Figure 1, unless
Numbers in parentheses refer to Figure 1, unless otherwise specified.
otherwise specified.
Note: The air cleaner body (1) should be thoroughly WARNING

cleaned twice a year. Do not apply heat in any form to Always shut down the engine before servicing
the air cleaner body (1). the air cleaner.
1. Release latches on the cover assembly (6) and Check the visual display unit for the air filter/element
remove the cover assembly from the air cleaner body warning symbol. The air cleaner elements should be
(1). serviced when the maximum allowable restriction has
been reached. The elements should not be serviced
2. Remove the primary element (2) and the safety on the basis of visual observation as this would lead to
element (3) from the air cleaner body (1). over servicing. When the restriction readings finally
indicate a change, remove the primary element (2)
3. Open the mounting bands (5) and remove them from carefully and clean/renew it as required. Refer to
the air cleaner body (1). 'Primary Element'.
4. Slacken the clamp (8), from the top port on the right- Never attempt to clean the safety element (3). Change
hand fender and remove the Rain cap (7) from the right- the safety element (3) after every third primary element (2)
hand fender. service.
5. Blank off the air cleaner body (1) outlets with tape or Make sure that the vacuator valve (4) is not damaged
cardboard. Reach inside the body with a compressed or plugged, and that the joint with cover assembly (6) is
air nozzle or brush and remove dust from the body. not broken. If the vacuator valve (4) is lost or
damaged, fit a replacement to maintain the pre-cleaner
6. Remove all loose dust from the air cleaner body (1) efficiency and normal filter element service life.
and remove the tape or cardboard from the body
outlets. Check the condition of the clamp (8), clamps (3,5 and
7, Figure 2), elbow (4, Figure 2) and the air intake tube
(1, Figure 2). Tighten/renew as necessary.
Assembly/Installation
Numbers in parentheses refer to Figure 2, unless
Primary Element
Note: Tighten all fasteners to standard torques listed in Numbers in parentheses refer to Figure 1.
Section 300-0080, Standard Bolt and Nut Torque
Specifications. Although a paper primary element (2) is used, it is
possible to remove excess dirt by tapping the element.
Assembly and installation of the air cleaner assembly
SM 2583 01-10 3
Section 110-0050
1. Release the latches on the cover assembly (6) and 3. Keep new or cleaned filter elements on hand for
remove the cover assembly from the air cleaner body replacement to prevent unnecessary downtime of the
(1). vehicle.
2. Remove the primary element (2) from the air cleaner

body (1) and clean/renew it. It is advised to renew the MEASURING AIR RESTRICTION
element rather than attempt to clean it thoroughly. Numbers in parentheses refer to Figure 2.
3. Using a damp cloth and a suitable solvent, wipe out As a dry air cleaner element becomes loaded with
all excess dust from the air cleaner body (1) and allow dust, the vacuum on the engine side of the air cleaner
it to dry. (air cleaner outlet) increases. This vacuum is generally
measured as 'restriction in mm (inches) of water'.
4. Install the primary element (2) in the air cleaner body
(1). The recommended maximum allowable intake
restrictions at rated speed and load are as follows:
5. Install the cover assembly (6) on the air cleaner
body (1) and secure it with the latches. a. 380 mm-H2O (15 in-H2O) with clean filter elements.
b. 635 mm-H2O (25 in-H2O) with dirty filter elements.
Secondary Element While the air restriction gauge sends a signal to

Numbers in parentheses refer to Figure 1. indicate the need for servicing, it does not give as
precise a measurement as a water manometer or
Since the safety element (3) is protected from vacuum gauge.
contamination by the primary element (2), it needs no
periodic cleaning and should be renewed only after Water Manometer
every third primary element (2) service.
a. Hold the water manometer vertically and fill both
1. With the primary element (2) removed from the air legs approximately half full of water. Connect one of
cleaner body (1), remove the safety element (3). the upper ends to port by means of a flexible hose.
2. Remove any dust dislodged into the air cleaner body (1) b. With the manometer held vertically and the engine
outlet and, using a damp cloth and a suitable solvent, drawing maximum air, the difference in height of the
wipe out all excess dust from the air cleaner body (1) water columns in the two legs is measured as the air
and allow it to dry. cleaner restriction.
3. Install a new safety element (3) followed by primary c. If the restriction exceeds the levels indicated, engine
element (2) in the air cleaner body (1). performance will be affected. Primary filter element
should be cleaned or replaced.
4. Install the cover assembly (6) on the air cleaner
body (1) and secure it with latches. Vacuum Gauge
a. Connect the hose from the vacuum gauge to the

Recommendations port and, with the engine drawing maximum air, take a
Numbers in parentheses refer to Figure 2. note of the reading on the gauge.
1. Under no condition should the vehicle be operated b. If the restriction exceeds the levels indicated, engine
without both filter elements in each air cleaner performance will be affected. The primary filter element
assembly. should be cleaned or replaced.
2. It is very important that the elbow (4), hose (2) and

air intake tube (1) from the air cleaner assembly to the SERVICE TOOLS
engine are airtight or the purpose of the air cleaner will Refer to Section 300-0070, Service Tools for part
be completely defeated. All clamps (3,5 and 7) (and numbers of service tools referenced in this section and
those supplied with the engine) should be checked general service tools required. These tools are
frequently and tightened to prevent leaks. available from your dealer.
* * * *
4 SM 2583 01-10
Transmission - Transmission and Mounting
Section 120-0010
SM3486
16 26
19
17 20
18 12 21 27
33
13 22 28
29
14 23
30
15 25 31
14
32
34
6
6
5 5
10
11 10
3 11
RH 2
LH
8
9 24
9
8
24
1
1
35
4
5 4
7 36 5
7
1 - Isolation Mount 8 - Bolt 15 - Hose 22 - Washer 29 - Flange

2 - Mounting Bracket 9 - Washer 16 - Bolt 23 - Bracket 30 - O-ring
3 - Mounting Bracket 10 - Bolt 17 - Washer 24 - Boss 31 - O-ring
4 - Snubbing Washer 11 - Lockwasher 18 - Locknut 25 - Fill Tube Seal 32 - Retaining Plate
5 - Washer 12 - Dipstick 19 - Clamp 26 - Oil Fill Tube 33 - Mudslinger
6 - Bolt 13 - Dipstick Tube 20 - Bolt 27 - Oil Fill Tube Bracket 34 - Bolt
7 - Nut 14 - Clip 21 - Lockwasher 28 - Screw 35 - Drain Plug
36 - Hose Adapter
Fig. 1 - Exploded View of Transmission and Mounting
DESCRIPTION
secured via mounting brackets (2 and 3, Figure 1) on
Numbers in parentheses refer to Figure 1.
either side of the transmission. Isolation mounts (1)
provide sufficient flexibility to absorb varying
For transmission make, model and specification, refer
transmission vibration and torsional loads.
to Section 000-0000, General Information. For
transmission servicing and repair data refer to the
The transmission consists of a number of major
transmission manufacturer's service manual.
assembly 'modules'. Integral with the transmission
assembly are torque converter and planetary gearing
The transmission convertor housing module is close-
modules.There are six forward gears, one reverse gear
coupled to the engine output flywheel housing, as the
and a neutral position, with automatic lockup in all
engine is secured to the chassis frame via isolation
speed ranges. Operation of the transmission is
mounts at it's front, refer to Section 110-0030 Engine
signalled by the electronic shift control via the 4th Gen
and Mounting for specific arrangement details, this in
Control system.
turn ensures that the front of the transmission is
secured in place. At its rear, the transmission is
SM 2584 Rev1 04-10 1

Section 120-0010
SM3487
4 5 6 7 10
8 9
1
11
12
2
20
3
13
17
14
x
18
16 15
19
1 - Turbine 7 - C2 Clutch 14 - C5 Piston

2 - Stator 8 - C3 Clutch 15 - Electro-hydraulic Control Module
3 - Lockup 9 - C4 Clutch 16- Rotating Clutch
4 - Torque Convertor Pump 10 - C5 Clutch 17 - Turbine Shaft
5 - Charging Oil Pump 11 - P1 Module 18 - Engine Speed Sensor
6 - C1 Clutch 12 - P2 Module 19 - Turbine Speed Sensor
13 - P3 Module 20 - Output Speed Sensor
Fig. 2 -Sectional View Of Typical 4000 Series Transmission.
A brief description and operation of the main Convertor Housing module

transmission modules follows: The convertor housing module connects the engine and
the gearbox modules. The provision for the Power take
Numbers in parentheses refer to Figure 2 unless Off (PTO) is on the convertor housing, with the helical
otherwise stated. PTO drive gear contained internal. The turbine shaft
(17) passes through the convertor housing to the
INPUT MODULES transmission gearbox module. PTO gear hub is driven
at engine speed by the torque convertor pump (4) hub
Input modules are required to connect the transmission drive. In turn the PTO gear hub drives the charging
to the engine, an input module is located between the pump (5).
engine and transmission gearbox modules. Input
modules include; Torque convertor module, Convertor Power takeoff at the left hand side of the transmission
housing and front support/ charging pump module. provides the drive for the main hydraulic pump which
supplies the braking, steering and body hoist systems.
Torque convertor module Refer to Section 120-0090, Power Take Off for details.
The torque convertor operates hydraulically and
transfers torque from the engine to transmission. It Front Support/ Charging Pump module
consists of a vaned turbine (1), a vaned stator (2) and The front support is bolted to the transmission main
a lockup clutch/ torsional damper assembly (3). housing and contains the convertor ground sleeve
2 SM 2584 Rev1 04-10

Section 120-0010
through which the turbine shaft passes to the rotating
Output Retarder module
clutch assembly. The charging pump pressurizes the
The output retarder module is to assist in stopping the
transmission fluid. Charging pump rotates with engine
vehicle and controlling the downhill speed of the
to provide a constant flow of pressurised fluid for the
vehicle.
transmission hydraulic system.
ELECTRO-HYDRAULIC CONTROL MODULE (15)
GEARBOX MODULES
The basic gearbox modules contain five clutch
The control module houses the solenoids, sensors,
assemblies and three planetary gear sets to provide six
valves and regulators that control the pressure and flow
forward speeds, neutral and one reverse.
of the transmission fluid to the clutches, the torque
convertor and the lubricating/cooling hydraulic circuits.
Rotating Clutch module
The control module also houses the transmission fluid
The rotating clutch (16) hub assembly is spilined to the
filters.
turbine shaft (17) and rotates with the turbine (1). The
rotating clutch module contains the turbine shaft
assembly, rotating clutch hub assembly, C1 and C2 (6 TRANSMISSION CONTROL MODULE
and 7) clutch assemblies, rotating clutch drum and sun
(TCM)
gear drive hub assembly for the P1 planetary gear set.
Refer to Figures 3 and 4 unless otherwise stated.
Main Housing module
The main housing module consists of the C3, C4 and SM3489
C5 clutches (8,9 and 10), ring gear component of the
P1 planetary gear set and the transmission main
housing. The clutches in the main housing are
stationary clutch assemblies and do not rotate when
hydraulically applied. The ECU signals solenoid valves
in the control module to apply and release clutches
based on power and speed requirements.
Fig. 3 - Transmission Control Module (TCM).
P1 Planetary Gear module (11)
P1 is the first planetary gear set assembly, consisting
of a sun gear driven by the rotating clutch drum. P1
WARNING
carrier assembly containing P1 pinion gears and the P1
ring gear housed in the C3 clutch assembly. The heatsink of the TCM must be electrically
isolated from all vehicle electrical systems,
P2 Planetary Gear module (12) including the chassis ground!
P2 is the second planetary gear set assembly,
consisting of a sun gear splined to the main shaft. P2 The transmission control module is the "brain" of the
carrier assembly containing the P2 pinion gears and P2 system. The independent controller is configured to run
ring gear splined to P1 carrier. off 24V. The TCM receives and processes signals from
various switches and sensors. These inputs are
Main Shaft module 13) processed and the TCM determines the optimum shift
The main shaft module passes through the centre of sequences, timing and clutch apply/release pressures.
the transmission gearbox. The P2 and P3 sun gears This is achieved by controlling the transmission
are part of or splined to the main shaft, enabling it to solenoids and valves.
transmit torque to the rotating clutch module. Input
torque to the main shaft is received either through
rotating clutch module or the P2 carrier. This main
shaft provides the primary path for transmitting torque
through the various stages of the transmission.
OUTPUT MODULES
The output modules contain components that transmit
power and torque to the vehicle driveline. The output
centerline of the transmission is in line with the
transmission input centreline.
SM 2584 Rev1 04-10 3

Section 120-0010
SM3488 transmission oil temp. and sends a signal back to the
SHIFT SELECTOR
TCM, which in turn transmits the data on the J1939
datalink, where it is read by the Instrument panel ECU
OIL LEVEL SENSOR
SPEED SENSORS
and is displayed on the Instrument panel by the temp
THROTTLE POSITION SENSOR SOLENOIDS
RETARDER MODULATION TCM DIAGNOSTIC PRESSURE SWITCH
gauge.
VEHICLE/ENGINE
TEMPERATURE SENSOR
COMMUNICATION LINKS
(SUMP / RETARDER)
The transmission temperature should display between
60 °C and 135 °C during normal operating and may
reach 165 °C when using the retarder. If the gauge
INPUTS OUTPUTS
reads above this, the transmission shifted to neutral
and engine speed increased to 1 200 - 1 500 rev/min.
Fig. 4 - TCM Inputs / Outputs.
Under this condition, oil temperature should drop to
normal values in about 2 - 3 minutes. If oil temperature
SWITCHES,SENSORS & SOLENOIDS does not drop, the cause should be investigated.
otherwise specified. Should the transmission reach a critical temperature
condition, this will cause the transmission oil
temperature critical warning to be displayed on the
Transmission Oil Temperature VDU screen.
Transmission oil temperature is monitored by the temp.
sensor (7) contained within the internal wiring harness
(5) of the transmission, located within the main control Transmission Oil Level
module. Oil temperature sensor (7) senses the The transmission oil level is constantly monitored by
SM3490
1 - Engine Speed Sensor

2 - Turbine Speed Sensor
3 - Output Speed Sensor
4 - Electro-hydraulic Control Module
5 - Internal Wiring Harness Location
6 - OLS Oil Level Sensor
10
7 - OTS Oil Temperature Sensor
8 - Solenoid Locations
9 - Transmission Filters
10 - Transmission Retarder
6
9
1
2 8
9
3 4
7
Fig. 5 - Location of Transmission Switches, Sensors and Solenoids.
4 SM 2584 Rev1 04-10

Section 120-0010
SM3597
5
4
6
7 3
1 - SS1 (Shift Solenoid) 5 - PS1 (Pressure Switch)

2 - PCS 2 (Proportional Control Solenoid) 6 - MODULATED MAIN Solenoid
3 - PCS1 (Proportional Control Solenoid) 7 - PCS4 (Proportional Control Solenoid)
4 - TCC (Torque Convertor Clutch) 8 - PCS3 (Proportional Control Solenoid)
Fig. 6 - Control Valve Solenoid Designation and Internal Wiring Harness.
the Oil level sensor (OLS) (6) located within the control Modulated Main
module. The oil level can be checked and monitored
via the display on the gearshift lever. To enter the oil 4th Gen controls include modulated main pressure for
information sequence, pressing the display mode improved cooler flow and reduced charging pump loses
button once on the gear shift lever. A two minute at low engine and output shaft speeds. The modulated
countdown will begin when the following conditions of main solenoid (6 Fig. 6) is a normally closed; On/Off
the vehicle system are met: solenoid.
The TCM (Fig. 3) commands the modulated main
1. Engine at idle. solenoid on when all of the following conditions are
2. Oil is at operating temp. within range 82 °C-104 °C. met-
3. Transmission is in neutral 'N'.
4. Transmission output shaft is stationary. • Sump temperature must be between 35 & 145°C.
Engine RPM must be less than 1200RMP in all
For further detail on displaying oil levels, refer to ranges (except neutral- no restriction).
gearshift displaying OLS information detail.
Throttle position must be less than 18% in all ranges
(except neutral-no restriction)
Lockup Clutch Transmission output speed must be below 250 rev/
The transmission lockup clutch (3, Figure 2) is min in reverse,neutral,1st or 2nd range.
automatically engaged. Engine speed is picked up by PTO input must be off
turbine speed sensor (2) which sends a signal to
energise the normally closed TCC solenoid (4, Figure A shift must not be in progress.
6) when the turbine speed reaches a predetermined
level, energizing TCC (4, Figure 3).
SM 2584 Rev1 04-10 5

Section 120-0010
Shift Solenoid SM - 3491
Normally closed On/Off SS1 (1, Figure 6) controls fluid

1
flow to the top of the latch valves.
PCS Solenoids
PCS1 through PCS4 produce pressure that is
proportional to the current supplied by the TCM.
1
2
3
DE
4
CT
MO
5
LE
D
PCS1 is normally open
SE
N
R
OR
NIT
PCS2 is normally open
MO
2
PCS3 is normally closed
3
PCS4 is normally closed.
4
Diagnostic Pressure Switch 5
PS1 (5, Fig. 6) is a normally closed switch which

1 - Hold/Override Button 4 - Range Attained
monitors the C3 clutch pressure, verifying the position 2 - Mode Button 5 - Display Mode Button
of C1 and C2 latch valves. 3 - Range Selected
Fig. 7 - 4th Gen Gear Shift Lever

OPERATION
4th Gen Automatic Shift Control transmission fault code information.
Numbers in parentheses refer to Figure 7 unless Displaying Oil Level Information (OLS)
otherwise stated.
To enter the oil information sequence, press the display
The 4000 series transmission is equipped with 4th mode (5) button once on the gear shift lever. A 2 minute
Generation controls and shift selector lever. The shift countdown begins when the following conditions are
selector communicates with the transmission TCM via met - 1.Engine at idle, 2. Oil at operating temp 82 °C-
the J1939 datalink. The shift selector is a remote 104 °C, 3. transmission in neutral and 4. transmission
mounted lever type. The selector has a 2-digit LED output shaft stationary.
display, that during normal operation will display the
range selected and range attained. The oil level will be displayed at the end of the 2 minute
countdown (to facilitate constant oil drain back). During
There is a hold override button (1) that must be the countdown, the display flashes out a numerical
pressed when shifting between R,N and D. The hold value starting at '8' in 15 second intervals, decreasing
override button (1) is released when the desired in value by 1 each time in sequence for example
selector position is reached. The selector can move 8,7,6,5,4,3,2 and 1. After the number sequence, the
freely between D and the number ranges without display will then sequentially flash the oil level
pressing the override button. information, 2 characters at a time; the following may
be displayed:
The transmission upshifts and downshifts oL ; oK Oil level OK
automatically between first range and the highest range oL ; Lo Oil level low 1 quart- or as many as req.
selected on the selector in direct response to throttle oL ; HI Oil level high 1 quart- or as many as req.
position and transmission output speed. When reverse (1 US quart = 0.95Litre = 0.2 gallon).
range is selected, the reverse alarm sounds and the
reverse light illuminates at the rear of the truck. Failure to meet any of the conditions 1-4 previously
listed, will stop the 2 minute countdown and the shift
The shift selector can be used to display a number of lever will display one of the following codes:
parameters, including oil level information and
oL0X Setting time too short.
o L EL Engine RPM too low.
o L EH Engine RPM too high.
6 SM 2584 Rev1 04-10

Section 120-0010
o L SN Neutral not selected. Mode selection / Shift Schedule
o L TL Sump fluid temperature too low.
o L TH Sump fluid temperature too high. The Mode button (2) gives the option to select between
o L SH Output shaft rotation detected. 'POWER' (primary shift schedule) and 'ECONOMY'
o L FL Oil level sensor failed. (secondary shift schedule) shift schedules which are
preprogrammed into the TCM memory. The
Displaying Diagnostic Fault codes
transmission must be in neutral before the switch will
Should there be a transmission fault, the check function. Proper selection of the shift schedules
transmission warning light will illuminate at the top of permits vehicle operation to be tailored towards fuel
the instrument panel bank of warning symbols, economy or maximized performance.
indicating that the TCM has registered a diagnostic
code. As many as five codes may be recorded in The primary shift schedule is the default setting each
memory, listed in order of newest to oldest, in which time the vehicle is started. This is used for normal
case fault codes can be retrieved through the 4th Gen operation. The secondary shift schedule can be
shift selector lever. requested by pressing the Mode button. A small red
To enter the diagnostic code sequence, press the light next to the mode button indicates that the function
display mode button (5), twice on the shift lever. Each has been selected.
code consists of 4 sequential elements; each being 1
or 2 characters. The display for each code will repeat Transmission Retarder
continuously until the next code is displayed (if
present). To display the next code if present, press the The transmission retarder is used to assist in stopping
mode button (2). The following cycle illustrates the the vehicle and reduce the need for service brake
display cycle: applications, thus reducing service brake wear and
preventing overheating.
d1 Code list position (d1 newest, d5 oldest). The retarder may be used at any time to slow the
vehicle down. If additional braking is required apply the
P service brakes.
25
34 Note: The retarder is not meant for bringing the vehicle
The code repeats until the next code (d2) is accessed to a stop, service brakes should be used for stopping.
by pressing the mode button (5)
The retarder consists of a stator, rotor, housing and
Clearing Diagnostic Fault Codes control valve body assembly. The rotor is splined to
the transmission output shaft and is driven at output
To clear active codes, press and hold the Mode button shaft speed. The retarder stator, rotor and housing all
(2) for 3 to five seconds. Similarly to clear inactive fault have integral vanes. The rotor rotates between the
codes, press and hold the mode button (2) for 8 to 10 stationary stator and retarder housing.
seconds.
Retardation occurs when the retarder housing is filled
Exiting Diagnostic mode
with transmission fluid and pressurized, thus impeding
Any of the following methods may be used to exit the and slowing the rotor, output shaft and vehicle.
diagnostic display mode -
For the retarder to engage, certain conditions must be
Momentarily press the display Mode button (5). satisfied:
Move the gearshift lever to any other position that the
one selected when the diagnostic display mode was 1. Accelerator released.
activated. 2. Transmission 'STOP' warning light must be out.
3. Transmission must be in lockup.
Wait until time out (approx. 10 minutes). The system
automatically returns to normal operating mode.
Turn the vehicle off - Eliminating power to
transmission ECU.
SM 2584 Rev1 04-10 7

8
Gear activation
The following table shows the condition of the individual solenoids, switched and latch valves to attain the full range of gears from the transmission. Note:
Intermediate stages i.e. neutral to reverse, have been ommitted, only the range attained is listed. For where to check pressure setting and measure
pressure values, see following detail.
Section 120-0010
Range Attained Solenoid Energised Latch Valve Position PS1 position Main Mod Press. Solenoid. SS1 Clutch apply
PCS1 PCS2 PCS3 PCS4 C1 C2 Open Closed Energised De-energized Energized
Neutral X X X Up Up X X C5
1st X X Down Up X X C1 + C5
2nd X X Down Down X X X C1 + C4
3rd X X Down Down X X X C1 + C3
4th Down Down` X X X C1 + C2

5th X X Down Down X X X C2 + C3
6th X X Up Down X X C2 + C4
Reverse X X Up Up X X C3 + C5
Main pressure modulation is checked at idle in Neutral, reverse, 1st convertor and second convertor. Main modulation pressure is checked at high speed
in neutral only. RPM in range 1780 - 1820.
SM 2584 Rev1 04-10

Section 120-0010
SM3937
PRESSURE CHECKS
Note: Check to verify whether there are

1 diagnostic codes present that are related to the
transmission difficulty which is being experienced.
Proceed to make mechanical preparations for
checking clutch pressures only after codes have
2 been evaluated first.
Checking individual clutch pressures helps to determine

if a transmission malfunction is due to a mechanical or
an electrical problem. Properly making these pressure
checks requires transmission and vehicle preparation,
recording of data and comparing data against
1 - Retarder Request Switch. specifications provided.
2 - Retarder Lever ( 6 position)
1. Remove the plug from the pressure tap and install a
Fig. 8 - Retarder Request Switch/Percentage Lever. suitable hydraulic fitting and pressure gauge at the
location where the measurement is desired. Pressure
gauge set J26417-A is available.
To apply the retarder, the dash mounted retarder Note: Allison DOC or Pro-link should be used for
request switch must be on (1, Figure 8). A signal is measuring engine speed.
then sent to the TCM to request retarder operation,
when all conditions are met. Note: The transmission sump fluid temperature can be
measured using Allison DOC or Pro-link.
The amount of retardation requested is operator
dependant. This is done via the six-position lever on
the right hand switch bank (2, Fig. 8). With maximum WARNING
retardation requested in the lowest position. Be sure that the transmission has enough fluid
for cold operation until an operating fluid level
can be set.
SM - 3493
LOCKUP PRESSURE DRAIN PLUG

TAP
MAIN
C4 C5
C3
C1 C2
MAIN
LUBE
OIL FILTER
COVERS
LUBE PRESSURE CLUTCH PRESSURE

TAP TAPS
Fig. 9 - Pressure Check Points
SM 2584 Rev1 04-10 9

Section 120-0010
SM - 3562A
Engine Range Clutches Main Press. Range Clutch Conv.Out Lube LU Clutch
RPM Applied Spec. Press. Spec* Press. Spec Press. Spec Press. Spec*
Idle Neutral C5 218 - 319 0 - 5.8 (C5) -
Reverse C3 C5 218 - 319 0 - 5.8 (C3 & C5) 0.5 min
1C C1 C5 189 - 261 0 -10 (C1) 0.5 min
0 - 5.8 (C5)
2C C1 C4 189 - 261 0 - 10 (C1) 0.5 min
0 - 5.8 (C4)
1780 - Neutral C5 261 - 319 0 - 5.8 11 - 44 7 - 28
1820 Reverse C3 C5 261 - 319 0 - 5.8 (C3 & C5) 25 - 44 17 -28
1C C1 C5 225 - 261 0 -10 (C1) 25 - 44 17 - 28
0 - 5.8 (C5)
2C C1 C4 225 - 261 0 -10 (C1) 25 - 44 17 - 28
0 - 5.8 (C4)
2L C1 C4 LU 152 - 203 0 - 10 (C1) 29 - 51 20 - 28 0 - 8.7
0 - 5.8 (C4)
3C C1 C3 225 - 261 0 -10 (C1) 25 - 44 17 - 28
0 - 5.8 (C3)
3L C1 C3 LU 152 - 203 0 -10 (C1) 29 - 51 20 - 28 0 - 8.7
0 - 5.8 (C3)
4C C1 C2 225 - 261 0 -10 (C1) 19 -36 13 - 22
0 -10 (C2)
4L C1 C2 LU 152 - 203 0 -10 (C1) 23 - 44 16 - 22 0 - 8.7
0 -10 (C2)
5C C2 C3 184 - 247 0 -10 (C2) 19 - 36 13 -22
0 - 5.8 (C3)
5L C2 C3 LU 131 - 181 0 -10 (C2) 23 - 44 16 - 22 0 -8.7
0 -5.8 (C3)
6C C2 C4 184 - 247 0 -10 (C2) 19 - 36 13 -22
0 - 5.8 (C3)
6L C2 C4 LU 131 -181 0 -10 (C2) 23 -44 16 -22 0 - 8.7
0 - 5.8 (C4)
Note: Pressure values are given in 'psi'
* Subtract clutch pressure from main pressure; the difference must fall within the specification given.
10 SM 2584 Rev1 04-10

Section 120-0010
SM - 3496
No. COLOUR WIRE# DESCRIPTION
1 U 101 Range Inhibit Signal

3 W 103 Signal Return
4 S 104 Engine Brake Enable
5 B/S 105 Diff Lock Relay
7 Y 107 Link For Termination Resistor(J1939)
9 B 109 Battery Ground
10 R 110 Battery Supply
11 O 111 PCS4 Modulated Main
12 K 112 Sensor Supply 61 41 21 1
13 W 113 Range Indicator Signal
15 W 115 Retarder Solenoid Supply
16 U 116 Oil Level Sensor Signal
19 - - 25 Ohm 3 watt Resistor
61
41
21
1
20 U 120 Turbine Speed Sensor Low
21 P/R 121 Not Used
24 Y/W 124 Retarder Warning Lamp
25 R/W 125 Speed Signal
28 Y 128 Link For Termination Resistor (J1939)
29 B/N 129 Check Transmission Lamp
30 W/U 130 Mid Axle Diff Lock Relay Enable
31 Y 131 Retarder/Lock Up Solenoid Return
33 Y 133 PCS3 Solenoid Supply
34 W 134 Shift Selector Position Indentifier
36 O 136 PCS1 Solenoid Supply
37 W 137 TCC Solenoid Supply
39 O 139 Engine Speed Sensor Low
40 G 140 Output Speed Sensor Low
41 W/G 141 Neutral Start Relay
42 N/Y 142 Range Inhibit
43 O/B 143 Diff Lock Request
48 U/R 148 CAN 1 Controller , High (+) (J1939)
49 U/Y 149 CAN 1 Controller Shield
51 W 151 SS1 Shift Solenoid
52 G 152 PCS2 Solenoid
54 N 154 Sump Temperature Signal
55 W 155 PCS4 Solenoid
56 Y 156 Retarder Modulation Request
57 K/S 157 Engine Brake Request
58 W/B 158 Analogue Return
59 N 159 Engine Speed Sensor High
60 Y 160 Output Speed Sensor High
61 W/S 161 Retarder Request
62 N 162 Service Brake Status
63 R 163 Ignition Battery Power
64 O/B 164 Sump retarder temp indicator
65 U/Y 165 Reverse Warning Signal
68 G 168 CAN 1 Controller, Low (-) (J1939)
69 B 169 Battery Ground
80
60
40
20
70 R 170 Battery Supply

71 Y 171 PCS1, PCS2, PCS3 & SS1
74 U 174 Modulated Main Solenoid Low
75 O 175 Retarder Temperature
76 Y 176 Trans ID 80 60 40 20
77 G 177 Diagnostic Pressure Switch
80 O 180 Turbine Speed Sensor High (+)
Fig. 11 - Transmission TCM Pin Designations
SM 2584 Rev1 04-10 11

Section 120-0010
GRY - Gray TN - Tan PNK - Pink
SM - 3494
WARNING
Before any welding is done on a machine
equipped with a 4th GEN system, disconnect 1
the following in this order: Battery earth cable,
battery supply cable, alternator earth cables,
alternator supply cables and electrical 2 STOP P
1
connections at the engine ECM, transmission
TCM and cab bulkhead to avoid damage to
electrical components. Turn off ignition key
switch to isolate the batteries before
disconnecting any components. After welding Fig. 12 - 'Check Trans' Warning Light
connect all of the above in the reverse order.
'Check Trans' Warning Light (Fig. 12) - Illuminates to

2. Bring the transmission to normal operating
alert of a minor fault in the transmission control system
temperature of 71 °C - 93 °C (160 °F- 200 °F). Check
or abnormal transmission temperature. The light will
for fluid leaks in the circuit being checked. Be sure that
come 'On' when the ignition key switch is turned to
THE fluid level is correct.
position '1' to provide a bulb and system check and
should go 'Off' a few seconds after the engine is
3. Compare clutch pressures recorder with those given
started and the transmission oil pressure rises.
in the table. If clutch pressures are not within
The check trans warning light will come 'On' during
specification take corrective action to redeem the fault.
operation, if the TCM has detected a minor fault in an
electrical component or abnormal transmission oil
4. Main pressure modulation is checked in neutral,
temperature. If transmission oil temperature is too high,
reverse, 1st and 2nd converter.
stop the vehicle, select neutral 'N', and increase engine
speed to allow a greater flow of oil to the cooler until oil
5. Main pressure modulation is checked at high speed
temperature drops to normal operating range. In most
in neutral only.
cases, a minor fault triggering the 'check trans' warning
light will not prevent normal operation from continuing
Refer to the following tables on pages 10 and 11, which
but, depending on the nature of the problem, the TCM
should be used as reference for checking pressures
could take action to protect the transmission from damage,
and troubleshooting the system.
such as preventing operating in high gear ranges. If the
'check trans' light comes 'On', have the problem
diagnosed and corrected at the earliest opportunity.
TRANSMISSION TCU CONNECTIONS
The transmission TCM has one 80-pin connector that TROUBLE-SHOOTING DIAGNOSTIC
provides the inputs and outputs for the transmission
CODES.
functions. Refer to Figure 11 for specific detail.
For colour designations, refer to 'Wire colours' in Note: Refer to tables on Pages 12 - 15 for a full list of
Electrical System - Circuit Diagrams, Section 190- diagnostic codes and their description.
0000. For colour designations not listed, use the
following for reference:
12 SM 2584 Rev1 04-10

Section 120-0010
Code Meaning of Code / Possible Cause of Fault

C1312 Retarder Request Sensor Failed Low
C1313 Retarder Request Sensor Failed High
P0122 Pedal Position Sensor Circuit Low Voltage
P0123 Pedal Position Sensor Circuit High Voltage
P0218 Transmission Fluid Over temperature
P0561 System Voltage Low Performance
P0562 System Voltage Low
P0563 System Voltage High
P0602 TCM Not Programmed
P0610 TCM Vehicle Options Error (Trans ID)
P0613 TCM Processor
P0614 Torque Control Mismatch (ECM/ TCM)
P0634 TCM Internal Temperature Too High
P063E Auto Configuration Throttle Input Not Present
P063F Auto Configuration Engine Coolant Temperature Input Not Present
P0658 Actuator Supply Voltage 1 Low (HSD 1 open/gnd)
P0659 Actuator Supply Voltage 1 High (HSD 1 batt)
P0701 Transmission Control System Performance
P0702 Transmission Control System Electrical (Trans ID)
P0703 Brake Switch Circuit
P0708 Transmission Range Sensor Circuit - High Input
P070C Transmission Fluid Level Sensor Circuit - Low Input
P070D Transmission Fluid Level Sensor Circuit - High Input
P0711 Transmission Fluid Temp. Sensor Circuit Performance
P0712 Transmission Fluid Temperature Sensor Circuit Low Input
P0713 Transmission Fluid Temperature Sensor Circuit High Input
P0716 Turbine Speed Sensor Circuit Performance
P0717 Turbine Speed Sensor Circuit No Signal
P071D General Purpose Input Fault
P071A RELS Input Failed On
P0720 Output Speed Sensor Circuit
P0721 Output Speed Sensor Circuit Performance
P0722 Output Speed Sensor Circuit No Signal
P0726 Engine Speed Input Circuit Performance
P0727 Engine Speed Input Circuit No Signal
P0729 Incorrect 6th Gear Ratio
P0730 Incorrect Gear Ratio
P0731 Incorrect 1st Gear Ratio
P0732 Incorrect 2nd Gear Ratio
P0733 Incorrect 3rd Gear Ratio
P0736 Incorrect Reverse Ratio
P0741 Torque Convertor Clutch System Stuck Off
P0776 Pressure Control Solenoid 2 Controlled Clutch Stuck Off
P0777 Pressure Control Solenoid 2 Controlled Clutch Stuck On
SM 2584 Rev1 04-10 13

Section 120-0010

P0842 Transmission Pressure Switch Solenoid 1 Circuit Low
P0843 Transmission Pressure Switch Solenoid 1 Circuit High
P0880 TCM Power Input Signal
P0881 TCM Power Input Signal Performance (Battery Voltage)
P0882 TCM Power Input Signal Low (Battery Voltage)
P0883 TCM Power Input Signal High (Battery Voltage)
P0960 Main Pressure Modulation Solenoid Control Circuit Open
P0961 Main Pressure Modulation Solenoid System Performance
P0962 Main Pressure Modulation Solenoid Control Circuit Low
P0963 Main Pressure Modulation Solenoid Control Circuit High
P0964 Pressure Control (PC) Solenoid 2 Control Circuit Open
P0965 Pressure Control (PC) Solenoid 2 System Performance
P0966 Pressure Control (PC) Solenoid 2 Control Circuit Low
P0967 Pressure Control (PC) Solenoid 2 Control Circuit High
P0968 Pressure Control (PC) Solenoid 3 Control Circuit Open
P0972 Shift Solenoid (SS) 1 Control Circuit Open
P0973 Shift Solenoid (SS) 1 Control Circuit Low
P0974 Shift Solenoid (SS) 1 Control Circuit High
P0975 Shift Solenoid (SS) 2 Control Circuit Open
P0976 Shift Solenoid (SS) 2 Control Circuit Low
P0977 Shift Solenoid (SS) Control Circuit High
P0989 Retarder Pressure Sensor Failed Low
P0990 Retarder Pressure Sensor Failed High
P1739 Incorrect Low Gear Ratio
P1891 Throttle Position Sensor PWM Signal Low Input
P1892 Throttle Position Sensor PWM Signal High Input
P2184 Engine Coolant Temperature Sensor 2 Circuit Low
P2185 Engine Coolant Temperature Sensor 2 Circuit High
P2637 Torque Management Feedback Signal (SEM)
P2641 Torque Management Feedback Signal (LRTP)
P2670 Actuator Supply Voltage 2 Low (HSD 2 gnd)
P2671 Actuator Supply Voltage 2 High (HSD 2 batt/open)
P2685 Actuator Supply Voltage 3 Low (HSD 2 gnd)
P2686 Actuator Supply Voltage 3 High (HSD 3 batt/open)
P2718 Pressure Control (PC) Solenoid 4 System Open
14 SM 2584 Rev1 04-10

Section 120-0010

P2740 Retarder Oil Temperature Hot
P2742 Retarder Oil Temperature Sensor Circuit - Low Input
P2743 Retarder Oil Temperature Sensor Circuit - High Input
P2761 TCC PCS Control Circuit Open
P2762 TCC PCS Control Circuit Range/ Performance
P2763 TCC PCS Control Ciruit High
P2764 TCC PCS Control Circuit Low
P278A Kickdown Input Switch Circuit
P2793 Gear Shift Direction Circuit
U0001 Hi Speed CAN Bus Reset Counter Overrun (CAN2/IES CAN)
U0010 CAN Bus Reset Counter Overrun (CAN1/J1939)
U0100 Lost Communication with ECM / PCM "A"
U0073 CAN Bus Reset Counter Overrun (CAN2/GMLAN)
U0103 Lost Communication With Gear Shift Module 1
U0115 Lost Communication with ECM / PCM "B"
U0291 Lost Communication with Gear Shift Module 2
U0292 Invalid Data received from Gear Shift Control Module 2
U0304 Software Incompatibility With Gear Shift Control Module 1
U0333 Software Incompatibility With Gear Shift Control Module 2
SM 2584 Rev1 04-10 15

Section 120-0010
GENERAL TROUBLESHOOTING times to relieve any pressure in the steering system.
Performance Complaints 2. Operate the treadle valve continuously to discharge the

Make the following general checks before beginning brake accumulators, block all road wheels, place the
specific troubleshooting. steering lock bar in the 'Locked' position and the battery
master switch in the 'Off' position.
• Are there active diagnostic codes?
3. Disconnect the following cables and connectors in
• Is the shift lever in N to allow engine start? the order given, to prevent serious damage to the
• Is the battery properly connected and charged? vehicle's electrical components.
• Are all fluid levels correct?
• Is the voltage to the TCM correct? a - Battery earth cables
b - Battery supply cables
• Is engine properly tuned?
c - Alternator earth cables
• Is fuel flow to the engine correct? d - Alternator supply cables
• Is air flow to the cooler and radiator unrestricted? e - Body hydraulics joystick
• Is the driveline properly connected? f - Hydraulic ECU
• Are there signs of fluid leakage under the vehicle? g - Instrument panel (VDU) CPU
h - Transmission (4th GEN) connector
• What is the origination point of this leak?
i - TCM interface harness connector (80 pin)
• Are all hydraulic connections leak free? j - ECM power harness connector (5 pin RHS)
• Are all electrical connections correct? k - ECM sensor harness connector (30 pin LHS)
l - ECM engine to transmission datalink connector
After making these checks, some complaints involve (6 pin RHS)
diagnostic codes, so all troubleshooting checks should
involve checking the system for diagnostic codes. 4. Carefully loosen the brake pipes at the base of both
accumulators to check that the brake pressure has
been discharged. Tighten the brake pipes.
REMOVAL 5. Remove the blanking cap from the remote drain line
at the bottom of the hydraulic tank. Install a length of
Numbers in parentheses refer to Figure 1. hose on the remote drain fitting, open the drain cock
and drain the hydraulic oil into a suitable container.
Note: Tag all lines, cables and linkages disconnected Close the drain cock, remove the hose and reinstall the
during removal to aid in installation. blanking cap.
6. Disconnect the transmission harness at the cab

WARNINGS floor, and the earth strap between the rear left-hand
To prevent personal injury and property damage,
SM3499
be sure wheel blocks, blocking materials and
lifting equipment are properly secured and of
adequate capacity to do the job safely. 1 4 3
2
Hydraulic oil pressure will remain within
the braking system after engine shutdown.
Operate the treadle valve continuously until the
pressure has dissipated before removing any
brake lines or serious injury could result.
High electrical current can cause sparks

and personal injury from burns. Turn battery
master switch to the 'Off' position before
disconnecting any components.
1. Position the vehicle in a level work area, ensure the

body is fully lowered, apply the parking brake and switch Fig. 13 - Chassis Cross-member
off the engine. Operate the steering right and left several
16 SM 2584 Rev1 04-10

Section 120-0010
9 10 SM3502
8
6 7
4
16
1 3
17
11
12
13 14
15
(7,9,10 SAME ALL SENSORS)
Fig. 14 - Transmission Disassembly
side of the transmission and the frame.

12. Remove the drain plug (25) on the base of the
7. Remove the right-hand fender from the machine. transmission control module, and drain the
Refer to Section 100-0070, Fender and Mounting. transmission oil through hose (26) into a suitable
container.
8. Remove the air filter from the machine. Refer to
Section 110-0050, Air Cleaner. 13. Disconnect the retarder and cooler hoses.
9. Remove the cab from the machine. Refer to Section 14. Disconnect the driveline connected from the
260-0010, Cab and Mounting. transmission to the dropbox and secure it clear of the
transmission. Refer to Section 130-0010, Drivelines.
10. Refer to Figure 13. Remove the chassis frame
cross-member (1) from the machine, by removal of the 15. Disconnect the pressure and suction hoses from
bolts (2), washers (3) and nuts (4). the main hydraulic pump. Identify and tag all hydraulic
lines
11. Taking the fabricated engine support bracket
tooling (refer to the details at the end of the Note: Access to the suction hose is limited. Use a
Transmission Section), locate and secure the left-hand suitable 10 mm ball end allen key with an extension for
bracket and the right-hand bracket to the engine removal.
mounting holes and to the chassis frame. Secure it in
place using suitable bolts. 16. Identify and tag all hydraulic lines at the main
hydraulic, brake and emergency steering pumps.
Note: Height adjustment of the right-hand bracket may Disconnect the hydraulic lines and cap the lines and
be necessary to ensure mating to engine is correct. ports to prevent the ingress of contaminants.
SM 2584 Rev1 04-10 17

Section 120-0010
17. Remove the npt plug from the engine 3/4" square 9. Remove the bolt, retainer, speed sensor and O-ring
drive, situated below the starter motor, to access the from the convertor housing module (engine speed
12 bolts holding the flex plate damper, which connects sensor), main housing module (turbine speed sensor)
the engine to the transmission. and rear cover or retarder (output speed sensor).
18. The engine crank has to be turned, to allow access

to the 12 bolts. Use special tool 15502496. Removal of the Control Valve Module
19. Mount the holding bracket 15502498 to the

transmission and attach a hoist to ensure the lifting WARNING
attachments are placed such that the transmission is Control module weighs approx. 25 kg (55 Ib).
balanced. Ensure suitable support is in place to aid in
removal.
20. Remove the bell-housing bolts. Loosen off the two
engine/transmission mounts and retract the
transmission via the holding bracket, by approximately Note: The control module or filters or both may contain
3" to give adequate separation. residual transmission fluid. Ensure that the external
part of feed through the harness connector has been
21. Lift the transmission clear of the chassis frame and disconnected from the external brackets before
the engine. removing the control module.
DISASSEMBLY 1. Remove the 43 bolts retaining the control module to

the main housing module, including the bolts retaining
Numbers in parentheses refer to Figure 14, unless the filter covers.
2. Loosen the control module by applying pressure at
1. Remove the eight mounting bolts (1) securing the the reinforced tabs, or use jack bolts inserted into the
power take off (PTO) to the transmission left-hand control module bolt holes that bottom against the main
side. housing module.
2. Remove the PTO (2)]and gasket (3). Inspect the 3. Remove the covers and filters if a handhold is
PTO studs for damage and remove them if necessary. needed to remove the control module.
3. Remove the bolts (16) retaining the oil fill tube hose 4. Remove the control module assembly and gasket.
to the clamp over the top of the transmission. Remove
the bracket, fill tube, seal and dipstick from the 5. Refer to the transmission manufacturer's service
transmission. manual if further transmission service or repair is
required.
4. Remove the six bolts retaining the remote cooler
manifold to the main housing module.
5. Bend down the tabs of the lock washers (9) if INSPECTION

present, and loosen the two bolts (10). Numbers in parentheses refer to Figure 1.
6. Remove the bolt (15), washer (14) and lock washer Periodic Inspection of the exterior of the transmission is
(13) . an essential part of preventative maintenance. The
severity of service and operating conditions should be
7. Remove the yoke (11), complete with the integral taken into account when determining the frequency of
mudslinger (17). Remove the O-rings (12). inspection.
8. Inspect the journal sealing area for the minimum 1. Check the mounting brackets assembly (2 and 3),
allowed diameter of 85.0 mm (3.346"). for cracks and damage. Repair or renew as required.
18 SM 2584 Rev1 04-10

Section 120-0010
2. Check the condition of the engine output flywheel SM - 3500
housing for general damage before mating the
transmission to the engine.
3. Check the general condition of the transmission

assembly for wear and damage, loose bolts, fluid
leaks, or for damaged or loose hoses.
4. Check for worn or damaged driveline flanges and

excessive wear on mounting holes and isolation
mounts (1).
HOT
FULL
5. Check the condition of all electrical harnesses and
connections and repair/renew them as required. Check
the condition of all hydraulic lines on the transmission HOT
ADD
and renew them if damaged.
COLD
FULL
ASSEMBLY
COLD
Numbers in parentheses refer to Figures 1 and 14, ADD
unless otherwise specified.
Assembly is largely the reverse of disassembly.

Fig. 15 - Transmission Dipstick Markings
Replace faulty or damaged components where
applicable. If it is necessary to renew the integral
mudslinger (17) on the yoke (11) a hydraulic tool will be
required to separate the parts, and the new mudslinger
(17) requires a hydraulic press to fit it. WARNING
damage, be sure wheel blocks, blocking
WARNING materials and lifting equipment are properly
Do not exceed 5 kN when fitting the mudslinger secured and of adequate capacity to perform
to the yoke. the task safely.
Note: Tighten all fasteners without special torques 1. Install Fender assembly to chassis frame. Refer to
specified to standard torques listed in Section Section 100-0070, Fenders and Mounting.
300-0080, Standard Bolt and Nut Torque
Specifications. 2. Install the cab assembly on the front frame. Refer to
Section 260-0010, Cab and Mounting.
INSTALLATION
3. Connect all harnesses and electrical connections at
Numbers in parentheses refer to Figure 1, unless the front of the cab.
4. Fill hydraulic tank with hydraulic oil specified in
Note: Tighten all fasteners without special torques Section 300-0020, Lubrication System. Refer to
specified to standard torques listed in Section Section 230-0040, Hydraulic Tank for the fill level and
300-0080, Standard Bolt and Nut Torque procedure.
Specifications.
5. Fill the transmission with engine oil specified in
Note: Tighten all hydraulic lines fitted with ORFS Section 300-0020, Lubrication System. Check the oil
connections as described in Section 250-0000, Braking level as described under 'Oil Level Check'.
System Schematic. Renew all O-rings where used.
6. Connect the following cables and connectors in the
order given to prevent serious damage to the engines
electrical components.
SM 2584 Rev1 04-10 19

Section 120-0010
SM - 3501
MAIN
LUBE MAIN
2 1
LUBE
TRANSMISSION SUMP
3
4
1 - Main Filter
6
2 - Lube Filter
3 - 'O'-ring 5
4 - 'O'-ring
5 - Gasket
6 - Gasket
7 - Filter Covers * (Not Shown)
Fig. 16 - Transmission Oil Filters
a - Battery earth cables

b - Battery supply cables 11. Secure the rear of the transmission at the mounting
c - Alternator earth cables brackets (2 and 3), with the bolts (6) and washers (5).
d - Alternator supply cables Secure it on the underside using the two snubbing
e - Body hydraulics joystick washers (4) and nuts (7). Torque the bolts (6) at both
f - Hydraulic ECU the transmission and engine front, to a value of 921
g - Instrument panel (VDU) CPU Nm (680 Ibf ft).
h - Transmission (4th GEN) connector
i - TCM interface harness connector (80 pin) 12. Connect driveline from transmission to dropbox.
j - ECM power harness connector (5 pin RHS) Refer to section 130-0010 Front Drivelines for
k - ECM sensor harness connector (30 pin LHS) installation detail.
l - ECM engine to transmission datalink connector
(6 pin RHS) 13. Turn the battery master switch to the 'On' position,
start the engine and make an operational check of all
7. Install the two plates (24) to the underside of the lines and electrical connections disconnected during
transmission mounting brackets (2 and 3). Secure removal. Check for leaks and tighten lines and fittings
them in place using the bolts (10) and washers (11). as required. Allow the transmission to warm up and
Torque the bolts (11) to a value of 40 Nm ( 29.5 Ibf ft). recheck all connections for leaks.
8. Place the isolation mounts (1) in three places - either 14. Ensure parking brake is applied, disconnect
side of transmission and at the engine cross member. steering lock bar and secure in the 'Stowed' position.
Remove wheel blocks from all road wheels.
9. Refer to Section 110-0030, Engine and Mounting, for
details of installation of adapter plate and isolation 15. Check for correct operation of the transmission,
mount installation. shift selector and warning lights.
10. Lift the engine/transmission assembly into the

frame and secure it at the front mounting plate using
the two bolts. Refer to Section 110-0030, Engine and
Mounting.
20 SM 2584 Rev1 04-10

Section 120-0010
MAINTENANCE
Always check the fluid level reading at least twice using
Periodic Inspections the following procedure. Consistent/repeatable readings
For easier inspection, the transmission should be kept are important to maintain proper fluid level.
clean. Make periodic checks for loose mounting bolts If inconsistent readings persist, check the transmission
and leaking oil lines. Check the condition of electrical breather to ensure it is not clogged.
harnesses and connections regularly.
Cold Level Check
The transmission breather (8, Figure 2) should be
checked on a regular basis (every 250 hours), and as
frequently as necessary, depending on operating WARNING
conditions. A badly corroded or plugged breather Do NOT start the engine until the presence of
restricts proper breathing and causes a buildup of sufficient transmission fluid has been
condensation and subsequent oil deterioration. confirmed. Remove the transmission fluid
dipstick and be sure that static fluid level is
near the HOT FULL mark.
Oil Level Check
1. The purpose of the cold level check is to determine
Numbers in parentheses refer to Figure15, unless if the transmission has enough fluid to be operated
otherwise stated. safely, until a hot check can be made.
2. Park the vehicle on a level surface, block all road

WARNING wheels and apply the parking brake.
When checking the oil level, ensure that the
parking brake is applied and that all road 3. Run the engine at idle or at least one minute with the
wheels are securely blocked. transmission in N (neutral). Shift to D (Drive), then shift
to R (reverse) to clear the hydraulic system of air. Then
shift to N (Neutral) and allow the engine to idle.
Check the transmission oil level and add oil if low,
every 10 hours/daily. Use only oil specified in 4. With the engine running, remove the dipstick from
Section 300-0020, Lubrication System. Because the the tube and wipe clean.
transmission oil cools, lubricates and transmits
hydraulic power it is important that the proper oil level 5. Insert dipstick into tube and remove. Check fluid
be maintained at all times. If the oil level is too low, the level. Repeat the check procedure to verify the reading.
converter and clutches will not receive an adequate
supply of oil. If the oil level is too high, the oil will 6. If the fluid level is within the "COLD RUN" band, the
aerate and the transmission will overheat. It is transmission can be operated until the fluid is hot
absolutely necessary that the oil put into the enough to perform a "HOT RUN" check. If fluid level is
transmission is clean. not within the "COLD RUN" band, add or drain as
necessary to bring the fluid level to the middle of the
Oil level can be checked either manually, as described "COLD RUN" band.
in the following text, or through the 4th GEN gearshift
lever. 7. Perform a hot check at the first opportunity after
normal operating temperature is reached, 71 °C-93 °C
Refer to Displaying Oil Level Information (OLS) on (160 °F-200 °F).
Page 6, for specific detail on using the shift lever for
this purpose.
Manual Oil Level Check
Note: Clean dirt from around the end of the fluid fill tube
before removing the dipstick. Do not allow dirt or foreign
matter to enter the transmission. Dirt or foreign matter
in the hydraulic system may clog passages and cause
undue transmission part failure or wear.
SM 2584 Rev1 04-10 21

Section 120-0010
Hot Level Check
2. Remove and discard the gaskets (5 and 6), O-rings
(3 and 4), main oil filter (1) and lube oil filter (2).
WARNING
When checking the oil level, be sure that the 3. Lubricate and reinstall new O-rings (3 and 4) on each
parking brake is applied and all road wheels cover (7). Lubricate an O-ring inside each filter (1 and
are securely blocked. 2) and push a filter on to each cover (7).
4. Install new gaskets (5 and 6) on the respective

WARNING covers and align holes in gasket with the holes in the
An accurate fluid level check cannot be made cover.
unless the engine is idling (500-800 rev/min) in
'N' (neutral), the transmission fluid is at the 5. Install the filters (1 and 2) and cover (7) assemblies
proper operating temperature and the vehicle into the filter compartment. Index each filter/cover
is on a level surface. assembly to the holes in the channel of the sump.
Push them in by hand to seat the seals.
1. Operate the transmission in D (Drive) range until
normal operating temperature is reached: 6. Install the six bolts into each cover (7) and tighten
them to a torque of 51 - 61 Nm ( 38 - 45 Ibf ft).
• Sump temperature 71 °C-93 °C (160 °F-200 °F)
7. Refill transmission oil.
• The converter-out temperature 82 °C-104 °C (180 °F-
220 °F) The transmission breather should be checked on a
2. Park the vehicle on a level surface and shift to N regular basis, and as frequently as necessary,
(Neutral). Allow the engine to idle. depending on operating conditions. However, checking
should be carried out at a minimum of 250 hour
3. With the engine running, remove the dipstick from intervals and the breather replaced where necessary.
the tube and wipe it clean. A badly corroded or plugged breather restricts proper
breathing and causes a buildup of condensation and
4. Insert the dipstick into the tube and remove it. subsequent oil deterioration.
Check the fluid level. Repeat the check procedure to
verify the reading.
WARNING
5. If the fluid level is not within the "HOT RUN" band, DO NOT spray steam, water or cleaning
add or drain as necessary to bring the fluid level within solution directly at the breather. Spraying
the band. The safe operating level is within the "HOT steam, water or cleaning solution directly at the
RUN" band on the dipstick. breather can force water or cleaning solution
into the transmission and contaminate the
transmission fluid.
Oil and Filter Change
SERVICE TOOLS
Numbers in parentheses refer to Figure 16. unless
otherwise stated. Refer to Section 300-0070, Service Tools, for part
number of service tools which should be used in
The interval for oil filters change is 3000 hours. conjunction with procedures outlined in the
transmission manufacturers service manual, and,
The interval for oil change is 6000 Hours, assuming general service tools required. These tools are
that the correct/approved oil type has been put into the available from your dealer. Any fabricated tools are
transmission unit. Refer to Section 300-0020, shown on Page 23.
Lubrication System, for recommended lubricant details.
1.To replace the oil filters, remove the 12 bolts and the
filter covers (7).
22 SM 2584 Rev1 04-10

Section 120-0010
140 SM - 3529
ENGINE SUPPORT BRACKET (LHS)
85 43 90
25
" "
50 10 100 Ø 20 4 POS'N
332 245
210 12
75
¾"unc
10 100 50
190
(mm)
Fig. 17 - Engine Support Bracket
SM - 3530
140 ENGINE SUPPORT BRACKET (RHS)
10
25
"
43 90
"
5
" "
100
Ø 20
4 POS'N VIEW ON 'A'
"
377 280
50 "
155 70
10 80
'A'
12
5
5 ¾"unc
60
12
225 (mm)
Fig. 18 - Engine Support Bracket
SM 2584 Rev1 04-10 23

Section 120-0010

TORQUE
1 7 Nut 921 680
1 8 Bolt 228 - 266 168 - 196
1 10 Bolt 40 30
1 34 Bolt 921 680
* * * *
24 SM 2584 Rev1 04-10

TRANSMISSION - Power Takeoff
Section 120-0090
SM - 3402
7 8
10
28
26
27
5 6
11
12
1,2,3
13
4
14
25 26 27
15
24
23 16
22
17
21
20
19
18
1 - Stud 8 - Name Plate 15 - Circlip 22 - Idler Shaft

2 - Washer 9 - Key 16 - O-ring (4-Off) 23 - PTO Case
3 - Nut 10 - Bearing Housing 17 - Grubscrew 24 - O-ring (2-Off)
4 - Circlip 11 - Circlip 18 - Key 25 - Ball Bearing
5 - Pump Adaptor Plate 12 - Drive Shaft 19 - Idler Gear 26 - Bolt
6 - Idler Gear 13 - Ball Bearing 20 - Taper Bearing (2-Off) 27 - Bolt
7 - Drive Screw (2-Off) 14 - Idler Gear 21 - Shim 28 - O-ring
Fig. 1 - Sectional View of Transmission Power Take Off
DESCRIPTION Mounted off power takeoff housing is the main

hydraulic pump which is driven by drive shaft (12).
Refer to Section 230-0050, MAIN HYDRAULIC PUMP.
The power takeoff (PTO) is mounted off a machined
face on the front left hand side of the transmission. REMOVAL
Numbers in parentheses refer to Fig. 1. Unless
OPERATION otherwise stated.
Numbers in parentheses refer to Fig. 1. unless
otherwise stated.
WARNING
Idler gear (14) meshes with the transmission and
damage, be sure wheel chocks and lifting
rotates at transmission speed. Rotational movement is
transferred to drive shaft (12) through a series of gears
(19 & 6) which are keyed.
SM 2371 12-09 1
Transmission - Power Takeoff
Section 120-0090
1. Position the vehicle in a level work area, apply the 7 SM -3483
6 8
parking brake and switch off the engine.
14
2. Turn steering wheel in both directions several times 13
to relieve pressure in the steering circuit. Block all road

3,4,5
wheels. 2 9
1
3. Match mark the main hydraulic pump housing and
pump adaptor plate (5, Fig.1) to facilitate assembly.
Remove main hydraulic pump following procedures
outlined in Section 230-0050, MAIN HYDRAULIC
PUMP. 11
11
4. Attach suitable lifting equipment to the power takeoff 10
9
assembly and remove 10-off bolts (10, Fig .2) . Lift the 12
power takeoff assembly and shim (12, Fig.2 ) from the

transmission housing. Discard shim (12, Fig.2 ) as a 1 - O-ring 8 - Bearing Housing
2 - Pump Adaptor Plate
new shim must be fitted at assembly stage. Cover 3 - Stud
9 - O-ring
transmission housing with mating plate to prevent entry 10 - Bolt
4 - Nut 11 - Grubscrew
of dirt. 5 - Circlip 12 - Shim
6 - 'O' Ring 13 - Bolt
7 - PTO Case
Note: Identify or mark the number and thickness of 14 - Bolt
shim (12, Fig. 2) removed. This procedure is necessary
so as not to alter the backlash of the gears during Fig. 2 - Exploded View of Power Takeoff Assembly
assembly.
7. Remove bearing (13) from housing using a suitable
Note: The gasket used at the steering pump mounting
driver, plastic mallet or device which will not damage the
face should be discarded and replaced at installation.
bearing.
DISASSEMBLY 8. Remove circlips (4 & 11) from drive shaft (12).

Numbers in parentheses refer to Fig. 1 unless
9. Carefully chap drive shaft (12) from idler gear (6).
otherwise stated.
Remove key (9).
1. Remove main hydraulic pump to allow removal of
10. Remove grubscrew (17), chap idler shaft (22) from
the transmission pto. Refer to Section 230-0050, MAIN
bore of PTO case (23).
HYDRAULIC PUMP for detail.
11. Discard o-rings (16). Remove idler gears (14 &19),
2. Remove the bolts (13, Fig. 2) securing pump adaptor
bearings (20), key (18) and shim (21) from assembly.
plate (5) to PTO case (23). Remove adaptor plate.
12. Separate individual components as required.
3. Remove and discard o-ring (24) from adaptor plate
(5).
INSPECTION
Note: Careful removal of pump adaptor plate is required
so that bearing (25) is not damaged.
1. Clean all parts, except bearings (13, 20 & 25), in a
4. Remove bearing (25) from adaptor plate (5).
suitable solvent and dry with compressed air.
5. Remove bolts (27) securing bearing housing (10) to
2. Clean bearings (13, 20 & 25) in volatile mineral
PTO case (23). Carefully remove bearing housing (10).
spirits, and wipe dry with clean, lint-free cloth.
Note bearing (13) should be removed at this stage.
Lubricate with light oil, and spin by hand to check for
wear and roughness. Replace with new bearings if
6. Remove and discard 'O' ring (28) from bearing housing
excessively worn, or if operation is rough or noisy.
(10).
2 SM 2371 12-09
Section 120-0090
3. Check the condition of splines and teeth on all gears 11. Fit bearing (13) inner race to spigot end of driveshaft
and shafts for burrs or signs of excessive wear. (12), ensuring fully home.
12. Using a suitable device, orientate driveshaft (12)
4. Idler shaft (22) and drive shaft (12) should not be sub-assembly and chap home till contact is obtained
rough, worn, cracked or damaged. If either shaft is with bearing (13) inner race.
distorted, it should be replaced.
Installation
5. Check all threaded parts and tapped holes for Numbers in parentheses refer to Fig. 1.
stripped or battered condition.
Note: Tighten all fasteners to standard torques listed in
6. Inspect PTO case, bearing housing and pump Section 300-0080, STANDARD BOLT AND NUT
adaptor plate (23, 10 & 5) for cracks or bearing bores TORQUE SPECIFICATIONS.
out-of-roundness.
Note: Tighten all hydraulic lines fitted with ORFS
7. Gear teeth should not be worn, cracked or broken. connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
8. Any small nicks, scratches or burrs should be where used.
smoothed up with a fine stone or crocus cloth, and part
cleaned in solvent and dried with lint-free cloth.
WARNING
ASSEMBLY
Numbers in parentheses refer to Fig. 1. unless equipment are properly secured and of adequate
otherwise stated. capacity to do the job safely.
1. Sub assemble bearing (20), gear (19) and key (18), 1. Remove 10-off setscrews from the transmission PTO
secure using circlip (15). cover plate located on the front left hand side of the
transmission.
2. Locate in mating slot of PTO case (23).
2. Remove cover plate and existing gasket from the
3. Fit new o-rings (16) to idler shaft (22). Offer shaft to transmission. Clean the face to ensure no foreign
bore of PTO casing (refer to Fig. 1). Chapping lightly, particles are present on the face.
ensure bearings locate onto outer diameter of the idler
shaft. 3. Taking stud mounting kit 15502084, screw 2-off studs
into top and bottom of PTO opening on the
Note: Orientate idler shaft ensuring threaded bore transmission, ensure long thread portion is used for this
mates with hole on base of to casing. operation.
4. Once in place, secure using grubscrews (17) locking 4. Place new gasket (12) onto mating face of
idler shaft (22) in place. transmission and offer assembled PTO onto studs.
5. Locate bearing (13) outer race in place on bearing 5. Place nuts and washers provided onto the studs and
housing (10), using a suitable device, seat fully home. tighten.
6. Fit o-ring (28) to groove on bearing housing (10). 6. Take bolts (10, Fig. 2) and screw into remaining 8-off
positions.
7. Secure idler gear (6) in place to drive shaft (12)
using key (9), secure using circlip (11). 7. Main hydraulic pump must be fitted to PTO assembly
using the o-ring supplied in the stud mounting kit
8. Fit bearing housing (10) to mating surface on PTO 15502084. O-ring should be placed on the pump spigot
case (23). Fit bolts (27), securing housing to the case. before assembly. For detail of pump, refer to procedures
outlined in Section 230-0050, MAIN HYDRAULIC PUMP
9. Fit circlip (4) to drive shaft (12), now locate bearing for detail.
(25) inner race onto drive shaft (12), seating fully home
against circlip.
SM 2371 12-09 3
Section 120-0090
SERVICE TOOLS
Note: Stud mounting kit 15502084 is required for
installation of the PTO to the transmission.
Refer to Section 300-0070, SERVICE TOOLS for part

numbers of other tools referenced in this section and
general service tools required. These tools are
available from your dealer.
* * * *
4 SM 2371 12-09
Dropbox - Dropbox and Mounting
Section 125-0010
SM - 3840
30
7
29
5 25
15 1 7
6 25 27
16
2
11 7
17 6
12
14 4
9 12 11
(IF REQUIRED)
10
18 1
1
(WELDNUTS)
14 4
5
8 13 1
8
3 18
(IF REQUIRED)
23
6 5
13
8 8 22 8
34 31
32
19 28
26
20 33 24
21
1 - Isolation Mount 10 - Screw 19 - Drain Plug (non drip) 28 - Washer

2 - Front Mounting Bracket 11 - Bolt 20 - Hose Adaptor 29 - Bracket
3 - Cross-member 12 - Spring Washer 21 - Elbow 30 - Breather
4 - Rear Mounting Bracket 13 - Hardened Washer 22 - Dipstick Tube 31 - Security Kit
5 - Snub Washer 14 - Bolt 23 - Dipstick 32 - Lock
6 - Hardened Washer 15 - Antiflail Guard Assy. 24 - Bolt 33 - Key
7 - Bolt 16 - Bolt 25 - Elbow 34 - Washer
8 - Locknut 17 - Washer 26 - Lockwasher
9 - Spring Washer 18 - Spacer 27 - Tube
Fig. 1 - Exploded View of Dropbox and Mounting
DESCRIPTION gearbox taking drive from the engine and transmission

and feeding it to the front and centre axles via a
lockable differential.
For Dropbox make, model and specification, refer to
Section 000-0000, GENERAL INFORMATION. For OPERATION
dropbox servicing and repair data refer to dropbox
manufacturer's service manual. The Dropbox has self-contained hydraulic gear
selection and differential locking mechanisms. The
The dropbox is supported by the front mounting bracket hydraulic supply circuits for gear activation and
(2), which is bolted to the dropbox. This in turn is differential lock are separate.
secured to the frame mounted cross-member (3).Two
rear mounting brackets (4) which are bolted to the Gear activation is from a supply via the main hydraulic
dropbox and attached to front frame mounting brackets valve assembly at port 'DL', refer to Section 215-0050
through isolation mounts (1) secure the rear. Isolation MAIN HYDRAULIC VALVE ASSEMBLY.
mounts (1) provide sufficient flexibility to absorb
varying dropbox vibration and torsional loads. Differential lock supply is via a single stage gear pump
which is driven off the main hydraulic pump. This
The dropbox is a remote mounted two-speed transfer draws the sump oil from within the dropbox to satisfy
locking and lubrication requirements of the system.
SM 2585 Rev1 04-10 1

Section 125-0010
SM - 3392
1B 6
1A
10
4
2
1 - High Range Solenoid (A) 3 - Diff. Lock Relief Valve (CT5) 6 - Check Valve (CT6)
1 - Low Range Solenoid (B) 4 - Pressure Control Valve (CT1) 9 - Pressure Switch (SW5)
2 - Differential Lock Solenoid (CT4) 5 - Check Valve (CT3) 10 - Temperature Switch (SW6)
Fig. 2 - Valve Block Detail
Gear selection and differential lock are operated via 4.Engine RPM must be less than 750
switches in the vehicle by continuously rated 24 V DC 5. Press the high / low ratio request switch into the
solenoids. These solenoids (1 and 2, Fig. 2) are desired gear range.
located on the externally mounted valve block (Fig. 2).
6. Desired gear ratio will be activated.
SWITCHES AND PRESSURE POINTS 7. Release the service brake pedal.
Numbers in parentheses refer to Fig. 2 and 3. 8. The park emergency brake will automatically
disengage, when a transmission gear is engaged.
Gear Selection
When either high or low ratio is selected, the
Numbers in parentheses refer to Fig. 2 unless corresponding solenoid (1A or 1B) will be energized.
otherwise stated. On start up, the gear range the vehicle will be in is
dependant on the position that the gear selection switch
High and low range gear selection is by face driven dog was left in, prior to leaving the vehicle.
engagement. During High/low change an extra solenoid Diff. lock solenoid (2) is energized to select the
valve is used to cut of service brake. To engage high or differential lock. The inter-axle differential lock is a multi-
low gear ratio, the following steps must be adhered to: plate clutch device that locks the front and rear drives
together (50/50 torque split) to provide more traction in
1. Bring vehicle to a stop with the service brakes. arduous conditions. It is selectable on the move,
Maintain pressure on service brakes. provided the vehicle speed is not greater than 5 km/hr.
2. Transmission must be shifted to neutral. With the differential lock disengaged there is normal
3. The park/emergency brake will now automatically torque biasing of 2/3 to the rear and 1/3 to the front
apply. axle.
2 SM 2585 Rev1 04-10

Section 125-0010
SM - 3393
TP2
(12)
B
(13) 1 - Range Selector Solenoid (CT2)

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

P2
Diagnostic Points SM - 3615
1
Numbers in parentheses refer to Figures 2 and 3, 2
3
unless otherwise stated. 4
5
6
Differential lock actuation pressure can be checked at 9 7
10 8
the diagnostic test point (7, Fig. 4). This is set at 34-50 11
bar (493-725 Ibf/in²). 12
13
14
Note: Differential lock pressure setting must be carried 15
out with the oil temperature between 25°C and 50°C.

This can be measured using an infrared gun at the
fitting on the valve block to which the differential lock
hose is fitted.
1 - Front Brake Accumulator 9 - Steering Pressure
2 - Rear Brake Accumulator 10 - Transmission Pressure
Differential lock relief valve (3) is adjustable and may 3 - Primary Accumulator 11 - DropBox Lube Pressure
be set too low if the differential lock pressure is not 4 - Front Brake Pressure 'TP3'
reaching the correct value. This valve is set to 23 bar 5 - Rear Brake Pressure 12 - Main Pump (Front)
(334 Ibf/in²). 6 - Parking Brake Pressure 13 - Main Pump (Rear)
7 - Diff-lock Pressure 'TP1' 14 - Pump LS Pressure
8 - High / Low Select 'TP2' 15 - Body System Pressure
There may be high internal leakage, either in the clutch
device or externally mounted gear pump unit; in these Fig. 4 - Diagnostic Pressure Check Points Left Hand
cases adjustment of relief valve (3) will not restore or Fender
improve pressure.
Pressure will dip momentarily when the high or low
Gear selection actuation pressure can be checked at solenoids are energized, as the cylinder moves.
pressure test point 'TP2' (8, Fig. 4). This is set by Continued low pressure would indicate high internal
pressure control valve 'CT1' (4) to 15 bar (217 Ibf/in²). leakage in the section that is energized. Low pressure
SM 2585 Rev1 04-10 3

Section 125-0010
SM - 4032
123,109,
104
1
63 51
106
113 96
4 122 99 57 110
92
121 43 49
47
117 116 86
63 32
14 86 11 9
59 74 51 2
18 95
47 82 87
102 39 80 48 40 81 41,42
73 49 45 112
20 6 5 88 121
10 94 122
21 51 113
58 64 19
73
114 100 85 70 22 TO REAR AXLES
RHS 79 8
105 67
FROM TRANS. 7 68 114
95 87 52
23,119 128 78
127 59 3 46 72
51
17 65 35
65
115
54 53
30,16 61
106
44 84 28 27
90 26 101
34,77 69
66 93 45 119
89 25 108 29 68 108
71 76 62
61 114 23 36 15
TO FRONT AXLE 78
22 38
13 125
90 120
72 60
98 37 24 73 46 12
97 50 31 103 118
55
75 91 56 107 126 124
TEMP. SW.
SEC. 190-0270
2 - Input Gear 34 - Oil Distribution Ring 66 - Washer 98 - Lockwasher

3 - Gear 35 - Output Shaft 67 - Needle Roller 99 - Stud
4 - Gear 36 - Front Gear 68 - Needle Roller 100 - Set Screw
5 - Gear 37 - Pressure Plate 69 - Washer 101 - Key
6 - Gear 38 - Front Yoke 70 - Washer 102 - Capscrew
7 - Gear Differential 39 - Selector Rod 71 - Needle Roller 103 - Self-tapping Rivet
8 - Gear (Drop) 40 - Switch Housing 72 - Taper Roller 104 - Washer
9 - Input Shaft 41 - Primary Piston 73 - Oil Seal 105 - Dowel
10 - Countershaft 42 - Piston (secondary) 74 - Oil Seal 106 - Dowel
11 - Sleeve Selector 43 - Hydraulic Cylinder 75 - 'O'-ring 107 - Suction Tube
12 - Rear Case 44 - Diff. Case 76 - 'O'-ring 108 - Capscrew
13 - Front Case 45 - Washer 77 - 'O'-ring 109 - Stud
14 - Lifting Bracket 46 - Oil Seal 78 - 'O'-ring 110 - Washer
15 - Bearing Housing 47 - Needle Roller 79 - Bush 111 - Capscrew
16 - Diff. Support Ring 48 - 'O'-ring 80 - Bush 112 - Circlip
17 - Cover Plate 49 - 'O'-ring 81 - Rod Seal 113 - Plunger Switch
18 - Oilseal housing 50 - Taper Roller 82 - Piston Seal 114 - Bolt - flanged
19 - Rear Yoke 51 - Taper Roller 83 - 'O'-ring 115 - Set Screw
20 - Input Yoke 52 - Needle Roller 84 - Piston Ring 116 - Ball - Detent
21 - Retainer Plate 53 - Friction Plate 85 - Washer 117 - Spring Detent
22 - Retainer Plate 54 - Plain Plate 86 - Washer 118 - Name Plate
23 - Splash Guard 55 - Quad Ring 87 - Locknut 119 - Set Screw
24 - Shaft (rear) 56 - Quad Ring 88 - Key 120 - Washer
25 - Sun Gearshaft 57 - Cylinder Cap 89 - Shim 121 - Ball
26 - Planet Carrier 58 - O Ring 90 - Flanged Bolt 122 - Nut
27 - Planet Gear 59 - Shim 91 - Flanged Bolt 123 - Nut
28 - Planet Spindle 60 - Washer 92 - Speedometer Sensor 124 - Washer
29 - Annulus Gear 61 - Washer 93 - Pin 125 - Magnetic Plug
30 - Clutch Basket 62 - Shim 94 - Wiper Seal 126 - Adaptor
31 - Piston (difflock) 63 - Washer 95 - Adjustment Grubscrew 127 - Plug
32 - Fork Selector 64 - Taper Roller 96 - Locknut 128 - Dowty Seal
33 - Pump Drive Adapter 65 - Needle Roller 97 - Locknut
Fig. 5 - Sectional View Of Dropbox assembly
4 SM 2585 Rev1 04-10

Section 125-0010
indication when no solenoids are energized would removal. Carefully lift the dropbox clear of the frame,
suggest the supply to the valve from port 'DL' on the remove it to a suitable work area and mount securely
main hydraulic valve is not sufficient, or pressure on a work stand.
control valve 'CT1' (4) is set too low.
11. Remove the anti-flail guard assembly (15) as
necessary, by removing the two bolts (16), with
washers (17).
REMOVAL
Numbers in parentheses refer to Figure 1, unless 12. If necessary remove the front mounting bracket (2)
otherwise specified. from the dropbox, by removing the bolts (10) with
spring washers (9).
1. Position the vehicle in a level work area, ensure that
the body is fully lowered, apply the parking brake and 13. If necessary remove the rear mounting brackets (3)
switch off the engine. Operate the steering right and from the dropbox by removing the bolts (11) with spring
left several times to relieve any pressure in the washers (12).
steering system.
Note: Do not mix up the bolts (10) with the bolts (11),
2. Operate the treadle valve continuously to discharge as bolts (11) are a larger diameter and are not
the accumulators, block all road wheels, place the interchangeable with the front mounting bracket (2)
steering lock bar in the 'Locked' position and the bolts (10).
battery master switch in the 'Off' position.
3. Disconnect the following cables and connectors in DISASSEMBLY

order to prevent damage to vehicle electrical Numbers in parentheses refer to Figs. 6-10, individually
components. Disconnect all wiring and harness identified in the text, unless otherwise specified..
connections to the dropbox valve block and associated
switches and sensors located on the dropbox. Note: The major components of the dropbox assembly
are shown in the section view Fig. 5. This should be
4. Place a suitable container under the dropbox drain used for guidance only.
port. Remove drain plug (19) and drain oil through hose
adaptor (20) into a suitable container . After draining,
reinstall the drain plug and tighten it securely. WARNING
Seals contain Viton! and produce hydrofluoric
5. Remove the cab from the machine. Refer to Section acid when subjected to high temperatures of a
260-0010, CAB AND MOUNTING. Ensure that all fire. Hydrofluoric acid is extremely corrosive
connections and lines connecting to the cab are especially to living tissue. Do not attempt repair
disconnected. if the unit or vehicle has been on fire.
6. Disconnect all drivelines connected to the dropbox

and secure them clear of the dropbox. Refer to Section 1. Undo and remove the drain plug (125) with the
130-0010, DRIVELINES. copper washer (120) from the rear of the rear case,
draining the sump oil into a suitable container. The
7. Attach suitable lifting equipment to the lifting dropbox contains 13 l of oil and therefore the container
brackets on the dropbox and raise the lifting equipment must have a capacity greater than this. Retain the
to take up the slack. drain plug (125) and copper washer (120) in a prepared
area.
8. Remove three bolts (7), locknuts (8), snubbing
washers (5) and hardened washers (6) which secure 2. Undo and remove the filler plug (126) with the copper
the front bracket (2) and rear bracket (3) assemblies to washer (124), and retain them in a prepared area.
their respective frame mounting positions.
9. Check to make certain that all necessary lines and

electrical disconnections have been made before lifting
the dropbox.
10. If necessary remove the isolation mounts (1) to aid
SM 2585 Rev1 04-10 5

Section 125-0010
Speed Selection Cylinder Yokes

1. Unscrew the switches (113) from the switch housing
(40). Remove the switches (113) complete with the Numbers in parentheses refer to Figure 5, unless
Nut (122) from the switch housing (40), and retain them otherwise specified.
in a prepared area. Be prepared for the ball (121) for the
high range indicator switch to drop out of the 1. Undo and remove the screws (114 [two per yoke])
aperture as this switch is removed from the bottom of that secure the yoke retainer plates (21 and [2x 22]).
the switch housing (40). The corresponding ball (121)
for the low range indicator switch may remain in the 2. Slide each of the three yokes (19, 20 and 38) off the
aperture or be withdrawn with the switch as it is splines on the shaft ends.
removed.
3. Discard the 'O'-rings (58 [input shaft], 78 [differential
2. Undo and remove the adjustment screws (95) with shaft and output shaft]). Fit new 'O'-rings on
lock nuts (87) from the cylinder end plate (57) and the reassembly.
front case (12).
4. Discard the 'Gamma' face seal (73) for each of the
3. Undo and remove the nuts (96) with washers (110) three yokes. Fit new 'Gamma' seals (73) on
securing the cylinder end plate (57). Remove the end reassembly.
plate (57) and retain it in a prepared area with the nuts
(96) and washers (110). Casings
4. Withdraw the cylinder (43) and pistons (41 and 42). Numbers in parentheses refer to Figure 7, unless
5. Remove the switch housing (40).
1. Undo and remove the six screws (102) securing the
6. Discard the 'O'-rings (48 and 49), piston seal (82) seal housing (18) to the front case (13). Remove the
and wiper seal (81). Fit new seals on reassembly. seal housing (18) and discard the oil seal (74). Fit a
Retain all other components in a prepared area. new oil seal (74) on reassembly. Retain the seal
housing (18) in a prepared area.
2. Remove and retain the laminated shims (59) from

the input shaft end of the front case (13).
SM - 3939
LOW RANGE INDICATOR

SWITCH SW2
80,94 113
43
96,99,110
95,87 95,87
49,57
48 40, 45, 41,
79 39 49 81, 42,
32, 112 82
100 113
HIGH RANGE
INDICATOR SWITCH
SW4
Figure 6- Speed Selector Assembly
6 SM 2585 Rev1 04-10

Section 125-0010
SM - 3886
90
44
75 115
89
17 13 - Front Case
59
18
14 - Lifting Bracket
102
13 17 - Cover Plate
18 - Oilseal Housing
44 - Differential Case
90
75 - 'O'-Ring
14
89 - Shim
90 - Flanged Bolt
102 - Capscrew
106 - Dowel
115 - Flanged Screw
106
Figure 7 - Front Case Assembly
3. Undo and remove the six screws (115) securing the some resistance may be encountered when lifting the
cover plate (17) to the front case (13). Remove the front case (13).
cover plate (17) to a prepared area.
10. Remove the outer races of the counter shaft bearing
4. Remove and retain the laminated shim (59) from the (51) and of the input shaft bearing (51) from the front
front case (13) where the counter shaft (10) locates. case (13).
8. Transfer the lifting tackle to the differential shaft

5. Undo and remove the 10 flanged bolts (90) securing
assembly.
the clutch cover assembly to the front case (13).
Remove and discard the 'O'-ring (75). Fit a new 'O'-ring
(75) on reassembly. Draw the bearing outer race (50) Differential Shaft Assembly
out from the clutch cover (44) and remove and retain
the laminated shim (89). Numbers in parentheses refer to Fig. 9, unless
6. Locate the dropbox such that its front case (13) is
uppermost. 1. Carefully lift the differential shaft assembly (Figure
9) and transfer it to a prepared area for further
7. Undo and remove the 24 screws (90) securing the disassembly.
front case (13) to the rear case (12).
2. Undo and remove the tab washer (98) and nut (97)
Note: The two screws (90) at the upper end of the case from the shaft end.
also retain the dropbox lifting bracket (14, Figure 11).
3. Using pulling tackle, draw the bearing (50) from the
8. Use the threaded holes, through which the bolts (10, differential shaft (24).
Figure 1) for the front mounting bracket (2, Figure 1) fit,
as attachment points for eyebolts. Attach lifting tackle 4. Draw the oil distribution ring assembly off the clutch
to the front case (13) outer cover (30), exposing the piston rings (84).
Remove the two 'O'-rings (77) from the oil distribution
9. Carefully lift the front case (13) away from the ring (34). Discard the the 'O'-rings (77). Fit new 'O'-rings
dropbox assembly. The front case (13) is located on on reassembly.
the rear case (12) with dowels (106), and therefore
SM 2585 Rev1 04-10 7

Section 125-0010
5. Undo and remove the screws (91) securing the 12. Using pulling tackle, draw the bearing (64) from the
clutch outer cover (30) to the pressure plate (37). other end of the differential shaft (24).
6. Withdraw the clutch outer cover (30), complete with 13. Remove the thrust washer (70).
the assembled piston within, over the clutch plates.
14. Remove the thrust washers (61) and the thrust
Note: The first 10 mm (0.4") of withdrawal may be bearing (68) sandwiched between them.
tight, as there is a possibility that there is an
interference fit between the clutch outer cover (30) and 15. Using pulling tackle draw the gear (8) from the
the shaft (24). shaft.
7. Using pulling tackle, draw the clutch support ring 16. Remove the two thrust washers (69) and the thrust
(31) from the clutch outer cover (30). bearing (68) sandwiched between them.
8. Remove the two piston rings (84) from the grooves 17. Remove the needle roller bearings (67) from the
in the clutch outer cover (30). shaft.
9. Remove the differential lock piston (31) and the quad 18. Draw the differential drive gear/planet assembly as
rings (55 and 56) from the clutch outer cover (30). a complete unit from the sun gear shaft (25).
10. Remove the friction plates (53) and the alternate 19. Remove the sun gear shaft (25).
plain plates (54).
20. Remove the two thrust washers (66) and the thrust
11. Draw the pressure plate (37) and the annulus gear bearing (65) sandwiched between them.
(29) off the assembly.
21. Undo and remove the cap screws (108) securing
the planet carrier (26) to the differential drive gear (7).
22. Using pulling tackle, remove the differential drive

gear (7) from the planet carrier (26).
SM - 3881
63 51
4
47
86
2 - Gear
4 - Gear
9 9 - Input Shaft
86
127
128 11 - Sleeve Selector
11
116 47 - Needle Roller
117
51
51 - Taper Roller
63 63 - Washer
86 - Washer
116 - Ball - Detent
117 - Spring - Detent
127 - Pump Drive Adapter
47
128 - Fastener
2
Figure 8- Input Shaft and Gearing
8 SM 2585 Rev1 04-10

Section 125-0010
65 SM - 3882
67
7 - Gear
61
8 - Gear
52
16 - Differential Support Ring
64
24 - Shaft (Rear)
70
85
25 - Sun Gearshaft
26 - Planet Carrier
8 27 - Planet Gear
28 - Planet Spindle
68 105 29 - Annulus Gear
7 30 - Clutch Basket
31 - Piston (Difflock)
34 - Oil Distribution Ring
37 - Pressure Plate
45 - Washer
50 - Taper Roller
52 - Needle Roller
53 - Friction Plate
54 - Plain Plate
55 - Quad Ring
69 56 - Quad Ring
45 27 61 68
28 71 61 - Washer
26 64 - Taper Roller
65 66
66
108 66 - Washer
25
68 - Needle Roller
67
69 - Washer
70 - Washer
71 - Needle Roller
24 77 - 'O'-ring
84 - Piston Ring
84
85 - Washer
37
91 - Flanged Bolt
93 - Pin
97
98 97 - Locknut
53 98 - Lockwasher
54
31
105 -Dowel
55 108 -Capscrew
56
16 34 30
50 77
91
Figure 9- Differential Unit
23. Remove the washers (61 and 69) and the thrust Input Shaft and Counter Shaft Assemblies
bearing between them (68).
Numbers in parentheses refer to Figs. 8 and 10,
24. Carefully remove the planet gears (27) and washer individually identified in the text, unless otherwise
(45) from the spindle/bearing assemblies on the planet specified.
carrier (26).
25. Remove the needle roller bearings (71), two per

1. Undo and remove the fastener (100, Figure 5)
bearing, and washer (45), one per planet gear, from the
securing the shift fork (32, Figure 5) to the shift shaft
planet gear spindles.
(39, Figure 6).
26. Extract and discard the roll pins (93) from the
2. Using pulling tackle, withdraw the bearing (51) from
planet carrier (26). Fit new roll pins (93) on reassembly.
the shaft (9).
27. Remove the planet gear spindles (28).
3. Remove the spacer (63) from the shaft (9).
28. If the differential drive gear (7) is being replaced by
4. Remove the LOW gear (2) from the shaft (9).
a new gear, remove the three dowels (105) from the
gear.
SM 2585 Rev1 04-10 9

Section 125-0010
SM - 3883
6 5 88
51
3 - Gear
51 5 - Gear
10
6 - Gear
10 - Counter Shaft
51 - Taper Roller
88 - Key
Figure 10 - Counter Shaft Assembly
5. Remove the two needle bearings (47) from the shaft 13. Remove the spacer ring (86) from the HIGH end of
(9). the input shaft (9).
6. Remove the spacer ring (86). 14. Pull the selector (11) from the middle section of the
input shaft (9).
7. Attach lifting tackle to the counter shaft (Figure 10)
using the threaded hole in the end of the shaft for Note: Take care to retain the ball (116) and spring (117)
attachment of an eyebolt. Carefully remove the Counter which will be released from the blind hole in the
shaft assembly (Figure 10) from the rear case (12, selector as it is removed.
Figure 5).
15. Undo the capscrews (111) securing the pump drive
Note: The gears on the counter shaft (3, 5 and 6) adapter (33) to the LOW end of the input shaft (9).
cannot be removed, once fitted. Therefore, if one or Remove the pump drive adapter (33).
more of these gears is faulty it will be necessary to
build a new counter shaft assembly, with a new shaft, 16. Rotate the rear case (12) until the front shaft
gears and bearings. bearing housing (15) is uppermost.
8. Transfer the lifting tackle to the input shaft (9), using

the threaded hole in the end of the shaft for attachment Front Drive Gear
of an eyebolt. Carefully remove the input shaft
assembly to a prepared area for further disassembly. Numbers in parentheses refer to Figures 11 and 12,
unless otherwise specified.
9. Using pulling tackle, draw the bearing (51) from the
HIGH end of the input shaft (9). 1. Undo and remove the screws (108) securing the
bearing housing (15) to the rear case (12).
10. Remove the spacer (63).
2. Remove the bearing housing (15), complete with the
11. Using pulling tackle draw the HIGH gear (4) from outer race of the non-drive end bearing (72).
the input shaft (9).
3. Fit an eyebolt to the threaded hole in the upper end
12. Remove the two needle roller bearings (47) from the of the front (output) shaft (35).
HIGH end of the input shaft (9).
10 SM 2585 Rev1 04-10

Section 125-0010
4. Carefully remove the front drive shaft assembly to a 3. Wash all machined components in high temperature
prepared area. cleaner for a minimum of 10 minutes. Dry off all
components and check them for cleanliness, paying
Note: The front drive gear cannot be removed from the particular attantion to the internal surfaces of the case
shaft, once fitted. Therefore, if the gear is faulty it will castings and in particular the sump area of the rear
be necessary to build a new front drive shaft assembly, case.
with a new shaft, gear and bearings.
5. Remove and discard the 'O'-ring (76). Fit a new 'O'-

ring on reassembly.
6. Remove and retain the laminated shim (62).

SM - 3884
7. Remove the outer race of the non-drive end bearing

108
(72) from the bearing housing (15).
12 - Rear Case 15
15 - Bearing Housing
8. Remove the outer race of the drive end bearing (72) 76
35 - Output Shaft
from the rear case (12). 36 - Front Gear 62
72
60 - Washer
62 - Shim 35
72 - Taper Roller
INSPECTION 76 - 'O'-ring 36
108 - Capscrew
Numbers in parentheses refer to Fig. 1, unless 60
otherwise specified. 72
12
1. Inspect rubber isolation mounts (1) for damage and

replace them if required.
2. Check front and rear mounting brackets (2 and 3)

and mounting brackets of frame assembly for cracks
and/ or damage. Repair or replace as necessary.
Figure 11 - Front Drive Shaft Assembly in Rear Case
SM - 3880
72
35
35 - Output Shaft
60 36 - Front Gear
72 60 - Washer
72 - Taper Roller
101 - Key
101
36
Figure 12 - Front Drive Shaft Assembly
SM 2585 Rev1 04-10 11

Section 125-0010
ASSEMBLY Input Shaft Assembly

Numbers in parentheses refer to Figs. 13-18 inclusive, Follow the instructions below in conjunction with
individually identified in the text, unless otherwise reference to Figure 13. The numbers in parentheses
specified. refer to the annotations on this Figure.
Note: The major components of the dropbox assembly Only the lubricants and proprietary sealants specified
are collectively shown in the section view Fig. 5. This are to be used. Use 15W-40 grade Engine Oil as an
should be used for guidance only. assembly lubricant for all components. Grease may be
applied to oil seal lips and hydraulic seals, but must
Front Drive Gear not be used on any other components.
Follow the instructions below in conjunction with
reference to Figure 12. The numbers in parentheses
1. Assemble the pump drive adapter (33) on the end of
refer to the annotations on this Figure.
the input shaft (9), apply Loctite™ 243 (thread locker)
to the capscrews(111) and secure the pump adapter to
Only the lubricants and proprietary sealants specified
the input shaft using the capscrews, secured equally
are to be used. Use 15W-40 grade Engine Oil as an
with an applied torque of 45 Nm (33 lbf ft).
assembly lubricant for all components. Grease may be
2. Locate the ball (116) and spring (117) in the blind
not be used on any other components.
hole in the selector (11). Depress the ball using a
screwdriver then slide the selector (11) over the splined
middle section of the shaft (9).
specified to standard torques listed in Section 300-
0080, STANDARD BOLT AND NUT TORQUE
3. Slide a spacer ring (86) over the HIGH end of the
SPECIFICATIONS.
shaft (the right-hand end in Figure 13) until it is
adjacent to the shoulder of the splined portion of the
Note: The instructions for fitting the front drive gear to
shaft.
the shaft only apply to new components. Once fitted to
the shaft, the gear cannot be separated from it, and
4. Locate two needle roller bearings (47) on the HIGH
therefore will not require to be remounted on the shaft
side of the shaft (9). Lubricate the bearings.
on re-assembly, following refurbishment.
5. Locate the HIGH gear (4) on to the shaft (9) over the
1. Ensure that the key (101) is correctly located in the
needle bearings (47), orientated with with the selector
keyway of the shaft (35). Heat the gear (36) to
castellations on the side nearest the selector (11). Fit a
between 140-150°C (284-302°F), then taking care to
spacer (63) over the HIGH end of the shaft (9).
align its keyway with the key in the shaft, carefully
assemble it on the shaft until it abuts against the shaft 6. Heat a bearing (51) to 120°C (248°F) and fit it to the
shoulder. The gear is not 'handed' and thus can be HIGH end of the shaft. Ensure that the bearing inner
fitted either way round. It may be necessary to provide race is correctly located, with no clearance between it
a light pressing action to assist the movement of the and the spacer (63).
gear along the shaft.
Note: Take care to avoid injury from direct bodily
Note: Take care to avoid injury from direct bodily contact with the preheated bearing.
contact with the preheated gear.
7. Spin the gear briefly to ensure that there is no
2. Install the spacer (60) over the shaft until it abuts binding. DO NOT spin an unlubricated bearing for
against the gear. extended periods.
3. Heat the bearings (72F [front] and 72R [rear]) to Note: The remaining input shaft assembly activities are
120°C (248°F) and assemble them on the shaft, one on carried out after the input shaft has been installed in
each end. Ensure that the bearing races abut against the rear casing.
the spacer washer (72F) and shaft shoulder (72R)
respectively, with no clearance.
Note: Take care to avoid injury from direct bodily

contact with the preheated bearings.
12 SM 2585 Rev1 04-10

Section 125-0010
SM - 3881
63 51
4
47
86
9
111
86
11 33
116
117
51
63
47
2 - Gear
4 - Gear
9 - Input Shaft
11 - Sleeve Selector
33 - Pump Drive Adapter
47 - Needle Roller
51 - Taper Roller
63 - Washer
86 - Washer
111 - Capscrew
116 - Ball - Detent
117 - Spring - Detent
Figure 13 - Input Shaft Assembly
Differential Unit
Follow the instructions below in conjunction with 2. Press the planet gear spindles (28), into the
reference to Figure 14 overleaf. The numbers in alignment holes of the planet carrier (26). Secure each
parentheses refer to the annotations on this Figure. planet gear spindle (28) using a roll pin (93).
Only the lubricants and proprietary sealants specified Note: Ensure that the roll pins (93) are fitted flush with
are to be used. Use 15W-40 grade Engine Oil as an the surface of the planet carrier (26).
applied to oil seal lips and hydraulic seals, but must 3. Assemble the needle roller bearings (71), two per
not be used on any other components. planet gear, and washer (45), one per planet gear, on
the planet gear spindles.
1. Place the drive gear (7) on a work bench with the
holes uppermost. Locate the three dowels (105) in the 4. Oil the needle roller bearings (71), then fit the planet
holes of the gear (7). gears (27) and fit the remaining washers (45) over each
spindle/bearing assembly.
SM 2585 Rev1 04-10 13

Section 125-0010
5. Assemble the thrust bearing (68) with the washers 6. Place the thrust washers (66) and thrust bearing
(61 and 69), arranged with the thicker washer (61) (65) against the shoulder on the shaft, arranged such
adjacent to the planet gears (27), then the thrust that the thrust bearing (65) is sandwiched between the
bearing (68) and then the thinner washer (69); press the two washers (66).
differential drive gear (7) on to the planet carrier (26).
Secure the planet carrier (26) to the differential drive 7. Fit the two needle roller bearings (67) over the shaft
gear (7) using the cap screws (108), to an equal torque (24). Oil the bearings.
of 50 Nm (37 lbf ft). Spin the planet gears briefly to
confirm that they are not binding.DO NOT spin 8. Place the sun gear shaft (25) over the bearings, then
unlubricated bearings for extended periods. oil and insert the two remaining needle roller bearings
(67) between the shaft (24) and the sun shaft (25).
65 SM - 3882
67
7 - Gear
61
8 - Gear
52
16 - Differential Support Ring
64
24 - Shaft (Rear)
70
85
25 - Sun Gearshaft
26 - Planet Carrier
8 27 - Planet Gear
28 - Planet Spindle
68 105 29 - Annulus Gear
7 30 - Clutch Basket
31 - Piston (Difflock)
34 - Oil Distribution Ring
37 - Pressure Plate
45 - Washer
50 - Taper Roller
52 - Needle Roller
53 - Friction Plate
54 - Plain Plate
55 - Quad Ring
69 56 - Quad Ring
45 27 61 68
28 71 61 - Washer
26 64 - Taper Roller
65 66
66
108 66 - Washer
25
68 - Needle Roller
67
69 - Washer
70 - Washer
71 - Needle Roller
24
77 - 'O'-ring
84 - Piston Ring
84
85 - Washer
37 91 - Flanged Bolt
93 - Pin
97
98 97 - Locknut
53 98 - Lockwasher
54
31
105 - Dowel
55 108 - Capscrew
56
16 34 30
50 77
91
Figure 14 - Differential Unit Assembly
14 SM 2585 Rev1 04-10

Section 125-0010
SM - 3883
6 5 88
51
3 - Gear
51 5 - Gear
10
6 - Gear
10 - Counter Shaft
51 - Taper Roller
88 - Key
Figure 15 - Counter Shaft Assembly
9. Fit the pre-assembled differential drive gear/planet 16. Locate the annulus gear (29) and the pressure plate
assembly over the sun shaft, engaging the planets with (37) over the planet gears. Lift the annulus gear (29)
the gear on the sun shaft. Ensure that the thrust slightly away from the differential drive gear by a small
bearing elements are correctly located on assembly. distance, using wedges, to prevent the first plain plate
(54) from dropping off the spline on the sun shaft during
10. Oil, then fit the needle roller bearings (68) between the next stage of assembly.
the drive gear and the sun shaft.
17. Assemble the friction plates (53) and plain plates
11. Place a thrust washer (69) against the differential (54) on the shaft, stacking them alternately beginning
drive gear, and sandwich the thrust bearing (68) with a plain plate (54) against the pressure plate (37),
between it and a second thrust washer (69). and finishing with a plain plate against the differential
lock piston (31). Ensure that the tangs on the plain
12. Fit the gear (8) to the shaft, orientated with its plates are mutually aligned.
shoulder facing towards the differential drive gear.
18. Fit the quad rings (55 and 56) to the differential lock
13. Locate the thrust washers (61) against the gear, piston (31). Oil the quad rings (55 and 56) and insert
and sandwiching the thrust bearing (68), locate the the differential lock piston (31) in the clutch outer cover
thrust washer (70) on the smaller bearing diameter of (30).
the shaft.
19. Fit the clutch outer cover (30), complete with the
14. Heat the bearing (64) to 120°C (248°F), then assembled piston, over the clutch plates, locating the
assemble it on to the shaft, ensuring that the bearing plain plate tangs in the slots in the clutch outer cover
race is correctly located, with no clearance between it (30).
and the spacer.
Note: The final 10 mm (0.4") of closure may be tight,
Note: Take care to avoid injury from direct bodily as there is a possibility that there is an interference fit
contact with the preheated bearing. between the clutch outer cover (30) and the shaft (24).
15. Spin the gear briefly to ensure that there is no

binding. DO NOT spin an unlubricated bearing for
extended periods.
SM 2585 Rev1 04-10 15

Section 125-0010
SM - 3884
108
15
76
62
72
35
36
60
72
12 12 - Rear Case
15 - Bearing Housing
35 - Output Shaft
36 - Front Gear
60 - Washer
62 - Shim
72 - Taper Roller
76 - 'O'-ring
108 - Capscrew
Figure 16- Assembly of Front Drive in Rear Case
20. Apply Loctite™ 243 to the screws (91), then use then slide the oil distribution ring assembly over the
them to secure the clutch outer cover (30) to the clutch outer cover (30), covering the piston rings.
pressure plate (37) and annulus gear (29), tightened to
an equal torque of 50 Nm (37 lbf ft). Remove the 24. Heat the bearing (50) to120°C (248°F), then
wedges. assemble it on the shaft, ensuring that the bearing race
is correctly located with no clearance between it and
21. Heat the clutch support ring (16) to 140-150°C (284- the clutch outer cover (30).
302°F). Slide the ring over the bearing location
diameter, and tap it with a drift to engage it with the Note: Take care to avoid injury from direct
clutch outer cover (30). bodilycontact with the preheated bearing.
Note: Take care to avoid injury from direct bodily 25. Fit the tab washer (98) and nut (97). Tighten the nut
contact with the preheated clutch support ring. to a torque of 160 Nm (118 lbf ft), turning it clockwise
to align the tab in the nut castellations.
22. Fit the two piston rings (84) to the grooves in the
clutch outer cover (30). Use a pneumatic test rig to
check the operation of the differential lock mechanism.
Rectify any faults observed. Counter Shaft
23. Fit two 'O'-rings (77) to the oil distribution ring (34), reference to Figure 15 . The numbers in parentheses
refer to the annotations on this Figure.
16 SM 2585 Rev1 04-10

Section 125-0010
Only the lubricants and proprietary sealants specified 3. Temporarily fit the outer race of a taper roller bearing
are to be used. Use 15W-40 grade Engine Oil as an (72) to the bearing housing (15). Fit the bearing housing
assembly lubricant for all components. Grease may be to the rear case (12) and secure it with the screws
applied to oil seal lips and hydraulic seals, but must (108). Measure the axial end float of the shaft. Subtract
not be used on any other components. 0-0.05 mm (the permitted end float) from the measured
end float figure to obtain a round number - this value is
Note: The instructions for fitting the counter shaft the correct thickness for a laminated shim to be fitted
gears to the shaft only apply to new components. Once in order to achieve the required working end float.
fitted to the shaft, the gears cannot be separated from
it, and therefore will not require to be remounted on the Remove sufficient laminates from the shim such that
shaft on re-assembly, following refurbishment. the thickness of shim remaining is equivalent to the
value calculated above.
1. Locate the key (88) in the shaft (10). Heat the gears
(3, 5 and 6) to 140-150°C (284-302°F). 4. Remove the outer bearing race from the bearing
housing (15), fit the corrected shim then re-fit the
Note: Take care to avoid injury from direct bodily bearing race, retaining it with Loctite™ 638.
contact with the preheated gears.
5. Fit the 'O'-ring (76) into the groove on the inner face
2. Align the gears with the shaft key, then assemble of the bearing housing (15).
them in order on the shaft, up to the shaft shoulder.
Two of the gears (3 and 6) are not handed, and can 6. Fit the bearing housing (15) to the rear case,
thus be fitted either way around. The gear fitted nearest securing it with the 12 screws (108), tightened equallly
the shaft shoulder (5) should be fitted with its face to a torque of 85 Nm (62.7 lbf ft).
recess facing the shaft shoulder.
7. Rotate the rear case (12) in the assembly jig until
3. Heat the bearings (51) to 120°C (248°F) and the large orifice is horizontal and uppermost.
assemble them on the shaft, ensuring that the bearing
races are correctly located, with no clearance against 8. Fit the outer bearing races for the input shaft bearing
the shaft shoulder and gears (3 and 5). (51), the differential unit shaft bearing (64) and the
counter shaft bearing (51) in the rear case (12),
Note: Take care to avoid injury from direct bodily securing them with Loctite™ 638.
contact with the preheated bearings.
Note: The inner and outer races of bearings are
matched. Therefore take care to ensure that the outer
Casings
races fitted to the rear case (12) correspond to their
corresponding inner races on the shafts to be installed.
reference to Figures 16, 17 and 18. The numbers in
parentheses refer to the annotations on these Figures.
9. Lower the partially assembled input shaft carefully
into the rear case (12). Insert the shift shaft (39) into
Only the lubricants and proprietary sealants specified
the rear case (12) and locate the shift fork (32) over the
shaft and in the groove in the slide selector (11). Apply
Loctite™ 603 to the fastener (100) and fit it to the fork
(32), tightened to a torque of 45 Nm (33 lbf ft).
not be used on any other components.
10. Attach lifting tackle to the idler shaft assembly
1. Mount the rear case (12) on an assembly jig. Rotate
using the threaded hole in the end of the shaft for
the case until it is orientated in a horizontal attitude,
attachment of an eyebolt. Insert the idler shaft
with the large open end of the case pointing
assembly carefully into the rear case (12).
downwards.
11. Assemble the remainder of the input shaft as
2. Fit the outer race of a taper roller bearing (72) in the
follows: slide a spacer ring (86) over the shaft until it is
rear case (12) and retain it with Loctite™ 638. Using a
adjacent to the shoulder of the splined section of the
lifting eye fitted to the threaded end of the front drive
shaft (9). Oil the two needle roller bearings (47) and
gear shaft (35), lower the front drive gear assembly into
locate them on the shaft (9). Locate the LOW gear (2)
the case , locating the bearing rollers in the outer race
previously fitted above.
SM 2585 Rev1 04-10 17

Section 125-0010
SM - 3885
51
63
47
86
32
100
2 - Gear
32 - Fork Selector
39 - Selector Rod
47 - Needle Roller
51 - Taper Roller
63 - Washer
86 - Washer
100 - Set Screw
39
Figure 17 - Assembly of Shaft Assemblies in Rear Case
the hole. Secure the front case (13) to the rear case
on the shaft (9), over the needle roller bearings (47), (12) using the 24 screws (90), tightened equally to a
orientated with the castellations on the gear (2) facing torque of 85 Nm (62.7 lbf ft). The two screws (90) at the
towards the fork selector (32). Fit the spacer (63) over upper end of the case also retain the dropbox lifting
the shaft. Heat the bearing (51) to 120°C (248°F), then bracket (14, Figure 18). Tighten the screws in a
assemble it on the shaft (9), taking care to ensure that sequence working from the centre outwards, in a cross
the bearing races are correctly located, with no pattern, to ensure even clamping.
clearance between the races and the spacer (63).
16. Temporarily fit the outer race of bearing (50) in the
Note: Take care to avoid injury from direct bodily clutch cover (44). Fit the clutch cover (44) to the front
contact with the preheated bearing. case (13). Measure the axial end float of the shaft.
Subtract 0-0.05 mm (0-0.002") from the measured axial
12. Spin the gear briefly to ensure that there is no float to obtain a round number, which will be the
binding. DO NOT spin an unlubricated bearing for thickness of laminated shim (89) required to achieve
extended periods. the required end float in service.
13. Transfer the lifting tackle to the differential shaft 17. Remove the clutch cover (44) and the outer race of
assembly, then carefully lower it into the rear case bearing (50). Fit the corrected shim (89) and outer race
(12). Transfer the lifting tackle to the front case (13). again. Retain the outer race with Loctite™ 638. Fit an
'O'-ring (75) in the groove in the clutch cover (44).
14. Insert the two dowels (106, Figure 7) in their
respective mounting holes in the rear case (12). 18. Fit the clutch cover (44), complete with shim (89),
outer race of bearing (50) and 'O'-ring (75). Secure the
15. Apply a 2 mm (0.08") bead of Loctite™ 5910 to the clutch cover assembly to the front case (13) using the
mating face of the rear case (12). Lower the front case 10 screws (90), tightened equally to a torque of 85 Nm
(13) on to the rear case (12), taking care to locate the (62.7 lbf ft).
dowels, and positioning the selector shaft (39) through
18 SM 2585 Rev1 04-10

Section 125-0010
19. Fit the outer race of bearing (51) to the recess in
of 50 Nm (37 lbf ft).
the front case where the counter shaft assembly is
mounted. Temporarily fit the laminated shim (59) over
22. Fit the outer race of bearing (51) to the front case
the outer face of the outer race fitted above (51). Fit
(13) and the input shaft assembly. Temporarily fit the
the cover plate (17) to the front case (13) and secure it
laminated shim (59) on the top of the outer race of the
with the screws (115). The maximum thickness of shim
bearing (51).
(59) should eliminate any axial float. Measure the gap
between the cover plate (17) and the front case (13).
23. Fit the seal housing (18) to the front case and
Calculate the thickness of shims that will have to be
secure it with the six screws (102).The maximum
removed in order to alter the measured clearance to a
thickness of shim (59) should eliminate any axial float.
value of 0-0.05 mm (0-0.002").
Measure the gap between the seal housing (18) and the
front case (13). Calculate the thickness of shims that
20. Undo the six screws (115) and the cover plate (17).
will have to be removed in order to alter the measured
Remove the required number of shims to achieve the
clearance to a value of 0-0.05 mm (0-0.002").
axial clearance calculated above. Apply Loctite™ 638
to the bearing outer race (51), then fit the corrected
24. Undo the six screws (102) and the seal housing
shim (59).
(18). Remove the required number of shims to achieve
the axial clearance calculated above. Apply Loctite™
21. Apply a 2 mm (0.08") bead of Loctite™ 5910 to the
638 to the bearing outer race (51), then fit the corrected
front case mating face where the cover plate (17)
shim (59).
impinges. Fit the cover plate (17) to the front case (13)
securing it with the six screws (115), to an equal torque
SM - 3886
90
44
75 115
17
89 13 - Front Case
18
115
14 - Lifting Bracket
13 17 - Cover Plate
18 - Oilseal Housing
90 44 - Differential Case
14 75 - 'O'-ring
89 - Shim
90 - Flanged Bolt
106 - Dowel
115 - Flanged Screw
106
Figure 18 - Assembly of Front Case to Rear Case
SM 2585 Rev1 04-10 19

Section 125-0010
SM3939
LOW RANGE INDICATOR

SWITCH SW2
80,94 113
43
96,99,110
95,87 95,87
49,57
48 40, 45, 41,
79 39 49 81, 42,
32, 112 82
100 113
HIGH RANGE
INDICATOR SWITCH
SW4
Figure 19 - Speed Selector Assembly
25. Fit the oil seal (74) to the seal housing (18). 3. Apply Loctite™ 575 to the speedometer probe (92)
and fit it to the side of the rear case (12), tightened to a
26. Apply a 2 mm (0.08") bead of Loctite™ 5910 to the torque of 35 Nm (37 lbf ft)
front case (13) where the seal housing (18) impinges.
Fit the seal housing (18) with seal (74) to the front case 4. Slide the seal (83) over the hydraulic shift cylinder
(13), securing it with the six screws (102), to an equal piston (41 and 42). Press the plain bearing into the
torque of 50 Nm (37 lbf ft). switch housing (40). Insert a wiper seal (82) until it
locates flush with the housing (40).
Final Assembly
5. Insert a seal (49) into the switch housing (40),
Follow the instructions below in conjunction with ensuring that it is orientated correctly (lip biased away
reference to Figures 5 and 19. The numbers in from the piston). Retain the seal (49) in place using a
parentheses refer to the annotations on these Figures. washer (45) and circlip (112). Fit 'O'-rings (48 and 49) to
the switch housing (40). Fit the 'O'-ring (49) to the
Only the lubricants and proprietary sealants specified cylinder end cover (57).
assembly lubricant for all components. Grease may be 6. Screw the four studs (99) into the rear case (12).
applied to oil seal lips and hydraulic seals, but must Push the switch housing (40) into the rear case (12),
not be used on any other components. locating the rod selector (39) through the housing (40).
Locate the cylinder (43) on the switch housing (40),
1. Fit a 'Gamma' face seal (73) to each of the three then secure the piston (41 and 42) to the rod selector
drive yokes (19, 20 and 38). For each of the three (39) and the piston end plate (20), using Loctite™ 603,
yokes, align the splines, and slide the yoke on to the and tightened to a torque of 35 Nm (26 lbf ft).
shaft. Fit an 'O'-ring (58 [input shaft], 78 [differential
shaft and outpuit shaft]) to the groove of each yoke. 7. Locate the cylinder end plate (57) by passing the
stud ends (99) through the holes in the end plate. Fit
2. Fit the yoke retainer plates (21 and [2x] 22), the washers (110) and nuts (96), tightening them
securing them with the screws (114 [two per yoke]), equally to a torque of 10 Nm (7.4 lbf ft).
equally to a torque of 50 Nm (37 lbf ft).
20 SM 2585 Rev1 04-10

Section 125-0010
8. Fit the cylinder end stop adjustment screws (95) and INSTALLATION
lock nut (87) to the cylinder end plate (57) and the front
case (13). Adjustment is achieved by firstly applying Numbers in parentheses refer to Fig. 1, unless
pneumatic pressure to the LOW gear engagement port otherwise specified.
[nearest the front case (13)]. Rotate the input shaft, if
necessary, to achieve full engagement. View the
movement of the rod selector through the switch WARNING
mounting holes. Screw in the grubscrew (95) until To prevent personal injury and property
resistance can be felt against the shaft end, then damage, be sure lifting device is properly
screw in a further 1/2 turn, then torque the locknut to secured and of adequate capacity to do the job
20 Nm (14.75 lbf ft). Repeat this adjustment process safely.
using the adjustment screw at the other end, and the
pneumatic pressure applied to the HIGH gear Note: Tighten all fasteners without special torques
engagement port [furthest from the front case (12)]. specified to standard torques listed in Section 300-
0080, STANDARD BOLT AND NUT TORQUE
9. To fit the switches (113), place a ball (121) in each SPECIFICATIONS.
aperture of the switch housing (40), using grease to
hold them in place. Screw in the switches, complete Note: Tighten all hydraulic lines fitted with ORFS
with Nuts (122), into the switch housing (40). Check to connections, as described in Section 250-0000,
ensure that switching only occurs when the BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
switchplunger locates on the rod selector outside (20 where used.
mm) diameter, in each case. Use a hand held buzzer
or a test rig using indicator lights to identify when 1. Attach suitable lifting equipment to dropbox lifting
switching occurs. Seal the switch threads with brackets and carefully position dropbox assembly in
Loctite™ 575. the tractor frame.
10. Fit the filler plug (126) with the copper sealing 2. If previously removed, orientate the cross-member
washer (124) to the front of the rear case (12), to a (3) and secure in place using bolts (17), washers (13)
torque of 70 Nm (52 lbf ft). and locknuts (8). Torque bolts (17) to a value of 921Nm
(680 Ibf ft).
11. Fit the drain plug (125) and copper washer (120) to
the rear of the rear case (12), to a torque of 70 Nm (52 3.Lightly coat bolts (11) with retaining compound
lbf ft). (9371048). Secure rear mounting brackets (4) to either
side of the dropbox using bolts (11) and washers (12).
12. If this is a new installation, fit the new name plate Torque bolts (11) to a value of 410Nm (303 Ibf ft).
(118) in the location shown using self-tapping rivets
(103). Hard stamp the serial number on the rear case 4. Lightly coat bolts (10) with retaining compound
(12). (9371048). Secure front mounting bracket (2) to
dropbox using bolts (10) and washers (9). Torque bolts
13. Measure the torque required to turn the input shaft (10) to a value of 185Nm (136 Ibf ft).
with the HIGH speed selected. The reading should be
below 20 Nm (14.75 lbf ft). Higher readings indicate 5. Fit isolation mounts (1) in the correct orientation to
binding of bearings or seals. Check the bearing the front and rear mounting brackets (2 & 4).
settings and the seal conditions, rectifying any
problems before proceeding. Note: Orientation of snubbing washers (5) and
hardened washers (6) is different for front and rear
brackets. Ensure correct orientation during fit up.
6. Secure the brackets in place using the snubbing

washers (5), bolts (7), hardened washers (6) and
locknuts (8). Torque the locknuts (8) to a value of 921
Nm (680 Ibf ft).
SM 2585 Rev1 04-10 21

Section 125-0010
7. Remove the blanking caps and connect all Oil and Filter Change
solenoids, switches and sensor connections
associated with the dropbox, which were removed at The dropbox oil and oil filter cartridge should be
the dissassembly stage. changed every 500 hours. Clean oil filter head when
replacing the filter cartridge. Replace the oil filter.
8. Remove the blanking caps and connect the
associated hydraulic line to the main hydraulic valve Drop box suction screen filter is housed internally
block. within the transmission body and it filters and cleans
the hydraulic oil of debris, metal flashing, filing from the
MAINTENANCE gears, dirt, rust and other junk.
Periodic Inspections Oil must be changed whenever there are traces of dirt
For easier inspection, the dropbox should be kept or evidence of high temperature indicated by
clean. Make periodic checks for loose mounting bolts discolouring or strong residue; in certain operating
and leaking oil lines. Check the condition of electrical conditions filter and oil change periods may need to be
harnesses and connections regularly. Because the more frequent. Consult the relevant manufacturer with
dropbox oil cools, lubricates and transmits hydraulic any queries regarding change intervals.
power it is important that the proper oil level be
maintained at all times. It is absolutely necessary that
the oil put into the dropbox is clean.
Every 500 Hours
SM - 3638 Oil and filter must be changed; the system should be
refilled with approximately 8 litres of oil as specified in
COLD COLD Section 300-0020, LUBRICATION SYSTEM.
FULL ADD
Fig. 20 - Dropbox Oil Dipstick

WARNING
When checking the oil level, be sure that the
parking brake is applied and all road wheels are
Topping Up Oil securely blocked.
Oil Level Check- Engine Off
This check should be made to determine if the dropbox SERVICE TOOLS

contains sufficient oil for safe starting. Oil should be Refer to Section 300-0070, SERVICE TOOLS, for
well above the 'cold full' mark on the dipstick (Fig. 20) . service tools which should be used in conjuction with
If there is a deficit of oil, this must be replenished till it procedures outlined in the dropbox manufacturer's
is up to the correct level service manual and general service tools required.
These tools are available from your dealer.
Oil Level Check- Engine Running
1. Position the vehicle on a level work area, apply the

parking brake and block all road wheels securely.
2. With the transmission in neutral and the engine

running, allow the vehicle to run for 1 minute (vehicle
stationary). This allows for oil to distribute itself round
the circuits.
3. Check the oil levels in the dropbox. Oil should be

within the 'cold full' and 'cold add' level mark (Fig. 20)
on the dipstick. If there is a deficit of oil or indeed an
excess of oil this must be rectified till it is within the
correct band.
22 SM 2585 Rev1 04-10

Section 125-0010
Trouble Shooting:
Problem Possible Cause Corrective Action
Low Pressure Indication • Wiring or Pressure Switch • Check pressure at diagnostic test point - Pressure
(Engine Running). failure. at TP2 should be 15 bar (217 Ibf/in²). If OK check
wiring and switch.
• Partial/ Full blockage of • Check and replace filter element.
valve block filter.
• Failure of main hydraulic • Check flow and pressure to dropbox from main
system. hydraulic valve port 'DL'.
• Failure/wear in dropbox • Replace pump unit- checks must be made to
pump unit. establish primary cause i.e. contaminated oil.
• Low oil level • Check oil level and unit for leaks.
High Temperature Warning. • Check oil cooler circuit for failure, damage or
• Vehicle cooler circuit
failure. radiator blockage.
Differential lock Inoperative • Wiring or solenoid failure. • Check for power to solenoid and that solenoid
energises when differential lock switch activated-
replace or repair as necessary.
• Low pressure • Check oil pressure at pressure point TP1 on
dropbox valve block - should be 34-50 bar (493-725
Ibf/in²) on activation of diff. lock switch (measured
with oil between 25°C and 50°C). Low pressure
indicates either worn pump unit, leaking valve (CT3)
in the valve block or worn differential piston and/ or
shaft seals. Check and replace as necessary. Verify
and rectify primary cause i.e. contaminated oil.
• Clutch plate wear • If pressure is within specification check oil line for
blockage. If oil flow is present examine and replace
clutch plates in the differential.
Squeal from differential • Differential lock partially • Check oil pressure at pressure point TP1 on
with dif. lock not engaged. dropbox valve block- should be 0 bar with Diff. lock
engaged. off. If pressure is indicated, ensure solenoid (CT4) is
not being energized, check solenoid valve for
leakage. Replace as necessary.
• Clutch plates warped or • Examine and replace clutch plates in differential.
damaged
• Wiring or solenoid failure • Check pressure on dropbox valve block- Pressure

Cannot change gear at TP2 should be 15 ±2.5 bar (217 ± 36 Ib/in²). If OK
range check wiring and switch.
SM 2585 Rev1 04-10 23

Section 125-0010
Problem Possible Cause Corrective Action

• Low pressure • Check pressure on dropbox valve block- pressure
Fail To Engage Range - No at TP2 should be 15 ±2.5 bar (217 ± 36 Ib/in²).
Drive
• Check that pressure control valve (4) is not faulty.
• Ensure supply from main hydraulic valve is correct.
• Gear selector mechanism • Test selector mechanism manually by removing

hydraulic selector cylinder and push and pull on the
damage/ wear
selector rod.
Note: Full gear selection will require some rotation of
the input shaft to align dog selector. Check for bent
or broken shaft or selector fork. Strip dropbox and
replace where necessary.
24 SM 2585 Rev1 04-10

Section 125-0010

TORQUE
1 7 Bolt 921 680
1 8 Locknut 921 680
1 10 Bolt 185 156
1 11 Bolt 410 303
1 17 Bolt 921 680
DROPBOX ASSEMBLY TORQUE SPECIFICATIONS

TORQUE
5 97 Differential Locking Ring 160 118
5 90 Case Screws 85 62.7

5 90 External Clutch Cover 85 62.7
5 15 Large Bearing Cover 85 62.7
5 21, 22 Yoke Screws 50 37

5 92 Speed Sender Unit 35 26
5 125, 126 Drain and Level Plugs 70 52
108 DifferentialPlanet 50 37
5 Carrier Bolts
29 Annulus/Differential 50 37
5 Housing Screws
5 17 Bearing Cover Plate 50 37
5 100 Selector Fork Screw 45 33
111 Pump Drive Adapter 45 33

5 Screw
5 18 Seal Housing 50 37
5
96 Cylinder Stud Nuts 35 26
5 95 Cylinder Stroke 20 14.75
Lock Nut
SM 2585 Rev1 04-10 25

Section 125-0010
VALVE BLOCK TORQUE SPECIFICATIONS

TORQUE
2 1 CT2 20 14.75
2 2 CT4 30 22
2 3 CT5 45 33
2 4 CT1 60 44.25
2 5 CT3 45 33
2 6 CT6 45 33
* * * *
26 SM 2585 Rev1 04-10

Dropbox - Emergency Steering Pump
Section 125-0020
SM - 3940
2 17
26
4
11 15
33
18
27 12
21 1
20
5,6 3 31
23
13 29
32
24 8 7
28
34
22 25 14 30
19 10
16
1 - Steering pump Assembly 9 - Rotating Group 17 - Plug 25 - 'O'-ring

2 - Control Valve 10 - Control Plate 18 - Spring 26 - 'O'-ring
3 - Gasket 11 - Control Piston 19 - Shim 27 - 'O'-ring
4 - Screw 12 - Piston Rod 20 - Shim 28 - Circlip
5 - Plug 13 - Pump Housing 21 - Bearing 29 - Screw
6 - 'O'-ring 14 - End Cover 22 - Bearing 30 - Plug
7 - Adaptor 15 - Swash Plate 23 - Bearing Bush 31 - Pin
8 - 'O'-ring 16 - Driveshaft 24 - Shaft Seal 32 - Roll Pin
33 - Plug
34 - Spring
Fig. 1 - Exploded View Of Steering Pump
DESCRIPTION Note: Never drive a pump in the wrong direction of

Numbers in parentheses refer to Figs. 1 unless rotation as pump seizure may result.
otherwise stated
The major pump components include driveshaft (16),
The emergency steering pump is mounted on the pump housing (13), swash plate (15), rotating group
dropbox and can be identified as item 'C' in (9), control piston (11), bias spring (18), end cover
Section 220-0000, STEERING SYSTEM (14) and pump control valve (2).
SCHEMATIC.
The variable displacement unit incorporates a
The emergency steering pump is an axial piston, mechanism that governs the angle of bearing swash
variable displacement (adjustable) pump, capable of plate (15) which, in turn controls the stroke length of
high pressure operation. It provides flow to steering each piston as rotating group (9) assembly and
circuit in the event that the main pump can no driveshaft (16) rotate. End cover (14) includes the
longer function. Pump control valve (2) regulates inlet and outlet ports. Tapered bearing (21) in pump
system pressure at 240 bar (3 480 lbf/in²). housing (13) and tapered bearing (22) in end cover
(14) support driveshaft (16).
The emergency steering pump is assembled for
right hand (clockwise) rotation, as viewed from
driveshaft (16) end.
SM 2586 01-10
1
Section 125-0020
SM - 395
Fig. 2 - Pump Rotation and Oil Flow
OPERATION
SM - 553
Refer to Fig. 3 for hydraulic schematic of steering TO
ACCUMULATOR
pump operation. VALVE
TO BRAKE
MANIFOLD
Rotation of pump driveshaft causes rotating group
VALVE
cylinder block, shoe plate and pistons to rotate.
See Fig. 2. The piston shoes are held against the
yoke face by the shoe plate. The angle of the yoke
face imparts a reciprocating motion to each piston
within the cylinder block. Inlet and outlet ports
connect to a kidney slotted valve plate. As the
pistons move out of the cylinder block, a vacuum is
created and fluid is forced into the void by
SUPPLY CASE DRAIN
atmospheric pressure. The fluid moves with the
FROM TO TANK
cylinder block, past the intake kidney slot, to the TANK
outlet (pressure) kidney slot. The motion of the Fig. 3 - Hydraulic Schematic of Steering Pump
piston reverses and fluid is pushed out of the Operation
cylinder block into the outlet port.
angularity between the shoe plate and driveshaft
Oil flows from the outlet (pressure) port to the axes, as shown by views ‘A’, ‘B’ and ‘C’ in Fig. 4.
accumulator valve which supplies steering circuit
pressure. Pressure is tapped off from a tee in the During pump operation, load or system pressure is
accumulator valve to the brake manifold valve to continually fed to the bias piston and the control
supply brake circuit pressure. piston spool chamber.
Internal pump leakage oil is returned to tank The operation of the control piston is such that
through a line at the case drain port on the steering when the system pressure (pump outlet) reaches
pump. the spring setting, the valve spool moves to meter
fluid to the pump control piston. As the force
produced by the control piston overcomes the force
Variable Displacement
Variable displacement is effected by altering the
SM 2586 01-10
2
Section 125-0020
MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
VIEW A VIEW B VIEW C
Fig. 4 - Variable Displacement Action
SM - 3340
of the bias piston, the shoe plate angle moves
toward the minimum displacement position.
(View ‘C’ Fig. 4).
8,9
4,5
1
The amount of angular movement of the shoe plate
(i.e. displacement change) is determined by system
flow demand and the resulting system pressure.
Equilibrium is achieved when the new displacement
matches the system requirement.
REMOVAL
2,3 3,6 7
WARNING
damage, be sure wheel blocks, blocking 1 - Steering Pump 6 - Hardened Washer
materials and lifting equipment are 2 - Bolt 7 - Bolt
3 - Lockwasher 8 - Coupling
properly secured and of adequate capacity 9 - 'O' Ring
4 - Pump Adaptor
to do the job safely. 5 - Gasket 10 - Snap Ring
1. Position the vehicle in a level work area, raise Fig. 5 - Plan View of Steering Pump Installation
the body and secure in place with the body safety
pins. Apply the parking brake and switch off the drain plug from underside of steering pump (1)
engine. housing and drain the oil.
2. Turn steering wheel in both directions several 5. Ensure hydraulic lines connected to steering
times to relieve pressure in accumulator and pump (1) assembly are identified for ease of
steering system. Block all road wheels. installation and, with suitable containers available
to catch leakage, disconnect hydraulic lines. Fit
3. With a suitable container in position, remove blanking caps and plugs to all hydraulic lines and
drain plug from bottom of steering and brake tank ports.
control tank and drain the oil. Reinstall the drain
plug and tighten securely.
6. Support steering pump (1) with a suitable lifting
4. With a suitable container in position, remove device and remove two mounting bolts (2) and
lockwashers (3). Pull steering pump (1) rearward to
SM 2586 01-10
3
Section 125-0020
disengage pump driveshaft from drive coupling (8). SM - 3941
7. Pull steering pump (1) and gasket (5) straight

out from the mounting flange of pump adaptor (4).
Discard gasket (5). Do not remove pump adaptor
(4) from its mounting unless it is to be replaced.
8. Wash the outside of steering pump (1) thoroughly

with a suitable solvent and move to a clean work
area for disassembly.
OVERHAUL
In most cases, the pump will not require a complete
Fig. 6 - Pump Control valve Removal
overhaul as described within this section of the
manual. Repair of this unit is intricate and should
not be attempted without proper tools.
(13) to aid at assembly stage.
DISASSEMBLY
Numbers in parentheses refer to Fig. 1 unless 3. Remove control valve (2) by removal of screws
otherwise stated. (4). Discard gasket plate (3). Refer to Fig 6.
Note: Cleanliness is essential when working on a 4. Remove 4-off screws (29) from end cover (14).
hydraulic system or component. Always work in a Using suitable lifting equipment, remove end cover
clean area, as contamination can cause serious (14) from the pump assembly (1). Refer to Fig 7.
damage to a hydraulic system.
SM - 3432
Pump Control Valve

1. Remove four screws (4) securing pump control

valve(2) to housing (13) and remove control valve
(2) from the housing. Take care not to lose or
damagegasket plate (3) when removing the control
valve assembly. Refer to Figure 6.
Note: The pump control valve assembly (2) can

only be replaced as an assembly. Therefore, no
further disassembly is required.
Pump
Numbers in parentheses refer to Fig 1 unless
otherwise stated. Fig. 7 - End Cover Removal
1. Secure pump assembly in a suitable jig or fixture.

Orientated with end cover (14) and screws (29) 5. Control plate (10), 'O'-ring (25), bearing (22)
facing upwards for disassembly. outer race & pin (32) should be accessible for
removal from end cover (14). Discard 'O'-ring (25).
2. Match mark end cover (14) and pump housing Refer to Fig 7.
6. Pull bearing (22) outer race from control plate

(10) using a suitable bearing puller. Refer to Fig 8.
SM 2586 01-10
4
Section 125-0020
SM - 3432 9. Remove plug (17) and 'o'-ring (26) from control

piston (11). Prise control piston (11) out of pump
housing (13) using the flat surface with a suitable
screwdriver. Refer to Fig. 11.
SM - 3436
Fig. 8 - End Cover Removal
7. Remove bearing (22) inner race and shim (19) Fig. 11 - Control piston Detail
from end of driveshaft (16). Take care not to
damage sealing surfaces. Refer to Fig 9. 10. Remove piston rod (12) and swash plate (15)
using a suitable tool. Slight rotation of swash plate
SM - 3434 (15) through the z-axis may be required to aid in
removal from inner bore of the housing. Refer to
Fig. 12.
SM - 3437
Fig. 9 - Bearing / Seal Removal
8. Using suitable lifting equipment, lay pump Fig. 12 - Piston Rod Removal
assembly (1) horizontal on the bench. Remove
rotating group (9) from the pump housing (13). 11. Remove bearing bushes (23) and spring (18)
Refer to Fig 10. from the assembly. Refer to Fig. 12.
SM - 3435 12. Remove driveshaft (16), bearing (21) inner

race will be mated to the driveshaft at this stage.
Refer to Fig. 13.
13. Remove circlip (28) and shaft seal (24) from

the opposite end of the pump housing. Refer to
Fig. 13.
Fig. 10 - Rotating Group Removal
SM 2586 01-10
5
Section 125-0020
SM - 3438
WARNING
The spring located within the cylinder block
is under high tension and can cause bodily
harm. Ensure retaining ring is removed
using the manufacturers guidelines.
INSPECTION
Numbers in parentheses refer to Fig. 1
Fig. 13 - Driveshaft Removal
Note: Before inspection of parts, clean all parts with
a suitable solvent.
14. Using suitable lifting equipment, secure pump
housing (13) on the bench or fixture, in correct Note: Rotating group* (9) is made up of a cylinder
orientation for removal of the bearing (21) outer block (6, Fig. 14), shoe plate (3, Fig. 14.) and piston
race. assemblies.
15. Remove bearing (21) outer race from the bore

Rotating Group
of the housing, using suitable bearing pullers.
1. Inspect cylinder block for wear, scratches and/or
16. Remove shim (20) and plug (33) from the erosion. If cylinder block condition is questionable,
housing (13). replace the entire rotating group.
Rotating Group 2. Check each cylinder block bore for excessive

Numbers in parentheses refer to Fig. 14 unless wear. Use piston and shoe assemblies for this
otherwise stated. purpose. The pistons should be a very close fit and
slide in and out of the cylinder block bores. No
1. Remove piston assemblies and shoe plate from binding can be tolerated. If binding occurs, clean
cylinder block bores for inspection. cylinder block and piston and shoe assemblies.
Lubricate cylinder block bores with clean hydraulic
2. If removal of spring (7) from rotating group (9, Fig. oil and try again. Even minor contamination of the oil
1) is required, it is recommended that caution be may cause a piston to seize up in a cylinder block
taken during this step. bore.
3. Inspect shoe plate for heavy wear and/or cracks.
Replace if defective.
SM - 3425
Pump Housing and Associated Parts

1. Inspect pump housing (13) for erosion, cracks
and burrs. Clean up minor burrs with an India stone.
8
3
If erosion or cracks are noted, replace pump
4
2 housing (13).
1
2. Inspect inner and outer races of tapered bearings
7
5
(21 & 22) for nicks and pitting. Make sure the inner
6 race turns freely within the outer race. If either of the
Fig. 14 - Rotating Group Detail tapered bearings need replaced, both the inner and
outer races must be replaced. To remove the outer
races from pump housing (13) or end cover (14) do
so using tooling in accordance with manufacturers
guidelines.
SM 2586 01-10
6
Section 125-0020
3. Inspect control plate (10) for erosion, excessive moving parts.

wear, heavy scratches and cracks. If any of the
above conditions are found, replace the valve Assembly of the pump is largely the reverse
plate. sequence to disassembly, but note the following:
4. Inspect spring (34) and rotating group piston 1. Grease the sealing ring (20). Insert ring (20) into
parts for burrs, scratches and cracks. Clean up open end of pump housing (13). Tap lightly to
minor scratches with 500 grit paper. Remove burrs ensure that stop ring sits on shoulder face. Refer
with an India stone. Pistons should move freely to Fig. 15. Locate bearing (21) outer race in correct
over their respective rods. orientation inside pump housing and chap home till
fully seated on shoulder.
Bearing Bush SM - 3418
1. Inspect bearing bush (23) face for wear,

roughness or scoring. Check the hubs and bearing
surfaces for wear and cracks. Replace if defective.
2. Inspect bearing bushes (23) for heavy wear
and/or cracks. Replace if defective.
Driveshaft and associated parts

1. Inspect driveshaft (16) for wear, chipped splines
and burrs. Remove burrs with an India stone.
Inspect contact area of tapered bearings (21 & 22)
and shaft seal (24). Replace driveshaft (16) if wear
or scoring is greater than 0.127 mm (0.005 in) total
Fig. 15 - Pump Assembly Detail
indicator reading (T.I.R.).
2. Inspect inner and outer races of tapered Note: Orientate driveshaft (16) so that splined
bearings (21 & 22) for roughness, pitting of rollers end of shaft will be protruding through the end
and excessive end play. Make sure the inner race face of the pump housing (13) when the shaft
turns freely within the outer race. If the tapered is in the assembly positon.
bearing needs replacement, both the inner and
outer races must be replaced. 2. Take bearing (21) inner race and mount fit onto
3. Inspect pump housing (13) mounting flange for driveshaft (16), make sure race is fully home on
nicks and burrs. Remove minor nicks and burrs the shoulder. Refer to Fig. 16.
with an India stone. Also check pump housing (3)
for damaged or stripped threads. If any thread is 3. Take driveshaft (16) and fit the shaft through the
damaged, replace the pump housing. pump housing (13), chapping lightly on the end
face of the shaft till the bearing (21) is in position.
4. Check remaining pump parts for excessive
wear, damaged threads, burrs, cracks and/or
4. Taking end cover (14), secure on the bench or
erosion. Replace any part that is in a questionable
condition.
SM - 3419
ASSEMBLY
otherwise stated.
Note: Obtain a new shaft seal kit and a new

bearing kit, if required. Refer to the vehicle Parts
Book for kit part numbers. Apply a light film of
clean hydraulic oil to all new seals to make
assembly easier and provide initial lubrication of Fig. 16 - Driveshaft detail
SM 2586 01-10
7
Section 125-0020
suitable jig fixture. Insert new 'o'-ring (25) into 8. Remove end cover (14), bearing (22) inner race
mating groove. and shim (19) once the correct size has been
obtained.
5. Press in outer race of rear bearing (22) onto end
cover (14). Using a suitable driver and plastic 9. At this stage, rotate main pump housing (13)
mallet. Refer to Fig. 17. sub assembly; securing on a suitable jig or fixture.
10. Taking a suitable driver, chap seal (24) down

SM - 3420
to meet the seal ring (20). Correct orientation of
seal (24) is important. Refer to Fig. 18.
11. Taking suitable circlip pliers, fit circlip (28) into

groove end of pump housing (13). Visually check
to ensure circlip (28) is correctly located on the
groove and that all other components are fully
home.
SM - 3422
Fig. 17 - End Cover Detail
6. Locate shim (19) and inner race of bearing (22)

onto the end of driveshaft (16) that extends out of
the open end of the main housing (13). Ensure
items seat onto the shaft.
7. Taking end cover (14), orientate in the correct

position over the mating face of the housing (13)
and secure in place using 4-off screws (29). Fig. 17 - Seal Retention.
Measure the distance between the parallel faces of
the pump housing (13) and the end cover (14).
Refer to Fig. 18. With the screws tightened to the 12. Rotate pump housing (13) assembly in the
correct torque value, this gap should be within the fixture. Grease the bushes (23). Insert spring (18)
range of 0 - 0.05mm. If necessary adjust the and bushes (23) into the housing body, in the
thickness of the shim (19) to meet this correct orientation. Refer to Fig. 18.
requirement.
13. Assembly swash plate (15) and piston rod (12)
SM - 3421
SM - 3423
0 - 0,05
Fig. 17 - Measurement Detail
Fig. 17 - Spring Assembly
SM 2586 01-10
8
Section 125-0020
Into the pump housing (13) using suitable tool.

SM - 3426
Ensure correct position of rod and spring. Refer to
Fig. 18.
SM - 3424
Fig. 19 - Rotating Group Assembly
4. Taking a suitably sized ‘o’-ring, secure in place

round piston assembly to aid insertion. Insert
Fig. 18 - Swash Plate / Control Assembly
rotating group into position in the pump housing (13,
Fig.1). Refer to Fig. 20.
14. Apply loctite 242 to threads of plug (1). Fit
control piston (11), 'o'-ring (26) and plug (1) in SM - 3427
place over the piston rod (12). Secure in place,

tighten the plug (17) to a torque of 190-210 Nm
(140-155 Ibf ft).
Assembly of rotating group.

otherwise stated.
1. Taking pins (5), spring (7) and circlip (8), fit into
the bore of the cylinder housing (6). Ensure
orientation is correct. Refer to Fig. 14.
2. Taking a suitable combination of bolt, nut and Fig. 20 - Insert Rotating Group
washer type to allow the spring and pins to be
enclosed and compressed in tightening of the bolt / 5. Remove ‘o’-ring used in previous step. Locate
nut combination. Do so sufficiently enough to allow shim (19) and bearing (22) inner race in position on
the circlip to be locked in place. On removal of driveshaft (16) as shown in Fig. 21.
assembly aids, the spring face will be held against
full extension by the inner face of the circlip, 6. Locate bearing (22) inner race, control plate (10)
similarly the pins will be held on the inner shoulder and end cover (14) over the assembly. Secure in
of the piston housing, thus retaining the assembly. place, tightening screws (29) to a torque of 100 -
130 Nm ( 74 - 96 Ibf ft).
3. Lubricate piston group (9, Fig.1) and retaining
plate with oil. Fit tapered end cap, retaining plate 7. Assemble control valve (2) to pump housing
and piston group in place (Refer to Fig.19) into (13), ensuring gasket plate (3) is in place. Secure
piston housing (13, Fig.1 ). valve using screws (4). Torque screws (4) to a value
of 12-15.5 Nm (9-11.5 Ibf ft).
SM 2586 01-10
9
Section 125-0020
INSTALLATION Note: Tighten all fasteners to standard torques

Numbers in parentheses refer to Fig. 5. listed in Section 300-0080, STANDARD BOLT
AND NUT TORQUE SPECIFICATIONS.
SM - 3428

connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all
'O' rings where used.
WARNING
materials and lifting equipment are
properly secured and of adequate capacity
to do the job safely.
Fig. 21 - Internal assembly 1. Coat steering pump (1) shaft splines with
molybdenum disulphide grease and place steering
SM - 3429 pump (1) and gasket (5) on pump adaptor (4)
mounting flange.
2. Push steering pump (1) inward to engage pump

driveshaft with drive coupling (8) and PTO drive.
Secure steering pump (1) to pump adaptor (4) with
two bolts (2) and lockwashers (3).
3. Remove caps and connect outlet and inlet lines to

steering pump (1). Before connecting the case drain
line, fill steering pump (1) with clean hydraulic oil
specified in Section 300-0020, LUBRICATION
SYSTEM. Connect the case drain line to steering
pump (1).
Note: It is very important that the pump cavity is

completely filled with hydraulic oil. This will ensure
proper lubrication of the internal parts of the pump
when it is initially operated.
Fig. 22 - Rotating Group Assembly
4. Fill the steering and brake control tank with
SM - 3942 clean hydraulic oil specified in Section 300-0020,
LUBRICATION SYSTEM. Refer to Section 220-
0040, STEERING AND BRAKE CONTROL TANK
for correct oil level.
5. Refer to 'PUMP STARTING PROCEDURE' for

proper pump priming and start-up procedure.
Fig. 23 - Control Group Assembly
SM 2586 01-10
10
Section 125-0020
PUMP STARTING PROCEDURE it is flush with the compensator body.

8. Start the engine and monitor the system
1. Make sure the reservoir and circuit are clean pressure gauge. Pressure should register within 30
and free of dirt and debris prior to filling with seconds. If not, re-check to assure that the system
hydraulic fluid. Fill the reservoir with filtered oil to a is properly filled with oil and that there is no
level sufficient to prevent vortexing at suction restriction to the pump inlet.
connection to pump inlet.
With the engine at Maximum No Load rev/min,
read the pressures on both the tank and the pump
Note: It is good practice to clean the system by
case. At no time should the case pressure be more
flushing and filtering the system using an external
than 0.07 - 0.14 bar (1 - 2 lbf/in²) above the tank
slave pump. Before starting the pump, fill with fluid
pressure.
through one of the ports. This is particularly
important if the pump is above the fluid level of the
If it is, there is either excessive restriction in the
reservoir.
case drain line (obstructed or possibly a kinked
line), or the leakage rate in the pump is too high. In
2. When initially starting the pump, remove all
either case, the cause should be corrected.
trapped air from the system. This can be done by
loosening the pump outlet fittings or connections
9. The system pressure can then be set by
before starting the pump. or by using an air bleed
screwing adjusting screw in until a system
valve. All inlet connections must be tight to prevent
pressure of 240 bar (3 480 lbf/in²) is attained. The
air leaks.
case tank pressure differential should still not
exceed
3. Once the pump is started, it should prime within
0.07 - 0.14 bar (1 - 2 lbf/in²).
a few seconds. If the pump does not prime, check
to make sure there are no air leaks in the inlet line
10. Shut off the engine, bleed off hydraulic
and connections. Also check to make sure that
pressure and remove the gauges.
trapped air can escape at the pump outlet.
11. Remove wheel blocks from all road wheels, start
4. After the pump is primed, tighten the loose
the engine and check steering system for proper
outlet connections, then operate for five to ten
operation.
minutes unloaded to remove all trapped air from
the circuit. If the reservoir has a sight gauge, make SPECIAL TOOLS
sure the fluid is clear- not milky. Add fluid to the
Details of recommended manufacturer tools to
reservoir up to the proper fill level.
follow, once confirmation and approval has been
given from the pump manufacturer.
5. The pump must be started with less than 40% of
normal system pressure. This is done by backing
Refer to Section 300-0070, SERVICE TOOLS for
off the steering pressure relief valve so that the
part numbers of special tools referenced in this
pump will start under no-load conditions.
section and general service tools and adhesives
required. These tools and adhesives are available
6. Be sure the pump case drain line is free from
from your dealer.
obstructions that restrict the pump case drain flow
back to tank and cause high case drain pressure
which can lead to an early pump failure.
7. Before starting the engine after pump

installation, remove the remaining case drain plug
from the pump and an appropriate plug from the
hydraulic tank and install 0 - 3.5 bar (0 - 50 lbf/in²)
gauges in both ports, as well as a gauge in the
pressure circuit which can be read for setting the
steering system pressure. Be sure to back out
adjusting screw in compensator assembly (1) until
SM 2586 01-10
11
Section 125-0020
TORQUE
6 4 Plug 5.5 - 6.8 4-5
6 7 Screw 13.5 - 16.3 10 - 12
6 10 Plug 36.6 - 40.7 27 - 30
6 12 Plug 145 - 178 107 - 131
6 22 Plug 36.6 - 40.7 27 - 30
6 28 Plug 13.5 - 16.3 10 - 12
6 31 Plug 5.5 - 6.8 4-5
6 32 Screw 118.4 - 144.7 87.3 - 106.7
* * * *
SM 2586 01-10
12
DROPBOX - Dropbox Pump Assembly
Section 125-0035
SM3897
11 1 - Front Cover
14
2 - Retaining ring
13 3 - Shaft Seal
12 4 - Seal Kit
8 4 5 - Plain Bearing
6 - Centering Pin
7 - Gear
10
1 8 - Frictional Gear
9
9 - Bearing
6 7 10 - Centering Pin
11 - Pump Housing
5 12 - End Cover
4 13 - Washer
14 - Bolt
3
2
Fig. 1 - Exploded View of Dropbox Pump
DESCRIPTION The dropbox pump is a gear pump, driven from an

Numbers in parentheses refer to Figure 1. The dropbox extension of the main hydraulic pump common drive
pump is mounted on one end of the Main Hydraulic shaft, at the rear end of the rear main hydraulic pump,
Pump, 230-0050, and operates in unison with it. via a splined fitting. The pump draws oil from the
dropbox sump, through a Suction Filter, 125-0050, and
The main hydraulic pump/dropbox pump assembly is discharges the pressurized oil though a Pressure Filter,
mounted on the left-hand side of the transmission 125-0045, to the dropbox control valve.
Power Take Off (PTO). The dropbox, pump, mounted
at the rear of the assembly, draws oil from the dropbox Valve CT6 (Item 12 on Figure 2) limits the oil pressure
sump, and delivers it to the dropbox differential lock to the dropbox shaft bearings to 4.5-8.5 bar (65-123 lbf/
circuit and the dropbox shaft lubrication galleries via a in2). Similarly, valve CT1 (Item 2 on Figure 2) limits the
dropbox control valve. The dropbox delivers oil at 35 oil pressure to the dropbox high/low actuation section
bar (507 lbf/in2) to the control valve, which reduces the of the circuit to 15 bar. Meanwhile, the differential lock
delivery pressure for shaft lubrication to 4.5-8.5 bar (65- actuation system is subject to the full pump discharge
123 lbf/in2), the dropbox high/low ratio actuation pressure of 34-50 bar (391-725 lbf/in2). A by-pass relief
pressure to 15 bar (217 lbf/in2) and the differential lock valve, set at 60 bar (870 lbf/in2), protects the circuit
pressure to 34-50 bar (493-725 lbf/in2). The shaft from excessive pressures that may occur when
lubrication oil passes through the Dropbox Oil Cooler, starting the machine in cold ambient temperatures.
210-0065 before being supplied to the dropbox shafts.
A two-stage temperature switch, either fitted to the
dropbox control valve (SW6) or to a tee connection on Note: Direction of rotation is clockwise as viewed from
the outlet from the Dropbox Pressure Filter (Section shaft end, and is indicated by an arrow.
125-0045), starts the cooler fan when the oil
temperature rises to 60°C, and illuminates a Warning DIAGNOSTIC POINTS
indicator on the VDU when the oil temperature reaches
120°C. A further (secondary) temperature switch, fitted
in the shaft lubrication line local to the dropbox also Dropbox lubrication pressure should be checked at
illuminates the VDU Warning indicator when the oil 'wide open throttle', and the readings obtained should
temperature at the dropbox (shaft 3) reaches 120°C. A be considered in conjunction with reference to the
pressure switch fitted to the dropbox control valve Dropbox Lubrication Temperature/Pressure Table
illuminates a Warning indicator on the VDU when the oil overleaf, as the pressure ranges vary with changing oil
pressure drops below 0.8 bar (11 lbf/in2). temperature. Lubrication pressure is checked at the
diagnostic point TP3 (2, Figure 3), while temperature is
OPERATION measured using an infrared gun at the filter hose fitting
on the rear right-hand side of the sump.
Numbers in parentheses refer to Figures 1,2 and 3.
SM2587 Rev1 01-10 1

Dropbox - Dropbox Pump Assembly
Section 125-0035
SM3393
TP2
(12)
B
1 - Range Selector Solenoid (CT2)

2 - Differential Lock Solenoid (CT4)
(13)
P1 GS1 3 - Differential Lock Relief Valve (CT5)
(17) (4) GS2
(14) 4 - Pressure Control Valve (CT1)
T1 6 - Check Valve (CT6)
(18)
A 7 - Oil Cooler Feed Port- OC1
(15) 8 - Oil Cooler Return Port- OC2
TP1 DL 9 - Pressure Switch- SW5
(11) (22)
(5) TP3 10 - Temperature Switch- SW6
11 - Differential Lock Test Point- TP1
(2) (7) OC1 12 - Pressure Test Point- TP2
(20) 13 - High Gear Range Port- GS1
(21) 14 - Low Gear Range Port- GS2
15 - Differential Lock Port- DL
(9)
SW5 17 - Supply Port - P1
(6)
(8) 18 - Return Port - T1
SW6 OC2
(10) (3) 19 - Relief Valve
SHAFT
LUBRICATION
20 - Check Valve
21 - Oil Cooler
(16)
22 - Dropbox Lubrication Pressure Test
P2
Point (TP3)
(19)
FROM
DROPBOX
PUMP
Fig. 2 - Dropbox Schematic Detail
SM4002
13 19
1 7
14 20
DROPBOX LUBRICATION
2 8
15 21
TEMPERATURE/PRESSURE TABLE
3 9
16 22 TEMPERATURE PRESSURE
4 10
17 23
5
°C °F bar lbf/in2
11
18
5 41 6.8-8.9 99-129
6 12
10 50 6.4-8.5 93-123
15 59 5.9-8.0 86-116
20 68 5.4-7.4 78-107
1 - Diff-lock Pressure 'TP1' 13 - Parking Brake Pressure 25 77 5.2-7.2 75-104
2 - DropBox Lube Pressure 14 - Main Pump (Front)
'TP3' 30 86 4.9-7.0 71-102
15 - Main Pump (Rear)
3 - DropBox High Select 'TP2' 16 - Front Pump LoadSense 35 95 4.9-7.0 71-102
4 - DropBox Low Select 'TP2' Pressure 40 104 4.9-7.0 71-102
5 - Cross Axle Diff.Lock 17 - Rear Pump LoadSense 45 113 4.8-6.9 70-100
6 - CT21 Pressure
7 - Body Hoist Raise 50 122 4.8-6.9 70-100
18 - Steering Pressure
8 - Body Hoist Lower 19 - Front Brake Accumulator 55 131 4.8-6.9 70-100
9 - Raise Pilot 20 - Rear Brake Accumulator
10 - Lower Pilot 21 - Primary Accumulator
11 - Transmission 22 - Front Brakes
12 - Rear Axle Disconnect 23 - Rear Brakes
Fig. 3- Diagnostic Pressure Check Points Left Hand Fender
2 SM2587 Rev1 01-10

Section 125-0035
REMOVAL
Note: Do not clamp the vice on the machined surfaces
of the assembly at any time.
WARNING 2. Remove the four nuts (12) with washers (13) from
To prevent personal injury and property the pump end of the assembly.
damage, ensure that wheel blocks, blocking
materials and lifting equipment are properly Note: Do not attempt to pry the pump assembly apart
secured, and are of adequate capacity to with a large screwdriver or pry bar. The machined
execute the job safely. surfaces of the assembly may be damaged.
1. Position the vehicle in a level work area, apply the 4. Remove the constituent parts of the assembly from
parking brake and switch off the engine. the pump end, through to the motor end and rear cover
(4).
switch in the 'Off' position. Place the steering lock bar 5. Remove and discard the seals that are to be
in the 'Locked' position. replaced with new seals in the kit (4).
3. Remove the cab from the machine. Refer to Section

260-0010, Cab and Mounting. Ensure that all
INSPECTION
connections and lines connecting to the cab are Numbers in parentheses refer to Figure 1.
disconnected.
1. Clean all of the parts in a suitable solvent and dry
5. Clean the pump assembly and the surrounding area them with compressed air.
with a suitable solvent. Identify and tag all oil lines
connected to the pump, to aid in 'Installation'. 2. Check the port threads and ensure that they are not
damaged or stripped.
6. With suitable containers available to catch leakage,
disconnect the oil lines. Fit blanking caps to all open
lines.
ASSEMBLY
7. Remove the four bolts (3) and lockwashers (4)
securing the pump to the rear main hydraulic pump (2). 1. From the seal kit, replace the seals on both ends of
the pump, prior to re-assembly.
DISASSEMBLY 2. Lightly oil parts prior to re-assembly.

3. Assemble the pump elements together and locate
1. Place the pump assembly in a soft-jawed vice, and them with the bolts(14) and washers (13). Torque the
apply the vice clamp to the body. Matchmark the pump bolts (12) to a value of 50 Nm (37 Ibf ft).
covers and body to aid in re-assembly.
SM3531 SM3532
13
1
14
LOOKING
FORWARD
2,7
4,8 3 11
5
VIEW
FROM
12,8
14 TOP
6,9
10
13
13
Fig. 4 - View from Rear of Dropbox Control Valve Fig. 5 - View Looking Down on Dropbox Control Valve
SM2587 Rev1 01-10 3

Section 125-0035
4 Install the hydraulic connectors and adaptors to the
correct ports and orientation, as noted on disassembly. 0010, Dropbox - Dropbox and Mounting.
FAULT DIAGNOSIS
Refer to the following Fault Diagnosis tips.
INSTALLATION
Numbers in parentheses refer to Figure 1. n It is not recommended that relief valve cartridge
assemblies are disassembled for maintenance
Note: Tighten all fasteners to standard torques listed in purposes. Ensure that the pump is cleaned off
Section 300-0080, Standard Bolt and Nut Torque prior to removal of any components, and that no
Specifications. contaminant is allowed to enter the internal
galleries.
connections, as described in Section 250-0000, n If investigation shows that the relief valves are
Braking System Schematic. Renew all 'O' rings where
in good clean condition and fit for use, the seals
used.
should be renewed, prior to re-assembly. Any
damage to the pump internals would
1. Secure pump assembly to the rear main hydraulic
necessitate renewal of the pump assembly.
pump with the mounting hardware as removed at
'Removal'.
SPECIAL TOOLS
2. Remove the blanking caps from the dropbox oil lines There are no special tools required for the procedures
and install the pipework to the pump as identified outlined in this section. Refer to Section 300-0070,
during 'Removal'. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
3. If the dropbox has been drained replenish it to the dealer.
level identified in Section 300-0020, Lubrication
System.
5. Place the battery master switch in the 'On' position,

start the engine and bring hydraulic oil to operating
temperature.
6. Check the drop box lubrication pump and the

hydraulic line connections for leaks and tighten them if
required.
7. Remove all blocking from the road wheels and place

the steering lock bar in the 'Stowed' position.
8. Check the dropbox pressures at TP1, TP2 and TP3

in accordance with the instructions in Section 125-
* * * *
4 SM2587 Rev1 01-10

DROPBOX - Dropbox Pressure Filter
Section 125-0045
SM3574
T
OU
3
IN
2 1
1- Filter Body
2- Filter Element
3- Clogging Indicator
4- Bracket
5- Bolt
6- Washer
7- O-ring
8- Filter Housing
Fig. 1 - Dropbox Oil Pressure Filter
DESCRIPTION
Numbers in parentheses refer to Figure 2. A visual clogging indicator (3) is fitted to the filter, and
this will begin to indicate that the filter element is
The dropbox presssure filter assembly is installed in getting clogged at a differential pressure of 5 bar (72.5
the discharge line from the dropbox pump, and is lbf/in2).
provided to remove solid contaminants from the
dropbox oil, to minimize wear, and thus contribute to Oil is drawn from the dropbox sump by the dropbox pump,
maximum service life for the dropbox. The filter which is mounted on the rear end of the rear main hydraulic
assembly is bolted to a bracket adjacent to the brake pump, and is supplied to the inlet side of filter housing (8)
accumulators, on the left-hand rear frame. where the oil will then take one of two paths:
A by-pass valve in the filter housing (8) ensures an a. If the oil is cold and thick, or element (2) is
adequate flow of oil to the dropbox if the element (2) clogged, oil pressure increases and opens the by-
becomes clogged, and cannot pass oil through pass valve allowing the oil to by-pass the filter
adequately enough to satisfy demand. The by-pass element and flow through the filter housing (8) and
valve opens at a differential pressure of 8 bar (116 lbf/ exit at the outlet port to the dropbox.
in²).
SM 2571 01-10 1
Dropbox - Dropbox Pressure Filter
Section 125-0045
b. If the oil is warm and the element (2) is not
1. Position the vehicle in a level work area. Apply the
clogged, oil will flow through the element (3) before
parking brake and switch off the engine. Turn the
returning to the dropbox.
steering wheel in both directions several times to
relieve the pressure in the steering system.
A two-stage temperature switche is fitted to the
dropbox control valve block and differential lock front
2. Operate the treadle valve continuously to discharge
cover (connection SW6, Figure 2) or to a tee
the brake accumulators. Block all road wheels.
connection on the outlet from the dropbox pressure
filter, starts the cooler fan when the oil temperature
rises to 60°C, and illuminates a Warning indicator on
the VDU when the oil temperature reaches 120°C.
TP2 SM3393
(12)
B
(13)
P1 GS1
(17) (4) GS2
(14)
(1)
T1
(18)
A
(15)
TP1 DL
(11) (22)
(5) TP3
(2) (7) OC1
(20)
(21)
(9)
SW5
(6) (8)
SW6 OC2
(10) (3)
SHAFT
LUBRICATION
(16)
P2
(19)
FROM
DROPBOX
PUMP
Fig. 2 - Dropbox Control Valve Circuit
3. Tag the filter inlet and outlet hoses, to aid in
installation, then disconnect them from the filter
REMOVAL housing (8). Cap the open hose ends and the housing
Numbers in parentheses refer to Figure 1, unless ports to prevent the ingress of contaminants.
4. Support the filter assembly, then remove the bolts
Note: If the filter element (3) only is being replaced, (5) and washers (6) securing the filter assembly to the
disassemble the filter assembly and replace the mounting bracket. Remove the filter assembly to a
element (3) as described under 'Changing Filter prepared area and drain the oil from the assembly into
Element'. It is not necessary to remove the entire filter a suitable container.
assembly to renew the filter element.
INSTALLATION
WARNING Numbers in parentheses refer to Figure 1, unless
To prevent personal injury and property otherwise specified.
damage, be sure wheel blocks are properly Note: Tighten all fasteners to standard torques listed in
secured and of adequate capacity to do the job Section 300-0080, Standard Bolt and Nut Torque
safely. Specifications.
2 SM 2571 01-10
Section 125-0045
Note: Tighten all hydraulic lines fitted with ORFS remove the body (1) complete with the O-ring (7) and
connections, as described in Section 220-0000, the element (2). Discard the element (2).
Steering System Schematic. Renew all O-rings where
used. 4. Remove and discard the O-ring (7) from the filter body
(1).
1. Position the filter assembly on the mounting bracket
and secure it with the bolts (5) and washers (6) retained 5. Clean the filter body (1) with solvent and dry it with a
at Removal. Take care to mount the filter assembly in clean, lint free cloth. Lubricate a new 'O' ring (7) and
the correct orientation, with the clogging indicator install it on the filter body (1). Lubricate the threads of
outermost. the filter body (1).
2. Remove the blanking caps from the inlet and outlet Note: Each new filter element is supplied complete
hoses, and from the inlet and outlet ports on the filter with a replacement O-ring for the filter body.
housing (8), all as tagged on Removal.
6. Install the new element (2) in the filter body (1). Fill
3. Start the engine and check for leaks. Tighten the the filter body with a charge of new oil, taking care to
hose fittings as required. keep it in a vertical attitude to avoid spillage.
4. Check the dropbox oil level and add oil if required. 7. Introduce the filter body (1), complete with the O-ring
Refer to Section 125-0010, Dropbox and Mounting for (7) and the element (2), to the filter housing (8).
the correct fill level and Section 300-0020, Lubrication
System, for the oil specification. 8. Start the engine and check for leaks. Tighten lines,
fittings and filter locking collar as required.
5. Ensure that the parking brake is applied. Remove
the wheel blocks from all road wheels. 9. Check transmission oil level and add oil if required.
Refer to Section 125-0010, Dropbox and Mounting for
correct fill level and Section 300-0020, Lubrication
CHANGING FILTER ELEMENT System for oil specification.
10. Ensure that the parking brake is applied. Remove
Change the filter element (2) at intervals specified in the wheel blocks from all road wheels.
Section 300-0020, Lubrication System. The element (2)
should also be changed whenever a dropbox overhaul
is performed, or other internal servicing is carried out. SPECIAL TOOLS
WARNING Service Tools, for part numbers of general service
To prevent personal injury and property tools required. These tools are available from your
damage, be sure wheel blocks are properly dealer.
safely.
1. Position the vehicle in a level work area. Apply the

parking brake and switch off the engine. Turn steering
wheel in both directions several times to relieve
pressure in the steering system.

the brake accumulators. Block all road wheels.
3. With a suitable container under the filter assembly to

catch draining oil, unscrew the filter body (1) and
* * * *
SM 2571 01-10 3
Section 125-0045
4 SM 2571 01-10
DROPBOX - Suction Filter
Section 125-0050
SM 3633
10 7
9
8 5
6
4
1- Filter Housing OUT

2- Element
IN
3- Indicator Gauge 3
4- Mounting Bracket
1
5- Bolt
6- Lockwasher
7- Mounting Plate
8- Bolt
9- Washer
10 - Nut
2
Fig. 1 - Suction Filter and Mounting
DESCRIPTION The pressure drop across the filter is minimal when

Numbers in parentheses refer to Figure 1. element (2) is clean. Contaminants (dirt) build up
across the element (2) as the dropbox sump oil passes
The dropbox suction filter is mounted on a bracket on through the filter. The pressure drop across the filter
the horizontal transverse frame member immediately increases, as dirt build up increases, and is applied to
forward of the dropbox. It is connected in the line an integral by-pass valve.The by-pass valve is
between the dropbox sump and the dropbox lubrication mechanically linked to the indicator gauge (3).
pump suction. The dropbox pump is shaft-mounted on
one end of the main hydraulic pump. Movement of the piston in the by-pass valve is
reflected on the indicator gauge (3). As dirt build up
The main components of the steering filter are; housing increases, the pointer of the indicator gauge (3) will
(1), spin-on element (2), and indicator gauge (3). The move from the green area into the yellow area on the
housing deatures a single inlet port and a single outlet indicator gauge (3). The element (2) should be changed
port immediately when the pointer registers in the yellow
'Needs Cleaning' area.
OPERATION Note: The internal by-pass valve is still not open at this
Numbers in parentheses refer to Figure 1. point.
The dropbox oil pump draws oil from the dropbox sump The internal by-pass valve starts to open when the
and it passes through the suction filter before entering pointer passes from the yellow area into the red area
the dropbox pump suction. The dropbox pump on the indicator gauge (3), which will occur at a
discharges the pressurized oil through a discharge differential pressure of approximately 0.25 bar across
filter, described separately in Section 125-0045, the element. If the indicator gauge (3) is in the red 'By-
Dropbox Discharge Filter. pass' area, the by-pass valve is open and this allows a
SM 2568 01-10 1
Dropbox - Suction Filter
Section 125-0050
relieve any pressure in accumulator and steering
certain amount of hydraulic oil to by-pass the clogged system. Block all road wheels.
element (2).
3. Remove the hydraulic lines at the inlet port and
outlet port, and drain the entrained oil into a suitable
WARNING container. Plug all exposed pipework connections to
Operating the machine with a clogged dropbox prevent the ingress of contaminants.
suction filter can lead to failure of the dropbox
pump and ultimately a catastrophic failure of the 4. Drain the hydraulic oil from the filter assembly into a
dropbox. Regular checking of the indicator suitable container by unscrewing the spin-on filter
gauge is vital to protect the equipment. element (2) from the housing (1). Remove the spin-on
filter element and dispose of it in accordance with local
regulations.
MAINTENANCE 5. Clean the housing (1) thoroughly with a suitable

Numbers in parentheses refer to Figure 1. solvent, prior to installation of a new spin-on filter
element (2).
The dropbox suction filter indicator gauge (3) should be
checked daily. The element (2) should be changed 6. Screw a new spin-on filter element (2) into the
immediately when the pointer registers in the yellow housing (1).
area, or every 1 000 hours, whichever occurs first.
7. Connect the inlet and outlet lines to the dropbox
suction filter.
Changing Filter Element
Numbers in parentheses refer to Fig. 1. 8. Remove wheel blocks and disconnect the shipping
bar and place it in the stowed position. Start the
Note: Tighten all hydraulic lines fitted with ORFS engine, check for correct dropbox operation in both
connections, as described in Section 220-0000, high and low ratios and check for leaks. Tighten all
STEERING SYSTEM SCHEMATIC. Renew all lines and fittings, as required.
O-rings where used.
WARNINGS
Dangerous pressure. Turn steering wheel several
times in each direction to relieve pressure in the
system. Failure to release pressure as stated can
result in personal injury and property damage.

damage, be sure wheel blocks are properly
safely.

2. Turn steering wheel in both directions several times to
* * * *
2 SM 2568 01-10
DRIVELINES - Front Drivelines
Section 130-0010
SM - 3943
10
12,13,14
11
15
17 9
16
DROPBOX
1
9
78
6
8
7 17
4
TRAILER
2
TRANSMISSION
FRONT AXLE
3
5
1 - Driveline Assembly 5 - Capscrew 9 - Bolt 13 - Washer

2 - Driveline Assembly 6 - X-member 10 - Anti-Flail Guard 14 - Bolt
3 - Driveline Assembly 7 - Locknut 11 - Support Plate 15 - Bolt
4 - Bolt 8 - Washer 12 - Locknut 16 - Washer
17 - Spacer
Fig. 1 - Front Drivelines and Mounting
DESCRIPTION
Numbers in parentheses refer to Fig. 1. compression loads from causing serious damage to the
components.
The function of the driveline is to transmit rotating
power from one point to another in a smooth and Note: Extra care should be taken when handling the
continuous action while allowing a degree of movement drivelines since chips, dents, burrs or deformity on any
or misalignment of the components it connects. rotating mass creates vibration and excessive wear
during any operation.
The drivelines must operate through constantly
changing relative angles between the components they There are three driveline assemblies installed between
are mounted to and must also be capable of changing various components in the tractor frame as follows:
length while transmitting torque.
Driveline assembly (1) is connected between the
A typical driveline consists of universal joints which transmission final drive and dropbox input drive.
allow some misalignment and permit the driveline to
pivot in any direction, and, a light rigid hollow slip yoke Driveline assembly (2) is connected between the front
and splined shaft assembly forming a slip joint. axle drive flange and dropbox final drive.
The slip joint accommodates length variations Driveline assembly (3) connects the rear final drive of
generated during operation, preventing tension or the dropbox to the articulation and oscillation pivot.
SM 2588 01-10 1
Drivelines - Front Drivelines
Section 130-0010
REMOVAL from its mating components with a soft faced hammer.

Note: Access to driveline assemblies (2 & 3) can be
obtained from underneath the vehicle.
Note: Extra care should be taken when handling
drivelines since carelessness can result in premature
8. Match mark universal joints and their mating
failure of the components. Chips, dents, burrs, or any
surfaces to ensure correct mating alignment when
other deformity of universal joints will prevent accurate
installing driveline assemblies (2 & 3).
mating. This will cause misalignment which is
accompanied by vibration and excessive wear.
9. Support driveline (3) with suitable lifting equipment
and remove capscrews (5) securing universal joints
WARNINGS to their mating components and remove driveline
To prevent personal injury and property assembly (2). If necessary tap driveline assembly (2)
damage, be sure wheel chocks, blocking from its mating components with a soft faced hammer.
materials and lifting equipment are properly
secured and of adequate capacity to do the job 10. Support driveline (7) with suitable lifting equipment
safely. and remove Bolts (4) securing Universal joints (8) to
their mating components and remove driveline
To prevent serious injury or death, DO assembly (3). If necessary tap driveline assembly (3)
NOT go under the vehicle when the engine is from its mating components with a soft faced hammer.
running. Rotating shafts can be dangerous. You
can snag clothes, skin, hair, hands, etc.. DISASSEMBLY
1. Position the vehicle in a level work area, apply the Universal Joint
parking brake and switch off the engine. Depress the
brake pedal continuously to relieve any pressure in the Numbers in parentheses refer to Fig. 1.
braking circuit. Turn the steering wheel several times to
relieve any pressure in the steering circuit. 1. Place the yoke end of driveline assembly (1) in a soft
jawed vice, clamping on the tube of shaft.
switch in the off position. Note: Do not distort the tube with excessive grip.
3. Remove mounting hardware securing insulation 2. Remove screws (5) and universal joint from driveline
quilts under the fenders to allow access to driveline assembly (1).
assembly (1). Remove insulation quilts.
3. Place the shaft end of driveline assembly (1) in a
Note: Access to driveline assembly (1) can be soft jawed vice.
obtained from underneath the vehicle.
4. Remove screws (5) and universal joint from driveline
4. Remove Locknuts (12), washers (13 ) and bolts (14), assembly (1).
securing Support plate (11) to anti-flail guard (10).
Remove support plate (11). 5. Repeat steps 1 to 4 for drivelines (2 & 3).
5. Remove bolt (15) and washer (16) securing anti-flail INSPECTION

guard (10) to cross-member (6). Remove anti flail guard
1. Clean all metal parts in a suitable solvent, and dry all
(10) clear of driveline assembly (1).
parts with compressed air.
surfaces to ensure correct mating alignment when 2. Inspect splines of shaft and yoke for nicks, burrs and
installing driveline assembly (1). excessive wear. Replace if wear is excessive or splines
are nicked. Burrs may be removed with a fine file or
medium India stone.
7. Support driveline (1) with suitable lifting equipment
and remove bolts (4) securing universal joints
3. Check the surfaces of the components that universal
to their mating components and remove driveline
joints mate against for parallelism. Refer to Fig. 2.
assembly (1). If necessary tap driveline assembly (1)
2 SM 2588 01-10
Section 130-0010
SM - 088 INSTALLATION
APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
specified to standard torques listed in Section
STRAIGHT EDGE
SPECIFICATIONS.

REMOVE ALL other deformity of universal joints will prevent accurate
BURRS AND mating. This will cause misalignment which is
PAINT FROM accompanied by vibration and excessive wear.
THESE SURFACES
WARNINGS
Fig. 2 - Checking Parallelism damage, be sure wheel chocks, blocking
4. Check condition of mounting capscrews and replace safely.
if required.
To prevent serious injury or death, DO
5. Check that anti-flail guard (10), support plate (11) NOT go under the vehicle when the engine is
and cross-member (6) are not damaged prior to running. Rotating shafts can be dangerous. You
assembly. can snag clothes, skin, hair, hands, etc..
ASSEMBLY
1. If removed at disassembly stage. Secure cross-
Universal Joint member (6) to chassis frame, using bolts (9), washers
(8), spacers (17) and locknuts (7). Tighten bolts to a
Numbers in parentheses refer to Fig. 1. torque of 921 Nm (680 Ibf ft).
1. Place the yoke end of driveline assembly (1) in a 2. Position driveline assembly (3) on the vehicle as
soft jawed vice, clamping on the tube of shaft. shown in Fig. 1 and align match marks on universal
joints with those on their mating surfaces.
Note: Do not distort the tube with excessive grip.
3. Apply Loctite 638 to the threads of bolts (4). Secure
2. Install universal joint to yoke end of driveline universal joints to their mating surfaces with bolts (4).
assembly (1) and secure with Bolts (4). Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
3. Place the shaft end of driveline assembly (1) in a soft 4. Position driveline assembly (2) on the vehicle as
jawed vice. shown in Fig. 1 and align match marks on universal
4. Install universal joint to shaft end of driveline
assembly (1) and secure with Bolts (4). 5. Apply Loctite 638 to the threads of bolts (4). Secure
universal joints to their mating surfaces with bolts (4).
5. Repeat steps 1 to 4 for drivelines (2 & 3). Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
6. Position driveline assembly (1) on the vehicle as

shown in Fig. 1 and align match marks on universal
SM 2588 01-10 3
Section 130-0010
7. Apply Loctite 638 to the threads of bolts (4). Secure Every 2 000 Hours: Check drivelines for leaks and
universal joints to their mating surfaces with bolts (4). damage, and replace if required.
Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
8. Locate anti-flail guard (10) over cross-member (6) Periodic Inspection

mating holes. Secure anti-flail guard (10) in place using Use a small pry bar to check the companion flange
bolts (15) and washers (16).Tighten bolts (15) to a yokes for looseness. If loose, drop one end of the
torque of 185 Nm (136 Ibf ft). driveline and twist the yoke to check the backlash
between the splines and yokes. Replace any yoke that
9. Secure support plate (11) to anti-flail guard (10) using does not fit snugly.
bolts (14), washers (13) and locknuts(12).
With the pry bar, check the universal joints for play. If
10. Secure insulation quilts under fenders and on to loose, replace the universal joints. Check the splines
mounting brackets with hardware removed during at the slip joint and replace the yoke if excessively
removal. worn.
11. Ensure the parking brake is applied and remove

wheel chocks from all road wheels. SPECIAL TOOLS
MAINTENANCE SERVICE TOOLS, for part numbers of general service
Universal Joints adhesives are available from your dealer.
Every 500 Hours: Check the universal joints for wear
and replace if required.
DRIVELINE DIAGNOSIS CHART

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

TORQUE
1 4 Bolt 153 113
1 9 Bolt 921 680
1 15 Bolt 185 136
* * * *
4 SM 2588 01-10
DRIVELINES - Rear Drivelines
Section 130-0020
SM - 2944
2,3
2,3 5,6 4 5,6
CENTRE AXLE REAR AXLE
1 - Driveline Assembly 3 - Capscrew 5 - U - Joint 7 - Capscrew

2 - U - Joint 4 - Driveline Assembly 6 - Bolt 8 - Bolt
Fig. 1 - Rear Drivelines and Mounting
DESCRIPTION centre and rear axles to the drive supplied from the
transmission, through the pivot drive arrangement, as
follows:
The function of the driveline is to transmit rotating
Driveline assembly (1) is connected between the
power from one point to another in a smooth and
articulation and oscillation pivot and the centre axle.
continuous action while allowing a degree of
movement or misalignment of the components it
Driveline assembly (4) is connected between the centre
connects.
axle and the rear axle.
The drivelines must operate through constantly
changing relative angles between the components REMOVAL
they are mounted to and must also be capable of
Numbers in parentheses refer to Fig. 1, unless
changing length while transmitting torque.
A typical driveline consists of universal joints which
allow some misalignment and permit the driveline to
pivot in any direction, and, a light rigid hollow slip yoke
and splined shaft assembly forming a slip joint.
other deformity of universal joints will prevent accurate
mating. This will cause misalignment which is
The slip joint accommodates length variations
accompanied by vibration and excessive wear.
generated during operation, preventing tension or
compression loads from causing serious damage to
the components.
WARNINGS
Note: Extra care should be taken when handling the
drivelines since chips, dents, burrs or deformity on any
rotating mass creates vibration and excessive wear
during any operation.
safely.
There are two driveline assemblies connecting the
SM 2589 01-10 1
Drivelines - Rear Drivelines
Section 130-0020
3. Place the shaft end of driveline assembly (1) in a
To prevent serious injury or death, DO soft jawed vice.
NOT go under the vehicle when the engine is 4. Remove screws (3) and universal joint from driveline
running. Rotating shafts can be dangerous. You assembly (1).
can snag clothes, skin, hair, hands, etc..
5. Repeat steps 1 to 4 for driveline (4).
Disconnecting or removing any of the
rear drivelines will make the parking brake INSPECTION
ineffective.
1. Clean all metal parts in a suitable solvent, and dry
1. Position the vehicle in a level work area, apply the all parts with compressed air.
parking brake and switch off the engine. Depress the
brake pedal continuously to relieve any pressure in the 2. Inspect splines of shaft and yoke for nicks, burrs
braking circuit. Turn the steering wheel several times to and excessive wear. Replace if wear is excessive or
relieve any pressure in the steering circuit. splines are nicked. Burrs may be removed with a fine
file or medium India stone.
switch in the off position. 3. Check the surfaces of the components that universal
joints mate against for parallelism. Refer to Fig. 2.
Note: Access to driveline assemblies (1 & 4) can be
obtained from underneath the vehicle. 4. Check condition of mounting capscrews and replace
if required.
surfaces to ensure correct mating alignment when ASSEMBLY
installing driveline assembly (1).
Universal Joint
4. Remove capscrews (3) and bolts (8) securing
universal joints (2) to their mating components and Numbers in parentheses refer to Fig. 1.
remove driveline assembly (1). If necessary tap driveline
assembly (1) from its mating components with a soft 1. Place the yoke end of driveline assembly (1) in a
faced hammer. soft jawed vice, clamping on the tube of shaft.
5. Match mark universal joints and their mating Note: Do not distort the tube with excessive grip.
surfaces to ensure correct mating alignment when
installing driveline assembly (4). 2. Install universal joint to yoke end of driveline
assembly (1) and secure with screws (3) and bolts (8).
6. Remove capscrews (7) and bolts (6) securing
universal joints (5) to their mating components and 3. Place the shaft end of driveline assembly (1) in a
remove driveline assembly (4). If necessary tap driveline soft jawed vice.
assembly (4) from its mating components with a soft
faced hammer. 4. Install universal joint to shaft end of driveline
assembly (1) and secure with screws (3) and bolts (8).
DISASSEMBLY 5. Repeat steps 1 to 4 for driveline (4).
Universal Joint
INSTALLATION
1. Place the yoke end of driveline assembly (1) in a otherwise specified.
soft jawed vice, clamping on the tube of shaft.
Note: Do not distort the tube with excessive grip. specified to standard torques listed in Section
2. Remove screws (3) and universal joint from driveline SPECIFICATIONS.
assembly (1).
2 SM 2589 01-10
Section 130-0020
SM - 088 shown in Fig. 1 and align match marks on universal

APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
4. Apply Loctite 648 to the threads of capscrews (7).
Secure universal joints (5) to their mating surfaces with
capscrews (7) and bolts (6). Tighten capscrews (7) to a
STRAIGHT EDGE torque of 153 Nm (112 lbf ft).
5. Ensure the parking brake is applied and remove

wheel blocks from all road wheels.
REMOVE ALL MAINTENANCE

BURRS AND
PAINT FROM
THESE SURFACES
Universal Joints
Every 500 Hours: Check the universal joints for wear
and replace if required.
Every 2 000 Hours: Check drivelines for leaks and

Fig. 2 - Checking Parallelism damage, and replace if required.

failure of the components. Chips, dents, burrs, or any Periodic Inspection
other deformity of universal joints will prevent accurate Use a small pry bar to check the companion flange
mating. This will cause misalignment which is yokes for looseness. If loose, drop one end of the
accompanied by vibration and excessive wear. driveline and twist the yoke to check the backlash
between the splines and yokes. Replace any yoke that
does not fit snugly.
WARNINGS
To prevent personal injury and property With the pry bar, check the universal joints for play. If
damage, be sure wheel blocks, blocking loose, replace the universal joints. Check the splines at
materials and lifting equipment are properly the slip joint and replace the yoke if excessively worn.
safely.
SPECIAL TOOLS
To prevent serious injury or death, DO There are no special tools required for procedures
NOT go under the vehicle when the engine is outlined in this section. Refer to Section 300-0070,
running. Rotating shafts can be dangerous. SERVICE TOOLS, for part numbers of general service
You can snag clothes, skin, hair, hands, etc.. tools and adhesives required. These tools and
Disconnecting or removing any of the
rear drivelines will make the parking brake
ineffective.

shown in Fig. 1 and align match marks on universal
2. Apply Loctite 648 to the threads of capscrews (3).

Secure universal joints (2) to their mating surfaces with
capscrews (3). Tighten capscrews (3) to a torque of 153
Nm (112 lbf ft).
SM 2589 01-10 3
Section 130-0020
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 3 Capscrew 153 113
* * * *
4 SM 2589 01-10
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 differential housings (2 & 31)
Lock when moving or when the wheels are spinning. and layshaft housing (3) with suitable lifting equipment.
Remove bolts securing differential housing (2) to axle
casing and carefully remove differential assembly clear
REMOVAL AND INSTALLATION of axle casing.
INSTALLATION
Installation is the reversal of the 'Removal' procedure.
WARNING
To prevent personal injury and property Note: Use sealing compound (Loctite 574) between the
damage, be sure wheel blocks, blocking axle housing and differential housing mounting faces.
secured and of adequate capacity to do the job Tighten bolts securing differential assembly to axle
safely. casing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure the Note: Tighten all fasteners to standard torques listed in
body in the partially raised position. Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
2. Apply the parking brake and switch off the engine.
Fill the layshaft housing (3) and the differential housing
3. Block all road wheels, place the steering lock bar in (31) with 1.5 litres (0.4 US gallon) of gear oil of the type
the 'Locked' position and the battery master switch in specified in Section 300-0020, LUBRICATION
the 'Off' position. SYSTEM, through the differential filler/level hole. Fill the
axle casing with gear oil of the type specified in Section
4. Drain the gear oil out of the axle housing and both 300-0020, LUBRICATION SYSTEM, through the
planetaries into a suitable container. differential filler/level hole until the oil is level with the
bottom of the filler/level hole. Fill the planetary
5. Remove the planetary assemblies and axle shafts assemblies up to the 'Oil Level Check Line'. Check oil
from the axle housing. Note from which side the long levels after a few minutes to ensure level remains
constant.
SM 2590 01-10 1
Section 150-0020
SM - 3022
2 9
8
28,29
19
18
92
17 91
1 90
20 89
88
96
87
93
80 3
83 75
79 74 26
78 77 23
76 27
40 71
69 73
72 4,5
6,7
68 30 98
24 63
86 10
73 25 16
71 70 97 84 85 15
82
81 96
65
34
33
35,36
64
22
31 32 21
62
60 12
37 14
67 59 13
66 43
60 42
41
45 42
11 44 43
38
39 37
94
95
61 42
43
Fig. 1 - Exploded View Of Centre Differential
2 SM 2590 01-10
Section 150-0020
SM - 3023
53 53
55
51
53
50
56
49
48
49
48
54
47
52 58
A
B
52
57
54
48
49
48
49
50
51
Fig. 2 - Exploded View of Limited Slip Cross-axle Differential
LEGEND FOR FIGS. 1 & 2.

1 - Adjusting Nut 26 - Spacer Ring 51 - Side Gear 76 - Spring
2 - Differential Housing 27 - Slotted Nut 52 - Thrust Washer 77 - Centering Ring
3 - Layshaft Housing 28 - Bolt 53 - Pinion Gear 78 - Cylinder
4 - Plug 29 - Bolt 54 - Thrust Washer 79 - Bolt
5 - 'O' Ring 30 - Slotted Pin 55 - Differential Axle 80 - Filter Element
6 - Plug 31 - Differential Housing 56 - Bolt 81 - Adjusting Bolt
7 - 'O' Ring 32 - Slotted Pin 57 - Housing Cover 82 - Nut
8 - Plate 33 - Plug 58 - Capscrew 83 - Disc
9 - Pin 34 - 'O' Ring 59 - Bearing 84 - Contact Pin
10 - Bushing 35 - Plug 60 - Shim 85 - Seal Ring
11 - Capscrew 36 - 'O' Ring 61 - Shaft Seal 86 - Contact Switch
12 - Bearing 37 - Differential Case Half 62 - Flange 87 - Drive Shaft Flange
13 - Bush Spacer 38 - Thrust Washer 63 - Bolt 88 - Flange
14 - Adjusting Ring 39 - Pin 64 - Bolt 89 - Shaft Seal
15 - Bearing 40 - Quill Shaft 65 - Bolt 90 - Bearing
16 - Shim 41 - Side Gear 66 - Washer 91 - Shim
17 - Bearing 42 - Pinion Gear 67 - Slotted Nut 92 - Retaining Ring
18 - Bearing 43 - Thrust Washer 68 - Sliding Dog 93 - Bolt
19 - Adjusting Nut 44 - Spider 69 - Shifter Fork Assembly 94 - Drive Flange
20 - Slotted Pin 45 - Flange 70 - Thrust Block 95 - Dust Cap
21 - Washer 46 - Ring Gear 71 - Shifter Fork Lock Pin 96 - Pinion Gear
22 - Slotted Nut 47 - Differential Housing 72 - Bolt 97 - Spur Gear
23 - Bearing 48 - Externally Splined Disc 73 - Seal 98 - Spur Gear
24 - Bearing 49 - Internally Splined Disc 74 - Piston 99 - Shim
25 - Adjusting Ring 50 - Thrust Ring 75 - 'U' Ring
SM 2590 01-10 3
Section 150-0020
DISASSEMBLY SM - 3024
Numbers in parentheses refer to Figs. 1 & 2.
WARNING
safely.
Note: The following removal procedure assumes the

Fig. 3 - Removing Drive Shaft Flange
complete axle assembly was removed from the
vehicle.
SM - 3025
1. Ensure oil is drained from planetaries, axle casing,

differential housings (2 & 31) and layshaft housing (3).
2. Remove bolts (93) securing flange (88) to axle

casing. Using special tools (15271101 Back-up Tool
and 15500905 Extractor) remove drive shaft flange (87)
as shown in Fig. 3.
3. Remove retaining ring (92) and shim (91) from drive

shaft flange (87). Press off flange (88) and bearing (90)
from drive shaft flange (87).
Fig. 4 - Removing Differential Assembly
4. Press shaft seal (89) out of flange (88).
SM - 2951
5. Remove both planetary assemblies and axle shafts
by following the procedure in Section 160-0030, AXLE
GROUP (HUB). Using suitable lifting equipment,
support differential assembly. If not done already,
remove nuts and bolts and remove the differential
assembly from the axle casing as shown in Fig. 4.
6. Loosen ring gear bolts (56) as shown in Fig. 5.
Fig. 5 - Removing Ring Gear Bolts
7. Remove slotted pins (20) before loosening adjusting SM - 2952

nuts (1 & 19) as shown in Fig. 6.
Fig. 6 - Removing Adjusting Nuts
4 SM 2590 01-10
Section 150-0020
SM - 2953 8. Using special tool (15269899 220V Hot Air Blower or

15269900 110V Hot Air Blower) heat the area around
the threaded holes and loosen bolts securing bearing
caps. Remove bearing caps.
Fig. 7 - Removing Bearing Caps
SM - 858 9. Lift the differential assembly out of differential

housing (2) with the special tool (15269929 Lifting
Pliers) as shown in Fig. 8.
Fig. 8 - Removing Differential
SM - 2954 10. Remove both bearings (17 & 18) inner rings using
special tools (15272560 Puller, 15500887 Gripping
Insert, 15500888 Gripping Insert and 15500889
Reducer) as shown in Fig. 9.
Fig. 9 - Removing Bearing Inner Rings
SM - 2955 11. Remove capscrews (58) and separate housing (47)

from cover (57). Remove single components as shown
in Fig. 10.
Fig. 10 - Differential Components
SM 2590 01-10 5
Section 150-0020
12. Using suitable lifting equipment, remove bolts (28 & SM - 3026
29) and separate layshaft housing (3) and differential
housing (31) from differential housing (2) as shown in
Fig. 11.
Fig. 11 - Separating Differential
13. Using special tool (15269899 220V Hot Air Blower SM - 3027
or 15269900 110V Hot Air Blower) heat the slotted nut
(67) to around 120 oC before loosening using special
tools (15500890 Socket and 15270120 Clamping Yoke)
as shown in Fig. 12. Do not remove nut (67) at this
point.
Fig. 12 - Loosening Nut
14. Remove bolts (65) and using suitable lifting SM - 3028
equipment, separate the inter-axle differential with

flanges (45 & 62) from housing (31) as shown in Fig.
13.
Fig. 13 - Separating Housing
15. Remove slotted nut (67), washer (66) and drive SM - 3029
flange (94). Press the inter-axle differential out of

flanges (45 & 62) as shown in Fig. 14.
Fig. 14 - Pressing Differential
6 SM 2590 01-10
Section 150-0020
SM - 3030 16. Separate flanges (45 & 62) and press out bearing (59).
Shims (60 & 99) should also be removed at this stage.
17. Pull off bearing inner race from differential case (37)
using special tool (15500906 Puller) as shown in Fig. 15.
Fig. 15 - Removing Bearing
SM - 3031 18. Remove capscrews (11) and separate inter-axle

differential as shown in Fig. 16.
Fig. 16 - Inter-axle Differential
SM - 3032 19. Loosen bolts (79) evenly and separate cylinder (78)
from the housing (31) as shown in Fig. 17.
Fig. 17 - Removing Cylinder
SM - 1111 20. Remove switch (86), seal ring (85) and contact pin
(84) from housing (31) as shown in Fig. 18. Remove
both shifter fork lock pins (71).
Fig. 18 - Removing Contact Switch
SM 2590 01-10 7
Section 150-0020
21. Remove shifter fork assembly (69) and piston (74) SM - 1116
assembly as shown in Fig. 19.
22. Remove adjusting bolt (81) and nut (82) from

housing (31).
Fig. 19 - Removing Shifter Fork And Piston
23. Using special tool (15500907 Fixture) lock quill SM - 3033

shaft (40) as shown in Fig. 20.
24. Using special tool (15269899 220V Hot Air Blower

or 15269900 110V Hot Air Blower) heat slotted nut (27)
to around 120 oC before removing using special tool
(15500908 Socket). Remove fixture installed in Step
23.
Fig. 20 - Locking Shaft
25. Press out quill shaft (40) using special tool SM - 3034
(15269946 Puller Set) as shown in Fig. 21.
Fig. 21 - Pressing Shaft
26. Remove adjusting ring (25) from shaft (40). Support SM - 3035
shaft (40) on sliding dog (68) and press off bearing (24)
inner race as shown in Fig. 22.
Fig. 22 - Pressing Bearing Inner Race
8 SM 2590 01-10
Section 150-0020
SM - 2962 27. Remove bearing (23) inner race and spacer ring (26)
from housing (3) as shown in Fig 23.
Fig. 23 - Removing Bearing Inner Race
SM - 3036 28. Remove bolts (64) securing differential housing (31)

to layshaft housing (3) and separate housings using
suitable lifting equipment as shown in Fig. 24. Remove
spur gear (97).
Fig. 24 - Separating Housings
SM - 3037 29. Using special tool (15269899 220V Hot Air Blower
to around 120 oC before removing using special tool
(15500891 Socket). Block spur gear (98) with wooden
block, as shown in Fig. 25.
Fig. 25 - Removing Slotted Nut
SM - 2965 30. Press pinion gear (96) out of bearing (12) using
special tool (15269946 Puller Set) as shown in Fig. 26.
Remove bearing (12) inner race from housing (3).
Fig. 26 - Pressing Out Pinion Gear
SM 2590 01-10 9
Section 150-0020
31. Pull off the bearing (15) inner race from the pinion SM - 2966
gear (96) using special tools (15500892 Gripping Insert
and 15272560 Bearing Puller).
Fig. 27 - Removing Bearing From Pinion Gear
32. Remove bush spacer (13) and adjusting ring (14) SM - 2967
from layshaft housing (3). Using special tool (15269946
Puller Set) press out bushing (10) as shown in Fig. 28.
33. Press out the bearing (15) outer ring from the
bushing (10) and remove the shim (16).
Fig. 28 - Pressing Out Bushing
INSPECTION SM - 2968
The importance of careful and thorough inspection

cannot be overstressed. Thorough inspection and
necessary replacement of parts now may eliminate
costly and avoidable trouble later.
1. Clean all parts in petroleum base solvent.
2. Immediately after cleaning, dry all parts, except

bearings, with compressed air, or with a soft, clean lint
free wiping cloth. Compressed air has a corrosive
effect on bearings, therefore, they must be wiped dry
with a cloth. Fig. 29 - Pressing Bearing Outer Race in Housing
3. Coat cleaned, dried parts immediately with light oil to SM - 2969
prevent corrosion. If parts are not to be assembled

immediately, treat them with a good rust preventive
and wrap them with treated paper or other suitable
material designed to prevent corrosion.
4. Before installing the differential assembly to the

machine, clean the inside and outside of the axle
housing to remove any foreign material.
5. Inspect all gears, pinions, and splines for cracked or

broken teeth, excessive wear, and pitted or scored
surfaces. Repair or replace as necessary. Fig. 30 - Pressing Bearing Outer Race in Housing
10 SM 2590 01-10
Section 150-0020
SM - 2970 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. 31 - Installing Spur Gear
SM - 2971 ASSEMBLY
Numbers in parentheses refer to Figs. 1 & 2 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. 32 - Installing Bushing
WARNING
SM - 2972 To prevent personal injury and property
safely.
1. Press bearing (12) outer race into housing (3) bore

as shown in Fig. 29.

Fig. 33 - Measuring Dimension 'A' 3. Insert spur gear (98) into housing (3) bore, ensuring
that inner diameter (85 mm) is facing down, as shown
SM - 2973 in Fig. 31.
4. Press the bushing (10) into housing (3) bore and

ensure it is firmly home, as shown in Fig. 32.
5. At this stage in the assembly procedure the

thickness of shim (16) must be determined to ensure
correct contact pattern between pinion gear (96) and
ring gear (46). As shown in Fig. 33, measure
Dimension 'A' from the mounting face of housing (3) to
the locating face of the bearing (15) outer ring, using
special tools (15270113 Gauge Blocks, 15269948
Fig. 34 - Assembling The Measuring Shaft Straight Edge and 15270114 Digital Depth Gauge).
SM 2590 01-10 11
Section 150-0020
Eg. Dimension 'A' = 29.70 mm SM - 2974
6. As shown in Fig. 34, use special tools (15500893

Shims, 15500894 Shims and 15269934 Measuring
Shaft) and place shims into the bores of differential
housing (2) and assemble the measuring shaft.
7. Measure Dimension 'B' from mounting face of

housing (2) to Measuring Shaft (see Fig. 35).
Eg. Dimension 'B' = 196.75 mm
Example: Fig. 35 - Measuring Dimension 'B'

Dimension 'A' 29.70 mm
+ Dimension 'B' 196.75 mm
SM - 868
- Dimension 'C' (1/2 diameter of Measuring
Shaft) 15.00 mm
= Dimension 'X' 241.45 mm
8. Measure thickness of bearing (15) as shown in Fig.

36 using special tools (15270113 Gauge Blocks and
15270114 Digital Depth Gauge). Record as Dimension
'D'.
Eg. Dimension 'D' = 42.70 mm

Fig. 36 - Measuring Bearing Thickness
9. The arrow in Fig. 37 is pointing to a dimension SM - 2975

stamped on the face of pinion gear (96). Record as
Dimension 'E'.
Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm
Example:
Dimension 'D' 42.70 mm
+ Dimension 'E' 197.90 mm
= Dimension 'Y' 240.60 mm
Fig. 37 - Dimension On Pinion Face
10. Calculate shim (16) thickness by subtracting SM - 2976

Dimension 'Y' from Dimension 'X'.
Example:
Dimension 'X' 241.45 mm
- Dimension 'Y' 240.60 mm
= Required thickness 0.85 mm
Install shim (16) of required thickness into the bushing

(10) as shown in Fig. 38.
Fig. 38 - Installing Spacing Washer
12 SM 2590 01-10
Section 150-0020
SM - 2977 11. Freeze bearing (15) outer race and install in
bushing (10), ensuring it is firmly home.
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
Fig. 39 - Installing Bearing Outer Race
SM - 873 12. Heat inner race of bearing (15) to approximately 90°

C (190° F) and press it on to the shaft of pinion gear
(96). Be sure it is firmly seated against the shaft
shoulder as shown in Fig. 40.
WARNING
Fig. 40 - Installing Bearing Inner Race
SM - 2978 13. Install assembled pinion gear (96) in layshaft

housing (3) using special tool (15269946 Puller Set) as
shown in Fig. 41. Do not remove special tool at this
point.
Fig. 41 - Installing Pinion Gear
SM - 2979 14. The adjusting ring (14) is used to obtain the rolling
resistance of the pinion bearing. Rolling resistance
should be 3.5 - 4.0 Nm (2.6 - 2.9 lbf ft). This rolling
resistance is checked once pinion gear (96) is secured
in housing (3) (Step 17).
As shown in Fig. 42, install bush spacer (13) with the

small collar showing up (ref. arrow) into the bore of the
spur gear (98) and install adjusting ring (14).
Fig. 42 - Installing Spacer Bush and Adjusting Ring
SM 2590 01-10 13
Section 150-0020
SM - 2980
15. Heat inner race of bearing (12) to approximately 90°
(96) until it is firmly home as shown in Fig. 43.
WARNING
After bearing (12) inner race has cooled, remove special

tool installed in Step 13.
Fig. 43 - Installing Bearing
16. Coat threads of slotted nut (22) with Loctite 649. SM - 2981
Locate washer (21) and install slotted nut (22). Using
special tool (15500891 Socket) tighten slotted nut (22)
Note: When tightening nut (22), rotate the pinion gear (96)
in both directions several times.
Fig. 44 - Tightening Slotted Nut
17. Check the rolling resistance of the pinion bearing as SM - 2982

shown in Fig. 45 by using special tool (15500895
Torque Spanner). If the rolling resistance is outwith
range (3.5 - 4.0 Nm), adjusting ring (14) thickness must
be changed.
Record this torque as Tpinion e.g. 3.5 Nm.
Fig. 45 - Checking Rolling Resistance
18. Install spur gear (97) in housing (3) as shown in SM - 2983

Fig. 46.
14 SM 2590 01-10
Section 150-0020
SM - 3038 19. Install bearing (24) outer race into bore of differential
housing (31) as shown in Fig. 47.
SM - 3039 20. Apply Loctite 574 to mounting face of layshaft

housing (3). Using suitable lifting equipment, install the
differential housing (31) to layshaft housing (3) as
shown in Fig. 48.
Fig. 48 - Installing Differential Housing
SM - 3040 21. Insert the slotted pin (32) (ref. arrow) and new bolts
(64) as shown in Fig. 49. Torque bolts (64) to 155 Nm
(114 lbf ft).
Fig. 49 - Tightening Bolts
SM - 3041 22. Install sliding dog (68) on quill shaft (40) with the
gearing showing downwards as shown in Fig. 50.
Fig. 50 - Installing Sliding Dog
SM 2590 01-10 15
Section 150-0020
23. Press bearing (24) inner race onto quill shaft (40) SM - 3042
until it is firmly home as shown in Fig. 51.
24. Install adjusting ring (25) in housing (31) before SM - 3043

installing sub assembled quill shaft (40) as shown in
Fig. 52.
Fig. 52 - Installing Shaft
25. Using special tool (15500907 Fixture) lock quill SM - 3033

shaft (40) as shown in Fig. 53.
Fig. 53 - Locking Shaft
26. The spacer ring (26) is used to obtain the rolling SM - 2985
resistance of the shaft (40) bearing. Rolling resistance
resistance (THo) is calculated once shaft (40) is
secured in housing (Step 29). As shown in Fig. 54,
install spacer ring (26) on shaft (40) with the collar
facing down.
Fig. 54 - Installing Spacer
16 SM 2590 01-10
Section 150-0020

C (190° F) and press it on to the shaft (40) until it is
firmly home as shown in Fig. 55.
WARNING
SM - 3044 28. Allow bearing (23) to cool, then coat threads of

slotted nut (27) with Loctite 649. Assemble slotted nut
(27) on shaft (40) and tighten using special tool
(15500908 Socket). Torque slotted nut (27) to 1200 Nm
(885 lbf ft) as shown in Fig. 56.
Note: When tightening nut (27), rotate the shaft (40) in

both directions several times.
SM - 2997 29. Remove special tool (15500908 Fixture) installed at

Step 25. As shown in Fig. 57, check total rolling
resistance of pinion gear (96) and shaft (40) by using
special tool (15500895 Torque Spanner). Record this
torque as Ttot e.g. 4.5 Nm.
Example:
Ttot e.g. 4.5 Nm
Tpinion e.g. - 3.5 Nm
Results in THo = 1.0 Nm
As specified in Step 26, rolling resistance (THo) of shaft

Fig. 57 - Checking Rolling Resistance (40) should be 0.5 - 2.0 Nm. If outwith this range,
spacer ring (26) thickness must be changed.
SM - 3045
X 30. Attach thrust blocks (70) to shifter fork assembly
(69) and install in differential housing (31) as shown in
Fig. 58. Thrust blocks (70) fit into sliding dog (68)
groove.
Note: Shifter fork assembly is not symmetrical, 'X'

denotes short side.
Fig. 58 - Installing Fork Assembly
SM 2590 01-10 17
Section 150-0020
31. Place 'U' section ring (75) on piston (74) with SM - 3046
sealing lip towards outside. Slide spring (76) on the
piston stem. Locate the centering ring (77) in the
recess as denoted by arrow in Fig. 59. Insert the
assembled piston into its bore in differential housing
(31). Be sure the piston stem makes contact with
shifter fork (69).
Fig. 59 - Installing Piston
32. Place new seals (73) on shifter fork lock pins (71). SM - 3047
Position the shifter fork assembly (69) and fix in place
with shifter fork lock pins (71) as shown in Fig. 60.
Secure lock pins (71) with bolts (72) and torque to
45 Nm (33 lbf ft).
Fig. 60 - Installing Lock Pins
33. Apply Loctite 574 to mounting face of cylinder (78) SM - 3048

and secure to differential housing (31) using bolts (79).
Ensure port is at top, as shown in Fig. 61. Tighten bolts
to 23 Nm (17 lbf ft).
Fig. 61 - Installing Cylinder
34. Sub-assemble inter-axle differential by installing SM - 3049

thrust washer (38) in differential case half (37), with
lubrication groove facing up. Secure thrust washer with
pins (39).
Note: Ensure pins do not protrude above contact face

of thrust washer.
Fig. 62 - Installing Thrust Washer
18 SM 2590 01-10
Section 150-0020
SM - 3050 35. Install side gear (41) in differential case half (37).
36. Sub-assemble differential spider (44), pinion gears

(42) and thrust washers (43), ensuring thrust washers
are correctly fitted. Install sub-assembly as shown in
Fig. 63.
Fig. 63 - Installing Spider Assembly
SM - 3051 37. Install differential case half (37) and fasten with
capscrews (11). Tighten capscrews to 115 Nm
(85 lbf ft).
Note: Use part number stamped on differential cage

halves (37) to ensure correct alignment, as shown in
Fig. 64.
ZF-No.:
Fig. 64 - Assembling Differential
SM - 3052 38. Install the pre-assembled inter-axle differential in

differential housing (31).
To meet required differential end float (0.18 - 0.23 mm)

shim (99) dimension should be calculated. Initially
measure Dimension 'A' from the housing (31) mounting
face to inter-axle differential locating face as shown in
Fig. 65.
Eg. Dimension 'A' = 5.00 mm
Measure at several points and determine average

Fig. 65 - Measuring Dimension 'A' dimension.
SM - 3053
39. On flange (45) measure Dimension 'B' from the
mounting face to the locating face as shown in Fig. 66.
Example:
Dimension 'B' 6.70 mm
Dimension 'A' - 5.00 mm
= 1.70 mm
Required End Float + 0.20 mm
Shim (99) Dimension = 1.90 mm
Fig. 66 - Measuring Dimension 'B' Place calculated shim (99) into the flange (45).
SM 2590 01-10 19
Section 150-0020
40. Press bearing (59) into flange (45) until firmly home. SM - 3054
41. Install both bearing (59) inner rings. Place

pre-assembled flange (45) on inter-axle differential and
press until firmly home as shown in Fig. 68.
SM - 3055
or 15269900 110V Hot Air Blower) heat housing (31)
bore and coat mounting face with sealing compound
Loctite 574.
Fig. 68 - Installing Flange to Differential
Note: Carry out following steps (43 - 46) promptly SM - 3056

before sealing compound hardens.
43. Install flange (62) on housing (31) as shown in Fig.

69. Use guide screws if necessary.
Fig. 69 - Installing Flange
44. To remove bearing (59) backlash, initially measure SM - 3057

Dimension 'X' from the bearing (59) face to the flange
(62) mounting face as shown in Fig. 70.
Eg. Dimension 'X' = 10.40 mm
Fig. 70 - Measuring Dimension 'X'
20 SM 2590 01-10
Section 150-0020
SM - 3058 45. Remove flange (62) and measure Dimension 'Y'

from mounting face to bearing contact face as shown in
Fig. 71.
Eg. Dimension 'Y' = 11.10 mm
Example:
Dimension 'Y' 11.10 mm
Dimension 'X' - 10.40 mm
Shim (60) Dimension = 0.70 mm
Place calculated shim (60) into the flange (62).

Fig. 71 - Measuring Dimension 'Y'
46. Again coat mounting face with sealing compound
Loctite 574. Assemble flange (62) complete with shim
SM - 3059
(60) on housing (31) and secure with bolts (65). Tighten
bolts to 155 Nm (114 lbf ft).
47. Using special tool (15500896 Driver) install shaft

seal (61) as shown in Fig. 72.
Note: If seal outer diameter is rubber coated, coat with

spirit. If seal outer diameter is metallic, coat with
Loctite 574.
Fig. 72 - Installing Shaft Seal

48. Press dust cap (95) onto drive flange (94) using
special tools (15500909 Driver and 15270121 Handle).
SM - 3060 49. Install drive flange (94) and secure with washer (66)
and slotted nut (67). Using special tools (15500890
Socket and 15270120 Clamping Yoke) tighten nut to
1 000 Nm (738 lbf ft).
Note: Coat threads of slotted nut (67) with Loctite 649.
Fig. 73 - Installing Drive Flange
50. Set inter-axle differential lock by installing special

SM - 3061
tool (15500910 Compressed Air Connection) and
pressurising piston with compressed air (maximum 10
bar (145 lbf/in2)) as shown in Fig. 74. Ensure differential
lock is engaged by turning the drive flange (94).
51. Coat threads of adjusting bolt (81) with sealing

compound Loctite 574 and hand tighten until bolt
contacts piston (74). Tighten adjusting bolt (81) a
further 1/3 of a turn, and lock with nut (82).
Fig. 74 - Compressing Diff-lock Cylinder
SM 2590 01-10 21
Section 150-0020
52. Install contact pin (84), seal ring (85) and contact SM - 3062
switch (86). Connect special tool (15500911 Indicator)
Fig. 75 - Installing Indicator
53. Pressurise piston with compressed air (maximum SM - 3063

10 bar (145 lbf/in2)) as shown in Fig. 76. Ensure
differential lock is engaged by turning the drive flange
(94). The warning lamp on the Indicator should
illuminate when the sliding dog (68) is fully engaged.
Fig. 76 - Checking Contact Switch
54. Install disc (83) and filter element (80) in bore SM - 3064
arrowed in Fig. 77. Cover port until final installation of
hose.
Fig. 77 - Installing Filter
SM - 3065
55. Coat mounting face of differential housing (2) with
sealing compound Loctite 574. Using suitable lifting
equipment, install pre-assembled layshaft housing on
the differential housing (2). Install new bolts (28 & 29)
and slotted pins (30) in correct locations (arrowed in
Fig. 78). Tighten bolts to 155 Nm (114 lbf ft).
Fig. 78 - Installing Pre-assembled Layshaft Housing
22 SM 2590 01-10
Section 150-0020
SM - 3074
56. Heat ring gear (46) and install it on the differential
housing (47) until it is firmly home as shown in Fig. 79.
WARNING
gloves when handling ring gear.
Fig. 79 - Installing Ring Gear
SM - 2999
57. Prior to assembly, coat components with gear oil

as specified in Section 300-0020, LUBRICATION
SYSTEM. Place both thrust washers (52 & 54) in the
housing (47), installing steel thrust washer (52) first as
shown in Fig. 80.
Fig. 80 - Installing Thrust Washers
SM - 3000
58. Install disc set A (Fig. 2) in housing (47), beginning

with externally splined disc (48) as shown in Fig. 81.
Fig. 81 - Installing Disc Set A
SM - 3001
59. Install thrust ring (50) as shown in Fig. 82.
Fig. 82 - Installing Thrust Ring
SM 2590 01-10 23
Section 150-0020
SM - 3002
60. Install side gear (51) as shown in Fig. 83. Ensure

both internally splined discs (49) of set A are located
on side gear (51).
Fig. 83 - Installing Side Gear
SM - 3003
61. Sub-assemble pinion gears (53) and differential

axles (55). Install sub-assembly as shown in Fig. 84.
Fig. 84 - Installing Differential Pinion Gears
62. Install second side gear (51) as shown in Fig. 85. SM - 3004
63. Install second thrust ring (50) as shown in Fig. 86. SM - 3005
24 SM 2590 01-10
Section 150-0020
SM - 3006 64. Install disc set B (Fig. 2) beginning with internally
splined disc (49) as shown in Fig. 87.
Fig. 87 - Installing Disc Set B
SM - 3007 65. The clearance between the assembled differential

housing and the cover (57) should be 0.2 - 0.6 mm.
Press outer externally splined disc (48) evenly on and
measure Dimension 'A' from the mounting face of
housing (47) to the outer disc (48) as shown on Fig. 88,
using special tool (15270114 Digital Depth Gauge).
Fig. 88 - Measuring Differential Housing Clearance
SM - 3008 66. Measure Dimension 'B' from the contact face to the
mounting face of housing cover (57) using special tool
(15270114 Digital Depth Gauge) as shown in Fig. 89.
67. With reference to Steps 65 - 66, calculate

clearance as shown in the example below.
Example:
Fig. 89 - Measuring Housing Cover Results in clearance 0.30 mm
SM - 3009
If clearance falls outwith specification (0.2 - 0.6 mm),
then thicker or thinner outer externally splined discs
(48) should be installed.
Note: If necessary to change the outer externally

splined discs (48) to obtain correct clearance, these
should be changed so that the overall thickness of disc
sets A and B (Fig. 2) are identical.
Note: If installing new discs, the lower clearance

should be aimed for.
SM 2590 01-10 25
Section 150-0020
68. Place both thrust washers (52 & 54) in the cover SM - 3010
(57), installing steel thrust washer (52) first as shown in

Fig. 90.
69. Secure cover (57) to housing (47) with two

capscrews (58). Torque capscrews to 46 Nm (34 lbf ft).
70. Heat bearings (17 & 18) inner races and install on
assembled differential, as shown in Fig. 91.
WARNING
To prevent personal injury, wear protective Fig. 91 - Installing Bearing Inner Race
SM - 3011
71. Using suitable lifting equipment, position the

assembled differential in the differential housing (2) and
install bearings (17 & 18) outer rings, as shown in
Fig. 92.
55˚
Fig. 92 - Installing Differential
SM - 3012
72. Install adjusting nuts (1 & 19) and locate bearing

caps using bolts and washers as shown in Fig. 93.
Coat thread of bearing cap bolts with Loctite 649.
Torque bolts to 390 Nm (288 lbf ft).
Note: Bearing adjusting nuts (1 & 19) have two basic

functions: preloading the bearings and positioning ring
gear (46) to obtain the correct backlash between it and
pinion gear (96).
Fig. 93 - Installing Bearing Caps
73. Install new bolts (56) in differential assembly and SM - 3013
torque bolts to 390 Nm (288 lbf ft) as shown in Fig. 94.
Fig. 94 - Tightening Differential Bolts
26 SM 2590 01-10
Section 150-0020
SM - 3014 74. Check the backlash between ring gear (46) and
pinion gear (96). Mount special tools (15500897
Magnetic Stands and 15500898 Dial Indicator) at right
angles to the outer diameter of the ring gear tooth flank
as shown in Fig. 95. Establish the backlash by
alternately setting both adjusting nuts (1 & 19). Rock
the ring gear back and forth being careful not to move
the pinion gear. Backlash should be 0.27 - 0.33 mm.
Fig. 95 - Measuring Backlash
SM - 3015 75. Determine the bearing (17 & 18) rolling resistance
and bracket dimension by further tightening of both
adjusting nuts (1 & 19). The bearing rolling resistance
should be 3 - 4 Nm (2.2 - 2.9 lbf ft). Measure bracket
dimension as shown in Fig. 96 using 15500899
Micrometer. Dimension should be 358-0.1 mm.
Fig. 96 - Measuring Bracket Dimension
SM - 891 76. To check the tooth pattern of ring gear (46), coat
about twelve ring gear teeth with prussian blue, oiled
red lead or some other easily removed print or dye.
When the pinion is rotated, the paint is squeezed away
by the contact of the teeth, leaving bare areas the
exact size, shape and location of the contacts as
shown in Fig. 97.
Compare the contact pattern obtained with the Gear

tooth patterns for the Gleason Gear Tooth system
shown on the following pages.
Fig. 97 - Checking Contact Pattern
SM - 3016 77. Fasten adjusting nuts (1 & 19) with slotted pins (20)
Fig. 98 - Installing Slotted Pin
SM 2590 01-10 27
Section 150-0020
78. Install studs in positions shown by arrows in Fig. SM - 3017
99. Apply Loctite 262 to studs and torque to 55 Nm
(40 lbf ft).
Fig. 99 - Installing Studs
79. Apply Loctite 574 to axle casing mounting face. SM - 3018

Using suitable lifting equipment, install differential
assembly in axle casing and secure using new bolts
and nuts. Torque bolts to 375 Nm (277 lbf ft) and nuts
to 280 Nm (206 lbf ft).
80. Install shaft seal (89) into flange (88) using special SM - 3066
tool (15500912 Driver) as shown in Fig. 101.
Note: If seal outer diameter is rubber coated, coat with

spirit. If seal outer diameter is metallic, coat with
Loctite 574.
81. Install flange (88) on drive flange shaft (87). Heat SM - 3067
bearing (90) to approximately 90° C (190° F) and press
it on to the drive flange shaft (87) and locate it on the
collar as shown in Fig. 102.
WARNING
28 SM 2590 01-10
Section 150-0020
SM - 3068 Install shim (91) and retaining ring (92) to secure
bearing on shaft.

or 15269900 110V Hot Air Blower) heat axle housing
bore and coat mounting face with sealing compound
Loctite 574.
83. Install pre-assembled flange shaft (87) and secure

with bolts (93). Tighten bolts to 23 Nm (17 lbf ft) as
shown in Fig. 103.
Fig. 103 - Tightening Bolts Install axle shafts as noted on removal. Refer to
Section 160-0030, AXLE GROUP (HUB).
SM 2590 01-10 29
Section 150-0020
GLEASON GEAR TOOTH SYSTEM SM - 893
Ideal tooth-contact patterns are shown in Figs. 104 & 105

indicating the pinion distance is correct.
If the patterns obtained are the same as that shown in

Figs. 106 & 107 then decrease the pinion distance.
Refer to Fig. 108.

Figs. 109 & 110 then increase the pinion distance.
Refer to Fig. 111.
MAINTENANCE
Proper lubrication of the differential assembly is
essential if the differentials are to deliver the service
intended. Section 300-0020, LUBRICATION SYSTEM Fig. 104 - Coast Side (Concave)
gives full information on the proper lubrication intervals
and the lubricant which should be used.
SM - 894
SPECIAL TOOLS
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
tools and sealants required.
Fig. 105 - Drive Side (Convex)
SM - 895
Fig. 106 - Coast Side (Concave)
30 SM 2590 01-10
Section 150-0020
SM - 896 SM - 899
Fig. 107 - Drive Side (Convex) Fig. 110 - Drive Side (Convex)
SM - 897 SM - 900
Fig. 108 - Pinion Distance Must Be Decreased Fig. 111 - Pinion Distance Must Be Increased
SM - 898
SM 2590 01-10 31
Section 150-0020

TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
1 22 Slotted Nut 1 200 885
1 64 Bolt 155 114
1 27 Slotted Nut 1 200 885
1 72 Bolt 45 33
1 79 Bolt 23 17
1 65 Bolt 155 114
1 67 Slotted Nut 1 000 738
1 28/29 Bolt 155 114
1 58 Capscrew 46 34
- - Bearing Cap Bolt 390 288
1 56 Bolt 390 288
- - Stud 55 40
- - Axle Casing Bolts 375 277
- - Axle Casing Nuts 280 206
1 93 Bolts 23 17
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
32 SM 2590 01-10
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
* * * *
SM 2590 01-10 33
Section 150-0020
34 SM 2590 01-10
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 & 11), externally splined discs (3), internally
splined discs (4), thrust ring (5), side gears (6), pinion
The differential is mounted to the axle housing. The gears (7), differential axle (8) and cover (9).
SM 2591 01-10 1
Section 160-0020
SM - 2949
7 7
8
6
7
5
10
4
3
4
3
11
9
2 12
A
B
2
1
11
3
4
3
4
5
6
1 - Cover 5 - Thrust Ring 9 - Housing

2 - Thrust Washers (Steel) 6 - Side Gears 10 - Bolts
3 - Externally Splined Discs 7 - Pinion Gears 11 - Thrust Washers (Brass)
4 - Internally Splined Discs 8 - Differential Axle 12 - Capscrews
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 (6, 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 2591 01-10
Section 160-0020
REMOVAL 9. Loosen and remove nuts and bolts from the

Numbers in parentheses refer to Fig. 3. differential and axle housings. Thread in three puller
bolts to break the seal between the differential and axle
housings and to partially pull the differential assembly
WARNING out of the axle housing.
damage, be sure wheel blocks, blocking 10. Using suitable lifting equipment, support the weight
materials and lifting equipment are properly of the differential assembly.
safely. Note: When removing the rear differential, weld a loop
to the bottom side of the body above the differential
1. Before attempting to remove the road wheels, drive and attach the lifting device.
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil. 11. Pull out the differential assembly until it clears the
axle housing, then carefully lower it to the floor. Slide
Note: If the rear differential is being removed, raise the the differential assembly out from beneath the vehicle.
body and prop it up with the body prop.
INSTALLATION
Installation is the reversal of the 'Removal' procedure.
3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in Note: Use sealing compound (Loctite 574) between the
the 'Off' position. axle housing and differential housing mounting faces.
4. Drain the gear oil out of the axle housing and both Tighten bolts securing differential assembly to axle
planetaries into a suitable container. housing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
5. Remove the planetary assemblies and axle shafts
from the axle housing. Note from which side the long Note: Tighten all fasteners without specified torques to
and short axle shafts are removed. Refer to Section standard torques listed in Section 300-0080,
160-0030, AXLE GROUP (HUB). STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
6. Identify the relationship of the driveline flange and
differential pinion flange with punch marks. Fill the layshaft housing (3) with 1.5 litres (0.4 US
gallon) of gear oil of the type specified in Section 300-
7. Disconnect the driveline from the differential drive 0020, LUBRICATION SYSTEM, through the differential
flange. The driveline can be removed if it is convenient filler/level hole. Fill the axle casing with gear oil of the
to do so. type specified in Section 300-0020, LUBRICATION
SYSTEM, through the differential filler/level hole until
8. Index mark differential housing (1) and the axle the oil is level with the bottom of the filler/level hole. Fill
housing to ensure that differential housing (1) is the planetary assemblies up to the 'Oil Level Check
installed in the same position. Line'. Check oil levels after a few minutes to ensure
level remains constant.
SM 2591 01-10 3
Section 160-0020
SM - 2950
1 43
42
40,41
10
44
12
10
38
18
19
26
14
20 21
22 32
23 33
24 34
2 25 35
3
27 28
39
29,30
5 36
31
4
6 11 37
15
7 8
16
9 45 17
13
1 - Differential Housing 16 - Bearing 31 - Pin

2 - Slotted Nut 17 - Pinion Gear 32 - Spacer
3 - Washer 18 - Ring Gear 33 - Bearing
4 - Drive Flange 19 - Bolt 34 - Shim Support
5 - Seal Holder 20 - Pin 35 - Retainer
6 - Dust Shield 21 - Slotted Nut 36 - Spur Gear
7 - Shaft Seal 22 - Washer 37 - Bushing
8 - Bearing 23 - Bearing 38 - Slotted Pin
9 - Spacer 24 - Adjusting Ring 39 - Bolt
10 - Adjusting Nut 25 - Spacer Bush 40 - Bolt
11 - Quill Shaft 26 - Layshaft Housing 41 - Bolt
12 - Bearing 27 - Plug 42 - Plate
13 - Spur Gear 28 - 'O' Ring 43 - Pin
14 - Cover 29 - Plug 44 - Bearing
15 - Spacing Washer 30 - 'O' Ring 45 - Slot Pin
Fig. 3 - Exploded View of Rear Differential
4 SM 2591 01-10
Section 160-0020
SM - 3020 DISASSEMBLY
WARNING
safely.
Note: The following removal procedure assumes the

Fig. 4 - Removing Drain Plugs
complete axle assembly was removed from the
vehicle.
SM - 3021
1. Ensure oil is drained from both axle casing and
layshaft housing as shown in Fig. 4.
2. Remove both planetary assemblies and axle shafts

by following the procedure in Section 160-0030, AXLE
GROUP (HUB). Using suitable lifting equipment,
support differential assembly. Remove nuts and bolts
and remove the differential assembly from the axle
casing as shown in Fig. 5.
Fig. 5 - Removing Differential Assembly
SM - 2951 3. Loosen ring gear (18) bolts as shown in Fig. 6.
Fig. 6 - Removing Ring Gear Bolts
SM - 2952 4. Remove slotted pins (38) before loosening adjusting

nuts (10) as shown in Fig. 7.
Fig. 7 - Removing Adjusting Nuts
SM 2591 01-10 5
Section 160-0020
5. Using special tool (15269899 220V Hot Air Blower or SM - 2953
15269900 110V Hot Air Blower) heat the area around
the threaded holes and loosen bolts securing bearing
caps. Remove bearing caps.
Fig. 8 - Removing Bearing Caps
6. Lift the differential assembly out of differential SM - 858

housing (1) with the special tool (15269929 Lifting
Pliers) as shown in Fig. 9.
Fig. 9 - Removing Differential
7. Remove both bearings (12 & 44) inner rings using SM - 2954
special tools (15272560 Puller, 15500887 Gripping
Insert, 15500888 Gripping Insert and 15500889
Reducer) as shown in Fig. 10.
Fig. 10 - Removing Bearing Inner Rings
8. Remove capscrews (12, Fig. 2) and separate SM - 2955

housing (9, Fig. 2) from cover (1, Fig. 2). Remove
single components as shown in Fig. 11.
Fig. 11 - Differential Components
6 SM 2591 01-10
Section 160-0020
SM - 2956 9. Remove bolts (40 & 41) securing layshaft housing

(26) to differential housing (1). Separate the housings
using suitable lifting equipment, and secure layshaft
housing to a suitable fixture.
Fig. 12 - Separating Layshaft Housing
SM - 2957 10. Using special tool (15269899 220V Hot Air Blower
or 15269900 110V Hot Air Blower) heat the slotted nut
(2) to around 120 oC before loosening using special tool
(15500890 Socket) as shown in Fig. 13. Remove
slotted nut (2), washer (3) and drive flange (4).
SM - 2958 11. Remove bolts (39) and seal holder (5) from cover
Fig. 14 - Removing Seal Holder
SM - 2959 12. Remove retainer (35) and shim support (34) from
layshaft housing (26) as shown in Fig. 15.
Fig. 15 - Removing Retainer
SM 2591 01-10 7
Section 160-0020
13. As shown in Fig. 16 use special tool (15269946 SM - 2960
Puller Set) to press quill shaft (11) out of the bearing.
Fig. 16 - Pressing Out Shaft
14. Remove spacer (9) and press the bearing (8) inner SM - 2961
race from the shaft (11).
Fig. 17 - Pressing Inner Race of Bearing
15. Remove bearing (33) inner race and spacer (32) SM - 2962
from housing (26).
Fig. 18 - Removing Inner Race of Bearing
16. Remove bolts (19) and separate cover (14) from SM - 2963
layshaft housing (26) as shown in Fig. 19. Remove
spur gear (13) at this time.
Fig. 19 - Separating Cover From Housing
8 SM 2591 01-10
Section 160-0020
SM - 2964
before removing using special tool (15500891 Socket)
SM - 2965 18. With the special tool (15269946 Puller Set) shown
in Fig. 21, press the pinion gear (17) out of the bearing
(23).
Fig. 21 - Pressing Out Pinion Gear
SM - 2966 19. Pull off the bearing (16) inner race from the pinion
gear (17) using special tools (15500892 Gripping Insert
and 15272560 Bearing Puller).
Fig. 22 - Removing Bearing From Pinion Gear
SM - 2967 20. Remove adjusting ring (24) and spacer bush (25)
from housing (26). Using special tool (15269946 Puller
Set) press out bushing (37) and spacing washer (15).
Fig. 23 - Pressing Out Components
SM 2591 01-10 9
Section 160-0020
INSPECTION SM - 2968
1. Clean all parts with a suitable solvent. Dry all parts,

except bearings, with compressed air or with soft,
clean lint free cloths. DO NOT spin bearings with
compressed air. Place bearings on a clean surface,
cover with lint free cloths and allow to dry.
2. Coat cleaned, dried parts immediately with light oil to

prevent corrosion. If parts are not to be assembled
immediately, treat them with a good quality rust
preventive and wrap them with treated paper or suitable
material designed to prevent corrosion.
Fig. 24 - Pressing Bearing Outer Race in Housing
3. Before installing the differential assembly into the
axle housing, clean the inside and outside of the axle SM - 2969
housing to remove any debris or dirt.
4. Inspect all gears, pinions and splines for cracked or

broken teeth, excessive wear, and pitted or scored
surfaces. Repair or replace as necessary.
Note: If either ring gear or pinion gear is defective, both

gears must be replaced, because they are serviced
only as a matched set.
5. Check for pitted, scored or worn thrust surfaces of

differential case halves. Fig. 25 - Pressing Bearing Outer Race in Housing
6. During assembly and installation, make sure that SM - 2970

mated, punch marked or otherwise identified parts are
returned to their original positions, if still serviceable.
ASSEMBLY

specified to standard torques listed in
Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNING
SM - 2971
safely.


Fig. 27 - Installing Bushing
10 SM 2591 01-10
Section 160-0020
SM - 2972 3. Insert spur gear (36) into housing (26) bore, ensuring
that inner diameter (85 mm) is facing down, as shown
in Fig. 26.
4. Press the bushing (37) into housing (26) bore and

ensure it is firmly home, as shown in Fig. 27.
5. At this stage in the assembly procedure the

thickness of spacing washer (15) must be determined
to ensure correct contact pattern between pinion gear
(17) and ring gear (18). As shown in Fig. 28, measure
Dimension 'A' from the mounting face of housing (26) to
Fig. 28 - Measuring Dimension 'A' the locating face of the bearing (16) outer ring, using
special tools (15270113 Gauge Blocks, 15269948
Straight Edge and 15270114 Digital Depth Gauge).
SM - 2973
6. As shown in Fig. 29, use special tools (15500893

Shims, 15500894 Shims and 15269934 Measuring
Shaft) and place shims into the bores of differential
housing (1) and assemble the measuring shaft.
Fig. 29 - Assembling The Measuring Shaft
SM - 2974 7. Measure Dimension 'B' from mounting face of

housing (1) to Measuring Shaft (see Fig. 30).
Example:
+ Dimension 'B' 196.75 mm
- Dimension 'C' (1/2 diameter of Measuring
Shaft) 15.00 mm
= Dimension 'X' 241.45 mm

Fig. 30 - Measuring Dimension 'B'
SM - 868 8. Measure thickness of bearing (16) as shown in Fig.

31 using special tools (15270113 Gauge Blocks and
15270114 Digital Depth Gauge). Record as Dimension
'D'.
Eg. Dimension 'D' = 42.70 mm
Fig. 31 - Measuring Bearing Thickness
SM 2591 01-10 11
Section 160-0020
9. The arrow in Fig. 32 is pointing to a dimension SM - 2975
stamped on the face of pinion gear (17). Record as
Dimension 'E'.
Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm
Example:
Dimension 'D' 42.70 mm
+ Dimension 'E' 197.90 mm
= Dimension 'Y' 240.60 mm
Fig. 32 - Dimension On Pinion Face
10. Calculate spacing washer (15) thickness by SM - 2976

subtracting Dimension 'Y' from Dimension 'X'.
Example:
Dimension 'X' 241.45 mm
- Dimension 'Y' 240.60 mm
= Required thickness 0.85 mm
Install spacing washer (15) of required thickness into

the bushing (37) as shown in Fig. 33.
Fig. 33 - Installing Spacing Washer
11. Freeze bearing (16) outer race and install in SM - 2977

bushing (37), ensuring it is firmly home.
WARNING
12. Heat inner race of bearing (16) to approximately 90° SM - 873

(17). Be sure it is firmly seated against the shaft
shoulder as shown in Fig. 35.
WARNING
12 SM 2591 01-10
Section 160-0020
SM - 2978 13. Install assembled pinion gear (17) in layshaft

housing (26) using special tool (15269946 Puller Set)
as shown in Fig. 36. Do not remove special tool at this
point.
Fig. 36 - Installing Pinion Gear
SM - 2979 14. The adjusting ring (24) is used to obtain the rolling
resistance of the pinion bearing. Rolling resistance
resistance is checked once pinion gear (17) is secured
in housing (26) (Step 17).
As shown in Fig. 37, install spacer bush (25) with the

small collar showing up (ref. arrow) into the bore of the
spur gear (36) and install adjusting ring (24).
Fig. 37 - Installing Spacer Bush and Adjusting Ring
SM - 2980
15. Heat inner race of bearing (23) to approximately 90°
(17) until it is firmly home as shown in Fig. 38.
WARNING
After bearing (23) inner race has cooled, remove special

tool installed in Step 13.
SM - 2981 16. Coat threads of slotted nut (21) with Loctite 649.
Locate washer (22) and install slotted nut (21). Using
special tool (15500891 Socket) tighten slotted nut (21)
Note: When tightening nut (21), rotate the pinion gear (17)
in both directions several times.
SM 2591 01-10 13
Section 160-0020
17. Check the rolling resistance of the pinion bearing as SM - 2982
shown in Fig. 40 by using special tool (15500895
Torque Spanner). If the rolling resistance is outwith
range (3.5 - 4.0 Nm), adjusting ring (24) thickness must
be changed.
Record this torque as Tpinion e.g. 3.5 Nm.
Fig. 40 - Checking Rolling Resistance
18. Install spur gear (13) in housing (26) as shown in SM - 2983

Fig. 41.
19. Install quill shaft (11) into housing (26) using special SM - 2984
tool (15269946 Puller Set) as shown in Fig. 42. Do not
remove special tool at this point.
Fig. 42 - Installing Quill Shaft
20. On the other side of shaft (11), install spacer (32) SM - 2985
with the collar facing down as shown in Fig. 43.
14 SM 2591 01-10
Section 160-0020

WARNING
SM - 2987 22. Install shim support (34) and snap in the retainer
Fig. 45 - Installing Shim Support and Retainer
SM - 2988 23. Remove special tool (15269946 Puller Set) installed

in Step 19, and install it to the retainer (35) end of shaft
(11). Press the shaft (11) until the shim support (34) is
located on retainer (35).
Do not remove special tool at this point.
Fig. 46 - Pressing Shaft
SM - 2989 24. Press bearing (8) outer race into cover (14) until firmly
home, as shown in Fig. 47.
Fig. 47 - Pressing Bearing Outer Race
SM 2591 01-10 15
Section 160-0020
25. Apply Loctite 574 to mounting face of housing (26) SM - 2990
as shown in Fig. 48. Place the housing cover (14) on
housing (26) and secure using pin (20) and new bolts
(19). Torque bolts (19) to 155 Nm (114 lbf ft).
E
CTIT
LO
Fig. 48 - Applying Loctite 574
26. The spacer (9) is used to obtain the rolling SM - 2991

resistance of the shaft (11) bearing. Rolling resistance
resistance (TAn) is calculated once shaft (11) is
secured in housing (26) (Step 32). As shown in Fig. 49,
install spacer (9) on shaft (11).
27. Heat inner race of bearing (8) to approximately 90° SM - 2992

WARNING
Once the bearing (8) has cooled, remove special tool

(15269946 Puller Set) installed in Step 23.
SM - 2993
28. Apply Loctite 574 to mounting face of cover (14).

Place the seal holder (5) on cover (14) and secure
using new bolts (39). Torque bolts (39) to 155 Nm (114
lbf ft) as shown on Fig. 51.
Fig. 51 - Tightening Seal Holder Bolts
16 SM 2591 01-10
Section 160-0020
SM - 2994
29. Coat outer diameter of shaft seal (7) with Loctite

574 and install in seal holder (5) using special tool
(15500896 Driver). Ensure sealing lip faces inboard.
SM - 2995 30. Press dust shield (6) over drive flange (4) as shown
in Fig. 53.
Fig. 53 - Installing Dust Shield
SM - 2996 31. Coat threads of slotted nut (2) with Loctite 649.
Coat faces of washer (3) with Loctite 574. Assemble
drive flange (4), washer (3) and slotted nut (2) on shaft
(11). Using special tools (15500890 Socket and
15270120 Clamping Yoke) torque slotted nut (2) to 750
Nm (553 lbf ft) as shown in Fig. 54.
Note: When tightening nut (2), rotate the shaft (11) in

both directions several times.
SM - 2997
32. As shown in Fig. 55, check total rolling resistance

of pinion gear (17) and shaft (11) using by using special
tool (15500895 Torque Spanner). Record this torque as
Ttot e.g. 5.5 Nm.
Example:
Ttot e.g. 5.5 Nm
Tpinion e.g. - 3.5 Nm
Results in TAn = 2.0 Nm
As specified in Step 26, rolling resistance (TAn) of shaft

Fig. 55 - Checking Rolling Resistance (11) should be 1.5 - 3.0 Nm. If outwith this range,
SM 2591 01-10 17
Section 160-0020
spacer (9) thickness must be changed. SM - 2998
33. Coat mounting face of differential housing (1) with

Loctite 574. Using suitable lifting equipment, install the
pre-assembled layshaft housing to the differential
housing (1).
34. As shown in Fig. 56, secure the pre-assembled

layshaft housing to the differential housing (1) with pins
(refer to arrows) and new bolts (40 & 41). Torque bolts
(40 & 41) to 155 Nm (114 lbf ft).
Fig. 56 - Installing Pre-assembled Layshaft Housing
SM - 3074
35. Heat ring gear (18) and install it on the differential

housing (9, Fig. 2) until it is firmly home as shown in
Fig. 57.
WARNING
gloves when handling ring gear.
Fig. 57 - Installing Ring Gear
SM - 2999
36. Prior to assembly, coat components with gear oil

as specified in Section 300-0020, LUBRICATION
SYSTEM. Place both thrust washers (2 & 11, Fig. 2) in
the housing (9, Fig. 2), installing steel thrust washer (2,
Fig. 2) first as shown in Fig. 58.
SM - 3000
37. Install disc set A (Fig. 2) in housing (9, Fig. 2),
beginning with externally splined disc (3, Fig. 2) as
shown in Fig. 59.
Fig. 59 - Installing Disc Set A
18 SM 2591 01-10
Section 160-0020
SM - 3001
38. Install thrust ring (5, Fig. 2) as shown in Fig. 60.
SM - 3002
39. Install side gear (6, Fig. 2) as shown in Fig. 61.

Ensure both internally splined discs (4, Fig. 2) of set A
are located on side gear (6, Fig. 2).
SM - 3003
40. Sub-assemble pinion gears (7, Fig. 2) and

differential axles (8, Fig. 2). Install sub-assembly as
shown in Fig. 62.
Fig. 62 - Installing Differential Pinion Gears
SM - 3004
41. Install second side gear (6, Fig. 2) as shown in Fig.
63.
SM 2591 01-10 19
Section 160-0020
SM - 3005
42. Install second thrust ring (5, Fig. 2) as shown in

Fig. 64.
SM - 3006
43. Install disc set B (Fig. 2) beginning with internally

splined disc (4, Fig. 2) as shown in Fig. 65.
Fig. 65 - Installing Disc Set B
44. The clearance between the assembled differential SM - 3007
housing and the cover (1, Fig. 2) should be 0.2 - 0.6

mm. Press outer externally splined disc (3, Fig. 2)
evenly on and measure Dimension 'A' from the
mounting face of housing (9, Fig. 2) to the outer disc
(3, Fig. 2) as shown on Fig. 66, using special tool
(15270114 Digital Depth Gauge).
Fig. 66 - Measuring Differential Housing Clearance
45. Measure Dimension 'B' from the contact face to the SM - 3008
mounting face of housing cover (1, Fig. 2) using special
tool (15270114 Digital Depth Gauge) as shown in Fig.
67.
Fig. 67 - Measuring Housing Cover
20 SM 2591 01-10
Section 160-0020
SM - 3009 46. With reference to Steps 44 - 45, calculate
clearance as shown in the example below.
Example:
Results in clearance 0.30 mm
If clearance falls outwith specification (0.2 - 0.6 mm),

then thicker or thinner outer externally splined discs (3,
Fig. 2) should be installed.
Fig. 68 - Installing Thrust Washers Note: If necessary to change the outer externally
splined discs (3, Fig. 2) to obtain correct clearance,
SM - 3010
these should be changed so that the overall thickness
of disc sets A and B (Fig. 2) are identical.
Note: If installing new discs, the lower clearance

should be aimed for.
47. Place both thrust washers (2 & 11, Fig. 2) in the

cover (1, Fig. 2), installing steel thrust washer (2, Fig.
2) first as shown in Fig. 68.
48. Secure cover (1, Fig. 2) to housing (9, Fig. 2) with

two capscrews (12, Fig. 2). Torque capscrews to 46
Nm (34 lbf ft).
49. Heat bearings (12 & 44) inner races and install on
SM - 3011
assembled differential, as shown in Fig. 69.
WARNING

55˚
assembled differential in the differential housing (1) and
install bearings (12 & 44) outer rings, as shown in Fig.
70.
SM - 3012 51. Install adjusting nuts (10) and locate bearing caps
using bolts and washers as shown in Fig. 71. Coat
thread of bearing cap bolts with Loctite 649. Torque
bolts to 390 Nm (288 lbf ft).
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. 71 - Installing Bearing Caps
SM 2591 01-10 21
Section 160-0020
52. Install new bolts (10, Fig. 2) in differential assembly SM - 3013
and torque bolts to 390 Nm (288 lbf ft) as shown in Fig.

72.
Fig. 72 - Tightening Differential Bolts
53. Check the backlash between ring gear (18) and SM - 3014
pinion gear (17). Mount special tools (15500897

Magnetic Stands and 15500898 Dial Indicator) at right
angles to the outer diameter of the ring gear tooth flank
as shown in Fig. 73. Establish the backlash by
alternately setting both adjusting nuts (10). Rock the
ring gear back and forth being careful not to move the
pinion gear. Backlash should be 0.27 - 0.33 mm.
Fig. 73 - Measuring Backlash
54. Determine the bearing (12 & 44) rolling resistance SM - 3015
and bracket dimension by further tightening of both

adjusting nuts (10). The bearing rolling resistance
should be 3 - 4 Nm (2.2 - 2.9 lbf ft). Measure bracket
dimension as shown in Fig. 74 using 15500899
Micrometer. Dimension should be 358-0.1 mm.
Fig. 74 - Measuring Bracket Dimension
55. To check the tooth pattern of ring gear (18), coat SM - 891
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. 75.
Compare the contact pattern obtained with the Gear

tooth patterns for the Gleason Gear Tooth system
shown on the following pages.
Fig. 75 - Checking Contact Pattern
22 SM 2591 01-10
Section 160-0020
SM - 3016 56. Fasten adjusting nuts (10) with slotted pins (38) as
shown in Fig. 76.
Fig. 76 - Installing Slotted Pin
SM - 3017 57. Install studs in positions shown by arrows in Fig.

77. Apply Loctite 262 to studs.
Fig. 77 - Installing Studs
SM - 3018 58. Apply Loctite 574 to axle casing mounting face.

Using suitable lifting equipment, install differential
assembly in axle casing and secure using new bolts
and nuts. Torque bolts to 375 Nm (277 lbf ft) and nuts
to 280 Nm (206 lbf ft).
Install axle shafts as noted on removal. Refer to

Section 160-0030, AXLE GROUP (HUB).
SM 2591 01-10 23
Section 160-0020
GLEASON GEAR TOOTH SYSTEM SM - 895
Ideal tooth-contact pattern shown in Figs. 79 and 80

indicating the pinion distance is correct.

Figs. 81 and 82 then decrease the pinion distance (Fig.
83). Refer to Steps 5 - 10.

Figs. 84 and 85 then increase the pinion distance
(Fig. 86). Refer to Steps 5 - 10.
SM - 893 SM - 896
Fig. 79 - Coast Side (Concave) Fig. 82 - Drive Side (Convex)
SM - 894 SM - 897
Fig. 80 - Drive Side (Convex) Fig. 83 - Pinion Distance must be Decreased
24 SM 2591 01-10
Section 160-0020
SM - 898
SM - 899
Fig. 85 - Drive Side (Convex)
SM - 900
Fig. 86 - Pinion Distance must be Increased
SM 2591 01-10 25
Section 160-0020
MAINTENANCE should be investigated before the differential is taken

apart.
Proper lubrication of the differential assembly is
essential if the differentials are to deliver the service
Whenever noises such as a grating or rattle are heard
intended. Section 300-0020, LUBRICATION SYSTEM
coming from the differential, stop the unit immediately.
gives full information on the proper lubrication intervals
One tooth from a gear can cause damage to all gears
and the lubricant which should be used.
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,
WARNINGS
tools and sealants required.
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
Removing the axle shafts or drivelines
transmitted and may be erroneously attributed to the
will make the parking brake ineffective.
differential. Therefore, all possible sources of noise
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
26 SM 2591 01-10
Section 160-0020

TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
2 12 Capscrew 46 34
2 10 Bolt 390 288
3 2 Slotted Nut 750 553
3 19 Bolt 155 114
3 21 Slotted Nut 1 200 885
3 39 Bolt 155 114
3 40, 41 Bolt 155 114
- - Bearing Cap Bolts 390 288
- - Axle Casing Bolts 375 277
- - Axle Casing Nuts 280 206
* * * *
SM 2591 01-10 27
Section 160-0020
28 SM 2591 01-10
Rear Axle Group - Axle Group (Hub)
Section 160-0030
SM - 3944
27 25
5
6
7
4
3
8
23
30
17 18
1
19
12 26
13
22 24
14
15 16
28
20
10 22 29
9
11
1 - Hub Carrier 11 - Snap Ring 20 - Planet Gear

2 - Shim 12 - Locking Plate 21 - Retainer Ring
3 - Shaft Seal 13 - Lock Screw 22 - Thrust Washer
4 - U-Ring 14 - Sun Gear Shaft 23 - Bolt
5 - Roller Bearing 15 - Washer Shim 24 - Capscrew
6 - Bolt 16 - Planet Carrier 25 - Wheel Nut
7 - Roller Bearing 17 - 'O' Ring 26 - Plug
8 - Hub 18 - Plug Screw 27 - Lockwasher
9 - Ring Gear Carrier 19 - 'O' Ring 28 - Slotted Nut
10 - Ring Gear 29 - Roller Bearing
30 - Drive shaft
Fig. 1 - Exploded View of Planetary and Wheel
OPERATION
Numbers and letters in parentheses refer to Fig. 1. (14) rotate anticlockwise. Ring gear carrier (9) is
splined to hub carrier (1) and does not rotate but
Power from the differential is transmitted through a causes planet gears (20), which are meshed with ring
fully floating axle shaft connected to sun gear shaft (14). gear (10), to move around it in a clockwise direction. As
As sun gear shaft (14) rotates in a clockwise direction, planet carrier (16) is bolted to wheel hub (8) the wheel
the three planet gears (20) meshed with sun gear shaft then rotates in a clockwise direction.
SM 2592 01-10 1
Section 160-0030
REMOVAL AND DISASSEMBLY SM - 3450
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 - Install adjusting screws.
safely.
9. Remove drain plugs and drain cooling oil from brake
packs into a clean container. Refit drain plugs.
damage, the procedure for removing tyre and
10. Index mark planet carrier (16) and hub (8) to aid in
rim assembly described in Section 160-0050,
installation as shown in Fig. 2.
WHEEL, RIM AND TYRE, must be strictly
followed.
11. Loosen bolts (23) and install adjusting screws
(15502331) to aid in removal of planet carrier (16) sub
When necessary to drive out components
assembly as shown in Fig. 2. Remove bolts (23) then
during disassembly, be sure to use a soft drift
prise planet carrier (16) from hub (8) and remove with
to prevent property damage and personal
suitable lifting equipment (15501178) as shown in
injury.
Fig. 3.
1. Before attempting to remove the road wheels, drive SM - 3966
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil.
3. Block the appropriate road wheels, place the

steering lock bar in the 'Locked' position and the
4. Whilst road wheels are still on the ground, loosen 16 8

wheel nuts (25).
Fig. 3 - Removing Planet Carrier Assembly
5. Jack up the axle and support with suitably placed
12. Place on the floor with planet gears (20) facing
stands or timbers.
upwards. Remove O-ring (19) as shown in Fig. 4.
6. Support tyre and rim assembly with a suitable sling
and lifting device. Remove wheel nuts (25) and remove SM - 3452
tyre and rim assembly from the machine. Remove

opposite road wheel in the same way. Refer to Section
160-0050, WHEEL, RIM AND TYRE.
7. Place suitable containers under the differential and

both hubs (8). Remove differential drain plug and drain
oil from the differential.
8. Rotate hubs (8) until plug screws (26) are at their

lowest points. Remove plug screws (26) and 'O' rings
and drain oil from hubs. Remove capscrew (24). Fig. 4 - Removing O-ring.
2 Sm 2592 01-10
Section 160-0030
SM - 3453 16. Remove two lock screws (13) and remove locking
plate (12) from the ring gear (10) as shown in Fig. 8.
17. Remove slotted nut (28) from hub carrier (1) with
the special tools (15500882, Socket and 15500883
Centering Bracket) as shown in Fig. 9.
18. By means of lifting tackle 15501170 and suitable

pry bar 15270131, separate hub (8) assembly from the
hub carrier (1) as shown in Fig. 10.
SM - 3456
Fig. 5 - Extracting Planet Gears.
13. Unsnap retaining rings (21) from planet gears (20)

using suitable pliers 15270145. Extract planet gears
(20) from the planet carrier (16) using extractor tool
15271107 as shown in Fig. 5. Remove thrust washer
(22).
Note: Roller bearings (29) within the planetary gear (20) Fig. 8 - Remove lock screws / Plate.
are fixed with a circlip and these components are
destroyed at separation. Planetary gear and roller SM - 3126
bearing must be replaced together at reassembly.
14. Remove sungear shaft (14) as shown in Fig. 6.

SM - 3967
14
Fig. 9 - Removing Slotted Nut.
WARNING
Fig. 6 - Removing Sungear Shaft
Apply Pressure brake before removing the hub or
else, the brake plate will fall down and damaged.
15. Remove drive shaft (30) as shown in Fig. 7. Note
that left and right driveshafts are of a different length.
19. Remove the hub Fig. 11.
SM - 3455
SM - 3457
Fig. 7 - Remove Driveshaft Fig. 10 - Removing Hub from Carrier
SM 2592 01-10 3
Section 160-0030
SM - 3458 23. For further disassembly of brake packs refer to

Section 165-0015, OIL COOLED DISC BRAKES.
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 washer (22) to make sure it is free of
Fig. 11 - Removing Hub. burrs and is absolutely flat. Replace all 'O' rings.
Note: Pay attention to released bearing inner ring and

ASSEMBLY AND INSTALLATION
the ring gear.
SM - 3459
10
300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
8
WARNING
damage, be sure lifting equipment is properly
safely.
Fig. 12 - Removing Hub from Carrier
20. Remove ring gear (10) from hub (8) as shown in Fig. SM - 3122
12.
SM - 3460
11
10
Fig. 13 - Removing Ring Fig. 14 - Inserting Shaft Seal
21. Unsnap snap ring (11) and separate the ring gear
carrier (9) from the ring gear (10) as shown in Fig. 13. 1. Install brake pack on axle as described in Section
165-0015, OIL COOLED DISC BRAKES.
22. Using a suitable pry bar 15270131, lever and press 2. Grease sealing lips and wet outer diameter of shaft
shaft seal (3) out of the hub carrier (1) bore and remove seal (3) to aid in installation of components.
U-ring (4). If required remove both bearing (5 & 7) outer
races from the bore of the hub (8).
4 Sm 2592 01-10
Section 160-0030
3. Insert roller bearing (7), U-ring (4) and shaft seal (3) 7. Push hub (8) until contact is obtained, now remove
into hub (8). Shaft seal (3) should be inserted with care, centering bracket and inner installer tools. Refer to
using special tools; mounting tool 15501177 and handle Fig 18.
15269898. Refer to Fig. 14. SM - 3465
4. Mount inner installer 15502336 on hub carrier (1) as

shown in Fig. 15.
SM - 3462
Fig. 18 - Remove Installer / Bracket
8. Heat inner race of roller bearing (5) using a suitable

hot air blower 15269899 or 15269900. Refer to Fig. 19.
Fig. 15 - Mounting Installer SM - 3466
5. Using suitable lifting tackle 15501170 and chain

15501178, mount hub (8) over the inner installer.
Ensure care is taken not to damage shaft seal (3)
during this process. Before fully seating sealing
elements in place, apply a thin film of oil onto sliding
surfaces. Refer to Fig. 16.
SM - 3463
1
Fig. 19 - Heating Bearing
9. Mount shim (2) and roller bearing (5) inner race onto
hub carrier (1) until contact is obtained. Refer to Fig.
20. Note: Shim (2) will be used to adjust the rolling
moment to the desired value.
SM - 3467
Fig. 16 - Mounting Hub
6. Use centering bracket 15500883 to centre hub (8) on

the inner installer. Mount hub (8) in the brake pack. 2
Ensure hub is free to rotate. Refer to Fig. 17.
5
SM - 3464
Fig. 20 - Shim Detail
10. Pre-assemble ring gear (10), ring gear carrier (9)

and snap ring (11). Insert ring gear sub assembly and
screw on slotted nut (28). Ensure chamfer on Slotted
Nut (28) is showing to outside. Refer to Fig. 21.
SM 2592 01-10 Fig. 17 - Centering Hub 5

Section 160-0030
SM - 3468 SM - 3471
28
30
Fig. 21 - Insert Slotted Nut Fig. 24 - Insert drive shaft
11. Using centering bracket 15500883 and slotted nut

SM - 3967
wrench 15500882, torque slotted nut (28) to a value of
2000 - 2200Nm (1475 - 1622 Ibf ft). Refer to Fig. 22.
SM - 3469
14
Fig. 25 - Mounting Sungear Shaft
15. Press roller bearing (29) into bore of planet gear

Fig. 22 - Torque Slotted Nut (20) until the circlip has snapped into place in planet
gear (20). Refer to Fig. 26.
12. Install locking plate (12), securing in place with 2-off
new lock screws (13). Torque lock screws (13) to a SM - 3473
value of 86 Nm (63.5 Ibf ft). Refer to Fig. 23. 1
SM - 3470
12
Fig. 26 - Planetary Gear Detail

13
16. Heat inner diameter of roller bearing (29), mount
planetary gears (20) onto planet carrier (16) and secure
Fig. 23 - Secure Lock Plate
in place by means of retaining ring (21). Refer to Fig.
26.
13. Insert driveshaft (30) into the unit until contact is
obtained. Ensure correct shaft is fitted, as left and right Note: Ensure correct orientation of planet gears in
shafts are of differing length. Refer to Fig. 24. planet carrier.
14. Mount sungear Shaft(14) until contact is obtained 17. Mount Planet gears (20) until fully home and secure
as shown in Fig. 25. in place using retaining rings (21). Refer to Fig. 27.
6 Sm 2592 01-10
Section 160-0030
SM -3464 SM - 3477
22
Fig. 27 - Mount Planet Gears Fig. 30 - Fit Thrust Washer
18. Adjust the axial float of the sun gear shaft (14); this 21. Example: Dim 'A'..................9.4 mm
should be within the range of 0.3 mm to 0.8 mm, as Dim 'B'..................4.0 mm
follows: Difference 5.4 mm
Required axial end play e.g 0.4 mm, hence thrust
SM - 3475 washer (22) should be 5.4 - 0.4 = 4.0 mm thick.
14 22. Once correct thrust washer (22) has been

determined, grease washer and locate in place in
planet carrier (16). Refer to Fig. 30.
23. Insert sun gear shaft (14) into position over thrust
washer (22) as shown in Fig. 31.
Note: Ensure o-ring (19) is greased and fitted at this

time as well.
Fig. 28 - Measurement SM - 3968
14
19. Insert sun gear shaft (14) until seated. Determine
the depth from the mounting face of the hub (8) to the
top face of the sun gear (14) using a straight edge
15269948 and digital depth gauge 15270114. Call this
dimension 'A'. Refer to Fig. 28.
20. Measure dimension from mounting face of planet

gear (20) to contact surface of thrust washer (22) using 19
measuring equipment used in previous step, including
block gauges 15502404. Call this dimension 'B'. Refer Fig. 31 - Fit Sun Gear
to Fig. 29.
24. Using suitable lifting tackle 15502405 and adjusting
screws 15502331 to aid in location, insert planet carrier
SM - 3476
(16) sub-assembly into ring gear (10) bore and locate it
in the hub (8) till fully home. Refer to Fig. 32.
SM - 3479
Fig. 29 - Measurement
Fig. 32 - Locate Planet assembly
SM 2592 01-10 7
Section 160-0030
Note: Ensure that planet carrier (16) is aligned to in 27. Install differential drain plug. Add gear oil of the type
correct orientation with hub so that drain and fill holes specified in Section 300-0020, LUBRICATION
are in the correct position as shown in Fig. 33. SYSTEM, through the differential filler/level hole until
the oil is level with the bottom of the filler/level hole.
SM - 3480
28. Fill the planetary assemblies up to the 'Oil Level

Check Line' with gear oil of the type specified in
Section 300-0020, LUBRICATION SYSTEM.
29. Fill the brake coolant tank with oil as specified in

Section 300-0020, LUBRICATION SYSTEM. Fill until
oil is halfway up sight glass. Install filler cap on brake
coolant tank filler neck. Once engine has been started,
oil level will drop as brake packs are filled. Top up oil
as necessary.
Fig. 33 - Alignment
30. Refit road wheels, securing with wheel nuts (25).
Remove stands or timber supports and lower the
25. Apply loctite 574 to threads of cap screw (24) and machine to the ground. Fully tighten wheel nuts to a
secure planet carrier (16) in place to hub (8); tightening torque of 600 Nm (442 lbf ft). Remove blocks from the
screw as shown in Fig. 34. Taking bolts (23), secure wheels.
carrier in place, torque bolts (23) to a value of 280 Nm
(207 Ibf ft). Note: Wheel nuts should be checked and tightened if
necessary, after the first 10 hours of operation. Check
SM - 3481
torque every 50 hours (weekly) thereafter.
23
MAINTENANCE
Proper lubrication of the axle group is essential if axles
are to deliver the service intended. Section
300-0020, LUBRICATION SYSTEM gives full
information on the proper lubrication intervals and the
lubricant which should be used.
24 SPECIAL TOOLS
Fig. 34 - Torque Bolts
The special tools referenced throughout this section
are available from your dealer. Refer to Section
26. Secure plug screw (18), o-ring (17) and plug (26) in 300-0070, SERVICE TOOLS, for part numbers of
place on planet carrier (16) face as shown in Fig. 35. general service tools and sealants required.
Torque plug (18) to a value of 40 Nm (29.5 Ibf ft) and
torque plug (26) to a value of 150 Nm (111 Ibf ft).
SM - 3482
18
26
Fig. 35 - Torque Plugs
8 Sm 2592 01-10
Section 160-0030
AXLE DIAGNOSIS True axle noises may be located by lifting or jacking

the machine up until all tyres are clear of the floor or
Noises originating in the tyres, transmission, brakes or
ground. Securely block the machine in this position.
drivelines might be attributed by mistake to the axle
Run power train at moderate speed. Be certain all tyres
components, therefore, all possible sources of noise
are off the ground to prevent damage to the differential
should be investigated before deciding the axle is at
and make sure that there is no brake drag.
fault.
WARNING
secured and of adequate capacity to do the
job safely.
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

TORQUE
1 25 Wheel Nut 600 442
1 13 Lock Screw 86 63
1 23 Bolt 280 206
1 18 Plug Screw 40 30
1 28 Slotted Nut 2 000 1 475
* * * *
SM 2592 01-10 9
Section 160-0030
10 Sm 2592 01-10
REAR AXLE GROUP - Wheel Rim and Tyre
Section 160-0050
SM - 1176
1 - Flanges 4 - Lock Ring 7 - Cap

2 - 'O' Ring 5 - Wheel Rim 8 - Driver
3 - Bead Seat Band 6 - Valve Assembly 9 - Wheel Nut
Fig. 1 - Cutaway View of Wheel Rim
DESCRIPTION AND OPERATION One of the following pieces of hoisting equipment

The wheel assembly is designed to allow the tyre and should be used to lift the tyre and rim: chain block and
rim assembly to be replaced with a pre-assembled tyre tackle, overhead crane, fork lift truck, boom truck, or
and rim. The tyre and rim may be removed from the tripod tyre changing tool.
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, dismounting tyre from rim and the use of
hand and special tools, are described in this section. WARNING
Before performing any service on the tyres or
The rim assembly consists of the following rim components, to prevent personal injury
components which are illustrated in Fig. 1: wheel rim, and property damage, completely deflate the
inner and outer flange, 'O' ring, bead seat band, driver tyre by removing the valve cap and core. Insert
and lock ring. a thin wire through valve to be sure valve is
not plugged. Even a flat tyre, in some cases,
When dismounting a tyre and rim assembly from the will retain sufficient air pressure to blow off a
machine, special equipment and careful handling are rim component with enough force to cause
required because of the size and weight of the tyres. bodily injury or death.
SM 2593 01-10 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. Turn the
relieve pressure in the steering system.
2. Block all road wheels, except the one to be raised,

and place the battery master switch in the 'Off' 1 - Outer Flange 4 - Lock Ring
position. 2 - Driver 5 - Wheel Rim
3 - Bead Seat Band 6 - Inner Flange
3. Break wheel nuts (9) loose with tyre still on the Fig. 2 - Typical Rim Assembly
ground, but do not remove from wheel studs.
4. Jack up the axle to the height required to allow SM - 205
removal of the tyre and rim assembly.
5. Place safety blocks under the axle.
6. Support tyre and rim assembly with a suitable sling

and attach a suitable lifting device.
Fig. 3 - Pry Bar
7. Remove wheel nuts (9) securing wheel rim (5).
SM - 206
8. With lifting device, remove tyre and rim assembly
from wheel and lift clear of machine.
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 2593 01-10
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 rim, be sure the
equipment is of sufficient capacity and 15. If necessary, remove inner flange (6).
properly secured to do the job safely.
Note: If tyre rim is on machine, and no tyre lifting
1. Remove valve cap and valve core and leave valve equipment is available, 'walk' tyre off rim as follows:
open to prevent trapping of air in tyre. Tape valve Force bottom of tyre outward as far as possible; lower
threads for protection. jack enough to allow weight of tyre to rest on ground;
force top of tyre out as far as possible; raise jack to
2. Remove driver (2) from bead seat band (3) and original height and repeat the above until tyre is off rim.
wheel rim (5).
3. Break outer tyre bead loose with pry bar shown in INSPECTION
Fig. 3.
Tyre
4. Insert flat hooked end of pry bar into breaking slots Check the interior surface of the tyre to determine its
between bead seat band (3) and outer flange (1) (See condition. Inspect for cuts or fabric breaks that have
Fig. 4). A pipe over the straight end of the pry bar will penetrated the tyre body. The casing should be
increase leverage. inspected closely for any sharp , pointed object that
may have penetrated the tyre body but is invisible from
5. Twist bar toward tyre to break bead. the outside. All dust, dirt, water or other foreign matter
should be cleaned from the inside of tyre.
6. A second bar may be inserted in space between
bead seat band (3) and outer flange (1). Twist second
Rim Assembly
bar to maintain space gained by the first bar.
Overloading, improper tyre inflation, rough terrain, high
7. Move the first bar around the rim, twisting and speed, accidents, dirt accumulation, and corrosion all
following with the second bar, until the outer tyre bead tend to reduce the service life of rims and rim
is loose. components. It is recommended that rims be
inspected, as below, not less often than at every tyre
8. Pry bead seat band (3) away from lock ring (4) by change and that, as the warranty limit approaches,
placing hooked end of pry bar in groove of wheel rim consideration be given to periodic replacement.
(5), between ends of lock ring (4), and prying up with
bar. Using two bars, as in Step 7, work completely The rim and its components are designed with built-in
around wheel rim (5). safety factors, to prevent the components from flying
off with killing force during inflation. Check components
9. Pry lock ring (4) out in same manner by starting at for cracks, bends, distortion, or other damage. If
prying notch in rim assembly and work all the way damage is found, the component must be replaced.
around rim with two pry bars.
10. Remove and discard 'O' ring (2, Fig. 1). WARNING
Never mix components of one manufacturer's
11. Remove lock ring (4), pry out and remove bead rims with those of another. Using the rim base
seat band (3). of one manufacturer with the lock ring of
another or vice versa is dangerous. The lock
12. Breaking slots are provided inside the rims. The ring of one may not fully engage with the lock
inner bead may be broken as described in Steps 4 ring groove of the other. Always consult the
through 8. If tyre and rim assembly are on the rim manufacturer for proper matching and
machine, the following procedure may be used for assembly instructions. Also, use and servicing
breaking the inner bead. of damaged, worn out, or improperly
assembled rim assemblies is a very dangerous
13. Place jack between inner flange (6) and machine practice. Failure to comply with the above
frame. Extend jack until tyre bead is broken. Continue warnings could result in explosions from tyre
around rim until tyre bead is broken at all points. pressure causing serious personal injury and
property damage.
SM 2593 01-10 3
Section 160-0050
Clean all rust and dirt from the rim parts and wheel SM - 207
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
should be carefully checked for distortion or mutilation
that would prevent an effective air seal when the tyre
and rim are reassembled.
Rubber 'O' rings are air seals for tubeless tyre and rim
assemblies and therefore should be carefully handled
to provide an airtight seal when the tyre is remounted
on the rim. Always use new 'O' rings when mounting a
tubeless tyre. 1 - Lock Ring 2 - Drive Lug
Fig. 5 - Installing Typical Lock Ring
Note: Handle 'O' rings carefully, as damage will
prevent an airtight seal for tyre inflation. soft hammer to rotate lug. Use bar for installing lock
ring, as illustrated in Fig. 5.
MOUNTING TYRE ON RIM 8. Force bead seat band (3) past 'O' ring groove in
Numbers in parentheses refer to Fig. 2, unless wheel rim (5) by prying, or with lift truck forks. Use
otherwise specified. blocking between the forks and tyre to prevent
damage. Insert a new 'O' ring (2, Fig. 1) in groove of
For mounting a tyre with rim on or off machine, the the rim behind lock ring (4). Lubricate area of front
procedure is basically the same. taper of bead seat band adjacent to 'O' ring, with a thin
solution of soap and water or another approved
lubricant which is not harmful to rubber. Avoid using an
WARNING excessive amount of lubricant.
When lifting tyre onto rim, be sure the
equipment is of sufficient capacity and 9. Install driver (2). Make sure all rim components are
properly secured to do the job safely. correctly assembled.
1. For off-machine installation, lay rim on blocks or 10. Lift the tyre upwards to effect a seal between bead
mounting stand with 'O' ring groove up. Rim should be seat band (3) and 'O' ring (2, Fig. 1). In some cases
off floor enough to allow tyre to rest on rim and not on the tyre will automatically spring out, making this step
floor. Blocks are not to extend more than 13 mm unnecessary.
(0.50 in) beyond rim base.
11. Refer to 'Tyre Inflation' in this section for the proper
2. If removed, install inner flange (6) over wheel rim (5). procedure for inflating the tyre.
3. Lubricate tyre beads and 'O' ring, with a thin solution

MOUNTING TYRE AND RIM ASSEMBLY
of vegetable base soap and water.
ON MACHINE
4. Using suitable lifting equipment, lower tyre onto rim. Numbers in parentheses refer to Fig. 1.
Seat tyre firmly against inner flange (6).
5. Install outer flange (1) on rim (5). WARNING

When jacking, lifting, or blocking the machine,
6. Align lock ring driver notch in bead seat band (3) be sure the equipment is of sufficient capacity
with notch in wheel rim (5) and install bead seat band to do the job safely.
on rim.
1. Support tyre and rim assembly with a chain, or rope
7. Install lock ring (4) in groove of wheel rim (5) so that sling. Attach sling to overhead lifting device. Slide
lock ring lug engages both notches. Notches and lock assembly on to wheel of machine, with lock ring (4)
ring lug must line up correctly. If necessary, use only a and bead seat band (3) facing outward.
4 SM 2593 01-10
Section 160-0050
2. Install wheel nuts (9) on wheel studs. Gradually C.

tighten nuts opposite each other until all nuts are snug. Be sure to thoroughly flush and blow off all
Torque tighten wheel nuts (9) to 600 Nm flammable solvents used for cleaning the air
(442 lbf ft). Torque tighten wheel nuts (9) again, after compressor inlet screen before using the
10 hours of machine operation. compressor for tyre inflation, or any other
purpose.
TYRE INFLATION D.
Do not charge batteries, either in or out of a
machine, near the air inlet of a compressor
WARNING used for inflating tyres. Charging batteries
To prevent personal injury and property produces highly explosive hydrogen gas
damage, the tyre and rim assembly should be which can be readily drawn into a nearby
placed in a safety cage before inflating. If no compressor inlet and pumped into the tyre.
safety cage is available or tyre is on the
machine, the tyre and rim assembly should be E.
wrapped with safety chains or with lash cables Never exceed the specified concentration of
before inflating. alcohol when adjusting the alcohol vaporizer,
or adding alcohol to the auxiliary air tank, used
Even with these precautions remember that on machine air systems to prevent freezing or
air-blast is a potential hazard. Tyre inflation moisture condensate in below-freezing
should be carried out away from busy working temperatures. Excessive alcohol, added to the
areas. machines air tanks in this manner can produce
flammable vapours that will be pumped into a
WARNING tyre when this air supply is used for tyre
To avoid personal injury and property damage, inflation if the tyre inflation kit is not equipped
never stand or sit in front of a mounted tyre with a moisture filter. Alcohol added to
during tyre inflation. Use a clip-on air chuck machine air systems in recommended
with a long hose and stand to one side while concentration to prevent condensate freezing
the tyre is being inflated. are below hazardous levels for tyre inflation.
WARNING F.
To prevent personal injury and property Another source of hazardous flammable
damage, always prevent flammable vapours vapours in tyres is the tyre bead lubricant.
that could produce tyre explosions, from being Always use bead lubricants that do not
pumped into tyres during inflation, by introduce flammable vapours into the tyre.
observing the following precautions:
A. Inflation
Use an air compressor and reservoir located Note: Always use tyre inflation equipment with an air
inside a heated building, when available, so filter that removes moisture from the air supply, when
that alcohol, methanol, or other flammable available, to prevent moisture corrosion of internal rim
antifreeze liquids are not needed in the air parts.
tanks to prevent moisture freezing in the tank
and lines in subfreezing outside temperatures. 1. Inflate tyre to 1 bar (15 lbf/in²) initially to seat
components and tap lock ring lightly to ensure correct
B. seating. Visually check that all components are in
Make sure that paints, lacquers, paint thinners, place, then continue inflation observing all safety
or similar materials that produce volatile, precautions. (See Step 2).
flammable vapours are not used or stored near
the air intake of the compressor that supplies 2. If the tyre is off the machine, place it in a safety
the air for inflating tyres. The compressor cage after initially inflating to 1 bar (15 lbf/in²) to seat
should be isolated from all such sources of components. See Fig. 6.
flammable vapours.
SM 2593 01-10 5
Section 160-0050
3. Inflate tyres to 5.2 bar (75 lbf/in²) to seat beads and SM - 208
seal the 'O' ring, then adjust to the recommended
inflation pressure.
4. For recommended operating air pressure, refer to

the 'Tyre Inflation Pressures Table'.
NITROGEN TYRE INFLATION

Note: All Warnings and procedures under 'Tyre
Inflation' will apply, except for differences covered by
this passage.
In certain environments it is recommended that tyres

be inflated with dry nitrogen gas, and that the resulting
oxygen content of the inflation does not exceed 5%.
All machines whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on the body
or frame.
Nitrogen gas improves tyre pressure retention, Fig. 6 - Typical Safety Cage
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 SM - 1040
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
DO NOT USE charging assembly, Part No.
9359489, for tyre inflation because this
assembly does not include a pressure
regulator, safety relief valve, and adequate
pressure gauging which is mandatory for tyre
inflation purposes. Tyre volume is as much as
90 times greater than the average accumulator
volume and hence it takes very much longer to
inflate a tyre - up to 40 minutes or more for
very large tyres.
Nitrogen gas cylinders used to inflate

tyres are generally charged to approximately Fig. 7 - Nitrogen Tyre Inflation Kit
152 bar (2 200 lbf/in2). A tyre blowout and/or
rim failure could occur if inflation equipment is 1. A nitrogen tyre inflation kit is available from your
not properly used. Proper nitrogen charging dealer and consists of the following. Refer to Fig. 7.
equipment and personnel training for its use is
a must to avoid over inflation. a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with
two dual pressure gauges.
6 SM 2593 01-10
Section 160-0050
b. Safety relief valve, 8.6 bar (125 lbf/in²), that will b. If the required service inflation pressure is greater
assure an upper limit to the pressure available for tyre than 4.1 bar (60 lbf/in²), further inflate, with dry
inflation. nitrogen gas only, to the pressure level required. Then
remove the clip-on chuck and adjust the pressure with
c. A 15.2 m (50 ft) length of flexible hose with the tyre gauge in the usual manner.
interconnecting fittings. On the tyre end of the hose is
a large bore quick connect/disconnect clip-on chuck.
New Tyre Mounts and Remounts
2. The pressure regulator is connected to a nitrogen To newly mount or remount a tyre to its rim, use only
compressed gas cylinder available from local suppliers. dry nitrogen gas; this includes the pressure required to
seat the beads. After seating the tyre beads, remove
3. The usual procedure for using this type of the clip-on chuck and adjust the pressure with the tyre
equipment is as follows: gauge in the usual manner.
a. Connect nitrogen tyre inflation kit to nitrogen Note: Although a little more nitrogen gas is used to seat
compressed gas supply. DO NOT connect clip-on beads than that used for re-inflation of a mounted tyre,
chuck to the tyre valve at this time. refer to 'Re-inflation of a Mounted Tyre', its cost is
generally negligible in comparison to the time and labour
b. Open valve on nitrogen supply. saving and, longer tyre life achievable with the reduced
oxygen content which results.
c. With flexible hose and clip-on chuck connected to
nitrogen tyre inflation kit assembly but not connected
to the tyre, adjust pressure regulator so that its output TYRE EXPLOSION HAZARD
pressure is not more than 1.4 bar (20 lbf/in²) higher
than the desired tyre inflation pressure.
WARNINGS
d. Connect clip-on chuck to the tyre valve. The tyre will Whenever a machines tyre(s) is (are) exposed
now inflate. Tyre pressure can be monitored by to excessive heat such as a machine fire or
observing the gauge at the pressure regulator. STAY extremely hot brakes the hazard of a
AWAY FROM THE TYRE. subsequent violent tyre explosion must be
recognized. All persons must avoid
e. When desired inflation pressure has been achieved, approaching the machine so as not to be
back off the regulator or close the valve on the physically endangered in the event of an
compressed gas cylinder. explosion of the tyre and rim parts. The
machine should be moved to a remote area,
f. Remove the clip-on chuck and adjust the tyre but only when this can be done with complete
pressure with the tyre gauge in the usual manner. safety to the operator operating or towing the
machine. All other persons should stay clear of
the machine. The fire or overheated brakes,
Re-inflation of a Mounted Tyre wheel, etc. should be extinguished or cooled
To re-inflate a tyre with dry nitrogen gas which is now from a safe distance. Do not attempt to
inflated with air, proceed as follows: extinguish the fire or cool the machine by use
of hand-held fire extinguishers.
1. Exhaust the tyre until only air at atmospheric
pressure remains in the tyre. If it is absolutely necessary to approach a
machine with a suspect tyre, approach only
2. Re-inflate the tyre using only dry nitrogen gas to from the front or the back. Stay at least 15 m
4.15 bar (60 lbf/in²) gauge as a minimum, or to bead- (50 ft) from the tread area. Keep observers out
seating pressure as a maximum. of the area and at least 460 m (1 500 ft) from
the tyre sidewall. Refer to Fig. 8. The tyre(s)
3. Adjust to the service inflation pressure required: should be allowed at least eight (8) hours
cooling time after the machine is shut down or
a. If the required service inflation pressure is LESS the fire extinguished before approaching
than 4.1 bar (60 lbf/in²), remove the clip-on chuck and closer.
adjust the pressure with the tyre gauge in the usual
manner.
SM 2593 01-10 7
Section 160-0050
SM - 3984
WARNINGS AT LEAST AT LEAST

There is always a possibility of a tyre explosion 15m (50ft) 460m (1 500ft)
whenever the smell of burning rubber or
excessively hot brakes is detected. The danger
is also present when a fire on the machine
reaches the tyre and wheel area. Under such
conditions, all personnel must avoid
approaching the machine in a manner that
could result in injury should an explosion
actually occur. Move the machine to a remote
area only if it can be done without endangering
the operator or other personnel in the area.
DO NOT WELD ON OR HEAT RIM

COMPONENTS. For several years the company
and tyre and rim manufacturers have warned
users never to weld rim components with the
tyre mounted on the rim. The gases that build
up inside the tyre during arc welding or
heating on rim components can ignite,
resulting in one of these explosive-like failures
of the tyre and rim. This warning also applies Fig. 8 - APPROACH AREA.
to nitrogen inflated tyres. Ignition will not Do Not Approach Tyre in Shaded Area
occur in the nitrogen atmosphere, but the
pressure buildup from the heat of welding may less than 13 mm (0.50 in) in size can be repaired with a
be sufficient to cause a blowout severe enough plug and hot patch. Insert a repair plug into the hole to
to injure or kill. It is recommended to scrap the keep out moisture and to back up the hot patch. Trim the
part if heat is necessary to repair any rim plug off flush with the inside of the casing, buff, and apply
component. the hot patch according to the instructions supplied with
the hot patch equipment.
TYRE AND WHEEL RIM MAINTENANCE Punctures 13 mm (0.50 in) or larger, large cuts, or
bruise breaks require sectional or reinforced
Tyre Repairs vulcanized repair. Cover the repair patch with a layer
Prompt repair of tyre injuries will prevent small injuries of cushion gum after application to the tubeless tyre to
from enlarging and causing tyre failure. Use the best ensure an airtight repair. Any cords of the inside ply
tyre facilities available. If good repair facilities are not that are exposed in buffing and are not covered with
available, have the nearest dealer make the necessary repair patch must be coated with cushion gum to
repairs. prevent air leakage into the carcass plies on tubeless
tyres.
Minor cuts, snags, or punctures should be repaired
upon discovery. Skive with a sharp pointed knife
around any cut in the tyre tread area that is of Recapping and Retreading
sufficient depth or shape to hold pebbles or dirt. The There are two general methods employed in restoring
angle of the skive should be no more than sufficient to the tread surface of off-the-highway tyres: recapping
expel all foreign material and should extend no deeper and retreading.
than the breaker. The skive should go to the bottom of
the hole. Tyres with shallow cuts, if treated promptly, A recapped tyre has a new tread cured right over the
may be allowed to continue in service. If the cut old tread surface.
extends deeper into the tyre carcass, the tyre should
be removed for repair. A retreaded tyre has the old tread removed entirely
and a new tread cured directly onto the body of the
The tyre must be removed from the rim to repair larger tyre. A tyre can be recapped or retreaded if the cord
punctures or cuts. Irregular shaped punctures or cuts body is free of cuts, bruises and separation, and is
thoroughly sound, including previous repairs.
8 SM 2593 01-10
Section 160-0050
TYRE CARE Prevent Contact with Oil

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

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

Prevent Overloading
Off-highway machines are designed to carry a If rim parts are stored outdoors, they should be given a
maximum allowable payload. Excessive loading will protective coat of a good commercial primer.
overstress both the machine and tyres and shorten the
life of both. Similar parts should be stacked neatly to prevent distortion.
SM 2593 01-10 9
Section 160-0050
Babbit or lead hammers, not sledge hammers, should machine is placed in operation. Refer to 'Tyre Inflation
be used in assembling rim parts. Pressures Table'.
'O' rings are seals and should be carefully stored in a Every 50 hours of operation (weekly), torque tighten
cool, dry place where they will not be injured or wheel rim nuts to 600 Nm (442 lbf ft).
damaged.
Check tyres regularly and replace or repair if required.
Valve cores should also be stored in a cool, dry and
clean place.
SERVICE TOOLS
Refer to Section 300-0070, SERVICE TOOLS for part
MAINTENANCE numbers of the nitrogen tyre inflation kit shown in
Check tyre pressures daily, preferably before the Fig. 7 and general service tools required.
TYRE INFLATION PRESSURES (BRIDGESTONE)

FRONT CENTRE AND REAR
2
MODEL TYRE SIZE bar lbf/in bar lbf/in2
TA40 29.5 R 25** 3.31 48 4.41 64
TYRE INFLATION PRESSURES (MICHELIN)

2
TA40 29.5 R 25** 2.90 42 3.86 56
TYRE INFLATION PRESSURES (GOODYEAR)

2
TA40 29.5 R 25** 3.24 47 4.6 66
TYRE INFLATION PRESSURES (CONTINENTAL)

2
TA40 29.5 R 25** 3.0 44 4.5 65

TORQUE
1 9 Wheel Nut 600 442
10 SM 2593 01-10
Section 160-0050
TUBELESS TYRE LEAK DIAGNOSIS

Occasionally, a tubeless off-highway tyre/rim assembly may leak in field service. To determine the 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 Fit a new lubricated O-ring

Tyre cuts and snags Repair tyre damage
Bead area awl holes Repair inner liner (preferred option)
Leakage between tyre bead With tyre removed from rim:
trim Cleantyre 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 parts. Note: Weld trim should follow rim
contour.
Mount the tyre using a lubricant such as Murphy's Tyre and Tube Mounting
Compound or equivalent on tyre beads and rim bead seat area.
* * * *
SM 2593 01-10 11
Section 160-0050
12 SM 2593 01-10
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
DESCRIPTION AND OPERATION

Numbers in parentheses refer to Fig. 1. Hydraulic fluid will remain within the
braking system after engine shutdown.
The service brakes are of the enclosed, forced oil- Operate the treadle valve continuously until
cooled multiple disc type. The service brakes are the pressure has dissipated before carrying out
actuated by hydraulic oil as specified in Section 300- any work on the braking system or serious
0020, LUBRICATION SYSTEM. DO NOT use BRAKE injury could result.
FLUID (J 1703). Multiple discs within the brake
assemblies are cooled by brake cooling oil as specified Use extreme caution to prevent personal
in Section 300-0020, LUBRICATION SYSTEM. injury when removing wheels. The exact
procedure must be followed as described in
The brake assembly is bolted to the stub axle and Section 160-0050, WHEEL, RIM AND TYRE.
houses a sandwich of friction discs splined to a hub
rotor. There are five friction discs (20) in each brake 1. Position the vehicle in a level work area, apply the
assembly. parking brake and switch off the engine.
When the treadle valve is actuated, hydraulic oil enters 2. Turn the steering wheel in both directions several
the brake assembly and forces the brake piston (14) times to relieve any pressure in the steering circuit.
against the rotating friction discs (20) which react with Operate the treadle valve continuously to relieve any
stationary reaction discs (21). The reaction discs (21) pressure in the braking system. Block all road wheels.
are retained by scalloped tangs at the outside
diameter, which in turn transfers the reaction torque to 3. Remove drain plug and drain cooling oil from brake
the rigid outside housing (1), slowing or stopping wheel packs into a clean container. Reinstall plugs.
rotation.
4. Drain oil from hubs and differentials. Refer to
In an emergency situation, application of the park/ Section 160-0030, AXLE GROUP (HUB) and Section
emergency valve will actuate the service brakes and 160-0020, DIFFERENTIAL DRIVE HEAD.
the parking brake to bring the machine to a halt. In this
condition, a restriction in the 'Px' line from the brake 5. Refer to Section 160-0030, AXLE GROUP (HUB) for
manifold valve will slow oil flow from the parking brake disassembly instructions.
allowing the service brakes to actuate momentarily
ahead of the parking brake. 6. Attach suitable lifting equipment to brake assembly
and support weight. Loosen and remove bolts securing
When the treadle valve or park/emergency brake is brake assembly and hub carrier to axle stub.
released, hydraulic pressure against piston (14) is
relieved and cup springs (24) force the piston (14) to 7. With brake assembly supported, remove brake
return to its original position, thus, relieving the assembly from axle stub.
pressure against the brake disc pack.
8. Place brake assembly on a clean work surface for
disassembly.
REMOVAL
9. Remove and discard all 'O' rings and oil seals from
brake assembly.
WARNINGS
secured and of sufficient capacity to do the job
safely.
SM 2594 01-10 1
Section 165-0015
SM - 3969
3 5
4
2
1
25
26
12
9 11
10
27
28 13
30
29
19
8 6
7 18
10 17
9
24
14
15
16
23
20
22 21
1 - Brake Housing 12 - 'O' Ring 22 - Clutch Disc

2 - 'O' Ring 13 - Screw 23 - Guide Ring
3 - Sealing Holder 14 - Brake Piston 24 - Cup Spring
4 - 'O' Ring 15 - 'U' Ring 25 - Stop Ring
5 - Seal Slide Ring 16 - Support Ring 26 - Screw
6 - Screw Neck 17 - 'U' Ring 27 - 'O' Ring
7 - 'O' Ring 18 - Support Ring 28 - 'O' Ring
8 - Vent Valve 19 - Guide Ring 29 - Plug
9 - Plug 20 - Friction Disc 30 - 'O' Ring
10 - 'O' Ring 21 - Reaction Disc
11 - Anchor Plate
Fig. 1 - Brake Pack Explosion
INSTALLATION
1. Refer to Fig 36. Using suitable lifting equipment, offer 4. Refill brake coolant tank with oil as described in
Anchor plate (3), brake assembly (5) and hub carrier (1) Section 250-0025, BRAKE COOLANT TANK.
up to axle stub (8) and secure with washers (7) and
bolts (6); applying adhesive 15500690 to bolts (6) and
WARNING
torquing to a value of 460 Nm (339 Ibf ft).
2. Refer to Section 160-0030, AXLE GROUP (HUB) for
assembly instructions.
secured and of sufficient capacity to do the job
safely.
3. Fill hubs and differentials with oil. Refer to Section
160-0030, AXLE GROUP (HUB) and Section 160-0020,
DIFFERENTIAL DRIVE HEAD.
2 SM 2594 01-10
Section 165-0015
DISASSEMBLY SM - 3145
3 13
Numbers in Parentheses refer to Fig. 1 , unless

otherwise stated. For removal of AXLE HUB refer to
section 160-0030.
1. Loosen the hex headed screws (13) and separate 1
the sealing holder (3) from the brake housing (1). As

shown in Fig 2. Install adjusting screws 15501167, to
maintain remaining assembly together.
Fig. 2 -Sealing Holder removal
3 SM - 3112
STEP 1 5
2. Lever the slide ring seal (5) out of the sealing holder
(3) using pry bar 15270132 and then remove the 'O'-ring
(4) from the holder (3). Shown in Fig 3.
4
STEP 2
3
Fig. 3 - 'O'-ring removal
SM - 3971
3.Remove the 'disc set' (20, 21 & 22) from the brake
housing (1).Now carefully remove the brake housing (1) 20,21,22
from the Anchor plate (11) by means of a lifting tackle 1
15501170 and Eyebolts 15270115 . Shown in Fig 4.
11
Fig. 4 - 'Disc set / Brake Housing removal'
26 14 SM - 3972
25
4. Drive back the Screw (26) to remove the stop ring

(25) from the Brake piston (14).shown Fig 5.
Fig. 5 Snap Ring removal
SM 2594 01-10 3
Section 165-0015
5. Press out the stop ring (25) by means of automatic SM - 3510
adjusting from the Brake piston (14). Shown
Fig 6. using tool 15270132.
SM - 3973
25 14
Fig. 8 - Loosening Hub carrier
10. Remove hub carrier (1, fig 36) from axle housing (8,
fig 36) using suitable lifting straps 15501168 as shown
in Fig. 9.
SM - 3511
fig. 6 - Support Shim Removal
SM - 3974
26
25
Fig. 9 - Separate Hub carrier
11. Separate anchor plate (11, fig. 1) from axle

housing (8, fig. 36) using suitable eyebolts 15270115
fig. 7 - Support Shim breakdown and lifting chain 15501178 as shown in fig. 10.
SM - 3512
6. Using the tools - Clamping pliers 15501175 and
Assembly fixture 15502408. Remove the O rings (26).
Preload the cup springs (24) to ease removal.
7. Remove O rings (27 and 28). Remove released Cup

springs (24) and guide ring (23)
7. By means of compressed air, press the piston out of

the brake housing (1).
8. Remove the guide ring (19), U-rings (15 & 17) and
support rings (16 & 18) from the annular grooves of the Fig. 10 - Separate Hub carrier
brake housing (1).
9. Loosen bolts (6, Fig 36) connecting hub carrier

(1, Fig 36) to axle housing (8), Fig 36). Install adjusting
screws to aid in removal. Remove bolts (6, Fig 36) and
washers (7, fig 36) as shown in fig. 8.
4 SM 2594 01-10
Section 165-0015
ASSEMBLY 4. Refer to Fig. 14, Install Bolts in direction of force
and by 180 Deg turned to each other.
otherwise stated. SM - 3130
1. Apply sealing compound to the mounting face of the

axle stub and install adjusting screws 15501167.
Shown in Fig. 11
SM - 3118
Fig. 14 Slotted Pins
5. Ensure adhesive 15500690 has been applied to bolts

(6, Fig. 33) prior to tightening. Now tighten bolt (6, Fig.
36 ) connections to 460 Nm (339 lb ft ).
Fig. 11 Sealing / adjusting screws
Note : It is now necessary to adjust the rolling moment

2. Refer to Fig 12. Taking Eyebolts 15270115, mount of the wheel bearing, prior to final fit of the brake pack
the Anchor plate (11) to the axle. Now apply sealing assembly.
compound to the face of the plate.
6. Press the wheel bolts into the output shaft until
SM - 3119
contact, using wheel bolt puller 15500884 and inserts
15269895.
7. Refer Fig.15, Press both bearing outer rings into the

hub until contact is made using a suitable Driver and
Handle 15269898.
SM - 3120
Fig. 12 Fitting Anchor Plate
3. Refer to Fig. 13. Locate the screw connection hub

carrier/axle housing & anchor plate (1,3,8 , fig 36) by
means of hex screws with washers provisionally until
contact is obtained ( do not tighten).
SM - 3120
Fig. 15 Wheel bolts & Bearing Mounting
8. Fig.16, Using a suitable lifting aid, mount the bearing

inner ring (1) onto the hub carrier (2).
9. Fig. 16, Heat the inner diameter of the bearing inner

Fig. 13 Screw Connection
ring to approximately 120 Deg Celsius using Hot air
blower 15269899. At which point mount the ring (1) and
bearing (2) onto the hub carrier (3) until seated home.
SM 2594 01-10 5
Section 165-0015
SM - 3123 Rotate Hub in a clockwise directions several times to
ensure free rotation.
SM - 3127
Fig. 16 Mounting to Hub.
10. Refer to Fig 17. Insert the ring gear carrier (1) into Fig. 19 - Checking Rolling Moment
the ring gear (2) and fasten it by means of snap ring

(3).
12. Refer to fig. 19, Check the rolling moment by
3 SM - 3124 means of a spring balance 15501169. As follows:
Rolling moment 'Torque' must be within range :-
T= 20 Nm (max) - 14.5 Nm (min)
(Hub dia. 444 mm therefore r = 0.222m.)

1
Tensile force Fmax = T / r = 20 / 0.222 = 90 N
Tensile force Fmin = T / r = 14.5 / 0.222 = 65 N
2
Note: If the rolling moment is not achieved, it has to
be corrected by means of the Shim (35, fig. 36). i.e.
Moment to low, then a thinner ring must be installed.
Conversely if the moment is too high, then a thicker
ring must be installed.
Fig. 17 - Ring Gear Sub-assembly.
If bearings are being used which have already been
run, it is acceptable to reduce the max and min rolling
11. Refer to Fig. 18, Insert the ring gear sub assembly
moment range by 50%. i.e. within the range of :-
(fig 14) . Now screw on the slotted nut (34, fig. 33) and
tighten nut to 2000 Nm Max, using Socket 15500882
32N - 45 N
and Centering bracket 15500883.
13. Now loosen the nut (34, fig. 36) and remove the
SM - 3125, 3126 hub (16, fig. 36) from the hub carrier (1, fig. 36) using
Socket- 15500882 & Centering bracket- 15500883.
STEP 1 STEP 2
THE BRAKE DISC ASSEMBLY CAN NOW BE

INSTALLED.
Numbers in parentheses refer to Fig 1. unless stated

otherwise.
1. Clean the annular grooves of the brake housing (1)

Fig. 18 - Securing Nut. with spirit.
2. Refer to Fig 20. Install the support rings (16) ,
U-rings (15 & 17) and guide ring (19) as shown.
6 SM 2594 01-10
Section 165-0015
Secure the guide ring with Loctite (type No 415) at its 27 SM - 3134
extremities.
SM - 3975
14
Fig. 27 - Retaining Support Shim in Piston
10. Insert the pre-assembled support shim into position

and fasten by means of Snap ring (27) as shown
in Fig. 27
SM - 3138
19
18
17
15
16
23
9 1
Fig. 29 - 'O'-Ring fitting
Fig. 20 - Brake Housing Assembly.

12. Refer to fig. 29, Grease 'O' -ring (4) and insert into
3. Refer to fig. 20, Insert the piston (14) into the Brake pressure oil supply bore.
housing, ensuring adequate levels of oil have been
applied to sliding /contact surfaces of the constituent 13. Grease the 'O' -ring (12) and insert into the annular
parts. groove. Install plug (9) with a new 'O'- ring (10) as
shown in fig. 29
4. Refer to fig. 21, Mount the piston by means of
tooling fixture, comprising of Sliding Pads 15501171, Note: Plug tightening Torque 60Nm max
Two armed puller 15501172 and Support shim
15501173. 14. Using Eye bolts 15270115, locate the brake carrier
onto the Anchor plate (11) and fasten 3 Hex screws at
equal intervals to the brake housing. As shown in fig.
SM - 3130
30.
SM - 3976
Fig. 21 - Piston Mounting / tooling Fig. 30 - Fit Brake Housing to Axle hub
SM 2594 01-10 7
Section 165-0015
15. Take Adjusting screws 15501167 and locate on

17. Grease 'O'-ring (4) and insert into the annular groove
Hub carrier (1, fig. 36). Using Spline mandrel 15501176,
of the sealing holder (3).
install Reaction & Friction Discs (20,21) alternately ,
starting with a Reaction disc, as shown in fig. 31.
18. Wet the 'O'-ring of seal slide ring (5) and insert into
the seal slide ring.
Note: Oil Disc to ZF list of Lubricants TE-ML 05
SM - 3977 19. Press the seal slide sing (5) into sealing holder (3)
ensuring the surface of the seal slide ring does not
show any profiled grooves, scratches or other damage,
which could affect the performance / integrity of the
sealing elements.
WARNING
Seal slide ring has a sharp edge so safety gloves
must be worn to prevent injury to user.
Fig. 31 - Install Frction / Reaction discs. 20. Mount sealing holder (3) on to the brake housing (1)
until contact is obtained and fasten with hex screws
16. There may be the requirement for a new lined
(13) to 390Nm max, as shown in Fig. 33.
(inner ) disc to keep the clearance within the specified
tolerance range: - SM - 3169
SM - 3978
Y 22
21 1
14 13
3
11
3
20
Fig. 33 - Mounting Sealing Holder / Mandrel
X
Fig. 32 - Lined Disc Clearance details. 21. Install valve vent plug (8), new 'O'-ring (7) and screw
neck (6). Now install a suitable adaptor and pressurize
Max clearance for new lines discs: 1.3 +0.3 / -0 mm
the piston with air to approximately 4 bar to fasten the
disc set. As shown in Fig. 34.
Max. Clearance (Worn ) : 4.1 mm
SM - 3979
To determine the clearance, proceed as follows;
Refer to Fig. 29, 8,6,7
Determination of clearance for lined disc:
X......................................= 28.00mm
Y......................................= 28.00mm
Clearance -1.40mm.
If required , correct the clearance with an adequate

outer disc.
Fig. 34 - Pressurizing Disc Set
8 SM 2594 01-10
Section 165-0015
22. Remove the Mandrel 15501176 for aligning the Disc Oil Change Period
set (20 & 21). As shown in Fig. 35.
Note: For recommended oils, refer to Section
SM - 3171 300-0020, LUBRICATION SYSTEM.
Drain (preferably after a short run to warm the oil) oil

from brake coolant tank every 1 000 hours. Refer to
Section 250-0025, BRAKE COOLANT TANK. Remove
drain plugs and drain brake cooling oil from each brake
assembly every 1 500 hours of operating. Change oil
filter every 1 500 hours. Refill brake coolant tank as
described in Section 250-0025, BRAKE COOLANT
TANK.
SPECIAL TOOLS
Fig. 35 - Removing Mandrel
Refer to Section 300-0070, SERVICE TOOLS, for
details of service tools and adhesives required. These
MAINTENANCE tools and adhesives are available from your dealer.
WARNING
job safely.
SM 2594 01-10 9
Section 165-0015
SM - 3970
6
7
5
3 4
10
16
15
14
2
1 18 19
17
34
13
12
11
35 36
8
9 29
24 25
37
22
21
20
28 38
27 33
26
23
32
30 31
1 - Hub Carrier 11 - Shaft seal 22 - Ring gear 33 - Planet Carrier

2 - Drive shaft 12 - Ring 23 - Slotted Nut 34 - Bolt
3 - Anchor Plate 13 - Roller Bearing 24 - Locking Plate 35 - 'O'-Ring
4 - 'O'-Ring 14 - Bolt 25 - Screw 36 - Plug Screw
5 - 'O'-Ring 15 - Lockwasher 26 - Washer 37 - Plug
6 - 'O'-Ring 16 - Wheel nut 27 - Sun Gear Shaft 38 - Cap Screw
7 - Brake Assembly 17 - Hub 28 - Thrust Washer
8 - Bolt 18 - Ring 29 - 'O'-Ring
9 - Washer 19 - Bearing 30 - Retaining Ring
10 - Axle Housing 20 - Snap Ring 31 - Roller Bearing
21 - Ring gear carrier 32 - Planet Gear
Fig. 36- Brake Assembly / Axle Stub installation
* * * *
10 SM 2594 01-10
Parking Brake - Parking Brake and Mounting
Section 170-0010
SM - 3519
7,8
13 10
2
12 15 11
9
4,5
1
6
14
3
1 - Mounting Plates 6 - Nut 11 - Washer

2 - Calliper Head Assembly 7 - Clevis Pin 12 - Control strap
3 - Slack Adjuster 8 - Cotter Pin 13 - Cap assembly
4 - Bolt 9 - Actuator 14 - Slack adjuster screw
5 - Washer 10 - Nut 15 - Bolt
16 - Bolt
Fig. 1 - Parking Brake Mounting
Operation is by a spring applied/hydraulically released

actuator (9). Actuator (9) is connected through slack
WARNINGS
adjuster (3) to the power screw shaft (19, Fig. 2) that is
Use only hydraulic oils meeting specifications
screwed into piston (6, Fig. 2) in calliper head
outlined in Section 300-0020, LUBRICATION
assembly (2). Calliper head assembly (2) slides on
SYSTEM. Do Not use Brake Fluid (J1703). Use
mounting plates (1) bolted to the frame. Slack adjuster
of improper fluids is destructive to rubber
(3) automatically maintains brake clearance after each
components of brakes resulting in loss of
application through the control strap (12). Control strap
braking and possible catastrophic failure.
(12) connects the slack adjuster (3) to the cap
assembly (13).
Exercise extreme caution while working
on the braking system.
A push control on the dash panel activates the park
brake solenoid in the main hydraulic valve, controlling
DESCRIPTION AND OPERATION oil pressure from the accumulators to actuator (9).
Application of the push control releases oil from
actuator (9) allowing internal springs in the actuator to
apply the parking brake. Pulling out the push control
directs oil pressure from the accumulators to actuator
The parking brake consists of a sliding calliper acting
(9), compressing internal springs, to release the parking
on a brake disc on a rear drive line. The parking brake
brake.
is of 'Inverted Design' i.e. requiring pressure to hold the
Note: The parking brake is automatically applied when
parking brake off.
the ignition is switched off or when the transmission is
in neutral and output speed is less than 75RPM.
(Approximately 0.8 m/h)
SM 2428 Rev1 04-10 1

Section 170-0010
REMOVAL 8. Disconnect and plug hydraulic line from actuator (9).

Cap actuator (9) to prevent ingress of dirt.
9. Remove nuts (10) and washers (11) securing
actuator (9) to cap assembly (13). Remove actuator (9)
from cap assembly (13).
WARNINGS
10. Support calliper head assembly (2) and remove
bolts (4 & 16), washers (5) and nuts (6) securing
mounting plates (1) to mounting bracket on the frame.
safely.
11. Remove mounting plates (1) and calliper head
assembly (2) from the vehicle.
within the braking system after engine shut SM - 3986
2 4 3
carrying out any work on the braking system or
serious injury could result.
1. Position the vehicle on a level surface, apply the

1
parking brake, block all road wheels and place the
steering lock bar in the 'Locked' position.
2. Raise the body and install body safety prop to

secure in partially raised position.
3. Remove storage box under the Instructor seat by 1 - Parkbrake switch 3 - Bolt
referring to operator compartment - Instructor seat and 2 - service alarm 4 - park brake switch Cover
Mountng, Removal and Disassembly Section 260-0110
Fig. 3 - Park brake over ride switch located under
4. Undo and remove the bolts(3) securing the park Instructor seat
brake service switch cover plate(4) . (Refer to fig. 3)
5.Press the bottom of the parkbrake service switch(1) DISASSEMBLY

to release the park brake. Numbers in parentheses refer to Fig. 2.
Note: The park brake service alarm (2) will remain on 1. Remove calliper head assembly as described under
continously while the auto park brake system is removal.
disabled. (Refer to fig. 3)
2. Remove snap ring (13) from power screw shaft (18),
5. Pull out push control to release the parking brake. and remove fasteners securing control strap (27) to
slack adjuster (14).
6. Release spring tension on slack adjuster clevis pin
(7) by unscrewing tensioning bolt on slack adjuster (3) 3. Slide slack adjuster (14) from power screw shaft (18).
until clevis pin (7) feels loose. Remove cotter pin (8)
and clevis pin (7) from actuator (9). 4. Remove and discard washer (16), wave spring
washer (15) and packing (17) from power screw
Note: The parking brake will automatically apply on shaft (18).
engine shutdown or when the transmission is in neutral
and output speed is less than 60RPM~1MPH. Ensure 5. Remove bolts (2) and washers (3) securing cap
there is sufficient clearance for actuator rod travel. assembly (21) to calliper (6).
7. Switch off the engine and place the battery master 6. Remove as a unit, power screw shaft (18),
switch in the 'Off' position. piston (5) and cap assembly (19 through 22) from
calliper (6).
2 SM 2428 Rev1 04-10

Section 170-0010
SM - 2802
18
19 20
21
6 3
2
12
'A'
11
22 26
24 25
17
10 15
14
16 7
1
'A'
27
4
8
23 5
9 13
AT POSITION 'A'
1 - Brake Pad 8 - Clevis Pin 15 - Wave Spring Washer 22 - Journal Bearing

2 - Bolt 9 - Cotter Pin 16 - Washer 23 - Plug
3 - Washer 10 - Nut 17 - Packing 24 - Pressure Relief Fitting
4 - Piston Seal 11 - Washer 18 - Power Screw Shaft 25 - Lockwasher
5 - Piston 12 - Actuator 19 - Thrust Bearing 26 - Nut
6 - Calliper 13 - Snap Ring 20 - Gasket 27 - Control Strap
7 - Clevis 14 - Slack Adjuster 21 - Cap Assembly
Fig. 2 - Exploded View of Parking Brake Assembly
7. Slide power screw shaft (18) and piston (5) from cap 2. Replace cap assembly (21) if excessively worn.
assembly (21).
3. Inspect all brake parts for cracks, excessive wear or
8. Unscrew piston (5) from power screw shaft (18). scoring. Replace brake parts as required.
9. Remove and discard thrust bearing (19) from power

screw shaft (18) and gasket (20) from cap ASSEMBLY
assembly (21). Numbers in parentheses refer to Fig. 2.
10. Remove and discard piston seal (4) from calliper (6). 1. Install new piston seal (4) into seal groove in calliper
(6).
INSPECTION 2. Apply grease (Lubriplate Aero or equivalent) to flat
Numbers in parentheses refer to Fig. 2. face of new thrust bearing (19).
1. Thoroughly clean all parts. Inspect journal bearing 3. Install and seat new thrust bearing (19) over splined
(22) in cap assembly (21) for wear. Journal bearing (22) end of power screw shaft (18) with greased side of
ID should not exceed 38.35 mm (1.51 in). Replace if thrust bearing (19) against thrust collar of power screw
necessary. shaft (18).
SM 2428 Rev1 04-10 3

Section 170-0010
Note: Ensure correct installation of thrust bearing (19) INSTALLATION
by verifying that installation was made over the larger
diameter end of power screw shaft (18), and, that thrust
bearing (19) ID lip is towards splined end of power
screw shaft (18).
WARNING
4. Lubricate threads of power screw shaft (18) with
grease (Lubriplate Aero or equivalent) and screw power
screw shaft (18) into piston (5).
5. Coat outside of piston (5) with grease (Lubriplate
safely.
Aero or equivalent) then slide assembled power screw
shaft (18) and piston (5) into cap assembly (21), shaft
1. Attach suitable lifting device and position mounting
end first.
plates (1) in mounting bracket and calliper head
assembly (2) over brake disc. Secure mounting plates
6. Line up gasket (20) and bolt cap assembly (21), with
(1) to mounting bracket on the frame with bolts (4 &
assembled power screw shaft (18) and piston (5), to
16), washers (5) and nuts (6). Tighten nuts (6) to a
calliper (6) using bolts (2) and washers (3). Tighten bolts
torque of 75 Nm (55 lb ft).
(2).
2. Remount actuator (9) on cap assembly (21, Fig. 2)
Note: Care should be taken not to push piston seal (4)
and install washers (11), lockwashers (25, Fig. 2) and
out of seal groove in calliper (6) when assembling cap
nuts (10). Tighten nuts (10) finger tight only at this
assembly (21), with piston (5) and power screw shaft
stage.
(18), to calliper (6).
7. Install new packing (17), wave spring washer (15) WARNING

and washer (16) over power screw shaft (18), in the
Do not pressurize actuator until the following
order shown in Fig. 2.
instruction has been carried out. Pressurizing
the actuator beforehand can result in serious
8. Mount actuator (12) on cap assembly (21) with nuts
brake damage.
(10), lockwashers (25) and washers (11). Tighten nuts
(10) finger tight only at this stage.
3. Turn adjustment screw (14) on the slack adjuster (3)
in a clockwise direction until the brake pads in calliper
9. Apply coat of grease (Lubriplate Aero or equivalent)
head assembly (2) are tight against the brake disc.
to mounting spline of slack adjuster (14).
4. Connect hydraulic line to actuator (9). Place the
10. With adjusting screw facing towards actuator (12)
battery master switch in the 'On' position, start the
slide slack adjuster (14) on power screw shaft (18)
engine. Ensure the park brake service switch is ON
aligning slack adjuster (14) arm with clevis (7).
and pull out parking brake control knob to extend the
actuator.
11. Install snap ring (13) on power screw shaft (18).
5. Connect slack adjuster (3) to actuator (9) by
12. Remove nuts (10), lockwashers (25) and washers
inserting clevis pin (7) through clevis (7, Fig. 2) on
(11) securing actuator (12) to cap assembly (21).
actuator (9). Secure clevis pin (7) with cotter pin (8).
Remove actuator (12) from cap assembly (21) to aid in
installation.
6. Align actuator (9) to slack adjuster (3) and tighten
nuts (10).
7. Loosen bolt (15) at the control arm of slack adjuster

(3) and control strap (12).
8. Position control arm of slack adjuster (3) in fully

released position (forcing it in a direction away from
actuator (9)) by turning adjustment screw (14) on the
4 SM 2428 Rev1 04-10

Section 170-0010
slack adjuster (3), until it comes to a positive stop MAINTENANCE
inside the control strap (12).
Every 250 hours
9. Tighten bolt (15) at the control arm of slack adjuster
Test park brake for proper operation. Check brake pads
(3) and control strap (12).
and disc for wear. Replace brake pads when lining
thickness is 3.0 mm (0.125 in) or less. Replace disc
Note: Failure to position the slack adjuster against the
when worn by 3.0 mm (0.125 in) or more.
internal stop may result in brake drag.
10. Use feeler gauges between brake pads in calliper Brake Pad Replacement
head assembly (2) and brake disc. Turn the
1. Remove calliper head assembly as described under
adjustment screw (14) on the slack adjuster (3) until
'Removal'.
the total pad-to-disc clearance is between 0.04 - 0.06"
(1.0 - 1.5 mm), which is 0.02 - 0.03" (0.5 - 0.75 mm)
2. Replace worn brake pad and carrier assemblies.
per side.
3. Install calliper head assembly and adjust slack
11. Remove feeler gauge and apply brake several
adjuster as described in 'Installation'.
times. The automatic slack adjuster will adjust the
brake pad clearance with each application, which can
be seen by the rotation of the adjustment screw (14). SPECIAL TOOLS
12. When the adjustment screw (14) stops rotating, the
specified clearance has been obtained and the brake is
ready for normal operation.
dealer.
13.Switch OFF Parkbrake service switch and refit
Cover and storage Box. (Refer to fig.3 )
14. Remove wheel blocks and place the steering lock

bar in the 'Stowed' position.

TORQUE
1 4 Bolt 680 501.5
1 6 Nut 680 501.5
1 16 Bolt 680 501.5
1 17 Bolt 70 52
* * * *
SM 2428 Rev1 04-10 5

Section 170-0010
6 SM 2428 Rev1 04-10

SUSPENSION SYSTEM - Front Suspension
Section 180-0020
SM - 3945
16
17
15
9
11
7 8 8,9,10,11
7
14 12,13,14,15
19 34 16,17,28,34
13
26
10
3 18
25 12 19
24 28 26
3
21,22 1
2 18
25
23 24
5,6 24
30
31
25 27
5,6 24
23 29
24
30
33 5,6 20
32 30
25
31 20
25
5,6 4
23
33
32
1 - Bracket LHS 10 - Chain 19 - Bolt 28 - Spacer

2 - Bracket RHS 11 - Adjusting Screw 20 - Nut 29 - Bolt
3 - Plate 12 - Pin 21 - Panhard Rod 30 - Hardened Washer
4 - Bolt 13 - Pin 22 - Bush 31 - Guard Assembly
5 - Control Link 14 - Suspension Bush 23 - Bolt 32 - Bolt
6 - Bushing 15 - Washer 24 - Locknut 33 - Washer
7 - Shock Absorber 16 - Nut 25 - Hardened Washer 34 - Circlip
8 - Front Suspension Mount 17 - Washer 26 - Washer
9 - Rebound Mount (Rubber) 18 - Bolt 27 - Bolt
Fig. 1 - Exploded View of Front Suspension
DESCRIPTION Suspension is provided by two heavy duty rubber

Numbers in parentheses refer to Fig. 1. suspension mounts (8 and 9) mounted on the central
plate of brackets (1 and 2) which have internal chain
The front axle assembly is mounted on the suspension (10) assemblies to provide extra retention on rebound.
brackets (assemblies 1 and 2) , which in turn are linked Additional damping is provided by four heavy duty
to the chassis frame through a system of shock double acting shock absorbers (7) (two on each side) to
absorbing/rubber mount assemblies through the smooth out the ride.
vertical axis.
Panhard rod (21), provides the traverse link between
the left and right hand sides of the suspension
SM 2595 01-10 1
Suspension System - Front Suspension
Section 180-0020
assembly, while control links (5) provide the means of shock absorbers (7) to the front frame mounting point.
retaining longitudinal control over the length of the 12. Remove nut (16) and washer (17), securing the
tractor frame, between the suspension and the front rebound mounts (9) to the chassis frame. Remove the
frame pivot. rebound mounts (9) and washers (15).
13. Remove the bolts (23), washer (25) and nuts (24)
REMOVAL securing the control links (5) to the chassis frame
brackets, on both the LHS and RHS of the frame.
WARNING 14. Remove the bolts (32) and washers (33) securing the
To prevent personal injury and property control links (5) to the guard assembly (31) on both the
damage, ensure that wheel blocks, blocking LHS and RHS of the frame.
secured and of adequate capacity to do the job 15. Remove the bottom Control Links (5) on both sides.
safely.
16. Using suitable lifting equipment and jacks, lower the
1. Position the vehicle in a level work area, ensure the axle/suspension assembly sufficiently to allow
body is fully lowered, apply the parking brake and disassembly of the remaining components.
switch off the engine. Turn steering wheel several
times to relieve any pressure in the steering system. 17. Ensure that the jacks are central under the
suspension frame brackets (1 and 2). Lower the jacks
2. Block rear road wheels, place the steering lock bar until the rubber mounts are free of compression.
in the 'Locked' position and place the battery master
switch in the 'Off' position. 18. Position a suitable trolley under the suspension
frame, carefully lower the suspension and axle on to
3. Whilst the front road wheels are still on the ground, the trolley and remove them from under the vehicle.
loosen the wheel nuts.
19. Remove Bolts (27 and 29), Washers (30) and Nuts
4. Using suitable lifting equipment, raise the machine (20) from the suspension frame and remove the LHS
until both front tyres are off the ground. Support the and RHS Brackets (1 and 2) from under the vehicle.
vehicle with suitable stands and blocking at the tractor
frame and articulation pivot area.
DISASSEMBLY
5. Support one tyre and rim assembly with suitable Numbers in parentheses refer to Fig. 1.
lifting equipment and remove wheel nuts securing the
rim to the axle. Remove tyre and rim assembly.
WARNING
6. Repeat step 5 for the opposite tyre and rim To prevent personal injury and property
assembly. damage, be sure lifting equipment is properly
7. Remove sump guards from chassis frame if safely.
necessary. Refer to Section 100-0010 CHASSIS.
1. Support the Panhard rod (21) prior to removal.
8. Prior to axle removal, support axle using suitable
fixture. 2. Remove the bolts (4 and 23), washers (25) and nuts
(24) securing the Panhard rod (21) between the LHS
9. Disconnect hydraulic brake line at tee on front axle and RHS brackets (1 and 2).
assembly. Disconnect differential breather line. Cap
lines and fittings to prevent ingress of dirt. 3. Remove the Panhard rod (21) from the assembly.
10. Support driveline and remove bolts securing 4. Remove the front suspension mounts (8) from the
driveline to front axle. Refer to Section 130-0010, brackets (1 and 2).
FRONT DRIVELINES.
5. Remove the Circlip (34) and Pin (13) securing the
11. Remove bolts (19) and washers (26) securing the chains (10) to the adjusting screws (11).
2 SM 2595 01-10
Section 180-0020
6. Remove the pin (12) securing the chains (10) to the INSTALLATION
brackets (1 and 2).
7. Remove the adjusting screws (11), chains (10) and
Suspension Bushes (14). WARNING
8. Remove the remaining bolts (18), washers (25) and
nuts (24) securing control links (5) to LHS and RHS
brackets.
safely.
9. Remove Bolts (32) and Washers (33) securing the
control links (5) to the guard assembly (31) on the LHS
Note: The LH and RH assemblies of the suspension are
and RHS of the frame.
largely the same. Where applicable, carry out the same
procedure steps for both sides of the suspension.
10. Remove top control links (5) on both sides.
1. Using suitable lifting equipment, lower the chassis
frame over the axle and on to suitable stands.
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 2. Pull the adjusting screw (11) through the front frame
bracket and fit the rebound mount (9). Fit the washers (15
Note: Tighten all fasteners without special torques and 17) over the adjusting screw (11) and on to the top of
specified to standard torques listed in Section the rebound mount (9), then fit the two nuts (16) to the
adjusting screw (11) threaded end.
SPECIFICATIONS.
3. Using two jacks centrally positioned under the axle,
draw the axle up to the chassis frame to set the initial ride
WARNING height.
damage, be sure lifting equipment is properly 4. The nuts (16) should be torqued to pre-compress the
secured and of adequate capacity to do the job mounts (8 and 9).
safely.
Note: Do not torque against the chain (10).
1. Ensure that the axle is positioned on a suitable trolley/
jig to allow sub-assembly of the suspension, prior to
SM - 3593
installation to the unit.
2. Fit the LH and RH bracket (1 and 2) in position with

155 mm
respect to the axle at respective points. Secure them in
place using the bolts (27 and 29), washers (30) and nuts
(20).
3. Install the spacer (28) and bush (14) to each bracket

fitted to the axle.
4. Secure the chains (10) to the boss on the axle through

spacer, using 2-off pins (12) with Loctite 638™ .
5.Install the adjusting screws (11) to the chains (10) using

the pins (13) and Circlip (34) with Loctite 638™.
Fig. 2 - Rubber Length
6.Install the front suspension mounts (8) over the chains
(10), and the adjusting screw (11) on to the axle.
SM 2595 01-10 3
Section 180-0020
5. Lock off the nuts (16) on the end of the adjusting screw 19. Attach the shock absorbers to the front frame
(11), and set the pre-compressed length of the rebound mounting points. Re-fit the nut, washer and rubber bush
mount (9) to the value shown in Fig. 2. to each shock absorber.
6. Torque the nut (16) to a value of 250 Nm (183 Ibf ft). 20. Using suitable lifting equipment, position one tyre
and rim assembly on a front wheel and secure it with
Note: The 203 mm dimension (pre-compressed length of wheel nuts. Tighten locknuts to a torque of 730 Nm
the rubber mounts) must be checked after the initial 250 (540 lbf ft).
hours of operation and adjusted if necessary. Perform this
check and adjustment for each rubber mount. 21. Using suitable lifting equipment, position the
opposite tyre and rim assembly on the opposite front
7. Install the Panhard rod (21) between the axle wheel and secure it with wheel nuts.
brackets on the LHS and the frame bracket on the
RHS. 22. Using suitable lifting equipment, raise the tractor
frame sufficiently to remove the stands and blocking
8. Secure the Panhard rod at the axle bracket using from the tractor frame and articulation pivot. Lower the
two bolts (4), washers (25) and nuts (24). Torque the vehicle to the ground and remove the lifting equipment.
bolts to a value of 570 Nm (420 Ibf ft). Tighten all wheel nuts to a torque of 730 Nm (540 lbf ft).
9. Secure the Panhard rod (21) at the rear frame 23. Remove the wheel blocks from the rear road wheels
bracket using two bolts (23), washers (25) and nuts and place the steering lock bar in the 'Stowed' position.
(24). Torque the bolts to a value of 570 Nm (420 Ibf ft).
24. Bleed all air from hydraulic brake lines. Refer to
10. Install top and bottom control links (5) to the guard Section 165-0010, BRAKE PARTS.
assembly (31) with bolts (32) and washers (33).
11. Install the bottom control links (5) to the frame ADJUSTMENTS
bracket and axle bracket using four bolts (23), washers Numbers in parentheses refer to Fig. 1.
(25) and nuts (24) on both sides. Torque the bolts to
570 Nm (420 Ibf ft).
WARNING
12. Install the top control links (5) and connect them to To prevent personal injury and property
the upper frame brackets using four bolts (18), washers damage, be sure lifting equipment is properly
(25) and nuts (24) on both sides. Torque the bolts to secured and of adequate capacity to do the
570 Nm (420 Ibf ft). job safely.
13. Release jack pressure to allow the axle to drop to 1. Position the vehicle in a level work area, ensure that
the set height. the body is fully lowered, apply the parking brake and
switch off the engine. Turn the steering wheel several
14. Place two shock absorbers (7) upside down in a times to relieve any pressure in the steering system.
suitable jig or fixture.
2. Following the instructions at 'Removal' adjust the
15. Remove the nut, washer and single rubber bush inner nuts (16) to give the desired compression of
from the bottom of each shock absorber. rubber mounts (9).
16. Fit the mounting plate (3) over the shock absorbers. 3. Apply Loctite Activator 'T'™ and Loctite 638™ to the
Re-fit the nut, washer and rubber bush to each shock threads above the inner nuts (16). Tighten down the
absorber. outer nuts (16) against the inner nuts (16), making sure
that the inner nuts (16) do not move.
17. Secure the plate (3) (and shock absorbers) to the
axle bracket using four bolts (19) and washers (26). 4. Complete the installation of the front suspension.
Torque the bolts (19) to a value of 169 Nm (125 Ibf ft). Refer to 'Installation'.
18. Remove nut, washer and single rubber bush from

top end of each shock absorber.
4 SM 2595 01-10
Section 180-0020
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for the
part numbers of the hydraulic jack, power press, press
tool, and general service tools and sealants required.
These tools and sealants are available from your dealer.

TORQUE
1 4 Bolt 570 420
1 18 Bolt 570 420
1 23 Bolt 570 420
1 16 Nut 250 183
1 19 Nut 169 125
- - Wheel Nut 730 540
* * * *
SM 2595 01-10 5
Section 180-0020
6 SM 2595 01-10
Suspension System - Rear Suspension
Section 180-0040
SM - 3521
12 15 12 14
11 'A' 30 DETAIL 'C'

12 5,6 19 'D'
'C'
34
'A'
24,23
'C' 4
26 17
7 5,6
13 29 30
21 20 11
22 4 12 19
25 30 16 8 'A'
30 19
27 DETAIL 'D' 19 19
7
3 'A'
8
29 'A' 9 18
33 2 16
16 32 10
18 'A'
19 7
19 33 5,6 'B'
33 'E'
31 33 8
1 5,6
32
33 31 32
9 'B' 'A'
'A' 33
10 7 'E'
29
'A' 33 9
39 5,6 32 'A'
33 10
1
5,6 16
35
29 19
37 8
51 38
39
DETAIL 'B' 36
3 FORWARD
9
'A' 10
35
37
14 39
12 40
36
28
38
DETAIL 'A' TYPICAL 39
DETAIL 'E' FRAME MTG.
1 - Bracket assembly 9 - Hardened Washer 17 - Washer 25 - Cover Plate 33 - Retainer

2 - Bracket assembly 10 - Locknut 18 - Bolt 26 - Bolt 34 - Bracket Assembly
3 - Bracket assembly 11 - Bolt 19 - Lockwasher 27 - Lube fitting 35 - Pin
4 - Equalizer Beam 12 - Hardened Washer 20 - Wear Ring 28 - Bolt 36 - Lockwasher
5 - Control Link 13 - V-Ring Seal 21 - Bushing 29 - Bolt 37 - Bolt
6 - Bushing 14 - Locknut 22 - Retaining Plate 30 - Locknut 38 - Washer
7 - Interleaf Mount 15 - Bolt 23 - Washer 31 - Panhard Rod 39 - V-Ring Seal
8 - Bolt 16 - Bolt 24 - Bolt 32 - Spherical Bearing 40 - Spacer
Fig. 1 - Exploded View of Rear Suspension
DESCRIPTION
Loads acting on the centre and rear axles are balanced by
centrally pivoting equalizer beams (4) with rubber cushioning
otherwise stated.
interleaf mounts (7) between axles and beam ends.
Interleaf mounts (7) are rubber/steel laminated
Each axle is coupled to the chassis by three rubber compression units with chain link ties.
bushed leading or trailing control links (5) which provide
longitudinal restraint. Lateral restraint is by transverse
Lubrication of spherical bearings (32) in panhard rods
panhard rods (31).
(31) is through remote mounted lube fittings (43, Fig. 2)
SM 2392 01-10 1
Section 180-0040
1 SM - 3520
47
BRACKET RH
48 41
43
41 49
42
44
41 31 42 45,46
1
47
42 50
31
51
BRACKET LH
47 TRAILER CHASSIS
LH FRAME RAIL
41 - Elbow 44 - Manifold Plate 48 - Hose Assembly

42 - Elbow 45 - Bolt 49 - Hose Assembly
43 - Nipple 46 - Washer 50 - Hose Assembly
47 - P-Clip 51 - Hose Assembly
Fig. 2 - Rear Suspension - Lubrication Lines
secured to manifold plate (43). Lubrication of bushings 4. Using suitable blocking equipment, block equalizer
(21) in equalizer beams (4) is through lube fittings (27). beams to prevent movement when raising the trailer
frame.
REMOVAL 5. Whilst the rear road wheels are still on the ground,
Numbers in parentheses refer to Fig. 1 unless loosen the wheel nuts.
otherwise stated.
6. Using suitable lifting equipment, raise the machine
until the rear wheels are off the ground. Support the
vehicle with suitable stands and blocking at the trailer
WARNING frame, articulation pivot area and centre and rear axle
To prevent personal injury and property assemblies.
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly 7. Support one tyre and rim assembly with suitable
secured and of adequate capacity to do the job lifting equipment and remove wheel nuts securing the
safely. rim to the axle. Remove tyre and rim assembly.
1. Position the vehicle in a level work area, raise the 8. Repeat step 7 for the remaining rear tyre and rim
body and install body safety prop to secure body in assemblies.
partially raised position
9. Disconnect hydraulic brake lines from tee at both the
2. Apply the parking brake and switch off the engine. centre axle and rear axle assemblies. Cap lines and
Turn steering wheel several times to relieve any fittings to prevent ingress of dirt.
pressure in the steering system.
10. Remove blocking equipment from equalizer beams
3. Block front road wheels, place the steering lock bar (4).
in the 'Locked' position and the battery master switch in
the 'Off' position. 11. Disconnect grease lines (48,49,50 & 51 Fig. 2) from
elbows (41 & 42, Fig. 2), on both panhard rods (31).
2 SM 2392 01-10
Section 180-0040
Cap lines and fittings. If necessary remove elbows (41 Remove mounting bracket (2).
& 42 , Fig. 2) from panhard rods (31).
26. Remove locknuts (10), hardened washers (9) and
12. If necessary, remove p-clips (47) and manifold bolts (8) securing mounting bracket (3) on the centre
bracket (44) from the chassis frame. Refer to Fig. 2. axle. Remove mounting bracket (3).
13. Remove locknuts (30), lockwashers (19) and 27. Remove locknuts (10), hardened washers (9) and
bolts (29) securing interleaf mounts (7) to equalizer bolts (8 & 18) securing mounting bracket (1) on the
beams (4). centre axle. Remove mounting bracket (1).
14. Remove bolts (16) and lockwashers (19) securing 28. Remove bolts (11) and hardened washers (12)
interleaf mounts (7) to brackets (1 & 3) mounted on the securing mounting bracket (34) on the centre axle.
centre and rear axles. Remove interleaf mounts (7).
INSTALLATION
15. Remove bolts (26) and washers (17) securing cover Numbers in parentheses refer to Fig. 1.
(25) to equalizer beam (4). Remove cover (25).
16. Remove bolts (24) and washers (23) securing WARNING

retaining plate (22) to shaft on frame. Remove retaining To prevent personal injury and property
plate (22). damage, be sure blocking materials and lifting
17. Using suitable lifting equipment, support equalizer adequate capacity to do the job safely.
beam (4) and withdraw from shaft on frame. If
required remove bushing (21) from equalizer beam (4). 1. Install bracket (2) on rear axle with holes on control
link (5) mounting lugs to the rear. Apply Loctite 243 to
18. Remove wear ring (20) and 'V' ring seal (13) from bolts (11) and secure bracket (2) to rear axle with bolts
shaft on frame. (11) and hardened washers (12). Tighten bolts (11) to a
19. Repeat steps 13 through 16 to remove the opposite
equalizer beam (4). 2. Install RH bracket (1) on rear axle with control link
(5) mounting brackets to underside and bracket
20. Remove locknuts (14), hardened washers (12) and extension to the front. Secure bracket (1) to rear axle
bolts (15 & 28) securing control links (5) between the with bolts (8 & 18), hardened washers (9) and locknuts
rear and centre axle brackets (1, 2 , 3 & 34) and frame (10). Install bolts from the top with hardened washers
mounting brackets. Remove control links (5). and locknuts at the bottom. Tighten bolts
(8 & 18) to a torque of 790 Nm (583 lbf ft).
21. Refer to detail 'B' & 'E'. Remove bolts (37),
lockwashers (36) and washers (38) securing pins (35) 3. Install LH bracket (3) on rear axle with control link (5)
through mounting brackets (1) on both centre axle/ LH mounting brackets to underside and pointing inwards
frame mounting bracket and the rear axle / RH frame towards the rear. Secure bracket (3) to rear axle with
mounting brackets. bolts (8), hardened washers (9) and locknuts (10).
Install bolts from the top with hardened washers and
22. Remove both panhard rods (31), v-ring seals (39) locknuts at the bottom. Tighten bolts (8) to a torque of
and spacers (51). If necessary remove retainers (33) 790 Nm (583 lbf ft).
and spherical bearings (32) from panhard rods (21).
4. Install interleaf mountings (7) on the rear axle. Apply
23. Remove locknuts (10), hardened washers (9) and Loctite 243 to bolts (16) and secure interleaf mounts (7)
bolts (8) securing mounting bracket (3) on the rear axle. on the rear axle with bolts (16) and lockwashers (19).
Remove mounting bracket (3). Tighten bolts (16) to a torque of 169 Nm (125 lbf ft).
24. Remove locknuts (10), hardened washers (9) and 5. Install bracket (2) on centre axle with holes on
bolts (8 & 18) securing mounting bracket (1) on the rear control link (5) mounting lugs to the front. Apply Loctite
axle. Remove mounting bracket (1). 243 to bolts (11) and secure bracket (2) to centre axle
with bolts (11) and hardened washers (12). Tighten
25. Remove bolts (11) and hardened washers (12) bolts (11) to a torque of 457 Nm (337 lbf ft).
securing mounting bracket (2) on the rear axle.
SM 2392 01-10 3
Section 180-0040
6. Install LH bracket (1) on centre axle with control link Locate spacers (51), v-ring seals (39) and panhard rod
(5) mounting brackets to underside and bracket (31) ends in place. Insert pins (35) into bores and
extension to the rear. Secure bracket (1) to centre axle secure pins (35) in place with washers (38),
with bolts (8 & 18), hardened washers (9) and locknuts lockwashers (36) and bolts (37).
(10). Install bolts from the top with hardened washers
and locknuts at the bottom. Tighten bolts (8 & 18) to a Note: Ensure that there is at least 2/3 mounting
torque of 790 Nm (583 lbf ft). surface area contact. Check contact area using a
0.05 mm (0.002 in) feeler gauge.
7. Install RH bracket (3) on centre axle with control link
(5) mounting brackets to underside and pointing 13. Using a suitable solvent, clean equalizer beam (4)
inwards towards the rear. Secure bracket (3) to centre shaft on the frame. Install new 'V' ring seal (13) and
axle with bolts (8), hardened washers (9) and locknuts new wear rings (20) on the shaft with flanges to the
(10). Install bolts from the top with hardened washers inside. Ensure mounting holes on the ends of the shaft
and locknuts at the bottom. Tighten bolts (8) to a are clean.
14. Using a suitable solvent, clean the bores of
8. Install interleaf mountings (7) on the centre axle. equalizer beams (4). Install new bushings (21) in
Apply Loctite 243 to bolts (16) and secure interleaf equalizer beams (4) aligning holes in bushings with
mounts (7) on the centre axle with bolts (16) and holes in equalizer beams.
lockwashers (19). Tighten bolts (16) to a torque of 169
Nm (125 lbf ft). 15. Using suitable lifting equipment, install equalizer
beam (4) on frame shaft. Apply Loctite 243 to bolts (24)
9. Install control links (5) between rear and centre axle and secure equalizer beam (4) to shaft with bolts (24),
mounting brackets (1 & 3) and frame mounting washers (23) and retaining plate (22). Tighten bolts (24)
brackets and secure with bolts (28), hardened washers to a torque of 169 Nm (125 lbf ft).
(12) and locknuts (14). Install bolts (28) with bolt heads
to the brackets. Tighten bolts (28) to a torque of 531 16. Apply Loctite 243 to bolts (26). Install cover plate
Nm (392 lbf ft). (25) to equalizer beam (4) and secure with bolts (26)
and washers (17). Tighten bolts (26) to a torque of
Note: Ensure that there is at least 2/3 mounting 73 Nm (54 lbf ft).
surface area contact. Check contact area using a
0.05 mm (0.002 in) feeler gauge. 17. Apply Loctite 243 to lube fitting (27) and install in
cover plate (25). Lubricate with grease specified in
10. Install control links (5) between rear and centre axle Section 300-0020, LUBRICATION SYSTEM, until
mounting brackets (2) and frame mounting brackets excess lube is seen.
and secure with bolts (15), hardened washers (12) and
locknuts (14). Tighten bolts (15) to a torque of 531 Nm 18. Repeat steps 15 through 17 to install opposite
(392 lbf ft). equalizer beam (4).
Note: Ensure that there is at least 2/3 mounting 19. Connect interleaf mounts (7) to equalizer beams (4)
surface area contact. Check contact area using a with bolts (29), lockwashers (19) and locknuts (30).
0.05 mm (0.002 in) feeler gauge. Tighten bolts (29) to a torque of 169 Nm (125 lbf ft).
11. Install panhard rod (31) between mounting bracket 20. Remove caps and connect hydraulic brake lines to
(1) on centre axle and LH frame mounting bracket. tees on centre axle and rear axle assemblies.
Locate spacers (51), v-ring seals (39) and panhard rod
(31) ends in place. Insert pins (35) into bores and 21. Using suitable blocking equipment, block equalizer
secure pins (35) in place with washers (38), beams (4) to prevent movement when installing rear
lockwashers (36) and bolts (37). wheels.
Note: Ensure that there is at least 2/3 mounting 22. Secure manifold bracket (43, Fig. 2) to chassis
surface area contact. Check contact area using a frame.
0.05 mm (0.002 in) feeler gauge.
23. Route grease lines (48,49,50 & 51, Fig. 2); securing
12. Install panhard rod (31) between mounting bracket to frame using p-clips (47, Fig. 2). Connect grease
(1) on rear axle and RH frame mounting bracket. lines to their respective elbows (41 & 42, Fig. 2).
4 SM 2392 01-10
Section 180-0040
24. Secure grease fittings (43, Fig. 2) to manifold 27. Remove wheel blocks from front road wheels and
bracket (44, Fig. 2). place the steering lock bar in the 'Stowed' position.
24. Using suitable lifting equipment, position one tyre 28. Bleed all air from hydraulic brake lines. Refer to
and rim assembly on one rear wheel and secure with Section 165-0010, BRAKE PARTS.
wheel nuts.
25. Repeat step 24 for remaining rear wheels. MAINTENANCE

26. Using suitable lifting equipment, raise trailer frame otherwise stated.
sufficiently to remove stands and blocking from the
axles, articulation pivot and trailer frame. Lower vehicle Every 250 Hours: Lubricate equalizer beam bushings
to the ground and remove lifting equipment. Tighten all (21) through lube fittings (43, Fig. 2) with grease
wheel nuts to torque specified in Section 160-0050, specified in Section 300-0020, LUBRICATION
WHEEL RIM AND TYRE. SYSTEM, until excess lube is seen.

TORQUE
1 8 & 18 Bolt 790 583
1 11 Bolt 457 337
1 15 & 28 Bolt 531 392
1 16, 24 & 29 Bolt 169 125
1 26 Bolt 73 54
* * * *
SM 2392 01-10 5
Section 180-0040
6 SM 2392 01-10
Electrical System - Circuit Diagrams
Section 190-0000
COMPONENT DESIGNATIONS
A4 - 12V Radio Tuner/CD Player K23 - Ignition Engine Relay S1 - Battery Master Switch
A5 - Radio/Cassette Speaker K23 - Ignition Radio Tuner/CD S2 - Starter Keyswitch
Player S7 - Emerg/Park Brake Switch
B7 - Coolant Level Sensor K25 - Service Brake Status Relay S9 - Washer Switch, Front
B8 - Fuel Level Sender K27 - Mid-axle Difflock Relay S10 - Wiper Switch, Front
B13 - Rotational Speed Sensor K32 - Engine Brake Relay S11 - Rear Wash/Wipe Switch
B19 - Throttle Position Sensor K34 - Horn Relay S13 - Horn Button
B21 - Trans Oil Sump Temp Sender K47 - Intermittant Wipe Relay S14 - Hazard w/l Switch
B32 - Trans Oil Retarder Temp K48 - Range Inhibit Relay S15 - Direction Ind Switch
Sender K50 - Brake Lights Relay S18 - Lights Switch
B37 - Brake Axle Oil Temp K52 - Body Proximity Switch Relay S19 - Dipswitch
Sensor (TA40 only) K63 - Retartder Warning Light S20 - Headlamp Flash Switch
B38 - Trans Oil Level Sender Relay S22 - Body Proximity Switch
K64 - Dropbox Difflock Relay S29 - Trans Retarder Request Sw
E3 - Interior Light K66 - Engine Overspeed Protection S31 - Park Brake w/l Switch
E5 - Reverse Light Relay S37 - Axle difflock position Switch
E11 - Side Marker Light, Left K67 - Dropbox Difflock Relief Valve S38 - Hydraulic Filter restrict Press
E12 - Taillight, Left Relay Sw
E13 - Side Marker Light, Right K68 - Engine 2000 rev/min Limiting S41 - Auxilliary Lights Switch
E14 - Taillight, Right Relay S48 - Accumulator Press Sw
E15 - High/Low Beam H'lamp, Left K69 - Dropbox Port brake Interlock (Tractor)
E16 - High/Low Beam H'lamp, Right Relay S49 - Accumulator Press Sw
E19 - Rear Fog Lamp K71 - Park brake off relay (Trailer)
E21 - Rotating Beacon K72 - Transmission range indicator S56 - Air Cleaner restrict Press Sw
E23 - Work Light Relay S57 - Steering Pressure Switch
E26 - High Beam H'lamp, Left S60 - Difflock Request Switch
E27 - High Beam H'lamp, Right L3- Reverse / Back Alarm S68 - Engine Diagnostic
E35 - Heated Mirror L4 - Warning Buzzer request switch
L5 - Electric Horn S69 - Accel idle validation Switch
G1 - Generator/Alternator L7 - Reverse Camera Monitor S78 - Body Auxiliary Lower Switch
G2 - Battery L8 - Body Raise / Lower S79 - Heated Mirror Switch
joystick S80 - Engine brake 'med' and 'high'
H6 - Direction Indicator; F, L L9 - Transmission Shift Lever stages
H7 - Direction Indicator; B, L L10- Transmission Retarder Lever S82 - Engine brake 'low' stage
H8 - Direction Indicator; F, R L12- Brake service warning Buzzer S93 -OCDB High Press Switch
H9 - Direction Indicator; B, R S100 - Dropbox low ratio select Sw
H10 - Brake Light, Left M1 - Starter Motor
M4 - Washer Motor, Front S101 - Dropbox Primary High Temp.
H11 - Brake Light, Right S102 - Dropbox High Range
H29 - Work Socket Illumination M5 - Wiper Motor, Front
M6 - Wiper Motor, Back Indicator Sw
H33 - Autolube high pressure w / l S103 - Dropbox Low Range
H34 - Autolube over ride w / l M7 - Washer Motor, Back
M13- Air Seat Compressor Indicator Sw
M16- Auto lube pump S104 - Dropbox Low Oil Press Sw
K1 - Starter Relay S105 - Hood raise / Lower Sw
K4 - Start Interlock Relay S106 - Brake pedal Position Sw
K5 - A/C Comp Clutch/Relay N3 - 24V/12V Voltage Converter
N4 - Speedo Frequency Divider S108 - Dropbox Secondary High
K14 - Start Interlock Relay Temp. Switch
K15 - Headlamp Relay N7 - PWM/Analogue
convertor module S110 - Transmission Retarder/
K17 - Reverse Alarm/Light Relay Lockup Drop Out Pressure
K21 - Trans Shift / Actuator Clutch N9 - Auto lube control module
R10 - Rkr Switch 'Locating' LED Switch
K23 - Ignition Air/Con/Aux Supplies S111 - Dropbox Difflock Relief
Relay R11 - Rkr Switch 'Function' LED
S115 - Auto lube high pressure
K23 - Ignition Wipers/Auxiliary R12 - 12V Work Socket
Switch
Supplies Relay R13 - 24V Work Socket S116 - Auto lube over ride Switch
S117 - Parkbrake service Switch
SM 2596 Rev1 04-10 1

Section 190-0000
Y37 - OCDB Triple Pump Motor Solenoid
Y4 - Emergency/ Park Brake Y39 - Engine Radiator Fan Isolation Solenoid
Solenoid Y40 - Engine Radiator Fan Proportional Solenoid
Y7 - Difflock Solenoid (mid axle) Y41 - Low Range Select Solenoid
Y14 - Retarder Solenoid Y42 - High Range Select Solenoid
Y26 - Body Raise Solenoid Y43 - Difflock Solenoid (Dropbox)
Y27 - Body Lower Solenoid Y44 - Hood Raise/Lower Actuator
Y32 - Trans Radiator Fan Proportional Solenoid Y45 - Body Tailgate Open Solenoid
Y33 - System Hydraulics Unloader Valve Y46 - Body Tailgate Close Solenoid
Y34 - System Hyd Float Valve Y47 - Low Idle Load Sense Pressure Reducing Valve
Y36 - Trans Oil Cooler Fan Isolation Solenoid Solenoid
Y50 - Dropbox Park brake inter lock solenoid
Wire Colours
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 B - Black O - Orange
L - LEFT, R - RIGHT, F - FRONT, B - BACK N - Brown Y - Yellow
U - Blue P - Purple
DIODE FUSE RESISTOR PLUG R - Red W - White
G - Green S - Slate
TRAILER CONNECTION L - Light Green K - Pink
A
Harness interface - Dash Harness and Main Chassis Harness (48 way connector)
B Harness interface - Dash Harness and Main Chassis Harrness (102 way connector)
C Harness interface - Main Chassis Harness and Engine Harness (21 way socket housing on main chassis section)
D Harness interface - Main Chassis Harness and Engine Harness (21 way pin housing on main chassis section)
E Harness interface - Main Chassis Harness and Transmission Interface Harness
F
Harness interface - Main Chassis Harness and Dropbox Harness
G Harness interface - Main Chassis Harness and Hydraulic Valve Harness
H Harness interface - Main Chassis Harness and Rear Frame Harness
Harness Auxilliary Components Connection
All fuses and relays are located in the main fuse box/relay compartment in the cab, except for K1, which is located
at the rear left-hand side of the engine bay, K68, K69 and K72, which are located in the controls storage area under
the passenger's seat.
All stated dash harness splices, the main power busbar, the transmission ECU, the instrument panel CPU and the
hydraulics ECU (including the hydraulics diagnostic/programming port), Parkbrake service switch / Alarm are
located in the controls storage area underneath the passenger's seat.
The engine ECU, transmission ECU and instrument panel CPU/cluster diagnostic/programming connector is
located on the right-hand side of the passenger's seat (J1939 industry standard 9-pin Deutsch style connector).
2 SM 2596 Rev1 04-10

Section 190-0000
FUSES
Location Fuse No. Circuit Current Rating
1 Ignition Wipers 20 A
2 Keyswitch 15 A
3 Hazards 7.5 A
4 Rear Wash/Wipe 10 A
5 Horn Relay Coil, Front Wash/Wipe 10 A
Main Fuse Box - 6 Seat Air Compressor 10 A
Column A 7 Lights Switch 10 A
8 Main Beam/Flash 10 A
9 Wiper Park Front and Rear 7.5 A
10 Transmission Battery Supply 15 A
11 Transmission System Ignition Supply 10 A
12 Reverse Alarm/Light 7.5 A
13 Hydraulic Electronic Controls 30 A
14 Interior Light 5A
15 Direction Indicators/Rocker Switch Search LEDs 5A
16 Emergency/Park Brake 3A
Main Fuse Box - 17 Instrument Panel Ignition Supply 7.5 A
Column B 18 Heated Mirrors 15 A
19 Ignition Sensed Relay Coils 3A
20 +24V Auxiliary Work Socket 15 A
21 Neutral Start 3A
22 Washers, Front 3A
23 Washers, Rear 3A
24 Horn 10 A
25 Ignition Auxiliary Supplies 30 A
26 Air Conditioning/Heater/Ventilation System 15 A
27 Reverse Camera 10 A
28 Front Working Lights 15 A
Main Fuse Box - 29 Rear Working Lights 15 A
Column C 30 Rotating Beacon 5A
31 Engine Ignition Supply 10 A
32 Engine Battery Supply 30 A
33 Body Proximity Switch Supply 10 A
34 Dropbox/Difflocks Control System 15 A
35 Brake Pedal Switch 5A
36 24V/12V Voltage Converter Battery Supply 20 A
Instructor seat
Compartment 66 Park brake Antiroll 3A
Battery Box 61 Alternator System 100 A
Compartment 62 Vehicle System 100 A
As FL Hood Raise / Lower Actuator 10 A

Lettered FM Instrument Panel / CPU Battery Supply 15 A
(Main Fuse FK Auxiliary 12V Supply (12V Work Socket and Radio 20 A
Box) Tuner/CD Player)
FJ Auto lube system 20 A
SM 2596 Rev1 04-10 3

Section 190-0000
RELAYS
Location Letter Relay Circuit
Designation
Main Fuse Box A K67 Dropbox Difflock Relief Valve Relay
Column D B K66 Overspeed Relay
C K48 Range Inhibit Relay
D K25 Service Brake Status Relay
Main Fuse Box E K23 Ignition Air Con / Heater Relay

Column E F K23 Ignition Wipers Relay
G K34 Horn Relay
H K15 Headlamp Relay
Main Fuse Box I K17 Reverse Alarm / Light Relay

Column F J K14 Neutral Start Relay
K K71 Park brake Off Relay
L K63 Retarder Warning Light
Main Fuse Box M K50 Brake Lights Relay

Column G N K23 Ignition Engine ECU Relay
O K27 Mid-Axle Diff-lock Relay
P K4 Indicator Flasher Unit Relay
Main Fuse Box Q K32 Engine Brake Relay

Column H R K52 Body Proximity Switch Relay
S K64 Dropbox Diff-lock Relay
T K23 Ignition radio/cassette Relay
SM - 3600
Column A B C D E F G H
12 24 36
FD FH FM A E I M Q
FC FG FL
B F J N R
FB FF FK C G K O S
FA FE FJ D H L P T
1 13 25
Fig. 1 - Main Fuse Box - Fuse/Relay Location
4 SM 2596 Rev1 04-10

SM - 3988A Section 190-0000
SM 2596 Rev1 04-10 5

Section 190-0000
SM - 3988B
6 SM 2596 Rev1 04-10

SM -3988C Section 190-0000
SM 2596 Rev1 04-10 7

Section 190-0000
SM - 3988D
8 SM 2596 Rev1 04-10

SM - 3988E Section 190-0000
SM 2596 Rev1 04-10 9

Section 190-0000
SM - 3988F
10 SM 2596 Rev1 04-10

SM - 3988G Section 190-0000
SM 2596 Rev1 04-10 11

Section 190-0000
SM - 3988H
12 SM 2596 Rev1 04-10

SM - 3988I Section 190-0000
SM 2596 Rev1 04-10 13

Section 190-0000
SM - 3988J
14 SM 2596 Rev1 04-10

SM - 3988K Section 190-0000
SM 2596 Rev1 04-10 15

Section 190-0000
SM - 3988L
16 SM 2596 Rev1 04-10

SM - 3988M Section 190-0000
SM 2596 Rev1 04-10 17

Section 190-0000
SM - 3988N
18 SM 2596 Rev1 04-10

ELECTRICAL SYSTEM - Hydraulic System ECU
Section 190-0085
SM - 3565
Fig. 1 - IFM Electronic Control Unit
SM - 3566
DESCRIPTION 3
The hydraulic Electronic Control Unit (ECU), Fig.1 is a
stand alone control which controls the machines
hydraulic systems, including body hoist and oil cooler
fan drives. The IFM ECU communicates with a variety
of input and output devices. It utilizes analog/digital
inputs, proportional current outputs and digital outputs. 2
The ECU continuously monitors the system and warns
the operator when a fault develops, and also helps
diagnose the nature of the fault. ECU is located inside 1
the cab, on mounting plate, inside the instructor seat
(next to the transmission TCM) (see Fig. 2). 1 - Hyd ECU 2 - Trans TCM 3 - Bolt
Fig. 2 - Hydraulic ECU Location

WARNING
Before any welding is done on a machine
equipped with an Integrated hydraulic system, ECU Inputs
disconnect the following in this order:
Refer to Figure 3 and Section 190-0000, Circuit
Battery earth cable, battery supply cable,
Diagrams.
alternator earth cables, alternator supply
cables and electrical connections at the
engine ECM, transmission TCM, body control Analog Inputs
lever, hydraulics ECU, Instrument panel (VDU)
ECU, and cab bulkhead to avoid damage to Brake Temperature (Pin 8) - temperature sensor at
electrical components. Turn off battery master the front axle brake manifold sends an analog signal to
switch to isolate the batteries before ECU dependent on brake cooling oil temperature.
disconnecting any components. After welding
connect all of the above in the reverse order.
Body Control Lever (Pin 29) - The body control lever
sends an analog signal (0-5V) to the ECU dependant
SM 2597 Rev1 04-10 1

Electrical System - Hydraulic System ECU
Section 190-0085
SM - 3674
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Fig. 3 - Hydraulic ECU System Pin Order
upon the position the lever has been pulled or pushed

Dropbox Low Ratio Request (Pin 20) - When
into, indicating a raise or lower signal to the ECU.
dropbox low ratio switch (S100) is selected a signal is
sent to the ECU. When the ECU receives a dropbox
Digital Inputs low ratio request signal and the dropbox park enable
has been energized, the ECU will send a signal to
Body Up Proximity Switch (Pin 19) - When the body energize the dropbox low ratio solenoid. When the
is raised from the chassis the proximity switch is switch is open, it signals high request and when it is
closed circuit energizing 'body up' relay K52. From K52 closed , it signals low ratio request.
a signal is sent to the ECU indicating when the body is
up. With the body up, upshifts are restricted within the Service Brake Status (Pin 27) - the service brake,
transmission, the body up warning lamp is illuminated when depressed, operates a position switch (S106)
and the body control lever detent is energized for use. which in turn energizes relay K25. This relay (K25) in
When the body approaches the proxy switch (switch turn closes a contact permitting a signal to indicate to
open circuit) K52 is de-energized, removing the signal the transmission (via pin 63 of the transmission TCU)
from pin 19. The upshift inhibit is disabled, the lamp is
that the vehicle braking is being provided from this
off and the detent is de-energized. The ability to power
source rather than from the retarder. IFM needs this
down the body is cancelled and the float solenoid is
signal for dropbox low / high change.
energized.RPM will be limited to 2000.
Dropbox High Range Indicator Switch (Pin 11) -
Dropbox Primary High Temperature (Pin 55) - A
When Dropbox hi ratio is engaged , Dropbox High
two-stage temperature switch, S101, either fitted to the
Range Indicator Switch sends a digital signal to IFM.
dropbox control valve block and differential lock front
cover or to a tee connection on the outlet from the
Dropbox Low Range Indicator Switch (Pin 30) -
Dropbox Pressure Filter (Section 125-0045), sends a
When the dropbox low ratio is engaged, Dropbox Low
digital signal via pin 55, which initiates starting of the
Range Indicator Switch sends a digital signal to IFM.
transmission cooler fan when the oil temperature
reaches 60°C, and illuminates a Warning indicator on
the VDU when the oil temperature reaches 120°C. A
further (secondary) temperature switch, (S108) fitted in
the shaft lubrication line local to the dropbox, also ECU Outputs
sends a signal via pin 55 to initiate a Warning indicator
on the VDU when the oil temperature reaches 120°C. Digital Outputs
Transmission Cooling Fan Stop Solenoid (Pin 43) -
Air condition Signal (Pin 18) - When the air
The ECU sends a signal energizing the solenoid,
conditioning has been selected, a signal is sent to the
blocking hydraulic flow to the transmission cooling fan.
ECU to request the Engine Cooling Fan.
When any of the following parameters are met the Stop
solenoid is de-energized allowing hydraulic flow to the
fan:
))
2 SM 2597 Rev1 04-10
Section 190-0085
SM - 3989
ANALOGUE_IN DIG OUT

Brake Temp PIN 08 0
Dropbox High/Low,
PIN 09 1 PIN 40 Service brake pilot/Shift inhibit
Analog Inputs PIN 28 2
PIN 10 3
Body Control Lever PIN 29 4 PIN 39 Load sense reduction valve
DIG IN
Dropbox High Range Indicator Switch PIN 11 PIN 43 Transmission cooling fan stop solenoid
Dropbox Low Range Indicator Switch PIN 30
Digital Service Brake Status PIN 27
Body Up Signal PIN 19 PIN 04 Engine cooling fan stop solenoid
Inputs
Dropbox Temperature Switch PIN 55
Air Conditioning ON PIN 18
PIN 48 Brake cooling motor solenoid
Digital
Dropbox Low Ratio Request Switch PIN 20
PIN 03 Outputs
Park Brake Interface Solenoid PIN 22
PIN 41 PIN 49 Float solenoid
PIN 42
Binary Low O/P Transmission Range Indicator PIN 37
PIN 31 Cold start unloader solenoid
Park Brake
PIN 50 Off relay
FREQ IN
PIN 20
Frequency I/P Transmission O/P Speed PIN 02 PIN 51 Body Tailgate Close Solenoid
PIN 21
PIN 38
PIN 52 Dropbox Low Ratio Solenoid
PIN 16 Body Tailgate Open Solenoid
PIN 36 Dropbox High Ratio Solenoid
PWM/I OUT
PIN 44
Power Raise
VBBo
Proportional Solenoid
GNDo
PIN 45
VBBo Power Lower
POWER GNDo
Proportional Solenoid Current
Power Supply PIN 24 + 24VDC PIN 46 Outputs
Transmission Cooling Fan
Central Processing Unit/Sensors PIN 01 0VDC VBBo
Proportional Solenoid
Central Processing Unit/Sensors PIN 23 + 24VDC GNDo
Power In Ground Outputs GNDo PIN 15 0VDC PIN 47
Outputs Supply VBBo PIN 05 +24VDC VBBo Engine Cooling Fan
PIN 12 0VDC Proportional Solenoid
Ground Analogues GNDa GNDo
Supply Outputs VBBr PIN 34 +24VDC PIN 35
VBBr PWM / Analog Module Body Lever
RS-232 GNDo
PIN 06 RXD PIN 54
PIN 07 TXD VBBr
Communication Port GNDo
PIN 33 GND
PIN 24 TEST PIN 17
VBBr
PIN 14 GNDo
PIN 32 PIN 53
'CAN' Communication Port SAEJ1939 + [29] PIN 26 CAN2H VBBr
SAEJ1939 - [29] PIN 25 CAN2L GNDo
Fig. 4 - IFM ECU Pin Connections
l Trans Oil Temp greater than or equal to 80°C Engine Cooling Fan Stop Solenoid (Pin 4) - The
(176°F), ECU sends a signal energizing the solenoid, blocking
hydraulic flow to the engine cooling fan. When any of
l Retarder Oil Temp greater than or equal to 90° C the following parameters are met, the Stop solenoid is
(194° F), de-energized, allowing hydraulic flow to the fan:
l Dropbox Oil Temp greater than or equal to 60° C

l Inlet Manifold Temp greater than or equal to 54°C
(140° F), (129°F),
l Brake Cooling Oil Temp greater than or equal to l Engine Oil Temp greater than or equal to 108°C
59°C (138° F). (226°F),
SM 2597 Rev1 04-10 3

Section 190-0085
l Engine Coolant Temp greater than or equal to 89°C

(192°F), Body Tailgate Open Solenoid (Pin 16) - When the
vehicle is fitted with the hydraulically-operated, bottom
l Air Conditioning ON. hinged tailgate option, switch S37 closes as the body
begins to rise past it. The ECU sends a signal via pin
Brake Cooling Motor Solenoid (Pin 48) - Whenever 16 to solenoid A of the tailgate differential control valve
the ECU receives a signal indicating a temperature of (Y45), and solenoid B de-energizes (Y46, via pin 51).
50°C (122°F) a signal will be sent energizing the brake This operates the differential control valve in the
cooling motor solenoid, allowing flow to the brake direction to operate the tailgate cylinder, and thus the
cooling triple pump motor.When OCDB oil temperature tailgate, in the Open direction.
is more than 50°C, Brake cooling motor solenoid is
ON and when less than 50°C, it is OFF. Load Sense Pressure Signal (Pin 39) - When a low
engine speed of 900 rev/min coincides with a torque
Float Solenoid (Pin 49) - When the body approaches demand of 25% or greater, the ECU sends a signal
the proxy switch, the ECU outputs a signal to energize energizing the load sense control valve solenoid (Y47).
the body float solenoid. This ensures that the hoist When Y47 is energized, the load sense control valve
side of the body cylinders are vented to tank, allowing redirects the load sense pressure to the rear hydraulic
the body to lower on to the chassis under its own pump (LSPR) via the load sense pressure reducing
weight. It prevents pressure from being trapped in the cartridge of the load sense control valve, which is set at
hoist side of cylinders when travelling, ensuring that 160 bar. This pressure reduction minimizes the risk of
the body is resting on the chassis. If the body is not the engine stalling in these circumstances.
resting on the chassis when travelling, hinge points
and cylinders may be damaged, especially when the
body is laden. If the ECU receives a Raise request Drop box High / Low,Service Brake Pilot / Shift
from the body lever, the float solenoid signal is Inhibit (Pin 40) - During high / low change, when park
cancelled allowing pressure to build in the Raise brake is enabled this output energizes solenoid to
circuit. prevent service brake application and also energises
relay to signal the transition shaft inhibit.
Cold Start Unloader Solenoid (Pin 31) - When the
ECU receives the signal of the engine starting on the
communication link, the ECU sends an output signal Dropbox High Ratio Solenoid (Pin 36) - When the
to energize the cold start solenoid for 5 seconds. This ECU receives a dropbox High ratio request signal and
prevents the engine starting under hydraulic load. the dropbox park enable has been energized, the ECU
will send a signal to energize the dropbox high ratio
Park brake OFF relay (Pin 50) - When the ECU solenoid.
receives a transmission gear signal, it will send a
signal to energize relay K71 releasing the park brake
when a transmission gear is selected. PWM Outputs
Body Tailgate Close Solenoid (Pin 51) - When the Body Raise Proportional Solenoid (Pin 44) - When
vehicle is fitted with the hydraulically-operated, bottom the ECU receives a Raise signal from the body control
hinged tailgate option, switch S37 opens as the body lever, the ECU sends an output signal to the Raise
lowers past it. The ECU sends a signal via pin 51 to solenoid to shift the main control valve spool
solenoid B of the tailgate differential control valve accordingly. A typical output from the ECU is 0 - 1000
(Y46), and solenoid A de-energizes (Y45, via pin 16). mA, providing a delivery pressure in the range of 6 - 24
This operates the differential control valve in the bar (87 - 348 lbf/in2) at the main control valve spool.
direction to operate the tailgate cylinder, and thus the
tailgate, in the Close direction. Body Lower Proportional Solenoid (Pin 45) - When
the ECU receives a Lower signal from the body control
Dropbox Low Ratio Solenoid (Pin 52) - When the lever, the ECU sends an output signal to the Lower
ECU receives a dropbox low ratio request signal and solenoid to shift the main control valve spool
the dropbox park enable has been energized, the ECU accordingly. A typical output from the ECU is in the
will send a signal to energize the dropbox low ratio range of 0 - 1000 mA, providing a delivery pressure
solenoid. between 6 - 24 bar (87 - 348 lbf/in2) at the main control
valve spool.
4 SM 2597 Rev1 04-10

ELECTRICAL SYSTEM - Hydraulic System ECU
Section 190-0085
LED Colour Status Description

- Off No Operating Voltage
Orange 1 X on Initialisation or reset checks
5 Hz No operating system Loaded
Green 0.5 Hz Run,CANopen;PREOPERATIONAL
2 Hz Run,CANopen; OPERATIONAL
Constant Stop,CANopen; PREPARED
Red 0.5 Hz Run with error
(CANopen; PREOPERATIONAL)
2 Hz Run with error
(CANopen; OPERATIONAL)
On Fatal error or stop with error
Blue 0.5Hz Internal communication, Extended
Controller
Fig. 5 - LED Indicator Showing Different Modes
Engine Cooling Fan Proportional Solenoid (Pin 47) ECU Power and Ground
- When certain trigger temperatures are reached (see
engine cooling fan stop solenoid) the engine cooling fan The ECU has four, 24 V supply connections at pins 23,
will be commanded ON. The percentage of mA current 5, 24 and 34 respectively. It also has three
(in the range of 0-264 mA) sent to the engine cooling corresponding ground connections (0 V) at pins 1, 15
fan proportional solenoid is determined by the and 12.
measured temperature condition. This will cause the
fan to rotate at the desired fan speed. All power and ground connections are required for the
ECU to be fully operational.
Transmission Cooling Fan Proportional Solenoid
(Pin 46) - When certain trigger temperatures are Communication
reached (see transmission cooling fan stop solenoid)
The ECU is connected to the SAEJ1939 datalink at Pin
the transmission cooling fan will be commanded ON.
26 (CAN_H) and Pin 25 (CAN_L). This allows
The triggering temperature condition will dictate the
thehydraulic system ECU to communicate with the
percentage of mA current (in the range of 0-264 mA)
engine, transmission and VDO panel controllers to
sent to the transmission cooling fan proportional
receive signals such as engine speed (rev/min) or
solenoid. This will cause the fan to rotate at the desired
fan speed. transmission output speed.
PWM/AnalogModule (Pin 35) - A PWM signal is sent

to the PWM/Analog module (N7), which converts the System Diagnosis
signal to a 5 V supply for the body control lever. Refer to Figure 5.
An LED on the ECU is used to diagnose basic system

errors. The ECU indicates error status through the LED
System Safety as shown in Figure 5, giving an immediate diagnosis as
to the nature of the error that has occurred.
Input/Output Protection - all inputs to the ECU are
designed to withstand the maximum specified supply If there are no errors, the LED flashes green, twice
voltage. The outputs are protected against short circuit. every second to indicate the system is operational. Any
Additionally, an error on one input/output will not other colour designation indicates that there is a certain
influence other inputs/outputs. error condition, which should be investigated.
SM 2597 Rev1 04-10 5

Section 190-0085
3. Disconnect the battery ground cable first, then the

battery supply cable, before disconnecting the harness
WARNING from the IFM ECU inside cab.
Do not use the machine if an error code is
present. Shut down the machine until the 4. Remove bolts securing ECU to support inside the
problem is resolved. passenger seat, and remove ECU.
INSTALLATION
1. Secure ECU to support below the right hand console
using bolts removed previously.
REMOVAL
2. Firstly connect harness to ECU, then connect
battery supply cable and battery ground cable in that
WARNINGS order.
damage, ensure that wheel blocks, blocking 3. Turn master switch on, start engine and ensure that
materials and lifting equipment are properly the top LED runs through the correct operation
secured and of adequate capacity to do the sequence. Finishing with the LED flashing green at the
job safely. desired rate.

High electrical current can cause sparks
and personal injury from burns. Turn the
SPECIAL TOOLS
battery master switch to the 'Off' position
before removing any components. Remove the There are no special tools required for procedures
battery ground cable first, and reconnect it outlined in this section. To obtain IFM diagnostic
last, to avoid damaging electrical components. software, contact your dealer.

body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel several times
to relieve any pressure in the steering circuit.

the accumulators, block all road wheels, place the
steering lock bar in the 'Locked' position and the
* * * *
6 SM 2597 Rev1 04-10

Electrical System - Switches and Sensors
Section 190-0270
SM - 3946
LINES HOOD SW. STARTER

AIR CLEANER 9
SEC 250-0020 SOLENOID SW.
SEC 110-0050 29 HEADER TANK
A2 SEC 210-0040
14
A1
28 1
MASTER SW.
8
7
TREADLE 10
VALVE 32
PS1
SEC 250-0070
C
T
2
T
LOAD SENSE
VALVE
13
P
LS
MAIN HYDRAULIC
E
OD
HC
SEC. 230-0135
TC
BA
VALVE
31 SEC 215-0050 11
FUEL SENDER ON TANK 6
REF SEC 200-0010
PS3
21 22 25 4
DROPBOX
PS4 VALVE
20 PS2 5 SEC. 125-0025
24 BATTERY BOX
23 COOLANT/HYD. TANK
27 26 16 15 12 SEC 250-0025
RHS
RHS 2
30
RHS 3
DROPBOX
18 17 SEC 125-0010
19 MANIFOLD BLOCK
TRANSMISSION LHS - (FRONT AXLE) L.H. FRAME RAIL
ENGINE LHS - SENSORS SHOWN S.W.E. SENSORS SHOWN S.W.E. TRANS. SEC. 210-0052 (TRAILER)
1 - Hydraulic Filter Restriction Gauge 12 - Dropbox Temp. Switch 23 - Oil Temp Sensor
2 - Brake Cooling Oil Pressure Switch 13 - Float Switch 24 - Oil Pressure Sensor
3 - Brake Cooling Oil Temperature Switch 14 - Pressure Switch 25 - Coolant Temp Sensor (RHS)
4 - Parking Brake Pressure Switch 15 - Output Speed sensor 26 - Barometric Pressure Sensor
5 - Rear Brake Accumulator Pressure W/L 16 - Turbine Speen Sensor 27 - Timing Reference Sensor
6 - Front Brake Accumulator Pressure W/L 17 - Input Speed Sensor 28 - Hood Switch
7 - Coolant Level Sender 18 - Fuel Temp. Sensor 29 - Master Battery Diosconnect
8 - Starter Relay 19 - Fuel Pressure Sensor Switch
9 - Air Cleaner Restriction Gauge 20 - Synchronous Ref Sensor 30- Proximity Switch
10 - Main Hydraulic Pump Pressure Switch 21 - Air Temp Sensor 31- Fuel Sender
11 - Dropbox Pressure Switch 22 - Turbo Boost Pressure Sensor 32 - Load Sense Control Valve
Fig. 1 - Layout View of Switches and Sensors
DESCRIPTION Engine
Numbers in parentheses refer to Fig. 1, unless The DDEC engine management system monitors the
otherwise specified. engine at all times and sends a signal to the engine
check light (8, Fig. 2) and engine stop light (7, Fig. 2)
This section describes the location and function of on the dash panel to alert the operator of a fault in the
various switches and sensors fitted to the vehicle to engine circuit. Refer to Section 110-0030, ENGINE
monitor all major components and systems. Gauges AND MOUNTING.
and warning lights located in the dash panel, relay this
information to the operator. Engine Coolant Level Sender (7) - Located in the
radiator header tank, the sensor sends a signal to
Note: Always make sure all gauges, warning lights and engine ecm, indicating engine coolant level.
controls are working properly before operating the
vehicle. Engine Coolant Temperature Gauge (1, Fig. 2) -
Indicates the engine coolant temperature. The gauge
should read in the green zone after the engine has
warmed. If the gauge reads in the red zone, stop
engine and investigate the cause.
SM 2598 01-10 1
Section 190-0270
SM - 3982
5 6 7 8 9 10
3 4 11 12
2 13
2 STOP P
1
20 30 15
40 10 20
30 50
20 mph 60
10 40 r / min x100
km/h 5 25
10 70
80
0 0000000
0000 50 0 30
˚C 100
L H
70 135˚C 165
40 120 60 200
150 210 275 320
105 ˚F 250 ˚F 390
140
1 16 17 15 14
1 - Engine Coolant Temperature Gauge 7 - Engine Stop W/L 13 - Tachometer

2 - Speedometer 8 - Engine Check W/L 14 - Transmission Oil Temperature Gauge
3 - Front Brake Accumulator Pressure W/L 9 - Parking Brake Ind/L 15 - Dimming Button
4 - Rear Brake Accumulator Pressure W/L 10 - Transmission Check W/L 16 - Tripmeter Reset Button
5 - Headlight Main Beam Ind/L 11 - Emergency Steering W/L 17 - Not Used.
6 - Direction Indicators Ind/L 12 - Differential Lock Ind/L 18 - Visual Display Unit (VDU)
Fig. 2 - Layout View of Instruments and Indicator/Warning Lights
Engine Specific Sensors (18-27 Fig. 1) - A number of Transmission

engine mounted sensors which monitor timing, coolant, Transmission Specific Sensors (15-17, Fig. 1) -
fuel and oil temperatures and pressures. These send Refer to Section 120-0010, TRANSMISSION AND
signals back to the engine ecm to allow it to determine MOUNTING, for further information on switches and
how best to maintain outputs to keep the engine sensors fitted to the transmission.
running at its optimum level. For specific details of
individual sensors, refer to engine manufacturer for Oil Temperature Gauge (14, Fig. 2) - Indicates
detail. transmission oil operating temp. Gauge should read in
the green zone during normal operation and may reach
Tachometer (13, Fig. 2) - Driven from the engine ECU, the yellow zone when using the retarder or in convertor
the tachometer indicates the number of engine mode. If the gauge reads above this in the red zone,
crankshaft revolutions per minute. The needle shows stop engine and investigate the cause.
the variations in engine operating speed. Never
accelerate the engine to speeds indicated by the red
zone on the dial face. Dropbox System
Dropbox Pressure Switch (11) - Located on the
Hourmeter (8, Fig. 4) - Driven from the engine ECM, dropbox control valve the switch signals low pressure
the hourmeter records the total number of engine in the dropbox to the engine ECM.
hours.
Dropbox Temperature Switch (12) - Two dropbox
Starter Relay (8) - Mounted on the tractor frame rail, temperature switches are provided. One switch,
the starter relay powers up the starter motor when the mounted on the dropbox control valve, is a two stage
keyswitch is turned. switch, which is set to start the dropbox cooling
(radiator) fan when the temperature reaches 60°C
2 SM 2598 01-10
Section 190-0270
SM - 3981 (stage 1) and initiate the high temperature Warning

lamp on the VDU (stage 2) when the temperature
exceeds 120°C (9, Figure 3). The other temperature
1 2 3 4 5
switch is mounted on the dropbox casing and monitors
the oil temperature in the line supplying the dropbox
shaft lubrication points. This switch is also set to
15
initiate the high temperature Warning lamp on the VDU
(stage 2) when the temperature exceeds 120°C (9,
8
6 Figure 3).
9
7 10
Float switch (13) - This twin temperature switch
L H measures the temperature of the oil in the dropbox. If
the temperature is too high then the switch sends a
14 13 12 11 signal to the engine ECM and to the transmission
cooler.
1 - Low Fuel
2 - Alternator Charging
3 - Hydraulic Oil Filter Change Braking System
4 - Engine Air Filter Change
5 - Brake Cooling Oil Pressure Rear Brake Pressure Switch (5) - The normally closed
6 - Body Up (NC) pressure switch 'PS2', located in port ACC2S of
7 - Brake Cooling Oil Temp. the main hydraulic valve, senses the pressure in the
8 - Trans. Oil Temp High
rear brake circuit. The pressure switch sends a signal
9 - Trans. Dropbox Oil Temp. High
10 - Trans. Dropbox high/low Oil Press. to illuminate 'Red' rear brake accumulator pressure
11 - Trans. Dropbox, High ratio selected warning light (4, Fig. 2) when pressure drops to 122 bar
12 - Trans. Dropbox, Low ratio selected (1769 lbf/in2). An audible buzzer also sounds.
13 - Engine Brake
14 - Retarder
15 - Hydraulic oil level Front Brake Pressure Switch (6) - The normally
closed (NC) pressure switch 'PS3', located in port
Fig. 3 - Warning Symbol Screen
ACC1S of the main hydraulic valve, senses the
pressure in the front brake circuit. The pressure switch
SM - 3408C sends a signal to illuminate 'Red' front brake
Fuel Level accumulator pressure warning light (19, Fig. 2) when
1 pressure drops to 122 bar (1769 lbf/in2). An audible
0 25 50 75 100 buzzer also sounds.
Voltmeter
2 Parking Brake Pressure Switch (4) - The normally
8 12 16 20 24 28 32
closed (NC) pressure switch 'PS4', located in port PBS
Brake Cooling
3 of the main hydraulic valve, senses pressure in the
50 75 100 125 150 parking brake circuit. The pressure switch closes when
park brake pressure drops to 5 bar (70 lbf/in2) and
00000
L H sends a signal to illuminate 'Green' parking brake
indicator light (9, Fig. 2), indicating that the parking
4 5 6 7 8 brake is applied.
1 - Fuel Level
Brake Cooling Oil Pressure Switch (2) - The normally
2 - System Voltage open (NO) pressure switch, located in the front axle
3 - Brake Cooling manifold block, senses the pressure in the brake
4 - Retarder cooling oil circuit. The pressure switch sends a signal
5 - Engine Brake
6 - Engine Hours Counter
to illuminate brake cooling oil pressure warning light (5,
7 - Trans. Dropbox, Low ratio selected Fig. 3) when pressure rises to 1.5 bar (22 lbf/in2).
8 - Trans. Dropbox, high ratio selected
Brake Cooling Oil Temperature Switch (3) - The
Fig. 4 - Main Screen Display temperature switch, located in the front axle manifold
block, senses the temperature in the brake cooling
circuit. The temperature switch sends a signal to the
SM 2598 01-10 3
Section 190-0270
hydraulic ECU dependent on temperature.When a air cleaner, the restriction gauge indicates the degree of
temperature of 50°C (122°F) is reached the brake air cleaner element restriction as the red panel rises in
cooling pump is switched on. If the temperature the gauge window. The filter element(s) should be
continues to rise and reaches 60°C (140°F) the replaced if the red band locks in place when the engine
transmission cooling fan will be switched on and the is shut down. Reset the gauge by pressing the button
brake cooling temperature warning light (7, Fig. 3) will on the gauge with the engine running. Although should
illuminate. the restriction reach a predetermined level, the air filter
restriction warning symbol (4, Fig. 3) should flash up on
Brake Circuit Pressure Switch (14) - Stops the the VDU warning screen on the main dash panel.
machine going into a stall condition when under heavy
braking. Tw switch signals to the transmission to drop Fuel Tank
out of retard or lock up during the braking process. Fuel Level Sender (31) - Located into the top face of
the fuel tank, the fuel level sender sends a signal
Steering System which is displayed in the VDU main screen (1, Fig. 4)
Steering System Pressure Switch (12) - The as a bargraph, indicating the amount of fuel left in the
normally closed (NC) pressure switch is located in port tank. Should the fuel level drop below 25% a warning
PS1 of the main hydraulic valve. The pressure switch symbol (1, Fig. 3) will be displayed on the VDU warning
closes and sends a signal to illuminate 'Red' screen.
emergency steering warning light (11, Fig. 2) when
steering pressure drops to 5 bar (70 lbf/in2) or lower. An
audible buzzer also sounds. Body
Body Up Proximity Switch (25) - Mounted off the
inside of the trailer left hand frame rail. When the body
Hydraulic System is raised off the trailer frame, the switch sends a signal
Hydraulic Filter Restriction Gauge (1) - The hydraulic to the hydraulic ECU. The body symbol on the VDU
filter restriction gauge is located on top of hydraulic warning screen (6, Fig. 3) is displayed when the body
tank. After 1 000 hours or when the needle moves into is clear of the proximity switch.
the red zone, whichever comes first, the hydraulic filter Note: Never move the vehicle until body up warning
should be changed. Although should the restriction symbol on the VDU warning screen (6, Fig.32) goes
reach a predetermined level, the hydraulic filter out, indicating that the body is fully lowered onto the
restriction warning symbol (3, Fig. 3) should flash up trailer frame. When the body is up the transmission
on the VDU warning screen on the main dash panel. inhibits any upshifts.
Note: The proximity switch prevents the body being
Load Sense Control Valve (32) - The load sense fully powered down onto the frame. When the proximity
control valve is mounted on a bracket on the front side switch meets the body, the body control lever detent is
of the left-hand vertical member of the exhaust cradle de-energised and float solenoid at main hydraulic valve
assembly. The load sense control valve comprises a is energised.
pressure reducing valve set at 160 bar, a single acting
solenoid valve, and internal porting through the valve Hood
block. Hood Switch (26) - Thehood switch is used to raise or
lower the hood and is located on the right hand rail of
The load sense control valve is a composite valve the instructor seat. when the switch is actuated an
assembly that uses a integral solenoid valve operating electrical signal is ent to the hood actuator either
in conjunction with a pressure reducing valve to reduce extending or retracting the actuator rod depending on
the load sense pressure supplied to the rear main switch direction.
hydraulic pump when a particular low engine speed
coincides with a high torque demand. Reducing the
Battery Disconnect
hydraulic demand in this circumstance reduces the risk
of the engine stalling.
Master Battery Disconnect Switch (27) - Themaster
battery disconnect switch is used to isolate or connect
Air Cleaner the batteries to the rest of the vehicle electrical
system. The switch is located on the battery box at the
Air Cleaner Restriction Gauge (9) - Mounted on the
left hand fender.
* * * *
4 SM 2598 01-10
Fuel System - Fuel System
Section 200-0040
SM - 3947
29
45
27
TO ENGINE - REAR
26 30 32
25 44
24
22,23 31 36 43
28 21
39
38 42
20
34
6,7 40
8 19 40
9,10 18
2
3 11 14
1 12
13
49 38 37 41
5
46
4 47
40 48
15
51 16 17
5 50 35
52
4
1 - Fuel Tank 14 - Drain Valve 27 - Breather 40 - Elbow

2 - Filler / Strainer 15 - Screw 28 - Washer 41 - Fuel Cooler
3 - Gasket 16 - Washer 29 - Reducer 42 - Primary Fuel Filter
4 - Bolt 17 - Sender 30 - Fuel Line to Cooler 43 - Secondary Fuel Filter
5 - Washer 18 - Bushing 31 - Clamp 44 - Fuel Pressure sensor
6 - Washer 19 - Connector 32 - lamp 45 - Fuel Temp Sensor
7 - Bolt 20 - Hose 33 - Double Clamp 46 - Mounting Bracket
8 - Fuel Cap 21 - Connector 34 - P Clips 47 - Mounting Bracket
9 - Bolt 22 - Lockwasher 35 - Fuel Line to Tank 48 - Mounting Bracket
10 - Lockwasher 23 - Bolt 36 - Fuel Supply line 49 - Cover plate
11 - Gasket 24 - Bracket 37 - Elbow 50 - Spacer
12 - Bolt 25 - Nipple 38 - Bushing 51 - Capscrew
13 - Lockwasher 26 - Bushing 39 - Clamp 52 - Gasket
Fig. 1 - Fuel Lines and Components
DESCRIPTION (42). The word 'Primary' or 'Secondary is cast into the

Numbers in parentheses refer to Fig. 1. top of the respective adaptor.
The fuel system consists of the DDEC electronic fuel A Fuel pressure sensor (44) is installed into the side of
system controls, fuel manifolds (integral with the secondary fuel filter (43) and sends an electronic signal
cylinder head), primary fuel filter (42), secondary fuel to the ECM telling it what the engine fuel pressure is at
filter (43), fuel pump, electronic control module (ECM), any given speed.
N3 electronic unit injectors, fuel cooler (41), fuel tank
(1) and the necessary connecting fuel lines. Fuel temperature sensor (45) is installed in a tee on the
top of secondary fuel filter (43) and sends an electrical
There are two spin-on type fuel filters mounted on the signal to the ECM indicating fuel inlet temperature. The
left hand side of the engine. Primary fuel filter (42) is in ECM uses this information to calculate fuel
the fuel flow and acts as a strainer. Integral to the consumption.
Primary fuel filter (42) is the facility to manually prime
the pump via removal of the red cap located centrally Note: Both fuel pressure sensor (44) and fuel
on the filter head. The secondary fuel filter (43) filters temperature sensor (45) are non-serviceable items and
the fuel after having passed through primary fuel filter should be replaced as individual units.
SM 2599 01-10 1
Section 200-0040
The fuel pump is attached to a drive assembly A remote mounted fuel tank breather/filter assembly is
mounted on the rear side of the gear case at the front incorporated into the fuel tank (1), allowing fuel tank (1)
LH side of the engine and transfers fuel from fuel to vent to atmosphere, preventing pressure from
tank (1) to the N3 electronic unit injectors. building up within fuel tank (1) assembly.
The N3 electronic unit injector is a lightweight, compact

unit that injects diesel fuel directly into the combustion OPERATION
chamber. The amount of fuel injected and the Numbers in parentheses refer to Fig. 1.
beginning of injection timing is determined by the ECM.
The ECM sends a command pulse which activates the Fuel is drawn from fuel tank (1) through primary fuel
injector solenoid. filter (42) and enters fuel pump. Leaving fuel pump
under pressure, the fuel flows through secondary fuel
The N3 EUI performs four functions: filter (43) to the engine cylinder head. The fuel flows to
N3 electronic unit injectors in the cylinder head through
a. Creates the high fuel pressure required for efficient passages integral with the cylinder head. Surplus fuel
injection. exits at the rear of the cylinder head just above the
b. Meters and injects the exact amount of fuel required inlet, via fuel line (30) and flows through fuel cooler
to handle the load. (41) and back to fuel tank (1). Restricted fitting at rear
c. Atomizes the fuel for mixing with the air in the of engine maintains fuel pressure in the system.
combustion chamber.
d. Permits continuous fuel flow for component cooling.
REMOVAL
N3 Electronic unit injectors are self compensating and Numbers in parentheses refer to Fig. 1.
virtually eliminate engine tune-ups.
Note: Never apply 12 V directly to terminals on the WARNING

injector as it will burn out. Before removing injectors, To prevent personal injury and property
the fuel passages must be blown out to prevent fuel damage, be sure wheel blocks, blocking
flow from entering the cylinder head. materials and lifting equipment are properly
Fuel cooler (41) is mounted on the front of the radiator, safely.
off Mounting brackets (46 and 48), rested on Mounting
bracket (47) and cools fuel returning to fuel tank (1). 1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Operate
Flexible fuel lines (30,35 & 36) are used to facilitate steering right and left several times to relieve pressure
connection of lines leading to and from fuel tank (1), in the steering system.
and to minimize the effects of any vibration in the
installation. A 2.03 mm (0.08 in) restricted orifice is 2. Block all road wheels and place the battery master
incorporated in the fuel return fitting (23) at rear of switch in the 'Off' position.
engine to maintain fuel pressure in the system. The
restricted orifice is designed to provide the proper fuel 3. If required, remove mounting hardware securing the
system pressure under all conditions. front grille on the hood assembly and remove grille for
access to the fuel cooler (41).
Note: Do not alter or substitute another size of orifice
since this may alter engine performance and 4. Switch the hood raise button located inside the panel
emissions. at the front of the battery box and raise hood.
Note: Do not use restricted fittings anywhere else in 5. Place the battery master switch in the 'Off' position.
the fuel system and do not substitute a standard fitting
for the restricted fitting. 6. Remove padlock and remove fuel cap (8) from fuel
tank (1).
When installing fuel lines, it is recommended that
connections be tightened only sufficiently to prevent 7. With a suitable container in position, remove
leakage of fuel; thus flared ends of the fuel lines will drain valve (14) from bowl in the side of fuel tank (1)
not become twisted or fractured because of excessive and drain fuel from fuel tank (1). Reinstall drain
tightening. plug and tighten securely when fuel tank (1) is
2 SM 2599 01-10
Section 200-0040
completely drained. 7. Fill fuel tank (1) assembly with clean diesel fuel
specified in Section 300-0020, LUBRICATION
9. Remove Blanking caps and P Clips (34) .Identify and SYSTEM.
tag fuel lines (30,35 & 36) and, with a suitable container
available to catch leakage, disconnect fuel lines (30,35 9. Install filler cap (8) assembly on fuel tank filler neck.
& 36). Cap open line ends and elbows to prevent entry Tighten filler cap (8) securely and secure in place with
of dirt. padlock.
10. Remove bolts (4) and washers (5) securing fuel 10. Place the battery master switch in the 'On' position.
tank (1) assembly in the tractor frame. Using a suitable
lifting device, remove fuel tank (1) assembly from the 11. Lower hood assembly and secure front grille
vehicle. assembly to the hood with mounting hardware removed
at removal.
11. If required, remove fuel cooler (16). Refer to
Section 210-0100, HYDRAULIC OIL COOLER. 12. Start the engine and run for a few minutes to
ensure fuel is being supplied to the engine. Check for
12. If required, remove rubber pads from the tractor leaks at fuel lines (30,35 & 36) and tighten if required.
frame. Be sure to remove all rubber and adhesive from
the tractor frame. 13. Remove wheel blocks from all road wheels.
INSTALLATION MAINTENANCE
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
WARNING WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure wheel blocks and blocking
materials and lifting equipment are properly materials are properly secured and of adequate
secured and of adequate capacity to do the job capacity to do the job safely.
safely.
Note: Tighten all fasteners to standard torques General

specified in Section 300-0080, STANDARD BOLT AND Refill fuel tank (1) at the end of each day's operation to
NUT TORQUE SPECIFICATIONS. prevent condensation from contaminating the fuel.
When filling fuel tank (1), check that there is no buildup
1. If removed, apply a suitable adhesive to new rubber of dirt and sludge in the filler / strainer (2) and at the
pads and position on the tractor frame. filler cap (8). Remove and clean filler cap as required.
2. Using suitable lifting equipment, position fuel tank (1) Every 10 Hours/Daily:
assembly in the tractor frame. Make a visual check for fuel leaks at all engine mounted
fuel lines and connections, fuel cooler, and at the fuel tank
3. Secure the front of fuel tank (1) assembly to the suction and return lines. Examine lines for leaks and
tractor frame with bolt (4) and washer (5) as shown in check all fittings, clamps and ties carefully.
Fig. 1. Tighten bolt (4) to a torque of XXX
Make sure that fuel lines are not resting on or touching
4. Secure the rear of fuel tank (1) assembly to the rotating components, heated surfaces including
tractor frame with bolt (4), washer (5) as shown in Fig. 1. exhaust manifolds or sharp edges. If fittings have
Tighten bolt (4) to a torque of XXX loosened or cracked, or if lines have ruptured or worn
through, take corrective action immediately.
5. Remove blanking caps and P Clips (34), secure fuel
lines (30,35 & 36) to elbows, as identified at removal.
6. If removed, install fuel cooler (16). Refer to Section

210-0100, HYDRAULIC OIL COOLER.
SM 2599 01-10 3
Section 200-0040
Every 500 Hours: the fuel and engine operating conditions can influence
corrosion and deposit formation
Replace the primary and secondary fuel filters as tendencies. The use of diesel fuel oil with a MAXIMUM
follows: sulphur content of 0.5% is recommended for use. Refer
to Section 300-0020, LUBRICATION SYSTEM.
Note: There is a fuel system shut off cock on the
discharge side of the secondary fuel filter. Closing this
valve will prevent loss of fuel prime at time of filter TROUBLESHOOTING
replacement.
Locating Air Leaks in Fuel Lines
1. Close shut off valve at secondary fuel filter and, Air drawn into the fuel system may result in uneven
using a strap type filter wrench, remove and discard running of the engine, black or white smoking and
both the primary and secondary fuel filters from the stalling when idling, or a loss of power. Poor operation
engine. is particularly noticeable at lower engine speeds. If air
is found in the fuel, the source will normally be between
2. Fill the replacement filters and coat the gaskets the fuel tank and the fuel pump.
slightly with clean fuel oil as specified in Section
300-0020, LUBRICATION SYSTEM. Check for loose, faulty or improper fuel line connectors.
Presence of an air leak may be detected
3. Start new primary fuel filter on the filter adaptor and by following the procedures under 'Checking Fuel Flow'.
tighten it by hand until the gasket contacts the adaptor
fully with no side movement of the filter evident.
Tighten an additional 1/2 of a turn. Checking Fuel Flow
1. Disconnect the fuel return line from the fitting at the
Note: Mechanical tightening of fuel filters is not fuel tank and hold the open end in a suitable container.
recommended, and may result in seal and/or cartridge
damage. Tighten fuel filters by hand only. 2. Start and run the engine at maximum rev/min and
measure the fuel flow. Nominal fuel return spill with the
4. Repeat step 3 to install a new secondary fuel filter. standard 2.03 mm (0.08 in) restricted fitting is
4.1 litres/min (65 US gal/min).
5. Start the engine and check for leaks. If any leaks
are noted, have them corrected. 3. Immerse the end of the fuel return line in the fuel. Air
bubbles rising to the surface of the fuel will indicate air
Every 250 Hours: being drawn into the fuel system on the suction side of
the pump. If air is present, tighten all fuel lines
Open the drain at the bottom of the fuel tank to drain off connections between the fuel tank and fuel pump.
any water and/or sediment. Check the seal in fuel tank
filler neck cap and clean filler neck screen and cap. 4. If the fuel flow is insufficient for satisfactory engine
Check the condition of all fuel lines and replace if performance then proceed as follows:
required. Clean and inspect fins on fuel cooler.
a. Replace the primary and secondary fuel filters, as
Every 1 000 Hours: described under 'Maintenance'. Start the engine and run
it at maximum rev/min and recheck the fuel flow. If fuel
Fuel tank breather, replace flow is still unsatisfactory, perform step 'b'.
Diesel Fuel Oil b. Check the fuel lines for restrictions due to pinching,
The sulphur content of diesel fuel oil should be as low kinking or other damage. Be sure the correct restricted
as possible to avoid premature wear of piston rings and fitting is installed at the return port of the fuel tank. If no
liner, excessive deposit formation, and minimise problem is found, substitute another fuel pump that is
sulphur dioxide exhausted into the atmosphere. Limited known to be operating correctly and recheck the fuel flow.
amounts can be tolerated, but the amount of sulphur in When changing the fuel pump, inspect the fuel pump drive
assembly, hubs and coupling. Clean all fuel lines with
compressed air and be sure all fuel connections are tight.
c. Disconnect the fuel lines from the ECM cooling plate

and, using a suitable connector, connect the two fuel
4 SM 2599 01-10
Section 200-0040
lines, bypassing the cooling plate. Run the engine at
maximum rev/min and recheck the fuel flow. If the fuel
flow with the cooling plate bypassed is normal, the
cooling plate should be replaced.
SPECIAL TOOLS
dealer.
* * * *
SM 2599 01-10 5
Section 200-0040
6 SM 2599 01-10
FUEL SYSTEM - Electronic Foot Pedal
Section 200-0051
SM - 3607
3
2
1 - Pedal Assembly
2 - Bolt
3 - Washer
4 - Idle Validation Switch connection
Fig. 1 - Electronic Foot Pedal Assembly
DESCRIPTION Numbers in parentheses refer to Fig. 2. unless

otherwise stated.
otherwise stated.
The foot pedal receives a 5V supply from the engine
ECU through the vehicle interface harness connection
The electronic foot pedal assembly provides an
at wire 11. The return line is via wire 60. The signal to
electrical signal to the engine's fuel control system in
determine the level of acceleration requested by the
proportion to the degree of pedal actuation. Maximum
operator foot is received via wire 13.
and minimum stops are built into the pedal assembly
during manufacture. The pedal assembly comes preset
For safety there is an idle validation switch
and therefore no adjustment is necessary.
arrangement to determine that the pedal is at the idle
position. When at idle, the switch S69 is closed and
Note: The DDEC controlled engine will override the
the signal is sent back to the engine ECU. Should
pedal position until the engine is warmed up to the
there be a throttle signal problem, the engine ECU will
correct operating temperature. The engine MUST be
be able to determine this via the idle validation side of
started with foot 'OFF' pedal assembly (1).
the circuit.
SM 2395 01-10 1
Fuel System - Electronic Foot Pedal
Section 200-0051
SM - 3608
ECU
TPS
U/Y Signal
V-13 A
Y/R 5 Volt
V-11 B
Y/B Return
V-60 C
R/W IVS, Closed @ Idle

V-16 E
U Return
V-29 F
VHC
Fig. 2 - Electronic Foot Pedal Wiring Detail
REMOVAL
Numbers in parentheses refer to Fig. 1. 2. Connect electrical harness (5) and idle validation
switch (4) harness.
WARNING 4. Position floor mat on cab floor and ensure that pedal
To prevent personal injury and property assembly (1) is free to operate.
secured and of adequate capacity to do the job 5. Place the battery master switch in the 'On' position,
safely. remove wheel blocks and start the engine. Ensure that
pedal assembly (1) operates correctly.
body is fully lowered, apply the parking brake and Note: The engine MUST be started with the foot 'OFF'
switch off the engine. Turn steering wheel in both pedal assembly (1).
directions several times to relieve any pressure in the
steering circuit. MAINTENANCE
switch in the 'Off' position. Limited repair of the electronic foot pedal assembly is
by replacement of parts only. Refer to vehicle Parts
3. Disconnect electrical harness (4). Book for spare part numbers.
4. Move cab floor mat back and clear from pedal A number of checks can be made to determine correct
assembly (1) and mounting plates. voltages are being seen at the pedal, which can help in
diagnosis of problems. These are follows:
5. Remove bolt (2) and washer (3) from pedal assembly
(1) and remove pedal from the cab. Voltages range which should be seen assuming proper
operation:
INSTALLATION
Numbers in parentheses refer to Fig. 1. Input:
Y/R & Y/B = 5.05V - 4.95V
Section 300-0080, STANDARD BOLT AND NUT Idle:
TORQUE SPECIFICATIONS. U/Y & Y/B = 10 - 20% of Input (i.e. 0.5V to 1V)
1. Position pedal assembly (1) in position and secure with Full Throttle:
bolt (2) and washer (3). U/Y & Y/B = 70 - 85% of Input (i.e. 3.5V to 4.25V)
* * * *
2 SM 2395 01-10
COOLING SYSTEM - Cooling System (Series 60 Engine)
Section 210-0000
SM - 3635
12
6 10
14
7
9
1 3
5
13
8 2
1 - Header Tank 5 - Engine Oil Cooler 9 - Coolant Pipe 13 - Filter Inlet Line (not used)
2 - Radiator Assembly 6 - Thermostat Housing 10 - Bypass Line 14 - Filter Outlet Line (not used)
3 - Engine Water Pump 7 - Make-up Line 11 - Radiator Inlet Pipe
4 - Coolant Filter (not used) 8 - Radiator Outlet Pipe 12 - Deaeration Lines
Fig. 1 - Cooling Lines and Flow
DESCRIPTION
Numbers in parentheses refer to Fig. 1. thermostats located in thermostat housing (7), attached
to the right hand side of the cylinder head, control the
Two combination coolers are utilised in the system. flow of coolant.
Integral to the right hand cooler is the engine radiator ,
on the right hand side and charge-air-cooler on the left The main components of the cooling system are;
hand side. The Left hand combination cooler consists header tank (1), radiator assembly (2), engine water
of a transmission oil cooler, brake coolant oil cooler, pump (3), engine oil cooler (5) and thermostat housing
engine oil cooler and dropbox oil cooler as shown from (6).
left-to-right. Twin cooling fans are installed for cooling
the respective system elements. This system has a Attached to the front of right hand combination cooler is
centrifugal type water pump (3) to circulate coolant a condenser. Attached to the left hand combination
throughout the system. Two full blocking type cooler are hydraulic oil cooler and fuel cooler.
SM 2374 01-10 1
Cooling System - Cooling System (Series 60 Engine)
Section 210-0000
OPERATION SM - 3568
Numbers in parentheses refer to Fig. 1, unless 3

1
otherwise specified. 4
2
6
Upon starting a cold engine or when the coolant is 4
below operating temperature, the coolant is restricted 5
4 4
at thermostat housing (6) and bypass line (10) provides 5
4
water circulation within the engine during the warm-up
period. 7
Note: Engine coolant thermostats start to open at

88° C (190° F) and are fully open at 96° C (205° F). 4
Engine water pump (3) draws coolant from the radiator 6

4
through radiator outlet pipe (8). Engine water pump (3)
then pumps coolant through coolant pipe (9) into engine
oil cooler (5). The coolant then flows through the engine
block and passes up through the cylinder head to
thermostat housing (7).
1 - Air-to-Air Charge Cooler 5 - Hose
2 - Radiator 6 - Hose
Aerated coolant is drawn off to header tank (1) from 3 - Outlet Pipe 7 - Inlet Pipe
thermostat housing (6) through deaeration line (12). 4 - Clamp
Excess coolant at header tank (1) is discharged
Fig. 2 - Air-to-Air Charge Cooler Lines and Flow
through an overflow line from the filler neck.
When the coolant reaches operating temperature, the

thermostats open allowing coolant to flow into the Air-To-Air Charge Cooling
radiator through radiator inlet pipe (11). The coolant Numbers in parentheses refer to Fig. 2.
passes through a series of tubes in radiator assembly
(2) core, where the coolant temperature is lowered by In the air system used on the Series 60 engines,
the air stream created by the revolving fan, and into the outside air drawn into the engine through the air
radiator outlet pipe (8) to be re-circulated back through cleaner, passes through the air filter element and is
the system. pulled into the turbocharger where it is compressed. It
then exits the turbocharger through outlet pipe (3) and
Aerated coolant is drawn off to header tank (1) from the enters air-to-air charge cooler (1), integral to the Right
radiator, radiator inlet pipe (11) and thermostat housing hand cooler assembly, through inlet pipe (6). The hot
(6) through deaeration lines (12). Excess coolant at air travels through a series of tubes in
header tank (1) is discharged through an overflow line air-to-air charge cooler (1) core, where the air
from the filler neck. temperature is lowered from approximately 149° C
(300° F) to below 38° C (100° F). From here the air
The use of antifreeze is mandatory with the cooling flows through outlet pipe (6) and into the engine intake
system. The lack of coolant flow through the radiator manifold through inlet pipe (7). From the engine intake
with the thermostats closed allows the coolant in manifold the air travels into the cylinders where it
radiator assembly (2) to freeze under low ambient mixes with atomized fuel from the injectors. This cooler
temperature conditions. air aids combustion, thereby increasing fuel economy.
2 SM 2374 01-10
Section 210-0000
PREVENTIVE MAINTENANCE
To ensure the continued efficient functioning of the WARNING
cooling system, certain checks and operations should To prevent possible injury when using
be performed at regular intervals. compressed air, wear adequate eye protection
and do not exceed 2.75 bar (40 lbf/in²).
WARNING
Do not remove the pressure control cap from Every 1000 Hours
the radiator header tank or attempt to drain the Replace coolant filter. Check and replenish coolant
coolant until the engine has cooled. Once the inhibitor as required.
engine has cooled, use extreme caution when
removing the cap. Always release pressure Note: Failure to use and maintain coolant and coolant
from the system by depressing the pressure inhibitor mixture at sufficient concentration levels can
relief button on the cap. Remove cap slowly as result in damage to the cooling system and its related
the sudden release of pressure from a heated components. Conversely, over-concentration of coolant
cooling system can result in a loss of coolant and/ or inhibitor can result in poor heat transfer, leading
and possible personal injury (scalding) from to engine dropout or both. Always maintain
the hot liquid. concentration at recommended levels.
Inspect water pump drain hole to make sure it is open.

Every 10 Hours (Daily)
Check coolant level and add if low. Fill the radiator Note: A small chemical build up or streaking at the
header tank with coolant until coolant reaches the drain hole may occur. This is not an indication of a
bottom of the filler neck and holds at that level. defective water pump or seal. If coolant does not leak
from the drain hole under normal operating conditions,
Note: Any time a significant amount of coolant is do not replace the water pump.
added, the coolant inhibitor MUST be checked. If the
concentration is low, engine damage will result. Every 2000 Hours
Conversely, over-inhibiting antifreeze solutions can Check coolant level and add if low. Fill the radiator
result in silicate dropout. Refer to 'Test Kit Procedures'. header tank with coolant until coolant reaches the
bottom of the filler neck and holds at that level.
Check coolant lines, pipes and components for leaks
and wear. Note: Any time a significant amount of coolant is
concentration is low, engine damage will result.
Every 50 Hours Conversely, over-inhibiting antifreeze solutions can
Check all drive belts for wear and tension. Refer to result in silicate dropout. Refer to 'Test Kit Procedures'.
Section 110-0030, ENGINE AND MOUNTING for belt
tension specifications.
Every 250 Hours

Inspect the front of the radiator and air-to-air charge
cooler fins and, if necessary, clean with a quality
grease solvent such as mineral spirits and dry with
compressed air.
Note: Fuel oil, kerosene or gasoline should not be used

to clean fins.
Note: It may be necessary to clean radiator and

air-to-air charge cooler fins more frequently if the vehicle
is being operated in extremely dusty or dirty areas.
SM 2374 01-10 3
Section 210-0000
satisfactory, the cooling system may require cleaning
with a descaling solvent and back-flushing.
DRAINING AND FLUSHING
Back-flushing Engine Jacket
Whenever the engine water jacket is rust clogged,
pressure back-flushing should be used after the
WARNING
draining of the cleaning compound. Be certain to
Do not remove the pressure control cap from
remove both thermostats from thermostat housing
the radiator header tank or attempt to drain
before beginning back-flushing operation.
the coolant until the engine has cooled. Once
the engine has cooled, use extreme caution
1. Remove both thermostats from thermostat housing
when removing the cap. Always release
and clamp flushing gun to front neck of the water
pressure from the system by depressing the
manifold.
pressure relief button on the cap. Remove cap
slowly as the sudden release of pressure from
2. Temporarily block engine water pump inlet opening
a heated cooling system can result in a loss of
and fill engine jacket with clean, soft water.
coolant and possible personal injury (scalding)
from the hot liquid.
3. Unblock water pump inlet opening and blow water
1. With the engine cool, drain the coolant from the from the engine jacket with air from flushing gun
engine and radiator assembly. clamped to neck of water manifold. Use full air
pressure.
2. Refill the cooling system with clean, soft water and a
good radiator cleaning compound. If the engine is 4. Repeat operation by alternately filling engine with
warm, fill slowly to prevent the rapid cooling and clean, soft water and blowing out with air until flushing
distortion of the metal castings. water runs out clean.
3. Start the engine and operate the vehicle for fifteen Back-flushing Radiator
minutes to circulate the solution completely.
1. Disconnect all coolant lines at the engine.
4. Stop the engine and allow to cool. With the engine
2. Clamp flushing gun to lower hose on the radiator and
cool, drain the cooling system completely.
fill the radiator with clean, soft water from the gun.
5. Refill the cooling system with clean, soft water and
3. Apply air pressure gradually increasing to a pressure
operate it for fifteen minutes.
of 0.7 bar (10 lbf/in²). DO NOT EXCEED THIS
PRESSURE.
6. Stop the engine and allow to cool. With the engine
cool, drain the cooling system completely.
4. Alternatively fill radiator with clean, soft water and
flush with air until water runs out clear.
7. Refill the cooling system with the proper mix of
coolant and water. Refer to instructions under
'Recommended Coolants'. RECOMMENDED COOLANTS
8. Entrapped air must be purged after filling the cooling Antifreeze
system. To do this, allow the engine to warm up with
Use genuine Detroit Diesel Power Cool or an equivalent
the pressure cap on the remote header tank removed.
ethylene glycol base coolant (low silicate formulation)
With the transmission in neutral, increase engine speed
that meets or exceeds the standard of either the GM
above 1 000 rev/min and add coolant as required. Vent
6038-M formulation (GM 1899-M performance) or
the cock on the water return line at the water-jacketed
ASTM D 4985 requirements.
turbocharger until a steady stream of water (no air) is
seen. Close the cock.
A 50% antifreeze/water solution is normally used as a
factory fill. Concentrations over 70% are not
9. Install the pressure cap on the remote header tank
recommended because of poor heat transfer capability,
after the coolant level has stabilized at the bottom of
adverse freeze protection and possible silicate dropout.
the header tank filler neck.
Note: If the engine overheats and the coolant level is

4 SM 2374 01-10
Section 210-0000
SM - 1209 Methyl alcohol-based antifreeze is not recommended

for use because of its effect on the nonmetallic
components of the cooling system and its low boiling
point. Methoxy propanol-based antifreeze is also not
recommended for use because it is not compatible
with fluoroelastomer seals found in the cooling system.
Soluble oil additives are not approved for use in the

cooling system. A small amount of oil adversely
affects heat transfer; 1.25% concentration increases
the fire deck temperature 6% and 2.5% concentration
increases fire deck temperature 15%.
Supplemental Coolant Additives (SCA)

SCA's provide protection for the cooling system
components. The coolant must have the proper
concentration of SCA's. Detroit Diesel Maintenance
products are recommended for use in all Detroit Diesel
Engines.
The proper application of SCA will provide:
a. pH control to prevent corrosion.

b. Water-softening to deter formation of mineral
deposits.
c. Cavitation protection to reduce the effects of
cavitation.
Install a new precharge coolant filter at initial cooling

system fill and whenever the coolant is changed.
Replace the precharge filter with a maintenance filter
Fig. 3 - Coolant Freezing and Boiling Temperatures versus after 250 hours then every 500 hours thereafter. Refer
Inhibited Ethylene Glycol (IEG) Concentration (Sea Level) to the vehicle Parts Book for coolant filter part
numbers.
Concentrations below 30% offer little freeze, boil over
or corrosion protection. Refer to graph in Fig. 3. Note: Selection of the correct coolant filter element is
vital when precharging the cooling system and at
Antifreeze solution should be used year-round to maintenance intervals. A fully formulated cooling
provide freeze and boil over protection as well as a
stable environment for seals and hoses. In extremely SCA Concentration Limitations Table650
hot environments, clean, soft, properly inhibited water MINIMUM MAXIMUM
may be used if Detroit Diesel Maintenance Product PPM PPM
supplemental corrosion inhibitors are also added in the
right concentration. If water is used, supplemental Boron (B) 1 000 1 500
coolant additive levels should be increased from 3% to Nitrite (NO2) 800 2 400
6% by volume. Nitrates (NO3) 1 000 2 000
Silicon (Si) 50 250
Only non-chromate inhibitors should be used with Phosphorous (P) 0 500
coolant solutions. Chromate coolant inhibitors are not pH 8.5 10.5
compatible with ethylene glycol antifreeze (low silicate
formulation) and if these compounds are combined a system must not have SCA's added at initial fill.
green sludge will be produced. This sludge will deposit The concentration of SCA will gradually deplete during
on cooling system passages and reduce heat transfer normal engine operation and should be checked after
from the engine to coolant. every filter change. Additional SCA must be added to
SM 2374 01-10 5
Section 210-0000
the coolant when it becomes depleted below the level c. Sixty seconds (one minute) after dipping, compare
specified in the table on the following page. the nitrite pad.
Maintenance dosage of SCA must only be added if For best results make the tests while the coolant is
nitrite concentration is less than 800 parts per million between 10° - 60° C (50° - 140° F). Wait at least 60,
(PPM). If nitrite concentration is greater than 800 PPM, but not longer than, 75 seconds before reading the
do not add additional SCA. Refer to 'Test Kit nitrite level. Promptly replace and tighten container cap
Procedures'. after each use. Discard unused strips if they have
turned light pink or tan.
Test Kit Procedures Note: Failure to properly maintain coolant with SCA
Coolant Test Strips should be used to measure nitrite can result in damage to the cooling system and its
and glycol concentrations (See Special Tools). related components. Conversely, over-concentration of
Cavitation/corrosion protection is indicated on the strip SCA inhibitor can result in poor heat transfer, leading to
by the level of nitrite concentration. Freeze/boil over engine damage. Always maintain concentrations at
protection is determined by glycol concentration. Use recommended levels.
the test strips as follows:
a. Dip the strip into coolant for one second. Remove SPECIAL TOOLS
and shake briskly to eliminate excess fluid. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the coolant test strips and general service
b. Immediately compare end pad (% glycol) to the tools required. These strips and tools are available
colour chart. from your dealer.
COOLING SYSTEM DIAGNOSIS CHART

Engine coolant temperature too Low coolant level Fill cooling system to correct fill level
high
Check for leaks and repairs
Faulty radiator pressure cap Check pressure cap, replace if required
Air in cooling system Purge air from cooling system
Front of radiator obstructed Remove obstruction and clean radiator
preventing free flow of air fins
Fan drive belts broken or slipping Adjust or replace fan belts
Thermostats not opening Replace thermostats
Restricted cooling system passages Flush cooling system
Faulty engine water pump Repair or replace water pump
Engine coolant Thermostats remain open or open Replace thermostats
temperature too low at too low a temperature
Leakage around the thermostat seals Replace thermostat seals
Extremely cold weather Cover radiator or install radiator shutters
* * * *
6 SM 2374 01-10
COOLING SYSTEM - Brake Cooling System Schematic
Section 210-0005
DESCRIPTION Motor/Triple Pump (1)

Numbers in parentheses refer to Figure 2. Refer to Section 250-0045, Motor/Triple Pump
Assembly.
The braking system on the machine uses brake cooling
oil to cool the brake packs. This cooling oil is separate The motor/triple pump assembly, which is mounted on
from the hydraulic oil used in the main hydraulic brackets on the left hand frame rail, adjacent to the
systems. brake coolant tank, consists of three pump elements
coupled to a single direction hydraulic motor. The
A brief description of the individual components used in hydraulic motor within the assembly is protected by a
the brake cooling system is given below. Detailed relief valve, which is integral to the externally mounted
service and operating instructions can be found in the OCDB relief unloader valve. Refer to Section 250-0075
relevant component sections of this manual. OCDB Relief Unloader Valve.
A solenoid controls the motor by restricting flow

Service Brakes through the motor until the brake cooling oil
Refer to Section 165-0015, Brake Assembly, Oil temperature rises to 50 oC (122 oF). The motor is
Cooled Disc Brakes. supplied with hydraulic oil via the main hydraulic valve.
The motor and pump elements are connected by a
The service brakes are of the enclosed, forced oil- common shaft, therefore motor rotation causes pump
cooled multiple disc type. The service brakes are elements to draw brake cooling oil from brake coolant
actuated by hydraulic oil as specified in Section 300- tank (3). Brake cooling oil is then pumped to the brake
0020, Lubrication System. DO NOT USE BRAKE packs.
FLUID (J 1703). Multiple discs within the brake packs
are cooled by brake cooling oil as specified in Section The triple pump section supplies various circuits:
300-0020, Lubrication System.
a. the front section (closest to the driveshaft) supplies
The brake assembly is bolted to the stub axle and the rear brake cooling circuit.
houses a sandwich of friction discs splined to a hub b. the middle section supplies the centre axle brake
rotor. There are four friction discs in each brake cooling circuit.
assembly. c. the rear section supplies the front axle brake
cooling circuit.
When the treadle valve is actuated, hydraulic oil enters
the brake assembly and forces the brake piston
against the rotating friction discs which react with
stationary reaction discs. The reaction discs are
Brake Coolant Tank (3)
retained by scalloped tangs at the outside diameter, Refer to Section 250-0025, Brake Coolant/Hydraulic
which in turn transfers the reaction torque to the rigid Tank, or Section 250-0026, Brake Coolant/Hydraulic
outside housing, slowing or stopping wheel rotation. Tank (with pressurization).
In an emergency situation, application of the park/ The brake coolant tank is part of the integral brake
emergency valve will actuate the service brakes and coolant/hydraulic tank assembly. It is the reservoir for
the parking brake to bring the machine to a halt. In this the brake cooling oil, is mounted on the left hand frame
condition, a restriction in the 'Px' line from the brake rail in front of the fender, and is secured in three
manifold valve will slow oil flow from the parking brake places.
ahead of the parking brake. Integral with the brake coolant tank assembly are an oil
level sight gauge, a strainer (5) and access covers.
When the treadle valve or park/emergency brake is Located on top of the tank are a filler cap, a remote
released, hydraulic pressure against the piston is mounted breather and an anti-slip walkway plate.
relieved and cup springs force the piston to return to its
original position, thus relieving the pressure against the
brake disc pack.
Disc Brake Oil Cooler (4)
Refer to Section 210-0050, Disc Brake Oil Cooler.
The disc brake oil cooler is integral to the left hand
SM 2600 01-10 1
Cooling System - Brake Cooling System Schematic
Section 210-0005
radiator assembly, and is mounted on the left hand 'O' RING FACE SEALS (ORFS)
fender. The fan which supplies air flow to the brake oil
Where hydraulic lines are fitted with ORFS
cooler is driven by a hydraulic motor. The fan only turns
connections, the following procedure should be carried
when hydraulic motor is supplied with oil from the main
out during installation. Refer to Fig. 1.
hydraulic valve, Refer to Section 215-0050 Main
Hydraulic Valve Assembly. Brake cooling oil enters the
a. Ensure that the O-ring/seal is in place and that
top of the cooler and flows through the cooler before
joining surfaces are clean. If necessary, retain the O-
exiting at the bottom.
ring/seal in place with a light coating of grease or
Brake Cooling Oil Filter (6) vaseline.
The filter, mounted in the brake cooling line between
b. Initially, the nuts should be tightened by hand.
the motor/triple pump assembly and the front manifold
block, ensures that the brake cooling oil is filtered. The
filter is fitted with a visual indicator to show when the c. Where a hose is fitted, ensure that it is not twisted
filter is in bypass mode. or kinked when the nuts are tightened so that it is
allowed to adopt a natural position.
Brake Cooling Oil Pressure Switch (8)
A pressure switch is mounted on the front axle brake d. Where a tube is fitted, ensure that the connection is
manifold block. The normally open pressure switch aligned correctly.
closes when the brake cooling oil reaches a pressure
of 1.5 bar (22 lbf/in²). At this point, a signal is sent to e. Tighten the nut a further 1/4 to 1/2 a turn using the
the VDU which will display the brake cooling oil correct size of spanner (wrench).
pressure warning symbol on the VDU panel. Refer to
Section 190-0270, Switches and Sensors. f. Check that a satisfactory hose or tube routing has
been achieved.
Brake Cooling Oil Temperature Switch/ SM - 1335

Sender (9) FITTING NUT
This normally closed switch, mounted on the front axle TUBE
brake manifold valve block, opens when the brake
cooling oil temperature reaches 50 °C (122 oF), and
sends a signal to de-energize the solenoid on the
OCDB relief unloader valve, allowing increased
hydraulic oil flow from the main hydraulic valve
assembly to supply the motor side of the motor/triple
pump unit, thus increasing the flow of cooling oil to the SLEEVE
'O' RING 'O' RING
brakes. At the same time, a signal is sent to the fan
disconnect solenoid valve to de-energize, thus
Fig. 1 - Assembly of Typical ORFS Connector
supplying oil flow to the transmission cooling fan Refer
to Section 190-0270, Switches and Sensors.
Should the brake cooling oil temperature reach 60 °C BRAKE COOLING OIL
(140 oF), the sender emits a signal to the VDU, which The brake cooling system should be kept filled with
in turn displays the brake cooling temp warning symbol brake cooling oil as specified in Section 300-0020,
on the VDU display. Refer to Section 190-0270, Lubrication System.
Switches and Sensors.
Whenever there is a system failure, the brake cooling
Brake Cooling Oil Relief Valve (7) oil should be drained, the entire system flushed, oil
filter replaced, oil strainer thoroughly cleaned and clean
An internal pressure relief valve is contained within the
brake cooling oil added to eliminate all metal particles
valve manifold blocks mounted at each axle. Each
or foreign matter.
valve is set at 1 bar (14.5 Ibf/in²) to maintain the brake
cooling oil at this pressure. SERVICE TOOLS
It is recommended that the following tools are used
when carrying out pressure or temperature checks
2 SM 2600 01-10
Section 210-0005
during maintenance procedures. These tools, along

with other general service tools, are available from your
dealer. Refer to Section 300-0070, Service Tools, for
part numbers of these tools.
Multi-gauge
The multi-gauge is basically four pressure gauges in
one. Continuous system pressure readings are
indicated on one of three simultaneously reading
gauges through a pressure range of 762 mm (30 in) of
vacuum to 345 bar (5 000 lbf/in2).
Non-contact Infrared Thermometer

The infrared thermometer can be used to spot heat
problems early in electrical, mechanical and hydraulic
systems. Hand held and easy to use, the operator
simply aims, pulls the trigger, then reads the
temperature. Since there is no need to touch what you
are measuring, temperatures of hard-to-reach or
moving components can be taken without getting
burned or shocked.
SM 2600 01-10 3
4
FRONT AXLE MIDDLE AXLE REAR AXLE
BRAKE PACKS BRAKE PACKS BRAKE PACKS
Section 210-0005
11 3 12 3 13 3
7 9 7 7
10
4 1
2
3
FROM MAIN HYD.

3
HYD. VALVE TANK
COMPONENTS 6 - Brake Cooling Filter 11. Front Axle Distribution Manifold Valve Block
1 - Motor/Triple Pump 7 - Relief Valve 12. Middle Axle Distribution Manifold Valve Block
2 - OCDB Relief Unloader Valve 8 - Pressure Switch 13. Rear Axle Distribution Manifold Valve Block
3 - Brake Coolant Tank 9 - Temperature Switch/Sender
4 - Disc Brake Oil Cooler 10 - Return Manifold
5 - Strainer Fig. 2 - Brake Cooling System Schematic
SM 3617
SM 2600 01-10
COOLING SYSTEM - Cooling Fan and Motor
Section 210-0010
DESCRIPTION AND OPERATION SM-3622
Numbers in parentheses refer to Figures 1 and 2. 1
Note: There are two independently controlled fans

in the system. The functionality of the fans is identical.
Only the preset temperature conditions of the various
3
parts of the system which they serve is different. 2
The fan located on the left-hand side of the vehicle is 4
dedicated in the majority to transmission cooling

needs. The fan located on the right-hand side is
mostly dedicated to the engine cooling needs.The
rate of fan speed change and maximum fan speed for
each fan is preset to the cooling needs of the various
engine, transmission and brake cooling requirements 5
of the system.
The hydraulic fan drive system uses an electrical

signal from the hydraulic system electronic control
unit (ECU) to provide the appropriate fan speed
1 - Radiator 4 - Fan Guard
necessary to satisfy any cooling demand. Each fan 2 - Fan 5 - Hydraulic Motor
(2 and 3) is driven by a single vane type hydraulic 3 - Motor Carrier Frame
motor (5), which is supplied by a dedicated oil supply
from the main hydraulic valve assembly. Refer to
Section 215-0050 Main Hydraulic Valve Assembly. Fig. 1 - RHS - Hydraulic Fan Drive (Engine)
There are two fan control valves, which control oil

SM-3621
flow proportionally to the fan motors. Each serves
one of the cooling fans. These are integral to the 1
main hydraulic valve assembly. Refer to Section

215-0050 Main Hydraulic Valve Assembly.
The hydraulic ECU will send a signal to either of the

fan proportional solenoids, when it receives an input 2
signal that reflects any of the preset temperature

parameters that have been programmed to signal flow 4
to the fans.
Relative to each proportional solenoid, the

temperature conditions are as follows:
5
Proportional Solenoid 'CT22' (Engine Fan):

3
1. Engine coolant temperature reaches 85°C (185°F).
2. Engine oil temperature reaches 108°C (226°F).

1 - Radiator 4 - Fan Guard
2 - Motor Frame 5 - Hydraulic Motor
3. Air intake temperature reaches 54°C (129°F). 3 - Fan
4. Air conditioning is 'ON'

Fig. 2 - LHS - Hydraulic Fan Drive (Transmission)
If any of the above conditions are met, the hydraulic
system ECU will send a signal from PWM output PIN hydraulic system ECU at output PIN 04 to de-energize
47 between 0 and 264mA to solenoid 'CT22' which the engine fan disconnect solenoid. Refer to Section
will determine the pressure to the fan motor. 210-0044 Fan Disconnect Valve, allowing flow to the
At the same time, a signal will be sent from the engine hydraulic fan motor.
SM 2601 01-10 1
Section 210-0010
Proportional Solenoid 'CT23' (Transmission Fan): 6. Remove the bolts, nuts and washers securing the
fan (2) and motor (5) assembly to the motor carrier
1. Sump oil temperature reaches 80°C (176°F), frame (3). Remove the fan (2) and motor (5) assembly
from the motor carrier frame (3).
2. Retarder temperature reaches 90°C (194°F),
Right-hand Radiator:
3. Brake Cooling oil temp reaches 59°C (138°F),
Refer to Figure 1.
4. Dropbox oil temperature reaches 60°C (140°F).
7. Support the radiator assembly with suitable lifting
equipment. Remove the fan guard (4) and the motor
If any of the above temperatures are achieved, the
carrier frame (3) from the radiator assembly.
hydraulic system ECU will send a signal from PWM
output PIN46 between 0 and 264mA to solenoid
8. Remove the bolts, nuts and washers securing the
'CT23' which will determine the pressure to the fan
fan (2) and motor (5) assembly to the motor carrier
motor. Simultaneously, a signal will be sent from the
frame (3). Remove the fan (2) and motor (5) assembly
hydraulic system ECU at output PIN43 to de-energize
from the motor carrier frame (3).
the transmission fan disconnect solenoid (refer to
Section 210-0044 Fan Disconnect Valve), allowing MOTOR OVERHAUL
flow to the transmission hydraulic fan motor.
The internal parts of the motor are lubricated by the
operating fluid itself. Therefore, preventive
REMOVAL maintenance is limited to keeping the fluid in the
system clean. Dirt should not be allowed to
accumulate on the motor or around the shaft seal.
Check frequently that all fittings and bolts are tight.
WARNING
Service kits are available should overhaul be
necessary, these include - a cartridge kit, shaft and
damage, make sure blocking or lifting
bearing kit and seal kits. Refer to the relevant parts
equipment is properly secured and of
book for specific serial number ranges of units and
adequate capacity to performthe task safely.
parts.
1. Position the machine on a level floor. Switch off
the engine and operate the steering several times DISASSEMBLY/ASSEMBLY
to discharge the steering system.
Limited disassembly of the hydraulic motors is
available. For specific details on correct overhaul
2. Block all road wheels and place the battery
and replacement of parts, refer to the manufacturers'
master switch in the off position.
guidelines.
3. Remove mounting hardware securing the hood
assembly to the machine and, using suitable lifting INSTALLATION
equipment, remove the hood assembly as described
Numbers in parentheses refer to Figures 1 and 2.
in Section 100-0040, Hood and Mounting.
4. Remove both left-hand and right-hand radiator
specified, to standard torques listed in Section 300-
assemblies from the machine as described in Section
0080, Standard Bolt and Nut Torque Specifications.
210-0040, Radiators and Mounting.
Left-hand Radiator:
WARNING
Refer to Figure 2.
equipment is properly secured and of
5. Support the radiator assembly with suitable lifting
equipment. Remove the fan guard (4) and the motor
carrier frame (3) from the radiator assembly.
2 SM 2601 01-10
Section 210-0010
adequate capacity to performthe task safely. TESTING
Left-hand Radiator:
Fail-safe Check
1. Install the fan (3) on the motor frame (2). Install the
Note: This test is carried out with the machine static
motor (5) through the motor frame (2) and secure it.
and secured at rest. The hood should be raised and
secured.
assembly on the radiator assembly and secure the
1. Start the engine and increase engine speed to
motor frame (2) to the radiator.
2200 rev/min.
Note: Ensure that there is even clearance, all the way
2. Maintain engine speed at 2200 rev/min and
round, between the fan (3) and the fan guard (4).
disconnect the harness from the fan disconnect
valves. The fans should automatically engage to full
5. Install the fan guard (4) on the radiator assembly
flow speed.
and secure it with mounting hardware, as removed at
'Removal'.
MAINTENANCE
6. Using suitable lifting equipment, install the radiator Numbers in parentheses refer to Figure 2.
assembly on the machine as described in Section
210-0040, Radiators and Mounting. 1. DO NOT restrict the fan(s) rotation during engine
operation for ANY reason.
Right-hand Radiator:
4. DO NOT operate a machine with a damaged
1. Install the fan (2) on the motor frame (3). Install the fan(s) assembly. Replace a damaged fan as soon
motor (5) through the motor frame (3) and secure it. as the fault is noted.
2. Using suitable lifting equipment, position the 5. DO NOT disassemble ANY fan assembly or
assembly on the radiator assembly and secure the associated parts that are still within the warranty
motor frame (2) on the radiator. coverage period.
Note: Ensure there is even clearance, all the way 6. IMMEDIATELY investigate and correct ANY
round, between the fan (2) and the fan guard (4). operator complaint involving drive or cooling
system performance.
5. Install the fan guard (4) on the radiator assembly,
and secure it with the mounting hardware, as
removed at 'Removal'. SPECIAL TOOLS
6. Using suitable lifting equipment, install the radiator outlined in this section. Refer to Section 300-0070,
assembly on the machine as described in Section Service Tools, for part numbers of general service
210-0040, Radiators and Mounting. tools required. These tools are available from your
dealer.
7. Position the hood assembly on the machine, using
a suitable lifting device. Secure the hood assembly on
the machine with mounting hardware, as described in TROUBLESHOOTING
Section 100-0040, Hood and Mounting.
Refer to the tables on the following pages for
8. Start the engine and check for correct operation of guidelines on troubleshooting the system:
the fans (2 and 3). Refer to 'Testing' procedure
contained in this section.
9. Remove the wheel blocks.
SM 2601 01-10 3
Section 210-0010
MOTOR TROUBLESHOOTING GUIDE:
SYMPTOM QUESTION CORRECTIVE CHECKS

No rotation Is the flow coming to the motor? Check the circuit and
hydraulic schematic. Are the
hoses secure/free from leaks.
Check setting on main

pressure relief valve; ensure
it is not set too low.
Ensure main pump is supply-

ing oil flow.
Check that fan disconnect

solenoids are allowing flow
to the fan motor. Refer to
Section 210-0044 Fan Discon-
nect Valve. Check both fans
electrically and determine
whether the spools are stick-
ing in the wrong position.
Is the torque required higher Check pressure settings.
than the system is set at? Check if load is not greater
than what the pump is
capable of.
Is the pump ok? Check that main pump is
working correctly.
Are the motors' internal drain Check if a failing check valve
check valves working properly? would not allow some flow to
return to tank and therefore
limit flow to the motor.
Stalls Easily Is the load close to the limit of the Check relief valve setting and
system? compare it to the theoretical
pressure required to deliver
the torque.
Are motor internal drain check Check whether a failing check

valves working properly? valve might be preventing
some flow to return to the
tank and therefore limit flow
to the motor.
Is flow going to the motor Check the minimum flow

sufficient? required by the motor.
Check the pump flow.
4 SM 2601 01-10
Section 210-0010

Insufficient Speed Is the speed lower than desired? Compare the theoretical dis-
placement of the motor to the
observed flow of the pump.
Check that the pump flow is

reaching the motor.
Check the oil temp. Consider

that there may be internal
leakage due to oil viscosity.
Check that air is bled from the

system.
Erratic Speed Is the motor losing speed erratically? Check that the flow from the
pump is reaching the motor.
Check the working pressure.
Check the oil temperature, to

ensure that the oil viscosity is
not influencing the internal
leakage.
Unusual noise level Is the motor running? Consider that there might be air
in the system.
Check that the front shaft seal is

not leaking and allowing air into
the system.
Check that cavitation has not

been induced. If the inertia of
the load is such that it drives the
motor faster than the flow of oil
coming from the pump this
could be the result.
Unusual heat Is oil arriving to the motor already Check the oil quality. Ensure that
hot? the system has been bled properly.
Ensure that the hydraulic oil cooler

is working properly.
Ensure that the return of oil to tank

is not restricted.
Ensure that the filter is not blocked.
Check the velocity of the fluid (5 to

6m/s max).
SM 2601 01-10 5
Section 210-0010

Shaft seal leakage Is the seal leaking when pressurized? Check that seal profile and
consider whether the lips may be
degraded or damaged.
Ensure that the shaft surface is

not damaged by irregular seal
running.
Check the pressure in the drain

line of the motor.
Check the shaft alignment.

Ensure that there are no unbal-
anced loads that may create
wear on the shaft or seal.
* * * *
6 SM 2601 01-10
COOLING SYSTEM - Radiator and Mounting
Section 210-0040
SM - 3578
25
23
21
24
5 22 5
4 4
4 4
5 5
5
4
3 1
2
3
4
16 19 5
7
15
16 6
19
7
11 9 26
20 1
8 28
7 29
15
16 19 6
7
5 9 27
4
3 8
10 2
13 3
4
5
18 17
14
18 14
17
18
17
16
19
15 16
12 19
1 - Brace Rod 8 - Bolt 15 - Nut 22 - RH Combination Cooler

2 - Flexible Mount 9 - Washer 16 - Bolt 23 - Baffle plate
3 - Washer 10 - RH Baffle Plate 17 - lockwasher 24 - Baffle plate
4 - Lockwasher 11 - LH Baffle Plate 18 - Bolt 25 - Baffle plate
5 - Nut 12 - Mounting Bracket 19 - Lockwasher 26 - Baffle plate
6 - Rubber Mount 13 - Mounting Bracket 20 - Tie Plate 27 - Baffle plate
7 - Snubbing Washer 14 - Support Bracket 21 - LH Combination Cooler 28 - Bolt
29 - Washer
Fig. 1 - Radiators and Mounting.
DESCRIPTION The combination radiator assemblies consist of the

following separate cores:
Numbers in parentheses refer to Fig.2 & 3, unless
LH Combination Radiator (Fig. 4):
Transmission oil cooler (2), Brake oil cooler (4),
There are two Combination radiator assemblies
Dropbox oil cooler (5); mounted on front of the
mounted in front of the vehicle engine and transmission
combination radiator is a hydraulic oil cooler and fuel
cooling fans at the front end of the vehicle. The radiator
cooler.
component of the RH cooler assembly is fed from
header tank located in front of the operators
RH Combination Radiator (Fig. 5):
compartment and mounted to the goalpost
Radiator (2) & Charge-air cooler (3); mounted on front
arrangement.Refer to Section 210-0000, COOLING
of the combination radiator is an air conditioning
SYSTEM.
condenser (5). Refer to Section 210-0000, COOLING
SYSTEM.
SM 2602 01-10 1
Cooling System - Radiator and Mounting
Section 210-0040
SM - 3843
14
WARNING
1 15 damage, be sure wheel blocks, blocking
5
6 materials and lifting equipment are properly
3
7 8 secured and of adequate capacity to do the job
5 9
safely.
5
5 5 1. Position the vehicle in a level work area, apply the
4 3
10
5
5 4
13 11 5
12
2. Press hood switch under passenger seat and raise
hood.
2 13

switch in the 'Off' position.
1 - Water Tube 9 - Lockwasher
2 - Water Tube 10 - Bracket 4. Remove hood assembly from the vehicle. Refer to
3 - Elbow hose 11 - Clamp Section 100-0040, HOOD AND MOUNTING.
4 - Silicon Hose 12 - Bolt
5 - Clamp 13 - Hardened Washer
5. Disconnect electrical harness from horns, and
6 - Saddle Clamp 14 - Charge Air Cooler Core
7 - Bracket 15 - Radiator Core remove horns and mounting from front of radiator.
8 - Bracket Disconnect electrical harness from engine and
Fig. 2 - Radiator Hoses transmission cooling fans.
Fan plate assemblies fitted to both LH and RH 6. Remove filler cap carefully from header tank. Refer
assemblies improves the cooling fan efficiency, to Section 210-0000, COOLING SYSTEM.
providing a more uniform distribution of air over the
cooler cores integral to each combination cooler 7. Remove plugs and open shut-off valves at the
assembly. bottom of radiator core and transmission oil cooler core
and drain coolant and oil into suitable containers. Close
Recirculation baffles incorporated in the hood assembly shut-off valves when systems are drained and refit
prevent hot air from the engine cooling fan being plugs.
reintroduced into the cooling air circuit.
8. Remove nuts (5) and lockwashers (4) securing brace
rods (1) to the tops of the combination coolers (21 &
REMOVAL 22).
otherwise specified. 9. Remove nuts (5), lockwashers (4), washers (3) and
flexible mounts (2) securing brace rods (1) to
combination cooler supports. Remove brace rods (1).
WARNING
Do not remove the pressure control cap from 10. Ensure air conditioning lines from condenser
the radiator header tank or attempt to drain the mounted on front of RH combination cooler (22), and
coolant until the engine has cooled. Once the from receiver drier are identified for ease of
engine has cooled, use extreme caution when installation. Disconnect air conditioning lines. Fit
removing the cap. Remove cap slowly as the blanking caps to open lines and ports.
sudden release of pressure from a heated
cooling system can result in a loss of coolant Note: Refer to Section 260-0130, AIR CONDITIONING
and possible personal injury (scalding) from before disturbing the air conditioning circuit.
the hot liquid.
12. Ensure hydraulic lines connected to hydraulic oil
cooler mounted on front of LH combination cooler (21)
are identified for ease of installation and with suitable
containers available to catch leakage, disconnect
2 SM 2602 01-10
Section 210-0040
hydraulic lines. Fit blanking caps to open lines and SM - 3844
ports. 12
13. Disconnect deaeration line from the radiator

5 13
(2, Fig. 5) and deaeration line in engine. Disconnect 5
5 4
3
make-up line from coolant outlet pipe. Refer to Section 5
210-0000, COOLING SYSTEM. Identify lines for ease 1
of installation and cap open lines and ports. 7 5
6 3
5
14. Disconnect all clips and clamps securing air 10 9
8,11
conditioning lines, hydraulic lines and deaeration lines 2 5
to radiator assembly. Move all lines away from radiator
assembly to prevent fouling on removal of radiator
4
assembly.
15. Remove bolts, washers and nuts securing fan 1 - Tube 8 - Bolt
guards (7, Figs 4 & 5) to both combination cooler 2 - Tube 9 - Washer
3 - Hose Cuff 10 - Nut
(21 & 22) assemblies. Remove fan guards (7 Fig. 4 & 5) 4 - Elbow Cuff 11 - Bolt
from assemblies. 5 - Clamp 12 - Charge Air Cooler Core
6 - Saddle Clamp 13 - Radiator Core
16. Slacken saddle clamps (6,11 Fig.2),(6 Fig 3) 7 - Bracket
supporting the hoses. Fig. 3 - Air-To-Air Charge Cooler Piping
17. Slacken clamps securing cooler hoses to air inlet

pipe (2, Fig. 3) and remove air inlet pipe from charge air
DISASSEMBLY
cooler (12, Fig. 3) and engine turbocharger.
RH Combination Cooler
18. Slacken clamps securing cooler hoses to air outlet
pipe (1, Fig. 3) and remove air outlet pipe (1, Fig. 3) Numbers in parentheses refer to Fig. 5, unless
from charge air cooler (12, Fig. 3) and engine intake otherwise specified.
manifold.
Note: Take care not to damage charge air cooler core
19. Slacken clamps (5, Fig. 2) and remove coolant (3) and radiator core (2) during disassembly.
outlet pipes (2, Fig. 2), hose (3, Fig. 2). Remove
clamps (5, Fi.g 2) from radiator assembly and engine 1. Remove mounting hardware securing shroud (6) to
thermostat housing. radiator core (2) and charge air cooler core (3).
20. Slacken clamps (5, Fig. 2) and remove coolant 2. Remove top plate (10), base plate (9) and gasket (1)
outlet pipe (2, Fig, 2), hose (3, Fig. 2) and clamps (5, from the assembly. Separate the charge air cooler core
Fig. 2) from bottom of radiator assembly and engine (3) from the radiator core (2).
water pump inlet.
LH Combination Cooler
21. Using suitable lifting equipment support RH
combination cooler (22). Numbers in parentheses refer to Fig. 4, unless
22. Remove bolts (8) and washers (9) securing RH
combination cooler (22) to the frame. Note: Take care not to damage transmission oil cooler
core (2), sump oil cooler core (3), brake oil cooler core
23. Remove RH combination cooler (22) from the (4) and dropbox oil cooler core (5) during disassembly.
vehicle to a clean area for disassembly. Support cooler
standing upright to allow access to front and rear 1. Remove mounting hardware securing shroud (6) to
cooler cores (2,3,4 & 5).
24. Follow the procedure in steps 20 to 22, for removal
of the LH combination cooler (21). 2. Remove top plate (10), base plate (9) and gasket (1)
from the assembly. Separate the four individual cooler
core elements from each other.
SM 2602 01-10 3
Section 210-0040
SM - 3581
2
10
4
6
3
8 5
13
12
1
11
9
1 - Gasket 5 - Dropbox Oil Cooler Core 9 - Base Plate

2 - Transmission Oil Cooler Core 6 - Shroud 10 - Top Plate
3 - Transmission Sump Oil Cooler Core 7 - Guard 11 - Fan
4 - Brake Oil Cooler Core 8 - Motor Bearing 12 - Hydraulic Motor
13 - Quick Drain
Fig. 4 - Exploded View of LH Radiator Assembly
INSPECTION ASSEMBLY
Numbers in parentheses refer to Fig. 4 & 5 unless Note: Tighten all fasteners to standard torques listed in
otherwise stated. Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATION.
1. Steam clean all parts thoroughly with a suitable
solvent. RH combination Cooler
2. Examine all 7 individual cooler core elements which Numbers in parentheses refer to Fig. 5 , unless
were separated at the disassembly stage. Repair any otherwise specified.
damage discovered if equipped to do so, or, have
repairs made at a reputable radiator repair shop. 1. Fit new gasket (1) to radiator core (2) and charge air
cooler core (3).
2. Secure radiator core (2) and charge air cooler core

(3) with base plate and top plate (9 & 10). Use
fasteners removed during the disassembly stage.
3. Position shroud (6) and secure with fasteners
4 SM 2602 01-10
Section 210-0040
SM - 3582
3
10
8
11 5
7
4
12
1
13
9
1 - Gasket 5 - Condenser 9 - Base Plate

2 - Radiator Cooler Core 6 - Shroud 10 - Top Plate
3 - Charge Air Cooler Core 7 - Guard 11 - Fan
4 - Condenser Mtg Frame 8 - Motor Bearing 12 - Hydraulic Motor
13 - Quick Drain
Fig. 5 - Exploded View of RH Radiator Assembly
removed during the disassembly stage.

1. Fit new gasket (1) to trans oil cooler core (2), sump
4. Assemble elements of the fan (11) including oil cooler (3), brake oil cooler (4) and dropbox cooler
hydraulic motor (12) and secure elements in place to (5).
the complete cooler assembly.
2. Secure combination cooler core elements (2,3,4 & 5)
Note: When installing combination cooler, ensure with base plate and top plate (9 & 10). Use fasteners
clearance around cooling fan tips to plate assembly is removed during the disassembly stage.
of equal dimension all round.
3. Position shroud (6) and secure with fasteners
6. Install air conditioning condenser (5) to combination removed during the disassembly stage.
cooler assembly picking up mounting locations and
hardware as identified at 'Disassembly'. 4. Assemble elements of the fan (11) including
hydraulic motor (12) and secure elements in place to
LH combination Cooler the complete cooler assembly.
Numbers in parentheses refer to Fig. 4 , unless

SM 2602 01-10 5
Section 210-0040
INSTALLATION connect electrical harness to horns.

12. Install LH and RH fan guards (7, Figs 4 & 5) to
radiator assemblies with bolts, washers and nuts
removed during 'Removal'.
13. Remove blanking caps from deaeration lines
(12) and connect deaeration line (12) to connector in
SPECIFICATIONS.
top of radiator assembly and deaeration line (12) to
connector thermostat housing in engine. Do not clip
lines at this point. Refer to Section 210-0000,
WARNING COOLING SYSTEM.
damage, be sure lifting equipment is properly 14. Remove blanking caps from hydraulic oil cooler
secured and of adequate capacity to do the job lines and fittings. Connect all hydraulic lines to
safely. hydraulic oil cooler as identified at removal.
1. Position brace rods (1) and secure in place at 15. Remove blanking caps from air conditioning lines
bottom with nuts (5), washers (3), flexible mounts (2) and fittings. Connect air conditioning lines to condenser
and lockwashers (4). Do not tighten at this stage. and receiver drier. Refer to Section 260-0130, AIR
CONDITIONING for procedure on charging the system.
2. Using suitable lifting equipment, position each cooler
assembly on the frame and secure with bolts (8), 16. Secure all lines with clips and clamps as removed
rubber mounts (6) and washers (7). during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
3. Secure brace rods (1) to tops of coolers using nuts evident.
(5) and washers (4). Adjust brace rods (1) as
necessary at both ends and fully tighten nuts (5). 17. Ensure fittings, lines and pipes are securely
tightened to prevent leaks at initial fill and start up.
4. Install coolant outlet pipe (2, Fig. 2) between
radiator outlet port and engine water pump inlet, and 18. If removed, fit header tank to goalpost and secure
secure with hoses (3, Fig. 2) and clamps (5, Fig. 2). using bolts, nuts and washers removed as
disassembly stage.
5. Install coolant inlet pipe (1, Fig. 2) between radiator
inlet port and engine thermostat housing, and secure 19. Following installation instructions in Section
with hoses (4, Fig. 2) and clamps (5, Fig. 2). 100-0040, HOOD AND MOUNTING, install header tank
and goalpost assembly on the vehicle.
6. Install air outlet pipe (1, Fig. 3) between engine
intake manifold and charge air cooler (12, Fig. 3) and 20. Remove blanking from make-up line (7) and
secure with hoses (3 &5, Fig. 3) and clamps (4, Fig. 3). connect to header tank (1) and coolant outlet pipe (8).
Secure with clamps. Refer to Section 210-0000,
7. Install air inlet pipe (2, Fig. 3) between engine COOLING SYSTEM.
turbocharger and charge air cooler (12, Fig. 3) and
secure with hoses (3 & 5, Fig. 3) and clamps (4, Fig. 21. Remove blanking caps from deaeration lines
3). (12) and connect to appropriate fittings on header tank
(1), as noted on removal. Refer to Section 210-0000,
8. Secure pipes to the cross member with saddle COOLING SYSTEM.
clamps(6,11 Fig.2) (6 Fig. 3)
22. Connect overflow line to header tank.
9. Feed electrical harness from engine cooling fan
through hole in fan plate assemblies. 23. Secure all lines with clips and tie clips as removed
during removal. Ensure no lines are chaffing on sharp
10. Connect engine cooling fan electrical harness to edges or resting against areas where heat will be
main electrical harness. evident.
11. Install horns to front of radiator assembly and 24. Connect electrical harness to coolant level sensor
6 SM 2602 01-10
Section 210-0040
at bottom of header tank. solution to water contained in the radiator.
25. Refer to Section 210-0000, COOLING SYSTEM for Note: The solvent must always be added carefully to
correct selection of coolant. Fill the cooling system water, not water to solvent.
through filler in header tank with coolant until coolant
level stabilizes at the bottom of filler neck.
Transmission Cooler Core Internal
26. Check all line and pipe connections for leaks prior Cleaning - Oil Tubes
to starting the vehicle. Tighten as required. In the event of a major mechanical failure, the
transmission oil cooler core should be cleaned
27. Switch the battery master switch to the 'On' thoroughly or replaced.
position, start up the engine, check for leaks. Tighten
lines and fittings and top up coolant level as required. 1. Clean transmission oil cooler before sludge hardens.
After transmission oil cooler is completely drained,
28. Install filler cap on header tank after the coolant circulate a solution of Agmasol PS40 through the
level has stabilized at the bottom of filler neck. cooler core to remove sludge.
29. Following installation instructions in Section 2. If cooler tubes are badly clogged, circulate an oakite
100-0040, HOOD AND MOUNTING, install hood or alkaline solution through cooler. Solution should be
assembly on the vehicle. circulated through cooler, in the reverse direction to
normal flow, for approximately 15 minutes, after
30. Remove wheel blocks from road wheels. soaking for 10 minutes. The duration of circulation
depends on how badly clogged the cooler is. Flush
thoroughly with clean hot water.
CLEANING
External Cleaning
Radiator Core Internal Cleaning - Water Note: If a build up of dirt is apparent during routine
Tubes inspection, the following cleaning procedure should be
If scale deposits are present inside the water tubes of adopted.
the radiator core, it is necessary to use a suitable
scale remover such as 'Powdered Scale Solvent', or
equivalent. This material is a free-flowing powder, WARNING
inhibited to prevent attack on the cooling system To prevent possible injury when using
materials. compressed air or steam jet, wear adequate eye
protection and do not exceed pressure values
stated.
WARNING
Take care to avoid contact of skin or eyes with 1. Direct a steam jet at 100 - 300 kN/m², or
the solvent. If contact is made it should be compressed air at 500 - 700 kN/m² on to the faces of
washed off immediately with clean water and the cores.
medical advice should be taken.
2. Liberally brush a liquid detergent on to those
For general cleaning use it is recommended to use a surfaces which were not satisfactorily cleaned at
concentration of 50 - 100 kg/m³ of water at a step 1. Leave to soak for at least 1 hour.
temperature of up to 60° C. Rapid circulation or
agitation with compressed air will reduce the time for 3. Apply a high pressure steam jet at 100 - 300 kN/m², or
cleaning. compressed air at 500 - 700 kN/m² on to the treated
surfaces, forcing the fouling material out from the radiator
Note: If scale deposits within the radiator are core.
exceptionally heavy, concentrations up to 200 kg/m³ 4. Leave cores to dry before reinstalling the cooling
may be used. equipment.
The most convenient method of use is to prepare a Note: In the case of grossly fouled surfaces which are
concentrated solution by mixing the powder in hot not cleaned adequately in steps 1 through 4, the
water in a tank and then adding the concentrated following may be used.
SM 2602 01-10 7
Section 210-0040
9. Leave cores to dry before reinstalling the equipment.
5. Ensure that the cores are dry.
6. Liberally brush on to both sides of the cores an MAINTENANCE
emulsifying cleaner such as 'Gunk', or equivalent, and Refer to Section 210-0000, COOLING SYSTEM for
leave to soak for at least 1 hour. recommended preventive maintenance procedures,
service intervals and coolant selection procedures.
7. Apply a high pressure steam jet at 100 -300 kN/m²,
or compressed air at 500 - 700 kN/m² on to the treated
surfaces, from several different angles, forcing the SPECIAL TOOLS
fouling material out from the cores. There are no special tools required for procedures
8. For surfaces with stubborn deposits, it may be SERVICE TOOLS, for part numbers of general service
necessary to repeat steps 5 through 7, brushing the tools and adhesives required. These tools and
surfaces between stages using a stiff bristle brush. adhesives are available from your dealer.
* * * *
8 SM 2602 01-10
COOLING SYSTEM - Fan Disconnect Valve
Section 210-0044
SM - 3618
6
3
1 - Solenoid Coil 4 - Seal

4 2 - Cartridge Valve 5 - 'O'-ring
3 - Valve Body 6 - 'O'-ring
Fig. 1 - Fan Disconnect Valve
DESCRIPTION CT23 on the main hydraulic valve assembly, in the

signal range of 48-263 mA. Refer to Section 215-0050
Main Hydraulic Valve Assembly.
There are two fan disconnect valves located on the
The temperature conditions which will give the desired
truck. One is located on the left hand fender, the other
output are as follows:
is on the right hand fender. The fan disconnect
solenoids stop or allow hydraulic oil flow to either the
Engine Cooling Fan:
engine or transmission cooling fan circuits, Refer to
section 210-0010 Cooling Fan and Motor.
1. Engine coolant temperature reaches 85°C (185°F).
OPERATION 2. Engine oil temperature reaches 108°C (226°F).

3. Air intake temperature reaches 54°C (129°F).
The fan disconnect valves form part of the engine and
transmission cooling fan circuits. The integral solenoid
4. Air conditioning 'ON'
valve controls oil supply from the main hydraulic
valve, at port 'DF1' and 'DF2' respectively, Refer to
Transmission Cooling Fan:
section 215-0050 Main Hydraulic Valve Assembly.
1. Transmission sump oil temperature reaches 80°C
The fan disconnect valve will remain energized (Fig. 2)
(176°F).
until any of the preprogrammed temperature values
are seen by the IFM controller, Refer to Section 190-
2. Retarder oil temperature reaches 90°C (194°F).
0085 Hydraulic ECU.
3. Brake Cooling oil temp reaches 59°C (138°F).
When any of the following temperature conditions are
seen, a signal to de-energize the disconnect valve
4. Dropbox oil temperature reaches 60°C (140°F).
solenoid will be initiated (Figure 3) and oil flow will be
allowed to the fan motor. FUNCTIONAL CHECK
The various temperatures seen will also determine the
degree of flow seen at the fan motors, this is controlled Checking the proper operational function of the fan
by the internal proportional solenoid valves CT22 and disconnect valve can be simply executed by removing
SM 2603 01-10 1
Cooling System - Fan Disconnect Valve
Section 210-0044
the electrical harness connection, with the engine SM 3620A
running. An increase in either engine cooling fan or

transmission cooling fan speed should be observed. TO FAN TO FAN
MOTOR MOTOR
FAULT DIAGNOSIS
Possible points of failure:
1. The solenoid (1) coil. Although continuously rated

they may fail after long periods of service. This failure
is protected by the fail-safe design of the valve. If the
solenoid fails to energize, hydraulic oil will be allowed FROM 'DF1' FROM 'DF2'
to flow to the fan motor. This will default the cooling
fan to run constant at the higher speed setting, thus
safeguarding the system against high operating Fig. 2 - Fan Disconnect Valve - Solenoid Energized
temperatures.
SM 3620B
Solenoid Coil Rating: 29 Watt continuous.
2. The solenoid cartridge valve (2) to which the TO FAN TO FAN

MOTOR MOTOR
solenoid is attached. Failure is only likely to occur due
to contamination in the system. The valve is a low
leakage device and any contamination may cause
either damage to the components or cause
components to stick in position. Failure may be more
difficult to detect due to the different modes of failure.
Damage to the components will allow a progressively
increasing leakage, eventually resulting in some flow
not being shut off when the solenoid is selected. FROM 'DF1' FROM 'DF2'
Sticking components could hold the system at either a
low fan speed or a high fan speed depending on what Fig. 3 - Fan Disconnect Valve -
position the cartridge valve (2) is stuck. Solenoid De-energized
3. Temperature switch failure. The disc brake oil 1. Position the vehicle in a level work area, apply the
cooler temperature switch, mounted on the front axle parking brake and switch off the engine. Operate the
manifold block, should close when the disc brake treadle valve continuously to relieve the pressure in the
cooling oil temperature rises above 50°C (122°F). braking system.
Failure to close will result in the solenoid cartridge
remaining energized and the hydraulic oil flow will not 2. Block all road wheels and place the battery master
be allowed to the fan motors. Failure will result in switch in the 'Off' position. Place the steering lock bar
higher disc brake cooling oil temperatures. in the 'Locked' position.
REMOVAL 3. Remove the blanking cap from the remote drain line
Numbers in parentheses refer to Figure 1. at the bottom of the hydraulic tank. Install a length of
hose on the remote drain fitting, open the drain cock
WARNING Close the drain cock, remove the hose and reinstall the
To prevent personal injury and property blanking cap.
damage, ensure wheel blocks, blocking
materials and lifting equipment are properly 4. Clean the low temperature unloader valve and
secured and of adequate capacity to execute surrounding area with a suitable solvent. Identify and
the job safely. tag all hydraulic lines connected to the low temperature
unloader valve, to aid in 'Installation'.
5. With suitable containers available to catch leakage,
2 SM 2603 01-10
Section 210-0044
disconnect the hydraulic lines. Fit blanking caps to all ASSEMBLY

open lines. Numbers in parentheses refer to Figure 1.
6. Remove the electrical harness connector from 1. The level of assembly is dictated by the need to
solenoid valve (1). change any of the seals, O-rings or constituent parts of
the fan disconnect valve.
7. Remove the bolts and lockwashers securing the fan
disconnect valve to the fender. Remove the fan 2. Should any parts need to be replaced, assembly
disconnect valve from the fender. should be carried out as the reverse of disassembly.
DISASSEMBLY 3. Once the fan disconnect valve is ready to be fitted

to the unit, all ports should be unblanked.
Numbers in parentheses refer to Figure1.
5. Ensure hydraulic connectors and adapters are
installed to correct ports and orientation.
WARNING
If this vehicle is fitted with a pressurized
hydraulic tank, the hydraulic tank remains INSTALLATION
pressurized for 1-2 hours after the engine is Numbers in parentheses refer to Figure 1.
stopped. Before carrying out any maintenance
work on the tank, relieve the tank pressure by Note: Tighten all fasteners to standard torques listed in
opening the miniature ball valve (refer to Section 300-0080, Standard Bolt and Nut Torque
Section 250-0026, Brake Coolant/Hydraulic Tank Specifications.
[with Pressurization]). Close this valve after the
pressure has been relieved. Note: Tighten all hydraulic lines fitted with ORFS
1. Note the location and position of all hydraulic Braking System Schematic. Renew all O-rings where
connectors and adapters prior to removing them from used.
the valve body (3).
1. Secure fan disconnect valve to hydraulic front
2. Unscrew the solenoid cartridge valve (4) from the frame of the truck with bolts and lockwashers.
valve body (3). Disassemble the solenoid as required
for inspection. 2. Remove blanking caps from hydraulic lines and
install lines to the fan disconnect valve as identified
during 'Removal'.
INSPECTION
Numbers in parentheses refer to Figure1. 3. Re-connect the electrical harness connector to the
solenoid valve.
1. Clean all parts with a suitable solvent and dry them
with compressed air. 4. Fill the hydraulic oil tank with hydraulic oil as
specified in Section 300-0020, Lubrication System.
2. Check all port threads and ensure that they are not Refer to Section 230-0040, Hydraulic Tank, for
damaged or stripped. hydraulic oil levels. Install the filler cap on the hydraulic
tank filler neck.
3. Check the cartridge valve (2), ensuring that it is not
worn, nicked, cracked or scored. 5. Place the battery master switch in the 'On' position,
4. Check valve body (3) for damage. Ensure valve body temperature.
(3) is not worn, nicked, cracked or scored.
6. Check fan disconnect valve and hydraulic line
5. Examine solenoid coil for any defects. connections for leaks and tighten as required.
If any parts require to be replaced, this must be carried 7. Remove all blocking from road wheels and place
out prior to fitting the valve assembly. steering lock bar in the 'Stowed' position.
SM 2603 01-10 3
Section 210-0044
SPECIAL TOOLS
Service Tools, for part numbers of general service
dealer.
* * * *
4 SM 2603 01-10
COOLING SYSTEM - Disc Brake Oil Cooler
Section 210-0050
SM - 3948
BRACKET
RH FRAME RAIL 29
19 20 31
R.H. BRAKE
17 39 32,33,34
69
40
41
CHECK VALVE 71
46 21 21 9 31 70
40 64 72
TOP 42 41 10
30 58 8
57 46 PORTING
BLOCK
BTM
39 24
18 RELIEF 54,33,34 22
46 VALVE 23,43
SEC. 210-0045 14
60 BRACKET 11 48 47
77 LH FRAME RAIL 52
5
15
16 55
P P1 53
T T 12 38 56 22
59 4 3
61 62 MOTOR /
TRIPLE PUMP
56 6
35 37 MANIFOLD
13 7 2 1 TRACTOR
21 21
49,50,51 37 36
73 LH
78 74 RH
25 26 65
76
HYDRAULIC
CONTROL
27
44 45 44 66 L.H. BRAKE 75 VALVE
60 WB
67,68
HYDRAULIC TANK
28 FILTER SEC 250-0240
63
1 - Hose 14 - Hose 28 - 'O'-Ring 42 - Clamp 56 - Adaptor 70 - Nut

2 - Hose 15 - Hose 29 - Bolt 43 - Elbow 57 - Hose 71 - Washer
3 - Hose 16 - Hose 30 - Check Valve 44 - Reducer 58 - Hose 72 - Mounting Bracket
4 - Hose 17 - Hose 31 - Washer 45 - Adaptor 59 - Hose 73 - Support Bracket LH
5 - Hose 18 - Hose 32 - Bracket 46 - Adaptor 60 - Hose 74 - Support Bracket RH
6 - Hose 19 - Hose 33 - Bolt 47 - Adpator 61 - Adaptor 75 - Bolt
7 - Hose 20 - Hose 34 - Washer 48 - Plug 62 - Elbow 76 - Washer
8 - Hose 21 - Adaptor 35 - Elbow 49 - Bracket 63 - Adaptor 77 - Elbow
9 - Hose 22 - Elbow 36 - Elbow 50 - Bolt 64 - Nut 78 - Elbow
10 - Hose 23 - Manifold 37 - Adaptor 51 - Lock Washer 65 - Tee
11 - Hose 24 - Porting lock 38 - Special Adaptor 52 - Elbow 66 - Reducer
12 - Hose 25 - Split Flange 39 - Tee 53 - Adaptor 67 - Diagnostic Nipple
13 - Hose 26 - Bolt 40 - Tee 54 - Bracket 68 - Dustcap
27 - Lock Washer 41 - Elbow 55 - Elbow 69 - Bolt
Fig. 1 - Disc Brake Oil Cooler lines
The disc brake oil cooler (1) is an integral part of the

DESCRIPTION AND OPERATION LHS combination cooler ,refer to section 210-0040
Numbers in parentheses refer to Fig. 1. The disc brake RADIATOR AND MOUNTING for specific location
oil cooler can be identified as item 4 in Section 210- within the radiator assembly. The disc brake oil cooler
0005, COOLING SYSTEM SCHEMATIC. is a blast air type, air being supplied via the LH cooling
fan. The fan itself is driven by a hydraulic motor. The
Note: The disc brake cooling system described in this motor is supplied by a dedicated brake cooling section
Section only applies to the vehicles with the serial of the motor / triple gear pump, via the OCDB relief
numbers including and following those listed below. unloader valve. The speed of the fan is dependant on
the oil flow being supplied to the motor from the relief
unloader valve. Refer to Section 250-0075, OCDB
Vehicle Type Effective Serial Number RELIEF UNLOADER VALVE.
TA350 (972) A9721011 and later
Hydraulic Oil flows via an adjustable flow restrictor and
TA350 (975) A9751011 and later
a fixed flow restrictor within the OCDB relief unloader
TA400 (982) A9821010 and later valve, and exits into the motor section of the triple
SM 2604 01-10 1
Cooling System - Disc Brake Oil Cooler
Section 210-0050
pump assembly via inlet hose (58), and is returned to
the hydraulic tank via return hose (59). When the WARNING
temperature of the cooling oil rises above 50°C (122°F), To prevent personal injury and property
a solenoid at the relief unloader is de-energized which damage, make sure blocking or lifting
allows full bore flow through the unloader to the motor equipment is properly secured and of adequate
driving the triple pump, which will increase in speed capacity to do the job safely.
thus increasing the throughput of oil to the brakes and
thus to the cooler. Cooling oil is drawn from the 1. Position the machine on a level floor, apply the
coolant tank via the pump and is filtered before being parking brake and switch off the engine. Operate the
supplied to the manifold block (23) via supply hose steering several times to discharge the steering
(12), for the front brakes. The cooling oil to the centre system. Operate the treadle valve continuously to
and rear brakes is not filtered, and is separately discharge the braking system.
supplied from the pump via hoses (2 and 4
respectively) to a manifold at the rear of the tractor. 2. Block all road wheels and place the battery master
Intermediate hoses connect on to the tractor manifold switch in the off position. Place steering lock bar in the
and a similar manifold on the trailer, from which locked position.
successive hoses connect to the individual brakes via
manifold valve blocks local to the axles. Cooling oil 3. Remove drain plug from inboard face of the brake
returns from the brakes also pass through the local coolant tank. Install a length of hose and drain brake
manifold valve blocks and trailer and tractor manifolds. cooling hydraulic oil into a suitable container. Remove
The relief line from the centre and rear local manifold hose and reinstall drain plug.
valve blocks returns to the tank via hoses (1 and 14).
The common return from the rear brakes (hose 3) and
the common return from the centre brakes (hose 5) DISASSEMBLY
both feed into a porting block (24), the outlet from Numbers in parentheses refer to Fig. 1.
which passes through a hose (20) to join the cooler
inlet hose (19) at a tee (39). The tee (39) also features Note: Tighten all fasteners without special torques
a connection with the oil returning from the front specified, to standard torques listed in
brakes, via a common return from the front brakes Section 300-0080, STANDARD BOLT AND NUT
manifold valve block (hose 10). TORQUE SPECIFICATIONS.
From the manifold valve block serving the front brakes, Note: As the brake oil cooler is part of the combination
cooling oil is distributed to the wheels via hoses (7 and unit, refer to section 210-0040 RADIATOR AND
9). Return oil is sent to the brake cooler via hoses (6 MOUNTING for disassembly of major elements.
and 8), the front brake manifold block and hoses (10,19
and 17). There is an internal check valve within the 1. Remove hoses (17 and 18) from the inlet and outlet
manifold valve block serving each axle. Should the port of the brake cooler section of the LHS combination
pressure in the block reach 1 bar, the check valve will cooler. Refer to section 210-0040 RADIATOR AND
relieve the pressure, with flow going back to tank via MOUNTING.
hoses (11 and 14) in the case of the front brakes, and
via hoses (1 and 14) in the case of the centre and rear 2. Any excess fluid contained within the cooler should
brakes. The principle is the same for all three axle be drained prior to further disassembly.
manifold blocks.
2. Plug ports and hoses. Ensure hoses are tagged for
Brake cooling oil enters the top of the oil cooler and ease of installation at the assembly stage.
flows through it before exiting at the bottom via hoses
(18 and 16) via which it returns to the coolant tank. ASSEMBLY
REMOVAL
Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners without special torques
specified, to standard torques listed in
2 SM 2604 01-10
Section 210-0050
Note: Prior to start-up, ensure the hydraulic motor is
WARNING primed with clean hydraulic oil as specified in Section
4. Fill coolant tank with hydraulic oil as specified in
equipment is properly secured and of adequate
Section 300-0020, LUBRICATION SYSTEM. Refer to
capacity to do the job safely.
Section 250-00025, BRAKE COOLANT / HYDRAULIC
TANK, for oil levels. Install filler cap on coolant tank
Generally assembly is the opposite of disassembly. Be
filler neck.
careful not to damage oil cooler during installation.
5. Fill hydraulic oil tank with oil as specified in Section
Note: Ensure there is even clearance, all the way
300-0020, LUBRICATION SYSTEM. Fill until oil fills
round, between the fan and the radiator assembly.
the glass window nut. Install filler cap on hydraulic tank
Refer to section 210-0010 COOLING FAN AND
filler neck. Refer to Section 250-00025, BRAKE
MOTOR, for specific detail.
COOLANT / HYDRAULIC TANK.
INSTALLATION 6. Place the battery master switch in the 'On' position,

Numbers in parentheses refer to Fig. 1. and start the engine. Top up oil levels in hydraulic tank
and brake coolant tank as required. Bring hydraulic oil
Note: Tighten all fasteners without special torques to operating temperature.
specified, to standard torques listed in Section 300-
0080, STANDARD BOLT AND NUT TORQUE 7. Check all motor, valve and hydraulic line
SPECIFICATIONS. connections for leaks and tighten as required.
8. Remove all blocking from road wheels and place

WARNING steering lock bar in the stowed position.
damage, make sure blocking or lifting 9. Remove wheel blocks.
equipment is properly secured and of adequate
capacity to do the job safely. MAINTENANCE
Every 250 hours
Check radiator / Brake cooler fins for damage. Note fins
should be checked more often when working in
extremely dusty conditions.
where used.
Refer to Section 210-0040, RADIATORS AND
Note: As the brake oil cooler is an integral part of the
MOUNTING for in depth flushing and overhaul
LHS combination unit, refer to section 210-0040
procedure of the coolers.
RADIATOR AND MOUNTING for installation of the
radiator package.
SPECIAL TOOLS
1. Once installed, blanking caps should be removed
from hydraulic hoses (17 and 18).
2. Blaking caps should be removed from the cooler
ports.
dealer.
3. Install hoses (17 and 18) and secure them.
* * * *
SM 2604 01-10 3
Section 210-0050
4 SM 2604 01-10
Cooling System - Transmission Oil Coolers
Section 210-0060
SM - 3873
19 7
9 8 25
2
18 4
8
26 6
27
28
1
17 14
19 22
15
24 26 10
27 16
28
TRANSMISSION
31
30
29
22 11
14
25
TOP
32
14
BTM
14 5 22
BTM
23
13 3 21
TOP 12 19 20
1 - Hose 9 - Elbow 17 - Saddle Clamp 25 - Strap

2 - Hose 10 - Adapter 18 - Bracket Assembly 26 - Bolt
3 - Hose 11 - Elbow 19 - Single Clamp 27 - Lockwasher
4 - Hose 12 - Elbow 20 - Bracket Assembly 28 - Washer
5 - Adapter 13 - Adapter 21 - Clamp 29 - Bolt
6 - Hose 14 - Connector 22 - Clamp 30 - Lockwasher
7 - Check Valve 15 - Check Valve Plate 23 - OCDB Return Bracket 31 - Washer
8 - Tee 16 - Clamp 24 - Trans Bracket 32 - 'P'-clip
Fig. 1 - Transmission Oil Cooling Lines
DESCRIPTION AND OPERATION The purpose of the coolers is to cool the transmission
Numbers and letters in parentheses refer to Fig. 1. sump and retarder hydraulic oil circulating through the
transmission.
Note: The disc brake cooling system described in this
Section only applies to the vehicles with the serial Transmission Oil Cooler
numbers including and following those listed below.
Pressurized hydraulic oil exits the front of the
transmission through hoses (1 and 3) and enters the
Vehicle Type Effective Serial Number transmission oil cooler portion of the combination
TA350 (972) TBA cooler. Oil is cooled by air flow through the fins and
exits through hoses (2 and 4) at the top of the cooler
TA350 (975) TBA and passes back into the return port on the front portion
TA400 (982) TBA of the transmission sump.
Retarder Oil Cooler

The air cooled transmission oil and retarder oil coolers
are integral to the LHS Combination cooler. Each is a Hydraulic oil is drawn from the retarder cooler port,
separate cooler and has separate cooling flow to the through hose (5) and enters the retarder oil cooler
respective circuit. Refer to Section 210-0040 portion of the combination cooler. Oil is cooled by air
RADIATOR AND MOUNTING for the location of each flow through the fins and exits through the hose line (6)
within the radiator assembly.
SM2563 01-10 1
Section 210-0060
at the top of the cooler and passes back into the return 1. Inspect fins on both transmission oil and retarder oil
port on the back of the transmission. coolers carefully, for trapped debris and damage. If any
of the oil cooler fins show signs of leakage or are
REMOVAL excessively damaged, the respective cooler portion of
Numbers in parentheses refer to Fig. 1. the combination cooler must be replaced.
2. Check connectors in all oil cooler ports for damaged

WARNING threads. Replace if required.
damage, be sure wheel blocks and lifting 3. After both oil coolers are completely drained,
equipment are properly secured and of circulate a solution of Agmasol PS40 through the
adequate capacity to do the job safely. cooler tubes.
1. Position the vehicle in a level work area, apply the 4. If the cooler tubes are badly clogged, circulate an
parking brake and switch off the engine. Turn the oakite or alkaline solution through the hydraulic oil
steering wheel several times to relieve any pressure in cooler, in the reverse direction to normal flow, for
the steering circuit. Operate the brake pedal approximately 15 minutes. The duration of circulation
continuously to relieve pressure in the braking system. depends on how badly clogged the cooler tubes are.
Flush thoroughly with clean hot water and then finally
2. Block all road wheels and place the battery master flush compressed air to ensure all cleaning agent is
switch in the 'Off' position. removed.
3. Remove the inlet line (3) from the adapter (13) in the INSTALLATION
transmission oil cooler. Drain oil from the inlet line (3) Numbers in parentheses refer to Fig. 1.
into a suitable container. Plug the inlet line and cap the
port to prevent the ingress of contaminants. Note: Tighten all fasteners to standard torques listed in
4. Remove the outlet line (4) from the elbow (12). Drain TORQUE SPECIFICATIONS.
oil from outlet line (4) into a suitable container. Plug the
outlet line and cap the port to prevent the ingress of Note: Tighten all hydraulic lines fitted with ORFS
contaminants. connections, as described in Section 220-0000,
5. Remove inlet line (5) from the connector (14) in the 'O' rings where used.
retarder oil cooler. Drain the oil from the inlet line (5)
into a suitable container. Plug the inlet line (5) and cap
the port to prevent the ingress of contaminants. WARNING
6. Remove the outlet line (6) from the connector (14). damage, be sure wheel blocks and lifting
Drain oil from the outlet line (6) into a suitable equipment are properly secured and of
container. Plug the outlet line (6) and cap the port to adequate capacity to do the job safely.
prevent the ingress of contaminants.
7. If required, remove hardware and associated lines 1. If the transmission oil cooler or retarder oil cooler
from the combination cooler, Refer to section 210- were removed from the complete combination cooler
0040 RADIATOR AND MOUNTING, to allow for assembly, they must be reassembled to the cooler
removal of both transmission and retarder cooler prior to connecting cooling lines. Refer to Section 210-
portions of the combination cooler. 0040, RADIATOR AND MOUNTING.
2.Install the inlet line ( 3) into adapter (13) on the

CLEANING AND INSPECTION transmission oil cooler.
Note: Contaminated fins cause reduced cooling 3. Install outlet line (4) into the elbow (12) on the
performance. The condition of cooling air fins must be transmission oil cooler.
checked by conducting a daily visual inspection.
4. Install inlet line (5) to the connector (14) on the
2 SM2563 01-10
Section 210-0060
retarder oil cooler.
5. Install outlet line (6) to tee (10), however if any other
lines and fittings were removed at the disassembly MAINTENANCE
stage, fit these prior to filling the unit with oil. Check and clean transmission and retarder oil coolers
every 250 hours, or more frequently, if required. Debris
6. Ensure any oil that may have been lost during the in the cooling fins can restrict the flow of air through
removal stage is replenished, so that the correct oil the cooler which significantly reduces the cooling
level is in the transmission. Refer to section 120-0010, effect.
TRANSMISSION AND MOUNTING, for correct fill level
and Section 300-0020, LUBRICATION SYSTEM for Should fins need to be cleaned. apply compressed air
specifications of oil to be used. or water to the fins. Ensure the cleaning jet is applied
parrallel to the fins so that they do not get damaged.
7. Place the battery master switch in the 'On' position, The cleaning effect can be increased by adding
start the engine and operate the body hydraulics cleaning agents. Ensure that cleaning agent does not
several times to circulate the oil. Check hydraulic oil attack or degrade the cooler material.
cooler and lines for leaks. Tighten fittings as required.
8. Install front grille assembly to the hood with SERVICE TOOLS

mounting hardware, as removed at 'Removal'. There are no special tools required for procedures
tools and adhesives required. These tools are available
from your dealer.
* * * *
SM2563 01-10 3
Section 210-0060
4 SM2563 01-10
COOLING SYSTEM - DropBox Oil Cooler
Section 210-0065
SM - 3949
50
20 21 42 49
16 TR 16
9 19
23
DROPBOX
3 45 26 VALVE 19 LS1
125-0025
OC1 GS1 GS2 pc2 qc1
OC2
P1 T1 P2 DL
2 14 14 DROPBOX
BTM REF SEC 24 SEC 125-0010
1 125-0040
12
26 16 DC
8
13 45 43
15
6 11
10 7 9 CS3 17
1 1
TOP
5 40 44
SEC.
27 125-0026
DROPBOX 4 31
COOLER 25 P
SEC 210-0016 T
29 DROPBOX
46
46 SL
FILTER
SEC. 125-0045 36
54 22 32
TANK-RETURN TUBE 51,53 35
SEC. 250-0020 47
52 28 28 39
18 41
OUT
DROPBOX
37 48
PUMP IN
SEC 125-0035
30 SUCTION FILTER
34 38,53 AND MTG.
SEC. 125-0050
33
1- Adaptor 12 - Adaptor Reducer 23 - Hose 34 - Adaptor 45 - Tee
2- Hose 13 - Hose 24 - Hose 35 - Lock washer 46 - Adaptor
3- Hose 14 - Adaptor 25 - Hose 36 - Washer 47 - Bracket
4- Elbow 15 - Hose 26 - Adaptor 37 - PTO/Pump Mounting Bracket 48 - Bolt
5- Tee 16 - Adaptor 27 - Hose 38 - Flanged Bolt 49 - Tee
6- Check valve 17 - Hose 28 - Elbow 39 - Elbow 50 - Hose
7- Clamp 18 - Washer 29 - Hose 40 - Adapter 51 - Bolt
8- Tee 19 - Adaptor 30 - Hose 41 - Hose 52 - Adaptor
9- Clamp 20 - Hose 31 - Elbow 42 - Adaptor 53 - Loctite 243
10 - Clamp 21 - Hose 32 - Elbow 43 - Hose 54 - Washer
11 - Tee 22 - Bolt 33 - Elbow 44 - Hose
Fig. 1 - Dropbox Oil Cooling Lines
DESCRIPTION AND OPERATION cooler, where it is cooled by air flow through the fins
and exists through hose line (3) passes through hose
Numbers and letters in parentheses refer to Fig. 1. line (17) and back into port 'OC2' on the dropbox valve
through hose (23),where it returns to the oil sump on
The air cooled dropbox oil cooler is integral to the LHS the bottom of the unit.
Combination cooler assembly. Refer to Section 210-
0040 RADIATOR AND MOUNTING. The purpose of
this cooler is to cool the dropbox hydraulic oil REMOVAL
circulating through the dropbox. Numbers in parentheses refer to Fig. 1.
Hydraulic oil is drawn from the dropbox oil sump by

suction filter,through hose (41). Oil passes into the WARNING
pump assembly through inlet hose (30). Oil gets filtered To prevent personal injury and property
in the dropbox filter, enters into the pressure relief valve damage, be sure wheel blocks and lifting
and is then passed out of port 'OC1' through hose line equipment are properly secured and of
(13) and enters Top of the Dropbox cooler through hose adequate capacity to do the job safely.
(2) .
From here it flows to the bottom port of the dropbox oil parking brake and switch off the engine. Turn steering
SM 2605 01-10 1
Cooling System - DropBox Oil Cooler
Section 210-0065
wheel several times to relieve any pressure in the

steering circuit. Operate brake pedal continuously to Note: Tighten all hydraulic lines fitted with ORFS
relieve pressure in the braking system. connections, as described in Section 220-0000,
2. Block all road wheels and place the battery master 'O' rings where used.
3. Remove inlet line (30) from adaptor (34) and WARNING

connector in the dropbox oil pump (33). Drain oil from To prevent personal injury and property
inlet line into a suitable container. Plug inlet line and damage, be sure wheel blocks and lifting
cap port to prevent ingress of dirt. equipment are properly secured and of
4. Remove outlet line (3) from adaptor (1) and connector
in dropbox oil cooler. Drain oil from outlet line into a 1. If removed, reinstall combination cooler and
suitable container. Plug outlet line and cap port to associated lines prior to connecting dropbox (1) cooler
prevent ingress of dirt. lines. Refer to Section 210-0040, RADIATOR AND
MOUNTING
7. If required remove hardware and associated lines
from combination cooler, Refer to section 210-0040 2. Install inlet line (2) and outlet line (3) in their
RADIATOR AND MOUNTING, to allow for removal of respective ports, as removed at 'Removal'.
the dropbox cooler and its constituent parts.
start engine and bring transmission up to operating
CLEANING AND INSPECTION temperature. Check dropbox oil cooler and lines for
1. Inspect fins on dropbox oil cooler carefully, for leaks. Tighten fittings as required.
trapped debris and damage. If dropbox oil cooler fins
show signs of leakage or are excessively damaged, it 4. Remove wheel blocks from all road wheels.
must be replaced as an assembly.
2. Check connectors in dropbox oil cooler ports for MAINTENANCE

damaged threads. Replace if required. Debris in the cooling fins can restrict the flow of air
through the cooler which significantly reduces the
3. After dropbox oil cooler is completely drained, cooling effect. Check fins daily.
circulate a solution of Agmasol PS40 through the
cooler tubes. Note: In the event of a hydraulic failure, hydraulic oil
cooler should be removed and cleaned to prevent
4. If cooler tubes are badly clogged, circulate an oakite clogging.
or alkaline solution through the hydraulic oil cooler, in
the reverse direction to normal flow, for approximately For specific oil drain and refill intervals Refer to Section
15 minutes. The duration of circulation depends on how 300-000, LUBRICATION SYSTEM.
badly clogged the cooler tubes are. Flush thoroughly
with clean hot water.
SERVICE TOOLS
INSTALLATION outlined in this section. Refer to Section 300-0070,
Numbers in parentheses refer to Fig. 1. SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools are available
Note: Tighten all fasteners to standard torques listed in from your dealer.
* * * *
2 SM 2605 01-10
COOLING SYSTEM - Hydraulic Oil Cooler
Section 210-0100
SM - 3950
17
15
11
10
5 9
7 8
14 13 12
6
2
7
16
14 13 12 TANK
RETURN
1 3
4 6
1 - Hydraulic Oil Cooler 6 - Adaptor 11 - Nut 16 - Elbow

2 - Hydraulic Oil Cooler 7 - Elbow 12 - Bolt 17 - Tube Assembly
3 - Hose Assembly 8 - Bolt 13 - Lock Washer
4 - Hose Assembly 9 - Washer 14 - Washer
5 - Hose Assembly 10 - Lock Washer 15 - Cooler Mounting Bracket
Fig. 1 - Exploded View of Hydraulic Oil Cooler, Lines and Mounting
DESCRIPTION AND OPERATION Oil passes through a series of tubes in the cooler core,
where the oil temperature is reduced by air flow through the
cooler fins, before exiting hydraulic oil cooler (1) from the
bottom port of the cooler located on the RHS of the cooler.
The air cooled hydraulic oil coolers (1 and 2) are
Oil returns to tank through the hydraulic oil filter.
mounted to the cooler bracket mounting (15) on the
front face of the left hand radiator assembly, directly REMOVAL
below the fuel cooler, Refer to Section 200-0040 , FUEL
LINES for detail.
The purpose of the cooler is cooling hydraulic oil

WARNING
circulating through the hydraulic system.
Hydraulic oil cooler (2) is connected at tube Assembly
(17) between the return ports from the two hydraulic fan
motorsand the inlet to the hydraulic tank filter
safely.
assembly.
Hydraulic oil enters the hydraulic oil cooler from oil inlet
line (5) on the RHS of the cooler at the port located on the
switch off the engine. Turn steering wheel several
bottom. Then, oil enters hydraulic cooler (1) through the
times to relieve any pressure in the steering circuit.
hose assembly (3) on the LHS of the Hydraulic cooler (2).
SM 2606 01-10 1
Cooling System - Hydraulic Oil Cooler
Section 210-0100
2. Block all road wheels and place the battery master 15 minutes. The duration of circulation depends on how
switch in the 'Off' position. badly clogged the cooler tubes are. Flush thoroughly
with clean hot water.
3. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose on INSTALLATION
remote drain fitting, open drain cock and drain hydraulic Numbers in parentheses refer to Fig. 1.
oil into a suitable container. Close drain cock, remove
hose and reinstall blanking cap. Note: Tighten all fasteners to standard torques
specified in Section 300-0080, STANDARD BOLT
4. Remove mounting hardware securing the front grille AND NUT TORQUE SPECIFICATIONS.
on the hood assembly and remove grille for access to
both the hydraulic oil coolers (1 and 2). 1. Remove blanking cap from hydraulic oil
coolers (1 and 2), oil inlet hose line (5), connecting
5. Press the hood raise switch (located in the cab, hose line (3) and oil outlet hose line (4). Prior to
under the passenger seat). Raise the hood to allow for installation.
access to the cooler.
2. Secure coolers (1 and 2) to the bracket (15) using
6.Remove Bolts (8), Washer (9) and Lockwasher (10) washers (14), lockwashers (13) and bolts (12) at all
securing the cooler mounting bracket (15). mounting locations.
7. Remove oil outlet line (4) from hydraulic oil cooler (1) 3. If removed, fit adaptors (6) and elbow (7) to both inlet
and drain oil into a suitable container. and outlet ports of the cooler (1).hte
8. Remove oil inlet line (5) from hydraulic oil cooler (2) 5. Position oil inlet hose line (5), hydraulic coolers
and drain any remaining oil into a suitable container. (1 and 2), tanks connecting hose (3) and outlet hose
lines(4) on the vehicle following the route taken before
9. Remove the hose (3) connecting the hydraulic removal. Do not clip line in position at this stage.
coolers (1 and 2) and drain oil if any.
6. Secure oil lines to the cooler and the tube
10. Remove bolts (12), lockwasher (13) and washers Assembly (17).
(14) securing oil coolers (1 and 2) to bracket (15).
7. Clip oil inlet line (7) and oil outlet line (6) with clips
11. Remove oil coolers (1 and 2) from the vehicle. as noted at removal. Use tie clips where required to
maintain tidy line routing.
12. Fit blanking caps to all ports and hose lines which
will be fitted at installation. 8. Fill hydraulic oil tank with hydraulic fluid specified in
Section 300-0020, LUBRICATION SYSTEM. Refer to
Section 230-0040, HYDRAULIC TANK, for correct fill
CLEANING AND INSPECTION level. Install filler cap on hydraulic tank.
1. Inspect fins on hydraulic oil cooler carefully, for
trapped debris and damage. If hydraulic oil cooler fins 9. Check all line and pipe connections prior to starting
show signs of leakage or are excessively damaged, it the vehicle.
must be replaced as an assembly.
2. Check connectors in hydraulic oil cooler ports for start the engine and check for leaks. Tighten lines and
damaged threads. Replace if required. fittings as required.
3. After hydraulic oil coolers are completely drained, 11. Lower hood assembly using the hood switch
circulate a solution of Agmasol PS40 through the located beneath the passenger seat.
cooler tubes.
12. secure front grille assembly to the hood with
4. If cooler tubes are badly clogged, circulate an oakite mounting hardware removed at removal. Remove all
or alkaline solution through the hydraulic oil cooler, in wheel blocks.
the reverse direction to normal flow, for approximately
2 SM 2606 01-10
Section 210-0100
SPECIAL TOOLS
dealer.
* * * *
SM 2606 01-10 3
Cooling System - Hydraulic Oil Cooler
Section 210-0100
4 SM 2606 01-10
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
SM - 2828 When the pump is not running, the priority valve (7) is
closed. As the main pump starts rotating it builds up
residual pressure and the priority valve opens, feeding
the main pump pressure through to the fan drive valves
(22 and 23) and the body tipping valves (27 and 28).
During the body tipping operations and while the fan is

running, if the demand pressure at the brake charging
or the steering circuit is less than these functions, the
priority valve (7) remains open, but the oil takes the
path of the least resistance and the requirements of the
charging or steering circuits are met.
If the demand pressure for charging or steering is

higher than that demanded by the fan drive or body
tipping function, this higher pressure will be fed to the
main pump load sense line via the shuttle valves (16
Fig. 1 - Main Hydraulic Valve Assembly and 17) and therefore enables the main pump to meet
the charging or steering pressure requirements. At the
DESCRIPTION same time the higher load sense pressure assists the
Numbers in parentheses refer to Figure 2. spring in the priority valve (7), the priority valve will
then close to reduce the flow to the fan or body tipping
The Main Hydraulic Valve Assembly is mounted on the circuit and therefore making sure the brake charging
left hand side of the tractor frame next to the and steering always has priority over the other
transmission. functions.
The Main Hydraulic Valve Assembly controls the The rear pump displacement is influenced by a load
following functions; sense control valve , when the engine is operating at
speeds of less than 900 rev.min and a torque greater
(a) System relief protection for main pump. than 25%, in order to prevent the engine from stalling.
(b) Priority function Refer to Section 230-0135, Load Sense Control Valve.
(c) Steering function. Both pumps feed into a common pressure line to the
(d) Brake charging function. main hydraulic valve assembly.
(e) Park/emergency function.
(f) Body control function.
(g) Transmission cooler fan drive. Steering Function
(h) Engine cooler fan drive Refer to Section 220-0000, Steering System.
(i) Cold start function.
Steering actuation pressure is controlled by steering
Valves that control all the above functions are load sense orifice (15).The steering load sense orifice
integrated into the Main Hydraulic Valve Assembly and (15) controls main pump pressure in the steering load
are identified in Figures 2 to 4 inclusive. sense line. As pressure increases through steering
load sense orifice (15), main pump pressure increases
lifting steering check valve (5) allowing steering
System Relief actuation pressure to access the steering orbitrol
The system relief valve (1) protects the main hydraulic control valve.
valve assembly components against pressure spikes.
This system relief valve is pre-set at 260 bar (3770 lbf/
in2 ) and is non-adjustable. Emergency Steering Unload Valve
Refer to Section 220-0000, Steering System.
Priority Function The emergency valve (3) forms part of the emergency
This function automatically ensures that the steering steering system. It is connected to the main output line
and brake charging circuits are given preference over of the wheel-driven Emergency Steering Pump,
the fan and body tipping functions. mounted on the transmission.
SM 2607 01-10 1
2
PBP TS PB PS4 ACC1 B1 PS3 ACC2 B2 PS2 ACC3 PS5 DF1 DF2 DL
CT24 CT37
CT33
CT10 CT11 TPA
CT27
PPA
Section 215-0050
CT22 CT23
CT32 CT12
CT9
CT21
T2
CT31
CT41 CT42
CT8 CT13 CT25
CT1 LOWER
CT28 B
PS1
CT35 CT7 CT39
CT14
P1
CT3a A
CT43 HOIST
LSM CT15 CT29
CT44
PD
CT16 CT26
P2G
CT3 CT36
CT20
CT5
CT17 CT30
P2
CT34
CT4 CT38
CT6
CT2 CT18 CT19
T3 TPO ORB LSO LSP P3 T1 DB WB LSA TPB

PPB
1 - Relief Valve 'CT1' 12 - Brake Charging Valve 'CT12' 22 - Proportional Pressure Control Valve 'CT22' 32 - Directional Control Valve 'CT32'
2 - Relief Valve 'CT2' 13 - Orifice 'CT13' 23 - Proportional Pressure Control Valve 'CT23' 33 - Orifice 'CT33'
3 - Bypass sequence Valve'CT3' 14 - Cold start solenoid Valve 'CT14' 24 - Dual Check Valve 'CT24' 34 - Hoist LS Shuttle Valve 'CT34'
4 - Check Valve 'CT4' 15 - Orifice 'CT15' 25 - Shuttle Valve 'CT25' 35 - Orifice 'CT35'
5 - Check Valve 'CT5' 16 - Shuttle Valve 'CT16' 26 - Shuttle Valve 'CT26' 36 - Hoist LS Valve 'CT36'
6 - Check Valve 'CT6' 17 - Shuttle Valve 'CT17' 27 - Proportional Pressure Control Valve 'CT27' 37 - Relief Valve (Diff Lock) 'CT37'
7 - Priority Valve 'CT7' 18 - Shuttle Valve 'CT18' 28 - Proportional Pressure Control Valve 'CT28' 38 - Auxilliary Check Valve
8 - Check Valve 'CT8' 19 - Shuttle Valve 'CT19' 29 - Float Solenoid 'CT29' 39 - Shuttle Valve 'CT39'
9 - Pressure Reducing Valve 20 - Body Raise LS Relief Valve 'CT20' 30 - Orifice 'CT30' 41 - Body Control spool 'CT41'
10 - Check Valve 'CT10' 21 - Pressure Reducing Valve 'CT21' 31 - Park Brake Solenoid 'CT31' 42 - Check Valve 'CT42'
11 - Check Valve 'CT11' 43 - Relief Valve 'CT43'
44 - Check Valve 'CT44'
SM3538
Fig. 2 Main Hydraulic Valve Assembly Schematic - Based on Engine Shutdown 45 - Orifice 'CT3A'
SM 2607 01-10
Section 215-0050
Brake Charging Function 'body up' signal to the ECU. The ECU will energize the
float solenoid (29), opening the raise line to tank. This
Refer to Section 250-0000, Brake System. ensures hoist cylinders are vented to tank, allowing the
body to lower on to the chassis under its own weight.
The brake charge valve (12) and brake pressure
reducer valve (9) are integral valves that form part of The body relief valve (43) is located on the raise side
the brake charging function. The brake charge valve of the circuit, and prevents pressure spikes at
(12) ensures that there is sufficient load sense maximum extension of the cylinders when the body is
pressure to the main pump to allow the charge raised at maximum engine speed. The relief valve (43)
pressure to be generated. Brake pressure reducer is set at 250 bar (3 625 lbf/in2 ).
valve (9) maintains a safe operating pressure within the
front and rear brake accumulators. Engine and Transmission Cooler Fan
Drives
Park/Emergency Brake Function
The engine and transmission cooler fan speeds are
Refer to Section 250-0000, Brake System.
modulated by proportionally controlling the pressure at
the fan motors. Fan speed is a function of the pressure
The park/Emergency brake solenoid (31) is the integral
at the fan motors. Proportional valve CT22 controls the
valve that controls hydraulic pressure to the park and
flow to the engine fan and proportional valve CT23
Emergency brake function of the truck.
controls the flow to the transmission fan.
Body Control Function On a cold start, the cooler fans will not rotate. Fan
drive disconnect solenoid valves, mounted on the left
Refer to Section 230-0000, Body System.
hand engine baffle plate, will remain closed, blocking
actuating pressure to either the engine cooling fan or
The proportional pressure control valve (27) is the
transmission cooling fan until any of the following
integral valve that controls the body tipping function.
temperature conditions are met for each system:
This valve is operated via the body control lever
located in the operator's cab. The body control lever
Transmission Conditions
sends an electrical signal to the hydraulic ECU. (Refer
to Section 190-0085). The hydraulic ECU processes
ˇ Transmission oil temp 80 °C (176 °F).
this signal and delivers an actuating electrical signal to
ˇ Retarder oil temp 90 °C (194 °F).
the proportional pressure control valve (27). The
ˇ Dropbox oil temp 60 °C (140 °F).
proportional pressure control valve (27) converts this
ˇ Brake cooling oil 59 °C (138 °F).
electrical signal into a pilot pressure, that then is
allowed to stroke the body control spool to the lift
Engine Conditions
position.
ˇ Inlet manifold temp 54 °C (129 °F).
Proportional pressure control valve (28) is the integral
ˇ Engine Coolant temp 85 °C (185 °F).
valve that controls the body lower function. This valve
ˇ Engine Oil temp 108 °C (226 °F).
is operated via the body control lever located in the
operator's cab. The body control lever sends an ˇ Air conditioner 'ON'.
electrical signal to the hydraulic ECU (Refer to Section
190-0085). The hydraulic ECU processes this signal When any of the above conditions are seen, an
and delivers an actuating electrical signal to the electrical signal will be sent either directly or via the
proportional pressure control valve (28). The J1939 datalink to the hydraulic ECU. Once a signal
proportional pressure control valve (28) converts this reflecting any of the preprogrammed temperature
electrical signal into a pilot pressure, that then is parameters is met. The hydraulic ECU wil send a
allowed to stroke the body control spool to the lower signal to de-energize the appropriate fan drive solenoid
position. Subsequent load sense pressure for raise valve at the baffle, allowing actuation pressure to
and lower functions is directed back to the pump via access the fan drive circuit. The fan drive disconnect
hoist 'LS' shuttle valve (34). Orifice (30) dampens the solenoid valves are arranged to fail safe. If power or
load sense signal. electrical connection is lost, the fan drive disconnect
solenoid valves will de-fault to the open (de-energized)
condition.
During the lower condition, when the body reaches the
proximity switch on the chassis frame, opening the
SM 2607 01-10 3
Section 215-0050
Transmission signal The fan drive disconnect solenoid will remain de-
energized until the transmission oil temperature falls
The hydraulic ECU (Refer to Section 190-0085) cancels below 80°C . At this point the oil flow to the
the electrical signal from 'Digital Out' Pin '43' to the fan transmission cooling fan will stop.
drive disconnect solenoid valve. Cancelling this signal
de-energizes the fan drive disconnect solenoid, Engine signal
opening the transmission cooler fan drive circuit.
The hydraulic ECU (Refer to Section 190-0085) cancels
The transmission cooler fan speed pressure is the electrical signal from 'Digital Out' Pin '04' to the fan
controlled by the electro-hydraulic proportional control drive solenoid valve. This signal de-energizes the fan
valve (CT23). A varying current input into this valve of drive solenoid, opening the engine cooler fan drive
between 0 to 264 mA controls the pressure between 39 circuit.
bar (490 psi) and 138 bar (1260 psi). This pressure then
acts upon the shuttle valve (24) and on to the main The engine cooler fan speed pressure is controlled by
pump load sense connection via the shuttle valve (17). the electro-hydraulic proportional control valve (CT22).
This pressure acts upon the spring chamber of the A varying current input into this valve of between 0 to
logic valve (23) that controls the pressure at the fan. 264 mA controls the pressure between 39 bar (490 psi)
and 138 bar (1260 psi). This pressure then acts upon
The hydraulic ECU reads data on the J1939 datalink for the shuttle valve (24) and on to the main pump load
transmission temperatures and directly from brake sense connection via shuttle valve (17). This pressure
cooling oil and dropbox temperature sensors. The acts upon the spring chamber of the Logic Valve (22)
temperature sensor output is calibrated against actual that controls the pressure at the fan.
temperature within the hydraulic ECU. The hydraulic
ECU converts the temp signal into a varying current The hydraulic ECU reads data on the J1939 datalink.
output. This varying current output, from 'PWM Out' Pin The temperature sensor output is calibrated against
'46', controls the electro-hydraulic proportional control actual temperature within the hydraulic ECU. The
valve (23) increasing and decreasing pressure at the hydraulic ECU converts the temp signal into a varying
fan motor. The fan speed increases and decreases current output. This varying current output, from 'PWM
proportionally between transmission sump and retarder Out' Pin '47', controls the electro-hydraulic proportional
oil temperatures of 80 °C to 130 °C (176 °F to 266 °F). control valve (22), increasing and decreasing pressure
SM3539
7 - Priority Valve 'CT7'

14 - Cold Start Solenoid 'CT14'
16 - Shuttle Valve 'CT16'
22 - Hydraulic Proportional Control Valve 'CT22'
23 - Hydraulic Proportional Control Valve 'CT23'
26 - Shuttle Valve
26
7
Valve (14) Coil Rating

Ohms Amps Watts
41 0.6 14
Voltage: 24V
Valve (22 & 23) Coil Rating
Ohms Amps Watts
25 0.9 21
Voltage: 24V
22
14 23
16
Fig. 4 - Main Hydraulic Valve Assembly - Engine and Transmission Cooler Fan Valves/Cold Start Solenoid
4 SM 2607 01-10
Section 215-0050
SM3540
17
Fig. 5 - Main Hydraulic Valve Assembly - Transmission Cooler Fan Valves Continued
Transmission Cooler Fan Drive Trouble Shooting

Symptom Possible Cause Remedy
Fan idle speed to high Fan disconnect solenoid de-energized Check wiring to solenoid / replace
when transmission oil greater than solenoid.
Note fan will not rotate on truck start 90°C.
up. Residual current still on fan solenoid Check for voltage on connector of
valve (22) or (23). valve. Refer to Section 190-0085,
Hydraulic ECU.
Fan control valve (22) or (23) sticking Replace Valve.
open.
Leaking shuttle valve (24). Replace Valve.
Fan unstable over the speed range Fan proportional pressure valves Replace Valve.
when another function is selected. (22 and 23) faulty.
Faulty pump. Refer to Section 230-0050, Main

Pump.
at the fan motor. The fan speed increases and de- temp and coolant temperature will also cause the
creases proportionally between engine oil temperatures engine cooling fan to run at their preset temperature
of 108 °C to 114 °C (226 °F to 237 °F). conditions.
The Fan Drive Solenoid will remain de-energized until Refer to troubleshooting charts.
the engine oil temperature falls below 108 °C . At this
point the oil flow to the engine cooling fan will stop. Cold Start Function
The cold start solenoid (14) is the integral valve that
Note: the temperatures listed for the engine are controls the cold start function of the main hydraulic
specific to the engine oil temperature being monitored. valve assembly. The cold start solenoid (14) energizes
The other paramaters, for example the intake manifold
SM 2607 01-10 5
Section 215-0050
when the starter motor signal is high, this dumps all 4. The main hydraulic valve assembly is accessed by
load sense pressure from the main hydraulic pump, raising the operator's cab. (Refer to Section 260-0010,
rendering the pump off-load. This reduces parasitic Cab and Mounting.)
losses during engine cranking procedure.
There is about a two second delay before de- WARNING

energization of the cold start solenoid (14) (starter Never work under or near an unsupported
motor signal low). This function prevents brake raised operator cab assembly. Always ensure
charging during engine start up, which is particularly that the cab safety prop is in the correct
important in cold climates. position.
A starter motor high signal is received by the hydraulic
ECU at Digital In 'Pin 55'. The hydraulic ECU converts 5. Clean the outer area of the main hydraulic valve
this high signal into a digital output signal at 'Pin 31', assembly with a suitable cleaning solvent. Ensure that
energizing the cold start solenoid (14). The signal to all hydraulic lines connected to the main hydraulic
energize the cold start solenoid (14) will remain on until valve assembly are identified, for ease of installation.
a starter motor low signal is received by the hydraulic With suitable containers, catch any oil leakage when
E.C.U. at 'Pin 55', this will negate the digital output disconnecting hydraulic lines. Install blanking caps to
signal from 'Pin 31'. (Refer to section 190-0085 for full all open lines and fittings.
Hydraulic E.C.U. detail.)
6. Support the main hydraulic valve assembly with
REMOVAL suitable lifting equipment, using an eye bolt.
WARNING 7. Disconnect the mounting hardware securing the

To prevent personal injury and property main hydraulic valve assembly to the vehicle.
materials and lifting equipment are properly DISASSEMBLY
safely. All integral valves on the main hydraulic valve
assembly can easily be removed. On removal of all
1. Position the vehicle in a level work area, apply the integral valve assemblies, clean and examine them for
parking brake and switch off the engine. Turn the wear or damage.
battery master switch to the 'Off' position. Relieve the
stored pressure in the three accumulators. This is If an integral valve is badly damaged, inpect the bore
achieved by pressing and releasing foot brake pedal of the main hydraulic valve housing. If the main
continuously until all accumulator pressure is relieved. hydraulic valve housing is damaged, the main hydraulic
valve assembly will have to be completely replaced.
WARNINGS Always replace all 'O'-rings and seals after inspection.

Accumulators are charged with Nitrogen.
The service pressure in the primary ASSEMBLY
accumulator is 103 bar (1494 lbf/in²) and in the
Front and Rear Brake accumulators is 55 bar All integral valves must be re-installed into their correct
(798 lbf/in²) at 20 °C (68 o F). To prevent personal locations on the main hydraulic valve assembly. All
injury and property damage do not attempt to integral valves must be torqued to their correct value.
remove any valves or fittings until all nitrogen
pressure is completely relieved.
1. Re-install ORFS connectors into the correct ports.
2. Block all road wheels. Replace 'O'-rings and seals. Refer to Figure 6.
3. Remove the blanking cap from the remote drain line 2. Support the main hydraulic valve assembly with
at the bottom of the hydraulic tank. Install a length of suitable lifting equipment, using an eye bolt located on
hose on the remote drain fitting, open the drain cock the top face of the valve assembly.
Close the drain cock, remove the hose and reinstall the
blanking cap.
6 SM 2607 01-10
Section 215-0050
SM - 1335
FITTING NUT
TUBE
SLEEVE
'O' RING 'O' RING
3. Manipulate the main hydraulic valve assembly into

position and secure it to the vehicle with the mounting
hardware.
4. Remove the blanking caps from all hydraulic lines

and fittings. Re-connect hydraulic lines to correct
fittings as tagged at removal.
5. Lower the operator's cab and secure it. Refer to

6. Fill the hydraulic tank with hydraulic oil as described

in Section 300-0020, Lubrication System. Ensure that
the area around the fill point is clean. Install the filler
cap on the hydraulic tank.
7. Turn the battery master switch to the 'On' position,

remove any wheel blocks, start the engine. Operate the
body and steering systems. Check all hydraulic lines
and fittings for leaks. Tighten them where required.
When hydraulic pipework has been separated for
servicing activities, it is vital that air is bled from the
system on completion, in accordance with Section 230-
0050, Main Hydraulic Pump.
8. Check the hydraulic tank oil level and replenish it if

required.
9. Bleed brake system after main hydraulic valve

removal. Refer to Section 165-0010, Brake Parts.
SM 2607 01-10 7
Section 215-0050
Main Hydraulic Valve Assembly - Integral Valve Tightening Torques
Valve No. Description Qty. Tighten Torque Nm
CT1 Main Relief Valve 1 150
CT2 Ground Pump Relief Valve 1 60
CT3 Ground Pump Unload Cartridge 1 100
CT3A Ground Pump Unload Orifice 1 5
CT4 Ground Pump Check cartridge 1 80
CT5 Steering Pump Check cartridge 1 80
CT6 Ground Pump Reverse Flow Check 1 80
CT7 Priority Valve 1 150
CT8 Brake Check Valve 1 60
CT9 Bake Pressure Reducer 1 60
CT10 Accumulator Check Cartridge 1 60
CT11 Accumulator Check Cartridge 1 60
CT12 Unloader Pilot Cartridge 1 45
CT13 Unloader Orifice Plug 1 5
CT14 Cold Start Solenoid Valve 1 22
Coil Nut 1 3.5
CT15 Load Sense Orifice Plug 1 5
CT16 Steering Unload Shuttle 1 9
CT17 Load Sense Shuttle 1 9
CT18 Steering Orifice Plug 1 9
CT19 Pump Load Sense Orifice Plug 1 9
CT20 Hoist LS Relief Valve 1 45
CT21 DC Pilot Control Reducer 1 60
CT22 Fan Speed Solenoid Cartridge 1 60
Coil Nut 1 3.5
8 SM 2607 01-10
Section 215-0050
Main Hydraulic Valve Assembly - Integral Valve Tightening Torques
Valve No. Description Qty. Tighten Torque Nm
CT23 Fan Speed Solenoid Cartridge 1 60
Coil Nut 1 3.5
CT24 Dual Check 1 9
CT25 Hoist Pilot Shuttle 1 9
CT26 Hoist / Fan Shuttle 1 9
CT27 DC Pilot Control Reducer (Raise) 1 30
Coil Nut 1 3.5
CT28 DC Pilot Control Reducer (Lower) 1 30
Coil Nut 1 3.5
CT29 Body Float Solenoid Cartridge 1 22

Coil Nut 1 3.5
CT30 Hoist LS Orifice Plug 1 5
CT31 Park Brake Solenoid Valve 1 20
Coil Nut 1 3.5
CT32 Main Brake Pilot Valve 1 20
CT33 Pilot Valve Orifice Plug 1 5
CT34 Hoist Shuttle 1 9

CT35 Accumulator Orifice Plug 1 20
CT36 Hoist LS Pilot Cartridge 1 20
CT37 Diff Lock Relief 1 45
CT38 Check Cartridge 1 45
CT39 Fan Orifice Plug 1 5
CT41 Hoist DC Valve 1 50

CT42 Anti Cavitation Check 1 42
CT43 Hoist Relief Valve 1 42
CT44 Check Valve 1 Not Applicable (integral to CT41)
SM 2607 01-10 9
Section 215-0050
1 - Relief Valve 'CT1' SM3541

2 - Relief Valve 'CT2'
3 - Bypass sequence Valve'CT3'
5 - Check Valve 'CT5' 43
7 - Priority Valve 'CT7'
9 - Pressure Reducing Valve
10 - Check Valve 'CT10' 34
12 - Brake Charging Valve 'CT12'
13 - Orifice 'CT13' 26 7
14 - Cold start solenoid Valve 'CT14'
5
15 - Orifice 'CT15' 8,35
17 - Shuttle Valve 'CT17' 40
21
4
20 - Body Raise LS Relief Valve 'CT20' 22
21 - Pressure Reducing Valve 'CT21' 9
22 - Proportional Pressure Control Valve (Fan Drive)'CT22' 23
15,18 14
23 - Proportional Pressure Control Valve (Fan Drive) 'CT23' 33 16 29
24 17 20
27 - Proportional Pressure Control Valve (Body Raise) 'CT27'
28 - Proportional Pressure Control Valve (Body Lower) 'CT28'
29 - Float Solenoid 'CT29'
30 - Orifice 'CT30'
25
31 - Park Brake Solenoid 'CT31' 2
32 - Directional Control Valve 'CT32'
33 - Orifice 'CT33'
34 - Hoist 'LS' Shuttle Valve 'CT34' 36
35 - Orifice 'CT35'
36 - Hoist LS Valve 'CT36' 30
37 - Relief Valve (Diff Lock / Centre Axle) 'CT37' 38
38 - Auxiliary Check Valve 'CT38' 27
39 - Orifice 'CT39'
41 - Body Control spool 'CT41'
42 - Check Valve 'CT42' 1 28
43 - Relief Valve 'CT43'
44 - Check Valve 'CT44' (Integral to Body control spool)
45 - Orifice 'CT3A' 10
39
3
41
6 19
42
12
13
37
11
45
Fig. 7 - Main Hydraulic Valve Assembly - Integral Valve Positions
* * * *
10 SM 2607 01-10
STEERING SYSTEM - Steering System Schematic
Section 220-0000
SM - 3507
A - Steering Orbitrol Valve

B - Steering Cylinders
B B C - Emergency Steering Pump
D - Main Hydraulic Pump
L R Integral Valves to Main Hydraulic Valve Assembly

A 1 - (CT1) Relief Valve
2 - (CT2) Emergency Steering Relief Valve
3 - (CT3) Emergency Steering Unload Valve
4 - (CT4) Check Valve
7 - (CT7) Priority Valve
15 - (CT15) Steering Load Sense Orifice
16 - (CT16) Shuttle Valve
19 - (CT19) Pump Load Sense Orifice
T LS P
3 16
15
17
5
4
6
2 18 19
Fig. 1 - Steering System Schematic
DESCRIPTION of the cab floor, is connected to the steering column,

Numbers in parentheses refer to Figure 1 and controls the hydraulic oil flow to the steering
cylinders.
Steering Orbitrol Valve (A)
Refer to Section 220-0090, Steering Valve. The steering valve is of a closed centre design, which
ensures that oil is dead headed at the valve until it is
The steering valve, which is mounted on the underside operated.
SM 2608 Rev1 01-10 1

Section 220-0000
Steering Cylinders (B) Diagnostic Test Point

Refer to Section 220-0120, Steering Cylinder. Steering, main pump and load sense pressures can be
checked at the diagnostic check points located on the
There are two, single stage, double acting cushioned left hand fender at the cab door. Refer to Figure 2.
steering cylinders on the machine. In each case, the
cylinder base end is connected to the front frame, and, Maximum steering system pressure is set at 240 bar
the piston rod end is connected to the articulation and (3500 lbf/in2). This is set by the main cut off
oscillation pivot. Single stage double acting means that compensator on the main hydraulic pump.
the piston rod can have oil applied to either side,
extending or retracting the piston rod.
OPERATION
Cylinder mounting is by pins, spacers, seals and,
spherical bearings secured with circlips. Spherical PRIORITY FUNCTION
bearings permit a limited amount of cylinder
misalignment when travelling over rough terrain.
The priority function automatically ensures that the
Emergency Steering Pump (C) steering and brake charging circuits are given
The emergency steering ground driven pump, mounted preference over the cooler fans and tipping functions.
on the dropbox, provides flow to the steering circuit in
the event that the Main Pump (D) can no longer When the main pump (D) is not running, the priority
function effectively. valve (7) is closed. As the main pump (D) starts
rotating, it builds up residual pressure in the line
feeding the main hydraulic valve assembly at port P1.
Main Hydraulic Pump (D) The pressure opens priority valve (7), feeding the main
Refer to Section 230-0050, Main Hydraulic Pump. pump pressure through to the cooler fan drive and lift
valve.
The main hydraulic pump, which is mounted on the
transmission power takeoff,supplies hydraulic oil for During the tipping operations, and whilst the
operating the steering, body, brakes and cooler fan transmission cooler fan is running, if the demand
drive circuits. pressure at the brake charging or the steering circuit is
less than these functions, the priority valve (7) remains
The main hydraulic pump set is an axial piston, open, but the oil takes the path of the least resistance
variable displacement type, with load sense and and the requirements of the brake charging or steering
pressure regulator, and comprises two pumps mounted circuits are met.
on a common drive shaft, each of which is fitted with a
differential pressure spool and a cut off pressure spool. If the demand pressure for brake charging or steering
The rear pump displacement is influenced by a load circuit is higher than that demanded by the
sense control valve (not illustrated on Figure 1), when transmission cooler fan drive or tipping function, this
the engine is operating at rotational speeds of less than higher pressure will be fed to the main pump load
900 rev/min and a torque greater than 25%, in order to sense line via the shuttle valves (16 and 17) and
prevent the engine from stalling. Refer to Section 230- therefore enable the main pump (D) to meet the brake
0135, Load Sense Control Valve. For simplicity, the charging or steering circuit pressure requirements. At
main hydraulic pump set (D) is illustrated as a single the same time the higher load sense pressure assists
pump on Figure 1. Both pumps feed into a common the spring in the priority valve (7). The priority valve (7)
pressure line to the main hydraulic valve assembly. will then close to reduce the flow to the transmission
cooler fan or tipping circuit, and therefore ensure that
the brake charging and steering circuit always has
Valves 1, 2, 3, 4, 5, 6, 7,15,16,17,18 and 19 priority over the other vehicle functions.
These valves form part of the steering and emergency
steering circuit and are an integral part of the main
hydraulic valve assembly, mounted on the left hand
side of the tractor frame. Refer to Section 215-0050,
Main Hydraulic Valve Assembly.
2 SM 2608 Rev1 01-10

Section 220-0000
PRIORITY FLOW CONTROL TO pump (D) outlet and the load sense line will be
STEERING approximately 35 bar (507 lbf/in2) and the emergency
steering unload valve (3) will stroke against its spring
This function ensures that the flow from the steering
dumping the emergency steer pump (C) flow to tank.
valve (A) is maintained at all times regardless of the
other pressure demand within the system.
In the event of the main pump (D) not been able to
supply sufficient flow for the steering, the differential
To achieve this function, the pressure at the steering
pressure between the main pump (D) outlet and the
valve (A) has to be at a level equal to that demanded
load sense line will be reduced. As soon as the
by the steering plus the differential control pressure set
differential pressure drops below 6 bar (87 lbf/in2) the
by the steering valve.
emergency steering valve (3) will close and the ground
driven pump (C) flow will be diverted across check
The pressure demanded by the steering is fed back to
valve (4) and supply the steering system.
the main pump (D) and the priority valve (7) via shuttle
valve (16). The priority valve (7) will close, and the
Check valve (5) prevents the emergency steer flow
main pump will increase its displacement to make sure
going towards the main hydraulic pump (D), which may
there is enough flow and pressure available to meet
already have failed.
that demanded by the steering.
The steering load sense orifice (15) feeds oil from the STEERING PRESSURE SETTING
main pump supply, to boost the load sense pressure
back to the main pump during the steering operation. WARNING
This is to make sure that an adequate flow is always The machine has to fully articulate to set
available from the main pump (D) to meet that steering pressure, therefore the steering lock
demanded by the steering. This is commonly known as bar cannot be 'Locked'. To prevent personal
a dynamic load sense system. injury and property damage, exercise extreme
caution while working around articulation and
Note: The maximum steer pressure is set by the oscillation pivot area.
pressure cut off (compensator) on the main hydraulic
pump set (240 bar [3480 lbf/in2]). Refer to Section 230- SM4002
0050 Main Hydraulic Pump.
EMERGENCY STEERING
The emergency steering ground driven pump (C) 13 19
provides flow to the steering circuit in the event that 1 7

14 20
the main pump (D) can no longer function effectively. 2 8

15 21
3 9
16
Engine failure, transmission failure or internal failure of 22
4 10
the main pump set (D) could cause ineffective 17 23
performance. 5 11
18
6 12
The emergency steering pump (C) will also assist with

flow from the main pump to articulate the vehicle if the
main pump cannot deliver the flow required by the
1 - Diff-lock Pressure 'TP1' 13 - Parking Brake Pressure
steering circuit. This can happen at low engine speed 2 - DropBox Lube Pressure 14 - Main Pump (Front)
when the vehicle is moving and the operator attempts 'TP3' 15 - Main Pump (Rear)
to articulate the vehicle rapidly. 3 - DropBox High Select 'TP2' 16 - Front Pump LoadSense
4 - DropBox Low Select 'TP2' Pressure
5 - Cross Axle Diff.Lock 17 - Rear Pump LoadSense
To protect the ground driven emergency steering pump 6 - CT21 Pressure
(C), the maximum pressure at the pump is set by the 7 - Body Hoist Raise 18 - Steering Pressure
relief valve (2) to 240 bar (3480 lbf/in2). 8 - Body Hoist Lower 19 - Front Brake Accumulator
The emergency steering unload valve (3) senses the 11 - Transmission 22 - Front Brakes
main pump (D) pressure and the load sense pressure 12 - Rear Axle Disconnect 23 - Rear Brakes
at the spring end of the valve (3). During normal
Fig. 2 - Diagnostic Pressure Check Points Left Hand Fender
operation the differential pressure between the main
SM 2608 Rev1 01-10 3
Section 220-0000
SM - 3508
15 & 18
16 17
6 19
1 - (CT1) Relief Valve
2 - (CT2) Emergency Steering Relief Valve
3 - (CT3) Emergency Steering Unload Valve
7 - (CT7) Priority Valve
17 - (CT17) Shuttle Valve (under CT20)
19 - (CT19) Pump Load Sense Orifice
Fig. 3 - Steering System Valves Integral to Main Hydraulic Valve Assembly
4 SM 2608 Rev1 01-10

Section 220-0000
The maximum steer pressure is set by the pressure
cut off (compensator) on the main pump (240 bar [3480 FILLING AND BLEEDING THE STEERING
lbf/in2]). Refer to Section 230-0050, MAIN HYDRAULIC SYSTEM
PUMP.
1. Fill the hydraulic tank to maximum level. Be ready to
add oil when the engine is started. Do not let oil drop
Steering pressure can be checked at the diagnostic
below the pump suction line, to prevent air entering the
check point located on the diagnostic plate, located
system.
direclty outside the cab door on the base of the LH
fender stand point (refer to Fig. 2). Install a pressure
2. Start the engine and let it idle. Immediately add oil to
gauge capable of reading at least 240 bar (3480 lbf/in2)
the tank if it is required. When no more oil can be
to the correct diagnostic check point (9, Fig,2).
added and oil is clear, proceed as follows:
Steer the truck over the relief (against steering stops)
a. Turn the steering wheel from lock to lock to bleed
to observe a maximum cut-off pressure of 240 bar
the air in the steering cylinders and lines.
(3480 lbf/in2). Adjustment of the main hydraulic pump
should not be necessary, as the units are set by the
manufacturer. Should the pressure cut-off be incorrect, Note: Immediately upon valve spool actuation, oil must
follow the procedure given. Refer to Section 230-0050, be added to the hydraulic tank to replenish the oil
MAIN HYDRAULIC PUMP. moving into the circuit.
'O' RING FACE SEALS (ORFS)

Where hydraulic lines are fitted with ORFS WARNING
connections, the following procedure should be carried Do not operate the machine until all air is bled
out during 'Installation'. Refer to Fig. 4. from the oil.
b. When the oil in the tank is clear (not cloudy or

a. Ensure 'O' ring/seal is in place and that the joining
creamy), the system is free of air.
surfaces are clean. If necessary, retain 'O' ring/seal in
place with a light coating of grease or vaseline.
Note: Slight creep or drift of the steering wheel is
normal.
c. Fill the hydraulic tank to the recommended level and
c. Where a hose is fitted, ensure that it is not twisted
install the filler cap.
or kinked when the nuts are tightened, in order that it is
Hydraulic Oil
d. Where a tube is fitted, ensure that the connection is
The steering system should be kept filled with
aligned correctly.
hydraulic oil as listed in Section 300-0020, Lubrication
System.
e. Tighten the nut a further 1/4 to 1/2 a turn using the
correct size spanner (wrench).
When hydraulic pipework has been separated for
f. Check that a satisfactory hose or tube routing has servicing activities, it is vital that air is bled from the
been achieved. system on completion, in accordance with Section 230-
0050, Main Hydraulic Pump.
SM - 1335
FITTING NUT TUBE MAINTENANCE

Maintenance instructions, intervals and warnings, in
the individual steering and body hydraulic component
sections of this manual, should be adhered to at all
times.
SERVICE TOOLS
SLEEVE It is recommended that the following service tools are
'O' RING 'O' RING
used when carrying out pressure and temperature
SM 2608 Rev1 01-10 5

Section 220-0000
checks during maintenance procedures. These tools, Non-contact Infrared Thermometer
along with other general service tools, are available The infrared thermometer,15269785, can be used to
from your dealer. Refer to Section 300-0070, Service spot heat problems early in electrical, mechanical and
Tools, for part numbers of these tools. hydraulic systems. Hand held and easy to use, you
simply aim, pull the trigger, and read the temperature.
Multi-Gauge Since there is no need to touch what you are
measuring, temperatures of hard-to-reach or moving
The multi-gauge, 15269784, is basically four pressure components can be taken without getting burned or
gauges in one. Continuous system pressure readings shocked.
are indicated on one of three simultaneously reading
gauges through a pressure range of 30 in of vacuum to
5000 lbf/in². O' Ring Face Seals (ORFS) - Seal Kit
The steering system utilizes 'O' Ring Face Seal
The following items should be added to the multi-gauge (ORFS) connectors. An ORFS kit, 15271082, is
to enable the gauge to be used on the diagnostic available. This kit contains a minimum stock
pressure check points; requirement of all sizes of ORFS type seal.
15018226 Diagnostic Coupling
00118748 Connector (2 off)
15004085 Hose Assembly (-04 HP, 2130 mm long)
Steering System Troubleshooting

SYMPTOM POSSIBLE CAUSE REMEDY
System does not reach maximum Fault with main pump or pressure Reference main hydraulic
operating pressure cut off incorrectly set. pump.
Faulty relief valve (CT1) Replace valve
Faulty priority valve (CT7) Replace valve
Contamination in LS orifice (CT15) Replace / Clean.
or (CT18)
Fault with main pump or standby Reference main hydraulic
pressure incorrectly set. pump.
Faulty Orbitrol steer valve Check Orbitrol steer valve

output
Heavy steering due to insufficient Faulty priority valve (CT7) - Stick- Replace valve
pressure being available at the ing open.
steering valve but differential
pressure between the main pump Fault in LS orifice (CT15) or (CT18). Replace / Clean
outlet and load sense port is 35 bar
(507 lbf/in2) Leaking shuttle valve (CT16) Replace Valve
No steering flow available when the Emergency steer unload valve Replace Valve
vehicle is still travelling and engine (CT3) spool sticking open.
is switched off
Emergency steer relief valve (CT2) Replace Valve
- pressure set too low.
Faulty ground driven pump. Check output from ground

driven pump - replace if neces-
sary.
With no function operated pressure Emergency steer valve (CT3) spool Replace Valve.
at ground driven pump too high sticking closed.
* * * *
6 SM 2608 Rev1 01-10
STEERING SYSTEM - Steering Valve
Section 220-0090
SM - 3381
28
29
27
28
29
27
9
10
26
25
24 4 3 2 1
5
9
8 7 6
10
'T'
'P'
'L'
'R'
11
12
19
15
9
10
13
17 16
18
20 14
22 21
23 'X' - Designates Port Detail
1 - Cap Screw 8 - Valve Housing 15 - Spool 22 - Dust Seal

2 - End Cap 9 - 'O'-Ring 16 - Brg Race (Outer) 23 - Retaining Ring
3 - 'O'-Ring 10 - Plug 17 - Neddle Brg (Cage) 24 - Centering Spring
4 - Gerotor 11 - Driveshaft 18 - Brg Race 25 - Ball
5 - 'O' Ring 12 - Sleeve 19 - Seal 26 - Key
6 - Wear Plate 13 - Centering Pin 20 - 'O'-Ring 27 - Relief Valve Spool
7 - 'O'-Ring 14 - Ball Valve 21 - Front Retainer 28 - Plug
29 - 'O'-Ring
Fig. 1 - Exploded View of Steering Valve Assembly
DESCRIPTION (15), sleeve (12), driveshaft (11) and gerotor gear (4)
There are five ports on valve housing (8) as follows:
The Steering Valve can be identified as item 'A' in
Section 220-0000, Steering System Schematic. Port 'P' - Supply from main hydraulic valve
Port 'T' - Return to tank
The steering valve is connected to the steering column Port 'R' - Cylinder supply for right hand turn
and controls hydraulic flow in the steering system. A Port 'L' - Cylinder supply for left hand turn
pressure relief line in the neutral position, between Port 'LS' - Load Sensing to main hydraulic valve
steering cylinder ports 'L' & 'R' and tank return port 'T',
means that the steering valve must only be used with Turning action of the steering wheel is transmitted
a flow amplifier valve. Refer to Section 220-0100, Flow through the steering column to sleeve (8) and
Amplifier Valve. driveshaft (11), which is fastened to the sleeve with
centring pin (13). Rotation of driveshaft (11) causes
The steering valve consists of valve housing (8), spool gerotor gear to rotate in gerotor housing (4). When
SM 2609 01-10 1
Steering System - Steering Valve
Section 220-0090
gerotor gear rotates, oil in gerotor housing (4) pockets SM - 282
(see Fig. 2) is forced out and flows through spool (15)
POCKETS
and sleeve (12) to the steering cylinder port.
Spool (15) contains porting matched to sleeve (12)

and rotates within sleeve (12) to provide directional
control of the oil. See Fig. 3.
OPERATION
When the operator turns the steering wheel a certain GEROTOR HOUSING GEROTOR GEAR
number of degrees for either a left or right hand turn,
Fig. 2 - Gerotor Gear Set
the movement is transmitted through the steering
column to spool (15). After a minimum rotation of 2.5
degrees, the ports in spool (15) start to align with ports SM - 283
in sleeve (12). When the steering wheel is rotated to a RIGHT LEFT

maximum of 10 degrees the ports are fully aligned SYSTEM TURN TURN
allowing full oil flow. After 10 degrees of travel in either PRESSURE FEED FEED
direction the spool and sleeve rotate as an assembly METER TO
PORTS TANK
through centring pin (13).
Oil from the priority valve flows into valve housing (8)
at port 'P' and is channelled through sleeve (12) and
spool (15) to gerotor housing (4). Porting in gerotor
housing (4) permits oil to flow into pockets formed by
gerotor housing (4) and gerotor gear. As spool (15)
rotates, driveshaft (11) also rotates which, in turn,
rotates gerotor gear to which it is splined. When
gerotor gear rotates it progressively forces oil out of
the pockets (see Fig. 2) of gerotor housing (4). The oil Fig. 3 - Porting of Spool and Sleeve
is channelled through sleeve (12) and spool (15) and
exits valve housing (8) through port 'R' for a right hand REMOVAL
turn, or port 'L' for a left hand turn. Oil then travels
through steering lines to the steering cylinders. Numbers in parentheses refer to Fig. 4.
As the steering cylinder pistons move, oil forced out of

the steering cylinders returns to valve housing (8). The WARNING
return oil passes through valve sleeve (12) and spool To prevent personal injury and property
(15) and exits through port 'T' to tank. damage, be sure wheel blocks, blocking
When the steering effort is released, centring spring secured and of adequate capacity to do the job
(13) which was put under tension by the rotation of safely.
spool (15), forces sleeve (12) to rotate back to its
original position. This puts the ports out of alignment 1. Position the vehicle in a level work area, apply the
and stops pump oil flow to the steering cylinders. The parking brake and switch off the engine. Turn steering
vehicle stops turning further but will hold the present wheel several times to relieve any pressure in the
turning radius until spool (12) is rotated past the 2.5 steering circuit. Operate brake pedal continuously to
degree minimum. relieve pressure in the braking system.

3. Remove hydraulic tank remote drain plug and drain
2 SM 2609 01-10
Section 220-0090
SM - 3951
12 19
14
20
13
18
12
7
6
9
4
5
10
11 17
3
16
2
8
1
15
1 - Steering Valve 9 - Nitrile Seal 16 - Beading

2 - Locknut 10 - Bolt 17 - Steering Column Assy
3 - Washer 11 - Lockwasher 18 - Column Cover
4 - Rubber Mount 12 - Joint 19 - Steering Wheel
5 - Mounting Plate 13 - Bellows 20 - Nut
6 - Washer 14 - Steering Shaft
7 - Bolt 15 - Lever
8 - Stub Shaft
Fig. 4 - Exploded View of Steering Valve Installation
hydraulic oil into a suitable container. Reinstall drain tightens joint (12) onto stub shaft (8).
plug in hydraulic tank remote drain fitting.
7. Support steering valve (1) and remove bolts (7),
4. Pull floor mat back to allow access to bolts (7). locknuts (2) and washers (3 & 6) securing mounting
Raise cab and secure with prop. Refer to Section 260- plate (5) to cab floor. Remove steering valve (1) and
0010, Cab and Mounting. mounting plate (5) to a clean area for disassembly.
Remove nitrile seal (9) and discard rubber mounts (4),
5. Clean outer area of steering valve (1) with a suitable if damaged.
solvent. Ensure all hydraulic lines connected to
steering valve (1) are identified for ease of installation
and with suitable containers available to catch
leakage, disconnect hydraulic lines. Cap all lines and
plug all ports to prevent entry of dirt.
6. Slide bellows (13) over steering shaft (14) to gain

access to bottom joint (12) and loosen bolt which
SM 2609 01-10 3
Section 220-0090
DISASSEMBLY (19) over end of drive shaft (6) and engage special tool
with splined end of spool (16). Refer to Fig. 6.
8. Hold gerotor gear (19) and prevent drive shaft (6)
from turning. Twist special tool to compress centering
Note: Steering valves fitted with anti-cavitation valves
spring (11) radially CW or CCW, decreasing the coil
must be disassembled and assembled in the vertical
diameter of the centering spring (11) allowing spool
postion to prevent ball valves (24) becoming trapped in
and sleeve assembly to be removed. Refer to Fig. 7.
the wrong cavities within the valve housing (7).
SM - 2019
1. Remove bolts (10, Fig. 4) and washers (11, Fig. 4)
securing mounting plate (5, Fig. 4) to steering valve (1, 11
19
Fig. 4).
2. 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.
SM - 2018
10
19
10 - Pin 19 - Gerotor Gear
11 - Centring Springs
Fig. 7 - Compressing Centering Spring
9. 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
assembly, from valve housing (7). Refer to Fig. 8.
19 - Gerotor Gear
SM - 2020
Fig. 6 - Gerotor Gear and Splined Drive Engaged
19
Note: Hidden pin. If tension on this pin is released

before these parts are fully disengaged and the pin is
not horizontal, the pin can drop and lockup can occur.
3. Remove cap screws (1) securing end cap (2),

gerotor housing (4) and spacer plate (5) to valve
housing (7). Remove end cap (2) from valve
housing (7) and discard O-ring (3).
4. Remove gerotor housing (4) and gerotor gear (19)

19 - Gerotor Gear
from valve housing (7). Remove and discard O-ring (21)
from gerotor housing (4).
Fig. 8 - Removing Spool and Sleeve Assembly
5. Remove spacer plate (5) from valve housing (7).
10. Remove bearing race (13) and needle thrust bearing
6. Remove and discard O-ring (22) from valve (12) from spool and sleeve assembly.
housing (7).
7.Using a cloth to protect the hand, place gerotor gear
4 SM 2609 01-10
Section 220-0090
11. Using suitable pliers, remove retainer (20) and INSPECTION

bearing race (13) from spool (16) and sleeve (8)
1. Clean all metal parts in a suitable solvent and blow
assembly. Refer to Fig. 9.
dry with compressed air. Do not wipe dry with cloth or
paper towel as lint or other matter may get into the
12. Remove centering spring (11) from spool (16) and
hydraulic system and cause damage.
sleeve (8) assembly. Refer to Fig. 9.
2. Check all mating surfaces and replace any parts
SM - 2021 that have scratches or burrs that could cause leakage.
6 8 11 13 3. Do not use course grit or try to file any metal parts.

20
Note: Replace all 'O' rings and seals with new 'O' rings
and seals at 'Assembly'. Lubricate all 'O' rings and
seals with a petroleum jelly.
ASSEMBLY

9 9 10 16
300-0080, Standard Bolt and Nut Torque
6 - Driveshaft 11 - Centring Springs
8 - Sleeve 13 - Bearing Race Specifications.
9 - Ball - Check 16 - Spool
10 - Pin 20 - Retainer Note: Steering valves fitted with anti-cavitation valves
must be disassembled and assembled in the vertical
Fig. 9 - Sectional View of Spool and Sleeve Assembly
postion to prevent ball valves (24) becoming trapped in
the wrong cavities within the valve housing (7).
13. Remove pin (10) and slide drive shaft (6) from 1. Use a soda straw as a guide tool to insert the roll
spool (16) and sleeve (8) assembly. Refer to Fig. 9. pin (23) and ball valve (24) into the anti-cavitation
valve ports. Insert soda straw into anti-cavitation valve
14. Carefully remove spool (16) and ball checks (9) bore. Drop ball valve (24) through straw into bore.
from sleeve (8). Refer to Figure 9. Remove straw and drop roll pin (23) into bore. Repeat
for second anti-cavitation valve bore. Refer to Fig. 11.
15. Use a soda straw as a guide tool to remove the roll
pin (23) and ball valve (24) from the anti-cavitation 2. Apply a light coating of clean hydraulic fluid to spool
valve ports. Insert two soda straws, one in each anti- (16). Slide spool (16) and ball checks (9) into sleeve
cavitation valve bore. Remove valve housing (7) from (8). Refer to Figure 12.
vice and tilt until roll pins (23) and ball valves (24) slide
through the straws and out of the valve housing (7). 3. Insert drive shaft (6) into spool (16) in sleeve (8)
Refer to Figure 10. carefully so that holes line up. Install pin (10) through
sleeve (8), spool (16) and drive shaft (6) assembly
16. Remove and discard O-ring (14), seal (17) and until pin (10) becomes flush at both sides of sleeve (8).
backup ring (18) from valve housing (7). See Figures 12 and 13.
17. Using a thin blade screwdriver, pry dust seal (15) 4. Position one end of centring spring (11) into slotted
from valve housing (7). Take care not to damage dust end of spool (16). Compress centring spring (11)
seal seat. radially (CCW) and engage free end of spring into slot
in spool (16). See Figure 14.
5. Install bearing race (13) on to the spool (16). Using

suitable pliers install retainer (20) on to the spool (16).
See Figure 14.
SM 2609 01-10 5
Section 220-0090
SM - 2022 6. Apply a light coating of petroleum jelly to the inside

PORT FACE diameter of dust seal (15) and install in valve housing (7).
7. Apply a light coating of petroleum jelly to needle

thrust bearing (12), bearing race (13), O-ring (14), seal
ring (17) and backup ring (18). Install each item onto
spool (16), as shown in Fig. 15.
PORT
FACE
Note: Needle thrust bearing is positioned between the
two bearing races (13) and must be centered around
TOP retainer (20).
VIEW
24 Note: Clamp steering valve housing (7) vertically in a

Anti-Cavitation Valves -
Insert Soda Straws (2), soft jawed vice.
one into each of these
two threaded holes. 23 8. Using a cloth to protect the hand, place gerotor gear
(19) over end of drive shaft (6). Insert special tool
through valve housing (7) and engage with splined end
TILT of spool (16) and sleeve (8) assembly. Twist tool to
HOUSING compress centering spring (11) radially CW or CCW.
Refer to Fig. 16.
SODA STRAW
9. Keep centering spring (11) compressed and
carefully insert assembled parts into valve housing (7),
23 - Roll Pin
24 - Ball Valve
Fig. 10 - Removing Ball Valves 10. Release tension on centering spring (11) and
remove special tool and gerotor gear (19).
SM - 2023
PORT FACE 11. Lubricate and install new O-ring (22) in groove in
valve housing (7). Refer to Fig. 18.
23
12. Install spacer plate (5) with the O-ring groove up, on
valve housing (7). Align bolt holes in spacer plate (5) with
24
tapped holes in valve housing (7). Refer to Fig. 18.
13. Lubricate and install new O-ring (21) in groove in

GUIDE TOOL spacer plate (5). Refer to Fig. 18.
(Soda Straw)
14. Install gerotor housing (4) on valve housing (7).

Align bolt holes in gerotor housing (4) with tapped holes
Anti-Cavitation Valves in valve housing (7). Refer to Fig. 18.
15. Align gerotor gear (19) on driveshaft (6) and gerotor

housing (4), as shown in Fig. 18.
16. Lubricate and install new O-ring (3) in groove in

gerotor housing (4).
17. Install end cap (2) on gerotor housing (4), as shown

in Fig. 18.
23 - Roll Pin
24 - Ball Valve 18. Align cap screw (1) holes and install seven dry cap
Fig. 11 - Installing Ball Valves
6 SM 2609 01-10
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
INSTALLATION
Note: Tighten all fasteners to standard torques listed

in Section 300-0080, Standard Bolt and Nut Torque
Specifications.
11 16 13 20 Note: Tighten all hydraulic lines fitted with ORFS

Steering System Schematic. Renew all
11 - Centring Springs 16 - Spool O-rings where used.
13 - Bearing Race 20 - Retainer
Fig. 14 - Installing Bearing Race and Retainer

WARNING
screws (1) in end cap (2). Pre-tighten cap screws (1) to 17 damage, be sure wheel blocks, blocking
Nm (12.5 lbf ft) then tighten to a torque of 34 Nm materials and lifting equipment are properly
(25 lbf ft), in the sequence shown in Fig. 19. secured and of adequate capacity to do the job
safely.
19. Using bolts (10, Fig. 4) and washers (11, Fig. 4)
secure mounting plate (5, Fig. 4) to steering valve (1,
Fig. 4).
SM 2609 01-10 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
1. Make certain area of installation is clean. 260-0010, Cab and Mounting.
2. Install rubber mounts (4) if removed, and secure 7. Fill hydraulic tank with hydraulic oil, as specified in
steering valve (1) and mounting plate (5) to cab floor Section 300-0020, Lubrication System. Refer to 'Filling
with bolts (7), washers (3 & 6) and locknuts (2). and Bleeding The Steering System'.
3. Install nitrile seal (9) to steering shaft (14). 8. Remove wheel blocks from all road wheels, place
the battery master switch in the 'On' position and start
4. Slide bottom joint (12) of steering shaft (14) over the engine. Operate the steering and check hydraulic
stub shaft (8) and secure by tightening bolt. Slide lines for leaks. Tighten lines and fittings as required.
bellows (13) down over bottom joint (12) and stub
shaft (8).
5. Remove plugs from steering valve ports and caps

from steering lines and install steering lines to steering
valve (1), as identified at removal.
6. Lower cab and secure with pins. Refer to Section
8 SM 2609 01-10
Section 220-0090
SM - 313
WARNING
Do not operate the vehicle until all air is bled
from the oil.
b. When the oil in the tank is clear (not cloudy or

creamy), the system is free of air.
Note: Slight creep or drift of the steering wheel is normal.

Fig. 19 - Cap Screw Tightening Sequence
c. Fill hydraulic tank with hydraulic oil specified in
Section 300-0020, Lubrication System. Refer to
FILLING AND BLEEDING THE STEERING Section 230-0040, Hydraulic Tank, for correct fill level.
SYSTEM Install filler cap on tank.
1. Fill hydraulic tank to Maximum level. Be ready to
add oil when the engine is started. Do not let oil drop
below the pump suction line to prevent air entering the
SPECIAL TOOLS
system. Refer to Section 300-0070, Service Tools, for details of
the centring spring installation tool referenced in this
2. Start engine and let it idle. Immediately add oil to the section. This tool is available from your dealer.
hydraulic tank as required. When no more oil can be
added and oil is clear, proceed as follows:
a. Turn the steering wheel from lock to lock to bleed

the air in the steering cylinders and lines.
Note: Immediately upon valve spool actuation oil must

be added to the hydraulic tank to replenish the oil
moving into the circuit.
SM 2609 01-10 9
Section 220-0090

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 2609 01-10
STEERING SYSTEM - Steering Cylinder
Section 220-0120
SM - 3952
10 2 5 15 16 17 16
14
9 10
8 7 11
78
12,13 4 3 6
20 20
22 22
21 25 21
28
23 24
18 18
19 29 33 30 19
26
27 32 31
GREASE LINES
1 - Cylinder Assembly 10 - Nipple Grease 19 - Spacer / Thrust bearing 28 - P-Clip

2 - Shell Assembly 11 - Wiper 20 - Bolt 29 - P-Clip
3 - Piston 12 - Backup Ring 21 - Washer 30 - Bolt
4 - Retainer 13 - 'O' Ring 22 - Lock Washer 31 - Lock Washer
5 - Rod Assembly 14 - Rod seal 23 - Hose Assembly 32 - Washer
6 - Cushion Sleeve 15 - 'O' Ring 24 - Fitting Grease 33 - Nut
7 - Spherical Bearing 16 - Wear Ring 25 - Elbow
8 - Circlip 17 - Piston seal 26 - Nipple
9 - Screw Grub 18 - Pin Assembly 27 - Elbow
Fig. 1 - Sectional View of Steering Cylinder and Mounting
DESCRIPTION spherical bearings (7) secured with bolts, hardened

washers and lockwashers (20,21 & 22). Spherical
bearings (7) permit a limited amount of cylinder
misalignment when travelling over rough terrain.
The steering cylinders can be identified as item 2 in
Section 220-0000, STEERING SYSTEM SCHEMATIC.
OPERATION
There are two single stage, double acting cushioned
When the operator turns the steering wheel for a
steering cylinders on the machine. The Rod assembly
steering operation, movement of the Rod assembly
(5) end is connected to the articulation and oscillation
generates force required to pivot the tractor frame.
pivot, and, the cylinder base end is connected to the
front frame. Single stage double acting means that Rod
In the neutral position, with the steering valve
assembly (5) can have oil applied to either side,
centralized, oil movement between the steering
extending or retracting the Rod assembly .
cylinders and the steering valve is stopped. Trapped oil
in the system locks both steering cylinders and the
Rod end cylinder mounting is by pins (18), spacers
angle of steering set by the operator is maintained.
(19) and spherical bearings (7) secured with bolts,
Refer to Section 220-0090, STEERING VALVE, for
hardened washers and lockwashers (20,21 & 22). Base
operation of the steering valve.
end cylinder mounting is by pins (18), spacers (19) and
SM 2610 12-09 1
Steering System - Steering Cylinder
Section 220-0120
REMOVAL DISASSEMBLY
WARNINGS WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure lifting equipment is properly
materials and lifting equipment are properly secured and of adequate capacity to do the job
secured and of adequate capacity to do the job safely.
safely.
1. Ensure clean working conditions, remove any port
Hydraulic fluid pressure will remain plugs thus allowing easy entry of air into the cylinder,
within the system after engine shutdown. preventing a vacuum when parts are withdrawn from
Operate the treadle pedal continuously until the cylinder body (2).
pressure has dissipated before carrying out any
work on the hydraulic system or serious injury 2. Remove Circlips (8) from base end of cylinder body
could result. (2) and Rod assembly (5) end. Press out spherical
bearings (7).
parking brake and switch off the engine. Turn steering 3. Using special tool which can be fabricated, unscrew
wheel several times to relieve any pressure in the end cap until thread is disengaged from cylinder body
steering circuit. Operate brake pedal continuously to (2).
relieve pressure in the braking system.
4. Pull end cap and Rod assembly (5) out of cylinder
2. Place steering lock bar in the 'Locked' position. body (2) as an assembly.
Block all road wheels and place the battery master
switch in the 'Off' position. 5. PlaceRod assembly (5) on supports which will not
damage the chrome piston rod diameter.
3. Identify, tag and with a suitable container in position
to catch the spillage, disconnect all hydraulic lines on 6. Remove and discard O-ring (15) piston seal (17) and
one steering cylinder. Cap all lines and fittings to wear ring (16) from piston (3).
prevent ingress of dirt.
7. Provide an anti-torsion device through piston rod (5)
4. Support steering cylinder with a suitable lifting eye to allow unscrewing of piston (3). Unscrew piston
device. (11) from piston rod (5).
5. Remove bolt (20), lockwasher (22) and hardened 8. Remove and discard 'O' ring (15) from piston (3).
washer (21) securing pin (18) at base end of the
cylinder. Remove pin (18) securing base end to the 9. Pull end cap assembly off Rod assembly (5).
front frame. Remove and discard back up ring (12) and 'O' ring (13)
from end cap outer grooves. Remove and discard wiper
6. Remove bolt (20), lockwasher (22) and hardened (11) and rod seal (14) from end cap inner grooves.
washer (21) securing pin (18) at Rod assembly (5) end
of the cylinder. Remove pin (18) securing Rod 11. If damaged, remove grease fittings (24) from
assembly (5) end to the articulation and oscillation cylinder body (2) and Rod assembly (5).
pivot.
12. Remove Bolt (30), Lockwasher (31), Washer (32)
7. Remove cylinder assembly (1) from the machine. and nut (33) . Remove P Clips (28 and 29).
Spacers (19) will come free at this time.
13. Disengage Elbows (25 and 27) seecuring hose line
8. Remove cylinder assembly (1) to a clean area for (23) from cyllinder rod (2) and Rod assembly (5).
disassembly. Drain oil from cylinder assembly into a
suitable container.
9. Repeat steps 3 through 8 for opposite steering

cylinder assembly.
2 SM 2610 12-09
Section 220-0120
INSPECTION 8. Fully grease piston (3) OD and 'O' ring (13) in end
cap.
9. Ensure bore of cylinder body (2) is well lubricated
1. Clean all parts of the cylinder with a suitable solvent
with hydraulic oil. Carefully insert piston rod (5) and end
and dry with clean, lint-free cloths. Clean all grooves
cap (6) assembly into cylinder body (2).
carefully to remove any foreign material.
10. Engage end cap and cylinder body (2), thread
2. Check cylinder body (2), end cap grooves and outer
screw up fully. Tighten end cap to a torque of 542 - 610
diameter of piston (3) for scratches, cracks or other
Nm (400 - 450 lbf ft).
signs of damage. Remove ridges, nicks and scratches
with a fine stone and re-clean. Replace any
11. Replace lube fittings if required.
components which cannot be repaired.
3. Inspect Rod assembly (5) for distortion, cracks or INSTALLATION

other defects. Replace Rod assembly (5) if defective
area is irreparable.
4. Check spherical bearings (7) for wear and replace if
necessary.
ASSEMBLY Note: Tighten all hydraulic lines fitted with ORFS

'O' rings where used.
WARNING
WARNING
safely.
safely.
1. Press spherical bearings (7) in base end of cylinder
body (2) and Rod assembly (5) end. Secure spherical
1. Install a suitable strap, or other lifting device, around
bearings (7) with circlips (8).
one cylinder assembly and position cylinder assembly
(1) on the vehicle, with Rod assembly (5) end of
2. Install new rod seal (14) into bore of end cap with the
cylinder ready for mounting.
lip pointing towards the internal face of end cap (6).
Install new wiper (11) into bore of end cap.
2. Install spacers (19) either side of Rod assembly (5)
end of cylinder. Insert pin (18). Secure pin (18) to
3. Install new back up ring (12) and 'O' ring (13) in
articulation and oscillation pivot with bolt (20),
external groove of end cap (6).
lockwasher (22) and hardened washer (21).
4. Guide end cap (6) assembly onto Rod assembly (5),
3. Install spacers (19) either side of base end of
taking care not to damage rod seal (3) on the thread.
cylinder and insert pin (18). Secure pin (18) to front
frame with bolt (20), lockwasher (22) and hardened
5. Install new 'O' ring (15) into internal groove of piston
washer (21).
(11).
4. Connect hydraulic lines to steering cylinder ports, as
6. Using a suitable C-spanner or fabricated tool, screw
tagged during removal.
piston (3) on Rod assembly (5). Tighten piston (3) to a
torque of 746 - 813 Nm (550 - 600 lbf ft).
5. Repeat steps 1 through 4 for installation of opposite
steering cylinder.
7. Insert new O-rings (15), piston seal (17) and new
wear ring (16) in piston (3) external grooves.
SM 2610 12-09 3
Section 220-0120
6. Lubricate pins (18) through grease nipples (24 ) with start the engine and operate the steering, from lock to
lubricant, as specified in Section 300-0020, lock several times, to purge air out of the hydraulic
LUBRICATION SYSTEM. lines. Check hydraulic lines and fittings for leaks.
Tighten lines and fittings as required.
7.Follow reverse of removal process for installation of
grease fittings for cyllinder rod (2) and Rod assembly
(5) MAINTENANCE
Inspect steering cylinders regularly for leaks or
8. Check oil level in hydraulic tank and add oil if low. damage, repair as required. Lubricate cylinder pins
Refer to Section 230-0040, HYDRAULIC TANK, for every 250 hours, as specified in Section 300-0020,
correct fill level. Refer to Section 300-0020, LUBRICATION SYSTEM.
LUBRICATION SYSTEM, for the type of oil used.
9. Place the steering lock bar in the 'Stowed' position SPECIAL TOOLS
and remove wheel blocks. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools are
10. Place the battery master switch in the 'On' position, available from your dealer.

TORQUE
1 3 Piston 746 - 813 550 - 600
1 11 End Cap 542 - 610 400 - 450
1 9 Grub Screw 13 - 20 10 - 15
* * * *
4 SM 2610 12-09
BODY SYSTEM - Body System Schematic
Section 230-0000
SM - 3534
ACC3
PS5 DL
1 1
TPA
27
PPA
21
T2
28
8 41 42 LOWER
25
B
43
PS1
35
7
HOIST
P1 29 A
LSM
44
26
17
20 36
30
34
19
LSP T1 TPB
PPB
1 - Body Cylinders 26 - Shuttle Valve 34 - Shuttle

17 - Shuttle Valve 27 - Proportional Control Valve (Raise) 36 - Hoist Load Sense Valve
20 - Load Sense Relief Valve 28 - Proportional Control Valve (Lower) 41 - Control Spool
21 - Pressure Reducing Valve 29 - Float Solenoid 42 - Anti Cavitation Valve
25 - Shuttle Valve 30 - Orifice 43 - Relief Valve
44 - Check Valve
Fig. 1 - Body System Schematic
DESCRIPTION service and operating instructions can be found in the

Numbers in parentheses refer to Figs. 1 through 9. relevant component sections of this Manual.
Other useful reference reading; Sections 190-0000
Circuit Diagrams, 215-0050 Main Hydraulic Valve Body Control Lever
Assembly and 230-0081 Body Control Lever.
Refer to Section 230-0081, Body Control Lever.
The body hydraulic system enables the operator to lift
and lower the body in a safe manner with an electric The body control lever is mounted on the right-hand
output from the body control lever. side dash panel inside the operator's cab. The body
control lever is manually operated to control the 'lift and
A brief description of the individual components used in lower' functions of the body assembly.
the body hydraulic system are listed below. Detailed
SM 2611 Rev1 04-10 1

Section 230-0000
Body Cylinders (1) Valves

Refer to Section 230-0130, Body Cylinder. 17,20,21,25,26,27,28,29,30,24,36,41,42 & 43
These valves form part of the body cuircuit and are an
There are two single stage, double acting body hoist
intregal part of the main hydraulic valve assembly,
cylinders, cushioned at both ends of the stroke, on the
mounted on the left hand side of the tractor frame.
vehicle. The cylinder base end is connected to the
Refer to Section 215-0050, Main Hydraulic Valve
trailer frame and piston rod eye end is connected at the
Assembly.
body. Single stage double acting means that the piston
rod can have oil applied to either end, extending or
retracting the piston rod. OPERATION
The cushioning effect when the cylinder is being LIFTING THE BODY
extended is obtained by a tapered spear on the piston Refer also to Sections 190-0000 Circuit Diagrams and
rod passing through a cushioned sleeve. This gradually 215-0050 Main Hydraulic Valve Assembly.
slows the piston which in turn helps to control
destructive shock effects when the piston reaches the When the operator pulls back on the body control lever
full extent of its travel. a voltage between 0 and 5 volts is sent to the hydraulic
ECU, Analog input, 'Pin 29'. The hydraulic ECU
The cushioning effect when the cylinder is being converts this signal to an output current at PWM
retracted is obtained by a tapered spear at the base Output 'Pin 44' to between 0-1000 mA dependent upon
end of the cylinder body entering a cavity in the piston how far the lever is selected. This current is delivered
rod through a cushioning ring. This gradually slows the to the Electro-Hydraulic Proportional Pressure Control
piston which in turn helps to control destructive shock Valve (CT27) which converts this current into a pilot
effects when the piston bottoms. pressure.
Cylinder mounting is by pins, spacers and spherical The primary accumulator (ACC3) pressure is reduced
bearings secured in place by circlips. Spherical to a 25 bar (362 lbf/in2) pilot control pressure by
bearings permit a limited amount of cylinder pressure reducing valve (CT21). This pilot control
misalignment. pressure acts upon the proportional pressure control
valve (CT27) which reduces the pilot pressure to
Accumulator (9) between 6 bar (87 lbf/in2) and 24 bar (348 lbf/in2),
depending on the current output fom the hydraulic
Refer to Section 250-0060, Accumulator. ECU. This pilot pressure then selects the main spool
(CT41) in the lift valve section of the main hydraulic
The primary accumulator (9) is mounted of the rear left valve assembly to the raise position.
hand side of the tractor exhaust mounting frame. The
primary accumulator supports the service brake When the main spool (CT41) has been stroked to the
system and the body pilot pressure system. The raise position, oil from the main pump flows through the
primary accumulator is of the piston type and control spool (CT41) out of port 'A' on the main
precharged with nitrogen to 103 bar (1 493 lbf/in²). It hydraulic valve, onto the tip cylinders (1).
consists of a charging valve assembly, cylinder
assembly and piston. The charging valve is equipped When oil from the main pump flows through control
with a locking feature which, when opened, will allow spool (CT41), a load sense pressure is fed back to the
precharge to be checked or accumulator charged. load sense port of the main pump via shuttle valves
(34,26 & 17). Load sense relief valve (CT20) is set at
The piston acts as a separator dividing the cylinder 210 bar (3045 lbf/in2). This limits the maximum hoist
assembly into two sections. The section nearest the load sense pressure. The main pump then increases
charging valve contains the nitrogen precharge. its displacement and flow passes to port 'A' lifting the
Hydraulic oil from the accumulator charge valve flows body. Returning flow from the tipping cylinders (1)
through accumulator check valves in the brake passes to Port 'B', through the control spool (CT41)
manifold valve and into the other section of the back to tank.
accumulator.
Body relief valve (43) is located on the raise side of the
Accumulator pressure is monitored by pressure circuit and prevents pressure spikes at maximum
switches in the brake lines (Ref. Section 250-0000, extension of the cylinders when the body is raised at
Braking System).
2 SM 2611 Rev1 04-10
Section 230-0000
SM - 3504 The pilot control pressure of 25 bar (362 lbf/in2),

created by pressure reducing valve (CT21) is reduced
by the proportional pressure control valve (CT28) to
between 6 bar (87 lbf/in2) & 24 bar (348 lbf/in2),
depending on the current output from the hydraulic
ECU. This pilot pressure selects the main spool (41) in
the lift valve section of the main hydraulic valve
assembly to the lower position.
When the main spool (41) has been stroked to the

lower position, oil from the main pump flows through
the control spool (41) out of port 'B' on the main
hydraulic valve, onto the tip cylinders (1).
Fig. 2 - Body Control Lever (Operator's Cab) When oil from the main pump flows through control
spool (CT41), a load sense pressure is fed back to the
SM - 2867 load sense port of the main pump via shuttle valves
(34,26 & 17). The main pump then increases its
displacement and flow passes to port 'B' lowering the
body. Returning flow from the tipping cylinders (1)
passes to Port 'A', through the control spool (CT41)
back to tank.
During lowering the operator can fully select the body

control lever onto an electric detent within the lever
base which is connected to the body up relay circuit.
This detent holds the lever in the power down position
allowing the operator to drive the vehicle whilst the
body is still lowering.
Located on the chassis is a proximity switch which

supplies a 24 Volt signal to body up relay K52, which in
turn sends a signal to the hydraulic ECU Digital in 'pin
19'. When the body reaches the proximity switch the 24
Volt signal is switched off, this de-energises the
electric detent allowing the lever to spring back to the
mid position. At the same time the hydraulic ECU
ramps back the current to proportional pressure control
valve (28) to de-select the main spool (41) and
energises the coil on the float solenoid valve (29)
allowing the body to float down to the chassis over the
Fig. 3 - Body Control Lever Positions last few centimetres of travel.
maximum engine speed. Relief valve (43) is set at 250 To prevent damage to the body hinge points or the tip
bar (3 625 lbf/in2 ). cylinders (1) the float solenoid valve (29), which is
connected to 'Digital out' 'Pin 49' on the hydraulic ECU
LOWERING THE BODY is energised all the time the body is on the chassis and
When the operator pushes forward on the body control the engine is running. This ensures that the head side
lever a voltage between 0 and 5 volts is sent to the of the tip cylinders (1) is always vented to tank and the
hydraulic ECU, Analogue input, 'Pin 29'. The hydraulic body is sitting firmly on the chassis.
ECU converts this signal to an output current at PWM
Output 'Pin 45' to between 0 and 1000 mA dependent When the body meets the proximity switch on the
upon how far the lever is selected. This current is seen chassis the control spool (41)is de-selected and reverts
at the Electro-hydraulic Proportional Pressure Control to the neutral position.
Valve (28) that converts this current into a pilot
pressure. When the control spool (41) moves to the neutral
SM 2611 Rev1 04-10 3

Section 230-0000
SM - 3535
1 - Body Cylinders
17 - Shuttle Valve
20 - Relief Valve
21 - Pressure Reducing Valve 17 LOCATED UNDER 20
25 - Shuttle Valve 20
26 - Shuttle Valve
27 - Proportional Control Valve (Raise)
28 - Proportional Control Valve (Lower)
29 - Float Solenoid
30 - Orifice 25
34 - Shuttle
36 - Hoist Load Sense Valve
41 - Control Spool
42 - Anti Cavitation Valve 36
43 - Relief Valve
44 - Check Valve
30
Valve (27 & 28) Coil Rating 27

Ohms Amps Watts
21 0.9 25
Voltage: 24V
28
Valve (29) Coil Rating
Ohms Amps Watts
41 0.6 14
Voltage: 24V
TANK RETURN
43
42
34 41
26 SUPPLY/RETURN
(LOWER SIDE)
SUPPLY/RETURN
(LIFT SIDE)
21
29
Fig. 4 - Main Hydraulic Valve Assembly - Body Control Valve Locations
4 SM 2611 Rev1 04-10

Section 230-0000
position, oil delivery from the main pump is blocked. SM - 4002
To compensate for this over the last few centimeters

of travel, make up check valve (42) opens allowing a
controlled oil flow via port 'B' to the lower side of the tip
cylinders (1). The make up check valve (42) opening
safeguards the system against cavitation when the
main pump flow is blocked during the lowering 13 19
procedure of the body. 1 7
14 20
CHECKING SYSTEM PRESSURES 2 8
15 21
3 9
16 22
WARNINGS 4 10
To prevent personal injury and property 17 23
damage, be sure wheel blocks and blocking 5 11

18
materials are properly secured and of adequate
6 12
capacity to do the job safely.

within the system after engine shut down.
1 - Diff-lock Pressure 'TP1' 13 - Parking Brake Pressure
Operate the brake treadle pedal continuously 2 - DropBox Lube Pressure 14 - Main Pump (Front)
until the pressure has dissipated before 'TP3' 15 - Main Pump (Rear)
carrying out any work on the system or serious 3 - DropBox High Select 'TP2' 16 - Front Pump LoadSense
injury could result. 4 - DropBox Low Select 'TP2' Pressure
5 - Cross Axle Diff.Lock 17 - Rear Pump LoadSense
6 - CT21 Pressure
7 - Body Hoist Raise 18 - Steering Pressure
CHECKING MAIN BODY SYSTEM 8 - Body Hoist Lower 19 - Front Brake Accumulator
PRESSURE 9 - Raise Pilot 20 - Rear Brake Accumulator
1. Position the vehicle in a level work area, apply the 11 - Transmission 22 - Front Brakes
parking brake, switch off the engine and turn steering 12 - Rear Axle Disconnect 23 - Rear Brakes
wheel in both directions several times to relieve any
Fig. 5 - Diagnostic Pressure Check Points Left Hand
pressure in the steering circuit. Fender
2. Operate the brake treadle valve continuously to Relief valve (20) actually sets the load sense pressure
relieve pressure in the accumulators. Block all road for the body circuit, controlling the load sense to a
wheels, place the steering lock bar in the 'Locked' maximum of 210 bar (3045 lbf/in2). This will result in a
position and the battery master switch in the 'Off' maximum main pump delivery pressure for the body
position. raise circuit of 240 bar (3480 lbf/in2). This is due to the
210 bar (3045 lbf/in2) maximum load sense pressure,
3. This following procedure will check that the body plus the 35 bar (435 lbf/in2) differential pressure and
raise/Lower pressure is properly set. Connect a 240 bar (3480 bf/in2) settings of the main pump. Refer
hydraulic gauge, capable of recording a pressure of 0 - to Section 230-0050, Main Hydraulic Pump. The
345 bar (0 - 5 000 lbf/in²), to body system pressure operator cab will require to be raised to access relief
diagnostic pressure point located on diagnostic plate valve (20). Refer to Section 260-0010, Cab and
on left hand fender at base of cab door (7,8 Fig. 5) Mounting.
4. Place the battery master switch in the 'On' position, 7. Adjust relief valve (20) until 240 bar (3480 lbf/in2) is
start the engine and allow all systems to be charged observed on the pressure gauge, while raising the body
normally. over relief.
5. Pull back body control lever. Allow body to raise 8. Shut off the engine and remove the pressure gauge
over relief. The pressure observed on the pressure from diagnostic check point.
gauge should be 240 bar (3480 lbf/in2).
9. Remove wheel blocks, place the steering lock bar in
6. Pressure setting can be adjusted by adjusting relief the 'Stowed' position, start the engine and check the
valve (20) on the main hydraulic valve assembly. body system for proper operation.
SM 2611 Rev1 04-10 5

Section 230-0000
CHECKING PILOT CONTROL PRESSURE SM - 1335
1. Position the vehicle in a level work area, apply the NUT

FITTING
parking brake, switch off the engine and turn steering
wheel in both directions several times to relieve any TUBE
pressure in the steering circuit.
2. Operate the brake treadle valve continuously to

relieve pressure in the accumulators. Block all road
wheels, place the steering lock bar in the 'Locked'
position and the battery master switch in the 'Off'
position. SLEEVE
'O' RING 'O' RING
3. The operators cab has to be raised at this stage so Fig. 6 - Assembly of Typical ORFS Connector
that port 'DL' on the main hydraulic valve can be
accessed. Refer to Section 260-0010, Cab and 'O' RING FACE SEALS (ORFS)
Mounting.
4. Remove fitting from port 'DL' on the main hydraulic connections, the following procedure should be carried
valve block and connect a tee connector with a diagnostic out during 'Installation'. Refer to Fig. 6.
coupling. Reconnect the original fitting between port 'DL'
and the tee. Connect a hydraulic gauge, capable of a. Ensure that the 'O' ring/seal is in place and that the
recording a pressure of 0 - 345 bar (0 - 5 000 lbf/in2), into joining surfaces are clean. If necessary, retain the 'O'
the diagnostic coupling on the tee. ring/seal in place with a light coating of grease or
vaseline.
start the engine and allow all systems to be charged b. Initially, the nuts should be tightened by hand.
normally.
c. Where a hose is fitted, ensure that it is not twisted
6. A hydraulic pressure of 25 bar (362 lbf/in2) should or kinked when the nuts are tightened so that it is
be observed on the pressure gauge. allowed to adopt a natural position.
7. Pressure setting can be adjusted by adjusting d. Where a tube is fitted, ensure that the connection is
pressure reducing valve (21) on the main hydraulic aligned correctly.
valve. Adjust pressure reducing valve (21) until 25 bar
(362 lbf/in2) is observed on the pressure gauge. e. Tighten the nut a further 1/4 to 1/2 a turn using the
8. Raise and lower pilot pressures can be checked by
installing a hydraulic gauge, capable of recording a f. Check that a satisfactory hose or tube routing has
pressure of 0 - 345 bar (0 - 5000 lbf/in2) ) into port 'TPA' been achieved.
(raise) and port 'TPB' (lower). When the raise or lower
action is requested through the body control lever the HYDRAULIC OIL
pressure should read from 0 - 24 bar (0 - 348 lbf/in2)
depending on degree of lever action. The body system should be kept filled with hydraulic oil
as specified in Section 300-0020, Lubrication System.
9. Check body system for proper operation.
Whenever there is a hydraulic system failure, the oil
10. Shut off the engine, remove pressure gauge and should be drained, the entire system flushed, oil filters
reinstate connection at port 'DL' to original condition. replaced, oil screens thoroughly cleaned and clean
hydraulic oil added to eliminate all metal particles or
foreign matter.
11. Operators cab should be lowered and locked into
travel position. Check hydraulic lines for any leakage. When hydraulic pipework has been separated for
servicing activities, it is vital that air is bled from the
12. Remove wheel blocks, place the steering lock bar system on completion, in accordance with Section 230-
in the 'Stowed' position, start the engine and check the 0050, Main Hydraulic Pump.
body system for proper operation.
6 SM 2611 Rev1 04-10
Section 230-0000
HYDRAULICALLY-OPERATED, BOTTOM the tailgate to the Open position. Directional control

of the cylinder is derived from a three position
HINGED TAILGATE OPTION solenoid-operated directional control valve, under the
Numbers and letters in parentheses refer to Figures 7 influence of two solenoids, A and B, identified on
and 8. Figure 7 (2 and 1 respectively).
SM3577
Note: The description below only applies to the 11 8
vehicles fitted with hydraulically-operated, bottom 4

hinged tailgates.
BA
TC T
CO H
DE
LS
5
The option for hydraulically-operating the body tailgate A 7
features a hydraulic cylinder fitted underneath the rear 6

6
end of the body, connected to suitable bracketry on the
T2
C
body and tailgate, a composite hydraulic valve
10
assembly, and associated hydraulic interconnecting 2 3
pipework and electrical harnesses. Figure 7 below is an 1
exploded view of the tailgate hardware.
The hydraulic cylinder (29) is clevis-mounted to the 1 - Solenoid B, CT2 7 - Pressure Inlet from Main
rear end of the body and to a linkage which in turn 2 - Solenoid A, CT2 Hydraulic Valve
3 - Flow Regulator, CT1 8 - Tank Return Connection
connects centrally to the tailgate (1). When the annulus 4 - Relief Valve, CT4 9 - Load Sense Connection
side of the hydraulic cylinder piston is pressurized the 5 - Tailgate 'Close' Hose Fitting 10 - Check Vavle, CT3
tailgate linkage pulls the tailgate in the Closed 6 - Tailgate 'Open' Hose Fitting 11 - Shuttle Valve, CT5
direction. When the full bore side of the hydraulic
Fig. 7 - Tailgate Hydraulic Valve
cylinder piston is pressurized the tailgate linkage draws
SM3902
10
22
21
16
6 32
5 17
8 30 6 31 15
16
19 18
12 20
B 4
A
11 9
14 7
29
22 22
15 13 25 26
28 3 23
21 22 23
27 25
21
23
24
1 - Bottom Hinged Tailgate 9 - Left-hand Side Boss 17 - Pin 25 - Bushing

2 - Link Plate 10 - Right-hand Side Boss 18 - Locking Plate 26 - Disc Spring
3 - Lever 11 - Pin 19 - Locking Washer 27 - 7 mm Spacer
4 - Lever 12 - Bolt 20 - Bolt 28 - 8.5 mm Spacer
5 - Pivot Bracket Assembly 13 - Lock-nut 21 - Bolt 29 - Tailgate Cylinder
6 - Tapped Block 14 - Washer 22 - Lock-nut 30 - Weld Plate
7 - Cylinder Assembly Bracket 15 - Grease Fitting 23 - Hardened Washer 31 - Bolt
8 - Cylinder Assembly Bracket 16 - Bearing 24 - Bolt 32 - Lock-nut
Fig. 8 - Exploded View of Tailgate Assembly
SM 2611 Rev1 04-10 7

Section 230-0000
The signals to operate the directional control valve Multi-Gauge

solenoids are derived from the hydraulic system ECU, The multi-gauge, 15269784, is basically four pressure
and are initiated by movement of the body being gauges in one. Continuous system pressure readings
detected by a proximity switch (S37). The signal are indicated on one of three simultaneously reading
cables for the solenoid connect to pin 16 (Solenoid A) gauges through a pressure range of 760 mm (30 in) of
and pin 51 (Solenoid B) of the ECU connector vacuum to 345 bar (5000 lbf/in²).
respectively.
The following items should be added to the multi-gauge
As the body begins to rise, its proximity to S37 causes to enable the gauge to be used on the diagnostic
the switch to close, and in turn Solenoid A of CT2 is pressure check points;
energized to open the tailgate. Similarly, when lowering 15018226 Diagnostic Coupling
the body, immediately before the body approaches its 00118748 Connector (two)
'Down' position, its movement out of proximity to S37
causes the switch to open, and in turn Solenoid B of
CT2 is energized to close the tailgate (Solenoid A is
de-energized). When the directional control valve, CT2,
The infrared thermometer, 15269785, can be used to
is in the central, dwell position, the hydraulic pressure
spot heat problems early in electrical, mechanical and
is relieved to tank.
hydraulic systems. Hand held and easy to use, you
SERVICE TOOLS Since there is no need to touch what you are
It is recommended that the following service tools are measuring, temperatures of hard-to-reach or moving
used when carrying out pressure and temperature components can be taken without getting burned or
checks during maintenance procedures. These tools, shocked.
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, Service
Tools, for part numbers of these tools. O' Ring Face Seals (ORFS) - Seal Kit
The body system utilizes 'O' Ring Face Seal (ORFS)
connectors. An ORFS kit, 15271082, is available. This
kit contains a minimum stock requirement of all sizes
of ORFS type seal.
SM3576
A B
CT4
CT3
CT5
LS
B A
CT2
CT1
P T
Fig. 9 - Tailgate Open/Close Hydraulic Circuit
8 SM 2611 Rev1 04-10

Section 230-0000
TAILGATE VALVE TORQUE SPECIFICATIONS

TORQUE
FIG. No. ITEM No. ITEM NAME Nm lbf ft
7 1, 2 CT2 20 14.75
7 3 CT2 75 55
7 4 CT4 45 33
7 10 CT3 45 33
7 11 CT5 8-10 (see note) 6-7.4 (see note)
Note: Apply Loctite™ 542 (hydraulic thread sealant).
SM 2611 Rev1 04-10 9

Section 230-0000
The numbers in the Parenthesis refer to Fig.4 unless specified.
Body System TroubleShooting

Body will not lift Pressure Level in the system not high Check pressure at the pump and
enough re-adjust Relief Valve (CT1). Refer
to Section 230-0050, Main
Hydraulic Pump. Relief valve (CT1)
stuck open.
No electric current at the proportional Check voltage at the electric

control valve; Body 'Raise' solenoid connector of CT27 when pulling
(CT27) back on the lever in the cab. If no
voltage is present refer to
Sections190-0085 Hydraulic ECU
and 230-0081, Body Control Lever
Replace coil/valve
Body 'Raise' solenoid faulty
Check output from lever. Refer to
Sections190-0085 Hydraulic ECU
Control lever in the cab faulty and 230-0081, Body Control Lever
Replace lift section of the main

hydraulic valve assembly
Main control spool (41) in the lift
section of the main hydraulic valve
assembly sticking Replace Valve
Clean orifice
Hoist pilot Valve (36) stuck Replace shuttle
Orifice (30) blocked
Hoist pilot shuttle (25) stuck Refer to Section 230-0050 Main
Hydraulic Pump, for correct setting
Main pump faulty procedures
Lift function too slow. Proportional control valve ; body raise Check the output from the body
solenoid (27 ) current not high enough control lever. Refer to Sections190-
0085 Hydraulic ECU and 230-0081,
Body Control Lever
Main control spool (41) not fully Replace lift section of main
selecting. hydraulic valve assembly.
Contamination in the load sense Clean orifice (30).

orifice (30).
Hoist shuttle (25) sticking Replace shuttle (25)
Main pump faulty. Refer to Section 230-0050 Main

procedures.
10 SM 2611 Rev1 04-10

Section 230-0000

Lift function too slow (cont.) Control lever in the cab faulty. Check lever outputs. Refer to
Sections 190-0085 Hydraulic ECU
and 230-0081 Body Control Lever
Can affect pump delivery. Check

Engine RPM too low. throttle pedal for correct signals.
Priority valve (7) will give pump

Check accumulator settings, pre- demand to accumulator charge
charge and charging cycle times cycle.
Body will not lower. Supply fuse to hydraulic ECU blown. Check power on light at controller
is illuminated. Replace fuse if
required. Refer to Section190-0000
Circuit Diagrams
No electric current at proportional Check link between body control

control valve; body'Lower' solenoid lever and the hydraulic ECU, and
(28) between the hydraulic ECU and the
body Lower solenoid (28). Refer to
Sections 190-0085 Hydraulic ECU
and 230-0081 Body Control Lever
Check connections. Replace body

Proportional control valve; body lower solenoid (28).
'Lower' solenoid (28) faulty.
Check for output from the control
Control lever in the cab faulty. lever. Refer to Sections 190-0085
Hydraulic ECU and 230-0081 Body
Control Lever
Check connections/replace
Proximity switch on chassis reading proximity switch.
LOW (float condition)
Body lowers too slow. Not enough electric current at the Check output from body control
proportional control valve ; body lever. Refer to Sections 190-0085
lower solenoid (28) Hydraulic ECU and 230-0081 Body
Control Lever
Pilot pressure not high enough Re-set pilot pressure at pressure

reducing valve (21). If it cannot be
reset replace pressure reducing
valve (21).
Main control spool (41) sticking. Replace lift section of the main
hydraulic valve assembly.
Faulty main pump. Refer to Section 230-0050 Main

procedures.
SM 2611 Rev1 04-10 11

Section 230-0000

Body lowers too slow (continued). Contamination in the load sense Clean orifice (30).
orifice(30).
Hoist shuttle valve (25) sticking Replace shuttle
Body will not hold Oil by-pass between control spool Replace lift section of main
(41) and valve body hydraulic valve aseembly
Oil by-pass body lift cylinders (1) Repair lift cylinders (1)
Control spool (41) not centering Check that there is zero pilot
pressure at both ends of control
spool (41). Either of proportional
control valves (27/28) could remain
active
Check body control lever. Should

be zero ouput signal from control
lever when in the neutral position
Control spool (41) damaged.

Replace control spool (41)
Power down available when body is Faulty proximity switch on chassis Check connections. Replace
on the chassis proximity switch. Refer to Section
190-0085 Hydraulic ECU, for check
tool
Body fails too slow down when Faulty proximity switch on chassis Check gap between body plate and
reaching the proximity switch on the proximity switch. Max. gap 15mm.
chassis Replace proximity switch
Faulty hydraulic ECU or connections Refer to Section 190-0085

Hydraulic ECU for check
procedure.
Main spool (41) sticking Replace main hydraulic valve

assembly
Body fails too go into float and stops Faulty float solenoid valve (29) Check connections. Replace
before it reaches the chassis valve(29). Refer to Section 190-
0085 Hydraulic ECU
No voltage at the float solenoid valve Check connections at the valve

(29) (29) and at the hydraulic ECU.
Refer to Section 190-0085
Hydraulic ECU
* * * *
12 SM 2611 Rev1 04-10

Body System - Main Hydraulic Pump
Section 230-0050
SM3543
15 14 16 2 16 14 15
30
23 6 34 34 7
19
22 27
29
12
11
24 5
9,17,33 39 40 20 13 8 20 26 39 10,18,33 19 22
2 - Control Valve (two) 13 - Splined Hub 26 - O-ring

5 - Cover 14 - Control Piston 27 - O-ring
6 - Front Housing 15 - Piston Rod 29 - Circlip
7 - Rear Housing 16 - Plug 30 - Dowel
8 - Centre Housing 19 - Bearing 34 - Plug
9 - Front Swash Plate 20 - Bearing 39 - Rotating Group
10 - Rear Swash Plate 22 - Stop Ring 40 - Front Control Plate
11 - Front Driveshaft 23 - Spring 41 - Rear Control Plate
12 - Rear Driveshaft 24 - Shaft Seal 45 - Cylinder Block
Fig. 1 - Sectional View Of Hydraulic Pump
DESCRIPTION together in a front and rear configuration to provide the

Numbers in parentheses refer to Figures 1 and 7. desired output levels.
The Hydraulic Pump can be identified as item D in The pump displaces 325 l/min at its maximum flow,
Section 250-0000, Braking System Schematic. and the pressure regulator cut off is set to 240 bar (3
480 lbf/in2).
The hydraulic pump is mounted on the left-hand side of
the transmission power take off (PTO). It is a 'tandem' The 'tandem' pump supplies hydraulic oil for the
axial piston, variable displacement pump with load steering, braking and body hoist systems, as well as
sense and pressure regulator to match the flow and the transmission and engine oil cooler fan drive
pressure to the demand. 'Tandem' in the sense that it system.
contains two complete pump assemblies mated
The components of the 'tandem' pump can be divided
SM 2612 Rev1 04-10 1

Section 230-0050
SM2845
42
11 & 12
43
40 & 41 45
A - Outlet Port
B - Outlet Kidney Slot 11 and 12 - Drive shaft 42 - Piston Group
C - Inlet Port 40 and 41 - Control Plate 43 - Retaining Plate
D - Inlet Kidney Slot 45 - Cylinder Block
Fig. 2 - Pump Rotation and Oil Flow
SM603
MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
VIEW A VIEW B VIEW C
Fig. 3 - Variable Displacement Action
into three sub-groupings, with each pump side having control plate (40), rear control plate (41), dowel (30),
the same make-up as that listed: centre housing (8), front housing (6) and rear housing
(7).
Rotating Groups (39) - Provides the main rotary
pumping action. Consists of respective driveshafts (11 OPERATION
and 12), cylinder block (45), piston and shoe (42), Numbers in parentheses refer to Figures 1, 2 and 3.
retaining plate (43), bush (44) and cylinder springs (48). Refer to Figures 4 and 5 for the hydraulic schematics
of the pumps.
Swash Plate Groups - Varies the pump's delivery flow
rate. Consists of respective swash plates (9 & 10), When the front pump's driveshaft (11) rotates, this
shoe plate (43), control piston (14), piston rod (15) and causes the rear pump's driveshaft (12) to also rotate,
spring (23). due to being linked to each other via splined hub (13).
As the cylinder blocks (45) for both front and rear
Valving Cover Groups - Provides the switching of oil elements are spline coupled to the respective shafts,
between suction and delivery ports. Consists of front these will also rotate. If the swash plates (9 [forward]
2 SM 2612 Rev1 04-10

Section 230-0050
SM3955
19
25
1 - Cap 14 - Spool 5 7
2 - 'O'-ring 15 - Spring 8 11 12 13 14
3 - Nut 16 - Spring
4 - Set screw 17 - Spring Seat
5 - Plug 18 - Spool
24
6 - Plug 19 - Capscrew 1 2 3 2 4
7 - O-ring 20 - Plug
8 - Spacer 21 - Plug
9 - O-ring 22 - O-ring 20
10 - Spacer 23 - Gasket plate 16 18
6 10 15 17 26
11 - Spring 9
24 - Plug
12 - Spring 25 - Plug
13 - Spring Seat 26 - Valve Body 23 22
21
Fig. 4 - Exploded View Control Valve
and 10 [rear]) have been tilted, the pistons and shoes P SM3878
(39) arranged in the cylinder blocks (45) due to the LS
shoes being retained on the retaining plates (43) will

both rotate with the cylinder blocks and reciprocate
once per revolution.
Paying attention to one such piston from either front or

rear pump rotating groups, then it will move away from
the control plate (40 [forward] or 26 [rear]) for half a
rotation (suction stroke), and move towards the control
plate (40 or 26) for the second half of rotation (delivery
stroke). The larger the tilt angle of the swash plate (9 or VENT
TO
S TANK
10), the longer the piston (42) stroke and the higher the
pump's displacement. As the swash plate (9 or 10)
tilting angle approaches zero, the piston (42) does not Fig. 5 - Pump Schematic - Unregulated Condition
stroke and therefore delivers minimum displacement.
(Refer to Figure 3).
Unregulated Condition - Refer to Figure 5. Pump
Control Valve pressure is low and the load sense signal is wide open.
Numbers in parentheses refer to Figures 1 and 4. The preload of cut-off pressure spool springs (15 and
16, Figure 4) shifts the cut-off pressure spool (18,
Figure 4) to its extreme left position. Since the
Note: The description below applies equally to both
pressure drop across the main hydraulic valve is low,
hydraulic pumps, as they are connected to a common
both sides of the differential pressure spool (14, Figure
drive shaft, except where the condition identifying
4) see the same pressure and therefore the spool (14,
operation of the load sense control valve is detailed,
Figure 4) remains in the extreme left position. This
and the orientation of the load sense pipework
condition causes the oil at the control piston (14,
connections.
Figure 1) and rod (15, Figure 1) to be vented, causing
springs (23, Figure 1 [forward and rear]) force to move
The control Valve (Figure 4) is a pilot-operated
piston rods and pistons (15 and 14, Figure 1) and thus
differential pressure type spool regulator for load sense
the swash plate (9, forward pump and10, rear pump
control. The load sense feedback signal from the main
[Figure 1]) to maximum pump displacement.
hydraulic valve is fed to the load sense port on top of
the forward pump control valve body (26, Figure 4), and
on the bottom of the rear pump control valve body.
This feedback signal acts on the spring chamber end
of the spool (14, Figure 4).
SM 2612 Rev1 04-10 3

Section 230-0050
P
SM3879 Low Speed-High Torque Condition.
LS When the rotational speed of the engine is less than
900 rev/min, and the torque demand is greater than
25%, the load sense control valve (Section 230-0135)
operates. This results in a lower load sense pressure
being delivered to the load sense inlet to the rear pump
differential valve. The differential pressure spool (14,
Figure 4) of the rear pump moves further to the right,
due to the greater pressure differential between the
pump delivery and load sense lines, increasing the leak
off via the cut-off spool by-pass to tank. The swash
VENT
plate angle reduces towards zero, limiting the output of
S
TO
TANK this pump. Operation of the load sense control valve in
these circumstances prevents the engine from stalling
Fig. 6 - Pump Schematic - Regulated Condition
in this particular condition.
Regulated Condition - Refer to Figure 6. Pump REMOVAL

pressure builds up and the pressure drop across the
main hydraulic valve increases. The preload of the cut-
off pressure spool springs (15 and 16, Figure 4) still
retains the spool (18, Figure 4) in its extreme left
WARNINGS
position. However, since the pressure drop is
increased, the pressure on the left hand side of the
differential pressure spool (14) (pump delivery pressure)
overcomes the combination of the preload of springs
secured and of adequate capacity to perform
(11 and 12, Figure 4) and pressure in the load sense
the task safely.
line in the right hand side of the differential pressure
spool (14, Figure 4). Therefore the spool (14) moves
towards the right, blocking vent line and causing
within the system after the engine is shut
pressure at large side of piston (14, Figure 1) to
increase, overcoming spring (23) force. This reduces
the swash plate (9 and 10) angle and hence pump
carrying out any work on the braking system or
displacement.
serious injury could result.
This will continue until the pump flow across the main
hydraulic valve reduces the pressure drop to the value
parking brake, switch off the engine and turn the
determined by the preload of the differential spool
springs (11 and 12, Figure 4). As the pressure builds
relieve any pressure in the steering circuit.
the preload of the differential spool springs (11 and 12)
ensures that the load sense pressure is 35 bar below
2. Operate the treadle valve continuously to relieve
the pump delivery pressure until the cut-off point is
pressure in the braking system. Block all road wheels
achieved.
and place the battery master switch in the 'Off'
position. Place the steering lock bar in the 'Locked'
The pump also has a pressure limiting function, used
position.
for example when steering cylinder reaches the end of
it's stroke. In this condition the delivery pressure will
3. Remove the blanking cap from the remote drain line
rise, and the load sense control will try to raise delivery
pressure above the now 'dead head' pressure. This
causes differential pressure spool (14) to shift to the
extreme right, allowing oil pressure to pass through cut-
off pressure spool (18) and reach the large side of
blanking cap.
piston (14, Figure 1), overcoming spring (23) force and
reducing swash plate (9 and 10) angle to zero.
4. Clean the pump housing and surrounding area with a
4 SM 2612 Rev1 04-10

Section 230-0050
SM3953
REAR PUMP
20
37 2
4 12 30
41 10 21 26
16
23
3 39
18
15
34 28
14
7
5 27 33
36 22 19 49
32 48
47
46
38
44 45
43 DETAIL OF 39
42
25 ROTATING GROUP
1
35
37 4
25 2
13 41
38
3
14 15
16
31
34
8
29
22 24 6
19
23
11
17
33
30 FRONT PUMP
21
20
39
40
1 - Pump Assembly 17 - Bearing Shell 33 - Screw

2 - Control Valve 18 - Bearing Shell 34 - Plug
3 - Gasket plate 19 - Bearing 35 - Pin
4 - Capscrew 20 - Tapered Bearing 36 - Washer
5 - Cover 21 - Shim 37 - Plug
6 - Front Housing 22 - Stop Ring 38 - Plug
7 - Rear Housing 23 - Spring 39 - Rotating Group
8 - Centre Housing 24 - Shaft Seal 40 - Front Control Plate
9 - Front Swashplate 25 - O-ring 41 - Elbow
10 - Rear Swashplate 26 - Rear control plate 42 - Piston and Shoe
11 - Front Drive Shaft 27 - O-ring 43 - Retaining Plate
12 - Rear Drive Shaft 28 - O-ring 44 - Plate
13 - Splined Hub 29 - Circlip 45 - Cylinder Block
14 - Control Piston 30 - Roll Pin 46 - Pressure Pin
15 - Piston Rod 31 - Capscrew 47 - Shim
16 - Plug 32 - Capscrew 48 - Spring
49 - Circlip
Fig. 7 - Exploded View Of Hydraulic Pump
SM 2612 Rev1 04-10 5

Section 230-0050
suitable solvent. Ensure that all hydraulic lines
connected to the pump are identified for ease of 4. Remove 2-off control valves (2) from the respective
installation and, with suitable containers available to housing units. Refer to Figure 9.
catch leakage, disconnect hydraulic lines. Fit blanking SM3954
caps to all open lines and fittings.
5. Support the pump assembly with suitable lifting

equipment. It is possible to set up a sling arrangement
using the exhaust cradle. Remove the bolts (56) and
lockwashers (57) securing the pump to the
transmission. Remove the pump assembly from the
transmission.
Note: The pump assembly comprises the main

tandem pump and the single stage gear pump
(serving the dropbox) mounted on the (rear) end
face of the 'tandem pump'. Once removed, it will be
Fig. 9 - Control Valve Removal
necessary to remove the gear pump from the
tandem pump. 5. Loosen the eight capscrews (31). Remove the four
capscrews securing the rear pump housing (7) to the
6. Remove 'O' ring from pump. Wash the outside of centre housing (8). Refer to Figure 10.
pump thoroughly with a suitable solvent and move to a
clean area. SM3548
DISASSEMBLY *
Numbers in parentheses refer to Figures1 and 7, unless *

*
otherwise stated.
*
Rear Pump
Note: Discard and replace all O-rings and seals
removed during disassembly.
1. Remove the drain plug and drain any entrained oil

from the pump housings (6, 7 and 8).
Fig. 10 - Removal of Capscrews
2. Secure the pump assembly (1) in a suitable fixture.
Refer to Figure 8. 6. Using suitable lifting tackle. Secure to assembly and
lift front housing (6) and centre housing (8) from the
3. Mark the location of the centre housing (8) in relation rear housing (7) assembly. Refer to Figure 11.
to the front and rear housings (6 and 7).
Note: The control plate (26) can drop out at this stage.
Refer to Figure 9.
Ensure this is held secure whilst removing assembly.
SM3546
SM3549
Fig. 8 - Locating Reference for Housings Fig. 11 - Removal of Front Pump from Rear pump
6 SM 2612 Rev1 04-10

Section 230-0050
7. Remove the bearing ( 20) and shim (21). Ensure not 10. Turn the swash plate (10) inside of housing along
to damage the sealing surface. Refer to Figure 12. the z-axis. Remove the piston rod (15) and swash plate
(10) from the housing (7) as shown in Figure 15.
SM3434
4 SM3552
Fig. 12 - Bearing / Shim Removal

Fig. 15 - Swash Plate / Piston Rod Removal
SM3550 SM3553
Fig. 13 - Rotating Group Removal Fig. 16 - Bearing Shell Removal
8. Orientate the rear housing (7), to allow removal of 11. Remove the two bearing shells (18) and spring (23)
the rotating group (39). Remove the rotating group as from the housing (7), as shown in Figure 17.
shown on Figure 13.
12. Remove the drive shaft (12) with the bearing (19)
9. Remove the plug (16). Pull out the control piston (14) inner race still fitted to the shaft. Refer to Figure 17.
using a suitably sized screwdriver. Refer to Figure 14.
SM3554
SM3551
Fig. 17 - Drive Shaft removal
Fig. 14 - Control Group Removal
SM 2612 Rev1 04-10 7

Section 230-0050
13. Pull outer race of bearing (19) out of housing (7) 2. Using suitable lifting equipment, remove centre
using a suitable bearing puller. Refer to Figure 18. housing (8) from the mating face on the front housing
SM3555 (6). Refer to Figure 21.
Note: The control plate (40) can drop out at this

stage. Ensure this is held secure whilst removing
assembly.
3. 'O'-rings (25), control plate (40) and splined hub (13)

should be removed at this stage. Refer to Figure 21.
4. Pull the bearing (20) from the centre housing (8)

using a suitable bearing puller, ensure not to damage
the sealing surfaces. Refer to Figure 22.
Fig. 18 - Bearing Race Removal

SM3558
SM3556
Fig. 21 - Housing Removal

Fig. 19- Shim Removal
SM3559
.
14. Remove the shim (22) as shown in Figure 19.
Front Pump
1. Remove the four capscrews (31) securing centre
housing (8) to the front housing (6). Refer to Figure 20.
SM3557
Fig. 22 - Bearing Removal
5. Remove the bearing (20) inner race and shim (21).

Take care not to damage the sealing surfaces. Refer to
Figure 23.
Fig. 20 - Housing Removal
8 SM 2612 Rev1 04-10

Section 230-0050
SM3434 SM3438
Fig. 23 - Shim and Bearing Removal
Fig. 26 - Drive Shaft and Bearing Removal

6. Orientate the front housing (6) horizontally on a
bench to allow for removal of the rotating group (39).
Remove the rotating group (39) as shown in Figure 24. 9. Remove the circlip (29) and shaft seal (24).
SM3435
10. Pull the outer race of the tapered bearing (19) out
from the housing (6), using suitable bearing pullers, as
shown in Figure 27.
SM3560
Fig. 24 - Rotating Group Removal
7. Remove the control piston (14), plug (16) and piston

rod (15). Refer to Figure 25.
Fig. 27 - Bearing Removal
SM3436
11. Remove the shim (22). Refer to Figure 28.
SM3561
Fig. 25 - Control Piston Removal
8. Remove the drive shaft (11). The bearing (19) inner

race should be attached to the driveshaft at this stage.
Refer to Figure 26. Fig. 28 - Shim Removal
SM 2612 Rev1 04-10 9

Section 230-0050
Control Valve 3. Inspect the retaining plate for heavy wear and for
cracks. Replace it if it is defective.
Numbers in paretheses refer to Figure 3, unless
otherwise stated.
Pump Housing and Associated Parts
1. If the control valve (2, Figure 1) has not already been
removed from the front and rear housings (6 and 7,
Figure 1), do so at this stage, by removing the four
1. Inspect both pump housings (6 and 7) for erosion,
capscrews (19).
cracks and burrs. Clean up minor burrs with an India
stone. If erosion or cracks are noted, replace the
Note: The control valve (2, Figure 1) is supplied as
affected pump housing (6 or 7 respectively).
a complete assembly.
2. Inspect the inner and outer races of the tapered
2. If it is necessary to disassemble the control valve
bearings (19 and 20) for nicks and pitting. Make sure
(2, Figure 1), the following steps should be followed.
the inner race turns freely within the outer race. If
either of the tapered bearings need replaced, both the
3. Remove the two protective caps (1) and O-rings (2).
inner and outer races must be replaced. To remove the
outer races from the pump housings (6 and 7), or the
4. Unscrew the nuts (3), then remove the nuts (3) and
centre housing (8), carry this out using tooling in
O-rings (2).
accordance with the manufacturer's guidelines.
5. Unscrew the plugs (5 and 6) . This should allow for
3. Inspect the control plates (26 and 40) for erosion,
careful removal of the following items contained within
excessive wear, heavy scratches and cracks. If any of
the control valve body (26); O-rings (7 and 9), shims (8
the above conditions are found, replace the plate.
and10), springs (11,12,15 and 16), spring seats (13 and
17) and spools (14 and 18).
4. Inspect the spring (23) and rotating group piston
parts for burrs, scratches and cracks. Clean up minor
INSPECTION scratches with 500 grit paper. Remove burrs with an
Numbers in parentheses refer to Figure 7. India stone. Pistons should move freely over their
respective rods.
Note: Before inspection of parts, clean all parts with a
suitable solvent. Driveshaft and associated parts
Note: The rotating group (39) is made up of a cylinder Numbers in parentheses refer to Figure 7.
block (45), retaining plate (43) and piston assemblies
(42). 1. Inspect the driveshafts (11 and 12) for wear,
chipped splines and burrs. Remove burrs with an India
stone. Inspect the contact area of the tapered bearings
Rotating Group (19 and 20) and of the shaft seal (24). Replace
1. Inspect the cylinder block for wear, scratches or anydriveshaft (11 or 12) if wear or scoring is greater
erosion. If cylinder block condition is questionable, than 0.127 mm (0.005 in) total indicator reading
replace the entire rotating group. (T.I.R.).
2. Check each cylinder block bore for excessive wear. 2. Inspect the inner and outer races of the tapered
Use piston and shoe assemblies for this purpose. The bearings (19 and 20) for roughness, pitting of rollers
pistons should be a very close fit and slide in and out and excessive end play. Make sure the inner race
of the cylinder block bores. No binding can be turns freely within the outer race. If a tapered bearing
tolerated. If binding occurs, clean the cylinder block needs replacement, both the inner and outer races
and the piston and shoe assemblies. Lubricate the must be replaced.
cylinder block bores with clean hydraulic oil and slide
the pistons in and out again. Even minor contamination 3. Inspect the mounting flange of each of the pump
of the oil may cause a piston to seize up in a cylinder housings (6 and 7) for nicks and burrs. Remove minor
block bore. nicks and burrs with an India stone. Also check the
pump housing (8) for damaged or stripped threads. If
any thread is damaged, replace the pump housing.
10 SM 2612 Rev1 04-10

Section 230-0050
4. Check the remaining pump parts for excessive wear, SM3586
damaged threads, burrs, cracks and/or erosion. Renew
any part that is in a questionable condition.
ASSEMBLY
Numbers in parentheses refer to Figures 1 and 7,
unless otherwise stated.
Note: Assembly is largely the reverse sequence to

disassembly.
Note: Where stated, the following assembly steps

apply to both front and rear pump units! Fig. 31 - Centre Housing / Bearing Race
1. For both the front and rear housings (6 and 7), press correct positions. Ensure that the bearing outer race is
in the stop ring (22) and the outer race of bearing (19) seated fully on the driveshaft. Refer to Figure 30.
using a suitable tool. Refer to Figure 29.
Note: Take care not to damage the shaft seal (24)
2. For both the front and rear housings (6 and 7), locate during steps 1 -3.
the plug (34) into housing. Secure the plug (34) to a
torque value of 127 Nm (93.7 Ibf ft). Refer to Figure 29. 4. Ensure that the splined hub (13) is located inside
bore of the centre housing (8).
3. For both the front and rear housings (6 and 7),
assemble the respective driveshafts (11 and 12) in their 5. Press in the outer races of bearings (20) into the
centre housing (8). Refer to Figure 31.
SM3418
6. Assemble the front and rear pump to the centre

housing. Ensure that the points marked during
disassembly match up.
SM3585
(21) (21)
Fig. 29 - Pump Assembly

'A' 'B' 'A' 'B'
SM3419 'C' 'C'
Fig. 32 - Measurement for Bearing Peload.
7. Tighten the eight screws (31) , to a value of 165 Nm

(122 lbf ft).
8. Refer to Figure 32. For both the front and rear

housings (6 and 7), measure the dimension between
the end face 'A' of the housing and the front face 'B' of
the centre housing (8).
Dimension: 'A' to 'B' = 'C'
Fig. 30 - Pump Assembly ; Drive Shaft 'C' should be within the tolerance of 0 - 0.05 mm.
SM 2612 Rev1 04-10 11

Section 230-0050
Note: If dimension 'C' is out side the specified SM3423
tolerance, machine the shim (21) to obtain the

desired value.
9. Assemble the rear housing (7) with the O-ring (27),

cover (5) and screw (32). Refer to Figure 33.
SM3587
Fig. 35 - Assembly of Bearing Shells and Spring
14. Assemble the control piston (14) and plug (16) into
both the front and the rear housing (6 and 7). Refer to
Figure 36. Use Loctite 242™ on the threads of the
plug (16) prior to securing it. Secure the plugs (16) to a
torque value of 190 Nm (140 Ibf-ft).
SM3424
Fig. 33 - Rear Housing Assembly
10. Assemble the shaft seal (24) using a suitable driver Z
to tap the seal into place.. Ensure that the sealing ring
is greased and that the surface the seal is running on is
not damaged. Refer to Figure 34.
11. Secure the circlip (29) in place using suitable pliers.
SM3422
15. Assemble the pressure pins (46) using a suitable

assembly aid. Use a suitable combination of bolt, nut
and washer type to allow the spring and pins to be
enclosed and compressed, in tightening of the bolt/nut
combination. Tighten the assembly aids sufficiently
enough to allow the circlip to be locked in place. On
removal of assembly aids, the spring face will be held
against full extension by the inner face of the circlip,
Fig. 34- Front Housing Assembly similarly the pins will be held on the inner shoulder of
the piston housing, thus retaining the assembly. Refer
12. Fit the bearing shells (17 and 18) and spring (23)
to Figure 37.
into both front and rear housings (6 and 7). Ensure that
ample grease is used. Refer to Figure 35.
13. Assemble the swash plate (9 and 10) and piston

rod (15) into the correct bore of both the front and the
rear housing (6 and 7). Refer to Figure 36.
12 SM 2612 Rev1 04-10

Section 230-0050
SM3425
SM3428
3
8
4
2
7
5
16. Oil the pistons and shoes (42). Assemble pistons

(42) with the retaining plates (43 [forward and rear]).
Fig. 39 - Drive Shaft Assembly
17. Fit the rotary groups to both the front and rear
pump housings (6 and 7 respectively). It may be 19. Insert the splined hub (13) into the bore of the
necessary to use a suitably sized O-ring to aid the centre housing (8). Assemble the control plates (40 and
assembly. Refer to Figure 38. 26), dowels (30) and O-rings (25) to the housing (8).
Ensure that the O-rings are greased prior to being
SM3427 inserted in the grooves.
Note: Maintain the correct location using the dowels

(30). Refer to Figure 40.
SM3588
Fig. 38 - Insert Rotating Group
18. Assemble the bearings (20) and adjustment shims

(21) to the front and rear drive shafts (11 and 12
Fig. 40 - Centre Housing Assembly
Note: Ensure that marked positions on all housing

components are matched correctly as they were
created at the disassembly stage.
20. Assemble the centre housing (8) to the front pump

housing (6), securely using the four screws (31).
SM 2612 Rev1 04-10 13

Section 230-0050
Torque screws (31) to a value of 165 Nm (122 Ibf ft). SM3591
Refer to Figure 41.
SM3589
Front pump
Ensure
marks match
Rear pump
Fig. 41 - Securing Centre and Front Pump Housings
Fig. 43 - Securing Pump Assembly

21. Use suitable slings to lift the sub-assembled front
pump and centre housing elements. Orientate these to
facilitate assembly into the rear housing unit. Refer to
Figure 42. 24. Assemble the control valves (2) to both pumps,
using the screws (4), with new Gasket plate (3).
SM3590
INSTALLATION

Braking System Schematic. Renew all O-rings where
used.
WARNING
safely.
1. Fit a new O-ring (7) to the pump.

Fig. 42- Assembly to Rear Pump
2. Push the pump inward to engage with the coupling in
the transmission power take off. Secure the pump
respectively). Refer to Figure 39. assembly to the transmission with the four nuts (10)
22. Ensure the correct position of the control plate (40), and washers (9). Secure the nuts (10) equally to a
and ensure that the O-ring (25) is fitted in the groove. torque of 230 Nm (170 lbf ft).
23. Secure the front assembly to the rear/centre pump
assembl;y with the four screws (31). Torque the screws
(31) to a value of 165 Nm (122 Ibf ft). Refer to Figure
43.
14 SM 2612 Rev1 04-10
Section 230-0050
SM3887
15
4 1 14
8 11
9 16
10
12
7
13
13
17
2 5
3 18
FROM TS PORT
HYD. VALVE TRANS. SUMP
SEC. 250-0020 (PILOT PRESS.)
1 - Power take Off Assembly 7 - 'O'-ring

12 - Gasket 17 - Tee
2 - Main Shaft 8 - Stud
13 - Dowel Pin 18 - Adaptor
3 - 'O'-ring 9 - Washer
14 - Adaptor
4 - 'O'-ring 10 - Nut
15 - Elbow
5 - Idler Shaft 11 - Bolt
16 - Hose Assembly
Fig. 44 - Power Take Off - Main Hydraulic Pump Location
3. Remove the caps and connect the outlet, inlet and 1. If the hydraulic system is being re-commissioned
load sense lines to pump. Before connecting case drain following component failure, flush and clean the entire
line, fill pump casing through drain port with clean sytem of contaminants.
hydraulic oil as used in the hydraulic tank. Connect the
case drain line to pump. Fill and bleed the hydraulic 2. Fill both sections of the Main Hydraulic Pump and
system as described in the Filling and Bleeding its ports with clean hydraulic oil. Refer to Section 300-
Procedure, detailed below. 0020, Lubrication System, for oil specifications.
Note: It is very important that the pump casing is 3. Apply petroleum jelly to the O-rings of the suction
completely filled with hydraulic oil. This will ensure pipe flanges, then attach them and tighten the bolts
proper lubrication of the internal parts of pump when it sequentially.
is initially operated. Fill the pump casing through the
drain port. Filling only the suction line is totally 4. Fit bleed elbows and tees to the hoist and return
insufficient. hydraulic connections at both body cylinders.
4. Refer to the Pump Starting Procedure for the proper 5. Fill the hydraulic tank in accordance with Section
start-up procedure. 250-0026, Brake Coolant/Hydraulic Tank , using a
pump connected through the filter housing via the quick
fill connection. This ensures that contaminants are
FILLING AND BLEEDING PROCEDURE prevented from ingress to the system.
WARNING
It is vital that the procedure detailed below is
followed following replacement of the Main WARNING
Hydraulic Pump, a Steering Cylinder, a Body Do not operate the machine until all air is bled
Cylinder or any other significant hydraulic from the oil.
component. Failure to remove air from the
system will lead to premature pump failure.
SM 2612 Rev1 04-10 15

Section 230-0050
Note: When filling the hydraulic system be 17. Taking hold of the body joystick, operate it in the
prepared for the tank level to fall as the individual hoist direction in short bursts, until the lower ends of
system components draw hydraulic fluid. the cylinders have been bled of entrained air. Close the
The tractor requires approximately 50 l and the bleed screws.
trailer a further 60 l approximately.
Note: A hoist cylinder, if renewed, will contribute
6. Remove the pump case drain hoses from the return the greatest volume of entrained air to the
ports on the hydraulic tank and cover the exposed hydraulic system, if not adequately purged.
orifices on the tank fitting with protective caps to
prevent the ingress of contaminants. The exposed 18. With the engine operating at idle speed, raise and
hose ends will be left open to allow the drains from lower the body several times to check its operation.
the pumps to be observed.
19. With the body in its fully lowered position, stop the
7. Operate the engine for a few seconds at a time, at engine and refit the ‘body down’ proximity switch to
idle speed, to purge air from the pump outlet to the the underside of the body, securing it using the bolts
brake accumulators. Air is removed by bleeding it with washers and nuts removed in Step 9.
off at the diagnostic points at the left-hand fender.
Bleed Accumulator 3 (Primary Accumulator, item 3 20. Recheck the hydraulic fluid level in the tank and
on Figure 46) first, followed by Accumulator 1 (Front top it up if necessary.
Brake Accumulator, item 1 on Figure 46) and then
Accumulator 2 (Rear Brake Accumulator, item 2 21. Check that all truck functions operate correctly.
on Figure 46). Once air has been bled from all three
accumulators, the engine can be continuously run for
the remainder of the bleeding activities.
8. Slowly steer the truck from lock to lock, in short

bursts, to remove air and fill the steering cylinders with
hydraulic fluid. Operating the steering in short bursts
minimizes the return flow of fluid to the hydraulic tank.
9. Undo and remove the two bolts with nuts and

washers that secure the striker plate for the ‘body
down’ proximity switch to the underside of the body,
and remove striker plate to a prepared area.
10. Open the bleed screws on the top of both body

hoist cylinders (fitted at Step 4 above).
11. Taking hold of the body joystick, operate it in the

lower direction in short bursts, until the lower ends of
the cylinders have been bled of entrained air.
12. Release the body joystick. Close the bleed screws.
13. Open the bleed screws at the bottom of both body

hoist cylinders (fitted at Step 4 above).
14. Taking hold of the body joystick, operate it in the

hoist direction in short bursts, until the raise ends of
the cylinders have been bled of entrained air.
15. Release the body joystick. Close the bleed screws.
16. Open the bleed screws on the top of both body

hoist cylinders again.
16 SM 2612 Rev1 04-10

Section 230-0050
PUMP STARTING PROCEDURE Differential Pressure (load sense pressure)

1. Be sure the pump case drain line is free from
Note: There are two compensators fitted to the unit.
obstructions that restrict the pump case drain flow
Each compensator must have the differential pressure
back to tank and cause high case drain pressure which
set. Both compensators' differential pressure setting is
can lead to an early pump failure.
35 bar (507 lb/in2). Install a pressure gauge capable of
2. Ensure that all hydraulic controls are set to a neutral measuring 240 bar (3480 lb/in2) into the main pump
position, the steering lock bar is in the 'Locked' position front section diagnostic checkpoint (14, Fig.46). Install
and the battery master switch is placed in the 'On' a pressure gauge capable of at least 240 bar (3480 lb/
position. Start the engine and allow the pump to run in2) into the front pump load sense diagnostic
unloaded for a period to ensure that all residual air checkpoint on the left hand fender (16, Fig. 46). With
within the system is released. the steering in the neutral position, the pressure at the
main pump front section gauge should be 35 bar (507
3. Check for external leakage, abnormal noise and lb/in2) greater than the pressure at the front pump load
vibrations. sense gauge.
SM4002
4. Remove the wheel blocks and place the steering

lock bar in the 'Stowed' position. Start the engine and
check hydraulic systems for proper operation.
13 19
PRESSURE CHECKS 1 7
14 20
To check pump delivery pressure (cut-off pressure) the 2 8

15 21
steering should be operated full lock against the stops. 3 9

16 22
The pump is checked against the steering system as 4 10
this is the highest pressure requirement in the 17 23
hydraulic circuit. 5 11
18
6 12
WARNING
Machine has to fully articulate to check pump 1 - Diff-lock Pressure 'TP1' 13 - Parking Brake Pressure
pressures, therefore steering lock bar cannot 2 - DropBox Lube Pressure 14 - Main Pump (Front)
be 'Locked'. To prevent personal injury and 'TP3' 15 - Main Pump (Rear)
3 - DropBox High Select 'TP2' 16 - Front Pump LoadSense
property damage, exercise extreme caution Pressure
4 - DropBox Low Select 'TP2'
while working around articulation and 5 - Cross Axle Diff.Lock 17 - Rear Pump LoadSense
oscillation pivot area. 6 - CT21 Pressure
7 - Body Hoist Raise 18 - Steering Pressure
8 - Body Hoist Lower 19 - Front Brake Accumulator
Delivery Pressure (cut-off pressure) 10 - Lower Pilot 21 - Primary Accumulator
Install a pressure gauge capable of at least 240 bar (3 12 - Rear Axle Disconnect 23 - Rear Brakes
480 lb/in2) into main pump front section diagnostic Fig. 46 - Diagnostic Pressure Check Points, Left-hand
checkpoint in diagnostic pressure point (14, Fig. 46) on Fender
the left hand fender. When steering against the stops, Repeat the procedure with pressure gauge installed in
the pressure should be 240 bar (3 480 lb/in2). When main pump rear section diagnostic checkpoint (15, Fig.
steering against the stops the pressure should be 240 46), and the rear pump load sense diagnostic
bar (3480 lb/in2). checkpoint (local to the load sense control valve).
If these pressures are not observed, then the pump

may require to be reset (refer to Troubleshooting).
TROUBLESHOOTING
If steering cannot be operated or is excessively heavy,
then pump delivery pressure is likely to be low and the
pump setting should be checked.
SM 2612 Rev1 04-10 17

Section 230-0050
PUMP TROUBLESHOOTING Differential Pressure Setting

Irregular Noise Rotation Speed too high, Numbers in parentheses refer to Figures 4 and 46,
air intake, cavitation or unless otherwise stated.
mechanical damage
1. Install a pressure gauge capable of at least 240 bar
No or insufficient Power comparison of engine (3 500 lb/in2) into main pump front diagnostic
flow pump (do outputs match each checkpoint pressure point (14, Figure 46) on the left
other), pump fails to swivel out, hand fender to measure pump delivery pressure (cut-off
inner leakage, dirt specific wear pressure) (Gauge A).
(stroke limitation on a too small
swivel angle) 2. Install a pressure gauge capable of at least 240 bar
(3 480 lb/in2) into the pump load sense diagnostic
No or insufficient Power comparison of engine checkpoint on the left hand fender (16, Fig. 46) to
pressure pump (do outputs match each measure the load sense pressure setting (Gauge B).
other), pump fails to swivel out,
inner leakage, dirt specific wear 3. Ensure that all hydraulic controls are set to a neutral
(stroke limitation on a too position, the steering lock bar is in the 'Locked' position
small swivel angle) and place the battery master switch in the 'On'
position. Start the engine and allow to run at low idle.
Pressure / flow Air suction, inner leakage, dirt This allows the pump to run unloaded for a period to
specific fluctuation wear, power ensure that all residual air within the system is
unit damage, controller unstable. released. Check for external leaks.
SM3639
If the difference (∆P) between delivery pressure and Pressure values are for one full Clockwise (CW) or
load sense pressure is equal to the desired value Counter-clockwise (CCW) rotation of the set screw.
proceed to 'Pump Setting Procedure - Pump Delivery
Pressure Setting'. 1
However, if ∆P is not equal to desired value carry out + 16 bar

complete 'Pump Setting Procedure'. - 16 bar
+ 50 bar
PUMP SETTING PROCEDURE - 50 bar

Note: It is very important that the pump casing is 2
completely filled with hydraulic oil before the pump is
operated. Fill the pump casing through the drain port.
Filling only the suction line is totally insufficient.
1 - Differential Pressure (LS pressure)
2 - Delivery Pressure (Cut-off pressure)
Fig. 47 - Pressure Adjustments at Control Valve
Bar value is ‘Per rotation of set screw
18 SM 2612 Rev1 04-10

Section 230-0050
4. Check readings on both pressure gauges. Pump Pump Delivery Pressure Setting
delivery pressure (Gauge A) should always be greater
than load sense pressure (Gauge B). This differential Numbers in parentheses refer to Figures 4, 46 and 47,
pressure (∆P) should be equal to 35 bar (507 lb/in2). If unless otherwise stated.
the ∆P pressure differs from the desired value, then
adjustment may be necessary. WARNING
The machine has to fully articulate to set pump,
Note: If the pump delivery pressure (Gauge A) is less therefore steering lock bar cannot be 'Locked'.
than the desired value disconnect either the left-hand To prevent personal injury and property
combination cooler or the right-hand cooler fan damage, exercise extreme caution while
disconnect solenoids, causing the solenoid valve to working around articulation and oscillation
default to an open position, allowing hydraulic oil to the pivot area.
fan motor. This will place a demand on the pump
causing the pump delivery pressure to increase. There should be no requirement to adjust the set screw
(2, Figure 47) at the delivery pressure (cut-off pressure)
5. At the differential pressure (load sense) valve (1, port, as this is factory set. The cut-off pressure sets
Figure 47) unlock the cap (1, Figure 4) to allow the nut the pump delivery pressure. If the set screw (2, Figure
(3, Figure 4) to be unlocked. Turn the set screw (1, 4) or nut (3, Figure 4) has been moved, it will be
Figure 47) clockwise (looking straight at set screw) to necessary to reset the pump delivery pressure by
increase the ∆P pressure, or counter-clockwise to following the procedure given below:
decrease the ∆P pressure.
1. Install a pressure gauge capable of at least 240 bar
Note: Pressure should always be adjusted on the (3480 lb/in2) into main pump front section diagnostic
increase. Hence if the ∆P pressure is too high, the set checkpoint on the left hand fender (14, Fig. 46) to
screw should be turned counter-clockwise first to bring measure the pump delivery pressure (cut-off pressure).
the pressure below the desired level, then increased to
attain the desired value. 2. Start the engine and run it at full throttle. Steer full
lock against the stops. Observe the pressure on the
6. Recheck the readings on both pressure gauges. gauge. This cut-off pressure should be 240 bar (3480
Pump delivery pressure (Gauge A) should be at correct lb/in2). If the pressure reading differs or the steering is
value. excessively heavy, then carry out steps which follow.
7. Once the correct ∆P pressure is achieved, tighten Note: Steering has to be operated over the relief
the nut (3, Figure 4) at the differential pressure (load (against stops), as this is the maximum pressure the
sense) port on the control valve. The protective cap pump must deliver. Setting pump against any other
should be replaced and tightened to 21 Nm (15.5 Ibf / operation would result in the pump being set at a lower
ft). maximum delivery pressure.
8. The differential pressure is now set. Repeat 3. At the delivery pressure (cut-off pressure) port,
procedure with gauge A connected to main pump rear unlock the nut (3, Figure 4) and turn the set screw (2,
section diagnostic checkpoint (15, Fig. 46). Both Fig. 47) clockwise to increase the cut-off pressure, or
differential pressure settings of both sections of the counter-clockwise to decrease the cut-off pressure
main hydraulic pump are now set. The low speed-high (adjustment is approximately 50 bar [725 lb/in2] per
torque load sense pressure (rear pump) is set as turn).
described in Section 230-0135, Load Sense Control
Valve. Note: Pressure should always be adjusted on the
increase. Hence if the cut-off pressure is too high, the
9. Switch off the engine and relieve the system set screw (2, Figure 47) should be turned counter-
pressures as described in 'Removal'. clockwise to decrease the cut-off pressure below 240
bar (3 480 lb/in2), then turn set screw (2, Figure 47)
10. Remove the pressure gauges from the diagnostic clockwise to attain 240 bar (3 480 lb/in2).
check points.
SM 2612 Rev1 04-10 19

Section 230-0050
4. Once the correct cut-off pressure has been attained, avoid the possibility of the fitting impinging on internal
revert the steering to the neutral position, then steer full components. The fitting procedure is itemized below.
lock against the stops. Observe the gauge to confirm
that the cut-off pressure is set to 240 bar (3480 lbf/in2). 1. Unscrew the lock-nut of the hydraulic fitting until is
fully backed off against the shoulder on the pipe, as
Note: A change in pump tone should be heard when shown on Figure 48.
cut-off pressure is reached, as the pump de-strokes to 2. Install the fitting in the housing, hand tight, as shown
standby condition. on Figure 49.
SM3894
5. If no change in pump tone is heard, the cut-off
pressure is too high. Return to step 3 of the procedure.
If problem persists, refer to Section 220-0000, Steering
System Schematic.
6. Once the correct pressure is achieved, tighten the

nut (3, Figure 4) at the cut-off pressure port on the
control valve. The protective cap should be replaced
and tightened to 21 Nm (15.5 Ibf ft).
7. The differential pressure (load sense) and cut-off Fig. 49 - Hydraulic Fitting Secured Hand Tight
pressure are now set.
3. Unscrew the fitting one full turn, while aligning the
Repeat the procedure with the pressure gauge elbow to the desired attitude to the appropriate angle
connected to main pump rear section diagnostic required by the connecting pipework, as shown on
checkpoint (15, Figure 46). Both sections of the main Figure 50.
pump are now set.
SM3895
Switch off the engine and relieve system the pressures
as described in 'Removal'.
8. Remove the pressure gauge from the diagnostic

checkpoint.
ADJUSTABLE O-RING SEAL HYDRAULIC

PIPE FITTINGS
It is vital that anyhydraulic pipe fitting which has the
facilityto be adjusted is correctly fitted, in order to
Fig. 50- Hydraulic Fitting Backed Off for Alignment
ensure that the male threaded stub of the fitting does
not extend too deeply into the tapped hole of the
housing where it is installed. Correct installation will 4. Tighten the lock-nut to the appropriate torque, as
itemized below. Figure 51 shows a cross-section of the
fitting in its fully tightened position. Figure 52 illustrates
SM3893 the complete hydraulic fitting in its installed condition.
SM3896
Fig. 48 - Hydraulic Fitting with Lock-nut Backed Off

Fig. 51 - Hydraulic Fitting Tightened to Correct Torque
20 SM 2612 Rev1 04-10

Section 230-0050
SM3892
LOCKNUT
BACK-UP
WASHER
O-RING
Fig. 52- Hydraulic Fitting, Installed Condition
recommended periodic oil change periods and oil

specifications.
All pump parts are lubricated by the hydraulic oil

therefore the oil must be kept clean to minimize pump
wear. Whenever there is a hydraulic system failure, the
oil should be drained, the entire system flushed, oil
filter replaced and clean hydraulic oil added to eliminate
all metal particles or foreign matter.
PUMP WEAR LIMITS

Before reassembling the pump after disassembly, the
Pump Wear Limits table should be consulted to
establish which components should be replaced.
SPECIAL TOOLS
There are no special tools required for the procedures
dealer.
* * * *
SM 2612 Rev1 04-10 21

Section 230-0050
22 SM 2612 Rev1 04-10

BODY SYSTEM - Body Control Lever
Section 230-0081
DESCRIPTION AND OPERATION SM - 3504
The body control lever is mounted on the right hand

side dash panel, next to the transmission shift
controller.
When the body control lever is operated, a voltage is

sent to the hydraulic ECU, which converts voltage to
current. This current controls the body raise and lower
proportional pressure control valves, producing a pilot
pressure to shift the control spool in the main hydraulic
valve. This allows the flow of oil to reach the body
cylinders, to either raise or lower the body. Refer to
Section 230-0000, BODY SYSTEM SCHEMATIC and
Section 215-0050, MAIN HYDRAULIC VALVE.
The three operating positions of the joystick from front Fig. 1 - Body Control Lever
to rear are as follows:
Power Down - Pushing the lever forward provides

hydraulic force to power-down the body. Pushing the
lever fully forward will engage the electric detent. When WARNING
the body reaches the body proximity switch, the lever Always disconnect body control lever before
springs back to 'NEUTRAL' and power down is ramped welding on the machine.
back to allow the body to float down onto the chassis.
Neutral - If the body is above the body proximity MAINTENANCE

switch, the lever in this position will stop and hold the
The body control lever is a non-serviceable item and
body at any desired height. If the body is below the
should be replaced completely, if damaged, as follows:
proximity switch, the hydraulic ECU defaults the
control spool in the main hydraulic valve to the neutral
position and energises the float solenoid, allowing the
body to float down onto the chassis. The body should
be fully lowered and in the 'NEUTRAL' position while
the machine is in motion. The lever will remain in the
'NEUTRAL' position when released.
WARNINGS
Raise - Pulling the lever back and holding it in this
position directs oil to extend the body hoists and raise
the body. When released, the lever will spring back to
the 'NEUTRAL' position.
safely.
In the event of an engine, hydraulic or hydraulic ECU
failure, the body can be lowered using a manual
release on the float vavle solenoid, which is located on
Operate the treadle pedal continuously until the
the main valve block.
work on the hydraulic system or serious injury
Note: The body must remain lowered with lever in the
could result.
'NEUTRAL' position until it is necessary to operate the
body again. Failure to comply to this could result in
overheating the hydraulic oil and failure of the hydraulic
system components.
pressure in the hydraulic system.
SM 2613 01-10 1
Body System - Body Control Lever
Section 230-0081
3. Block all road wheels, place the steering lock bar in 9. Place the battery master switch in the 'On' position,
the 'Locked' position and the battery master switch in start the engine and bring hydraulic oil to operating
the 'Off' position. temperature. Operate the body control lever to ensure
correct operation.
4. Disconnect body control lever harness from main
harness. 10. Remove wheel blocks and place the steering lock
bar in the 'Stowed' position.
5. Support body control lever and remove screws
securing body control lever on the right hand dash
panel. TROUBLESHOOTING
A faulty body control lever will cause an input error at
6. Remove body control lever from mounting location. the hydraulic ECU. Refer to Section 190-0085,
HYDRAULIC SYSTEM ECU.
7. Secure new body control lever on the right hand
dash panel with screws.
SPECIAL TOOLS
Note: Ensure harness from body control lever is at the There are no special tools required for procedures
front when lever is installed. outlined in this section. Refer to Section 300-0070,
8. Reconnect main harness to body control lever tools required. These tools are available from your
harness. dealer.
* * * *
2 SM 2613 01-10
BODY SYSTEM - Body Cylinder
Section 230-0130
SM - 3956
14
31
INSTALLATION OF
GREASE LINE
1 32
33
34
5 15
10 4
14
7 6 6 7
16 17 18 19 20 12 21 13 2 3 22 11 22 23 24 23 8 9
BODY MOUNTING FRAME MOUNTING
30 27
29 26
GROOVE
27 THIS SIDE
25
26 29
25 ORIENTATION OF 28
CUSHION SLEEVE
1 - Cylinder Assembly 10 - Screw Grub 19 - Backup Ring 28 - Pin Assembly Lower

2 - Shell 11 - Cushion Spear 20 - 'O' Ring 29 - Spacer
3 - Rod Assembly 12 - Cushion Sleeve 21 - 'O' Ring 30 - Pin Assembly Upper
4 - Piston 13 - Circlip 22 - 'O' Ring 31 - Elbow
5 - Retainer 14 - Nipple Grease 23 - Wear Ring 32 - Hose Assembly
6 - Spherical Bearing 15 - Lock Ring 24 - Piston Seal 33 - Coupling
7 - Circlip 16 - Rod Wiper 25 - Bolt 34 - Nipple Grease
8 - Cushion Sleeve 17 - Nylon Ring 26 - LockWasher
9 - Circlip 18 - Rod Seal 27 - Washer
Fig. 1 - Sectional View Of Body Cylinder and Mounting
DESCRIPTION REMOVAL
There are two single stage, double acting body hoist

cylinders (1), cushioned at both ends of the stroke on WARNINGS
the vehicle. The cylinder base end is connected to the To prevent personal injury and property
trailer frame and Rod assemly (3) end is connected at damage, be sure wheel blocks, blocking
the body. Single stage double acting means that piston materials and lifting equipment are properly
rod (3) can have oil applied to either side, extending or secured and of adequate capacity to do the job
retracting the piston rod. safely.
Cylinder mounting is by pins (28 & 30), spacers (29) Hydraulic fluid pressure will remain
and spherical bearings (6) are secured in place with within the body hoist system after engine
circlips (7). Spherical bearings (6) permit a limited shutdown. Operate the treadle pedal
amount of cylinder misalignment. continuously until the pressure has dissipated
before carrying out any work on the hydraulic
system or serious injury could result.
SM 2614 01-10 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 Shell
and operate the body control joystick continually to (2), preventing a vacuum when parts are withdrawn from
relieve pressure in the body hoist system. cylinder shell (2).
3. Block all road wheels, place the steering lock bar in 2. Remove circlips (7) from base end of cylinder shell
the 'Locked' position and the battery master switch in (2) and Rod Assembly (3) end. Press out spherical
the 'Off' position. bearings (6).
4. Install a suitable strap around the cylinder and 3. Remove Screw grub (10), so that the cyllinder shell
attach to a lifting device. is disengaged with Rod Assembly (3).
5. Position a suitable container at the base end of one 4. Support Rod Assembly (3) at the rod eye and
cylinder. Identify and remove the hydraulic lines. Cap withdraw Rod Assembly (3) from cylinder shell (2).
hydraulic lines and cylinder ports to prevent entry of Ensure centre lines of Rod Assembly (3) and cylinder
dirt. shell (2) remain coincidental during removal of Rod
Assembly (3).
6. Remove bolt (25), lockwasher (26), washer (27) and
upper pin (26) connecting piston rod (2) end of the 5. Place Rod Assembly (3) on supports which will not
cylinder to the body. If due to lack of maintenance the damage the piston rod diameter.
upper pin can not be removed from the front, there is
plate on the inside of the body that can be removed to 6. Remove and discard piston seals (24) and wear rings
allow access to the rear of the pin to ease removal. (23) from piston (4).
This plate is tack welded in place so a grinder is
required to remove it. 7. Provide an anti-torsion device through Rod Assembly
(3) eye to allow unscrewing of piston (4). Using suitable
7. Lower cylinder slowly and remove spacers (29). tool unscrew piston (4) from Rod Assembly (3).
Note: Cylinder will swing out sharply as it leaves its 8. Remove cushion spear (11) from Rod Assembly (3).
mounting.
9. Remove and discard cushion sleeve (8), rod seal
8. Remove bolt (25), lockwasher (26), washer (27) and (18), Rod wiper (16) , 'O' rings (20,21 & 22) and back
lower pin (28) connecting base end of the cylinder to up ring (19).
the frame.
9. Remove spacers (29) and remove cylinder assembly

to a clean area for disassembly.
10. Repeat steps 4 through 9 for opposite cylinder.
2 SM 2614 01-10
Section 230-0130
INSPECTION 9. Sling assembled Rod Assembly (3) in a manner to

allow careful leading of the assembled piston rod into
cylinder shell (2). Take care not to damage piston seal
(24) on cylinder shell (2) threads.
1. Clean all parts of the cylinder with a suitable solvent
and dry with clean, lint-free cloths. Clean all grooves
10. After piston (4) is inserted in cylinder shell (2), push the
carefully to remove any foreign material.
piston rod assembly into cylinder shell (2) maintaining
coincidental centre lines of piston rod and cylinder body.
2. Check cylinder shell (2) and outer diameter of piston
(4) for scratches, cracks or other defects. Remove
11. Push Rod Assembly (3) to the fully retracted position.
ridges, nicks and scratches with a fine stone and re-
clean. Replace any components which cannot be
repaired.
3. Inspect Rod Assembly (3) for distortion, cracks or INSTALLATION

other defects. Replace piston rod if defective area is
irreparable.
4. Check spherical bearing (6) for wear and replace if
connections, as described in Section 230-0000, BODY
necessary.
SYSTEM SCHEMATIC. Renew all 'O' rings where used.
ASSEMBLY
Numbers in parentheses refer to Fig. 1. WARNING
WARNING
safely.
1. Install a suitable strap around the cylinder and
position cylinder on unit with base end of cylinder ready
safely.
for mounting.
1. Press spherical bearing (6) in base end of cylinder
2. Install spacers (29) in base end of cylinder and insert
shell (2) and Rod Assembly (3) end. Secure spherical
lower pin (28) through mounting bores, spacers (29)
bearings (6) with circlips (7).
and cylinder. Secure lower pin (27) with washer (27),
lockwasher (26) and bolt (25). Tighten bolt (25) to a
2. Install new cushion sleeve (8), '0' rings (20,21 & 22), rod
seal (18) and backup ring (19) into their respective locations.
3. Install spacers (29) in rod end of cylinder, align
3. Install new 'O' rings (22) on Rod Assembly (3) and
spherical bearing (6) with bores in body and install
replace cushion spear (11).
upper pin (30) through mounting bores, spacers (29)
and cylinder. Secure upper pin (30) with washer (27),
4. Apply Loctite 243 to first two threads of piston (4).
lockwasher (26) and bolt (25). Tighten bolt (25) to a
Using suitable tool screw on piston (4) and tighten to a
torque of 1 356 Nm (1 000 lbf ft).
4. Connect the hydraulic oil lines to the cylinder ports
5. Ensure cushion spear (11) is secure to piston (4)
as tagged during removal.
end face and Rod Assembly (3) face .
5. Lubricate pins at lube fittings (14) with lubricant as
7. Insert new piston seal (24), wiper (16) and new wear
specified in Section 300-0020, LUBRICATION SYSTEM.
rings (23) in piston (4).
6. Check oil level in hydraulic tank and add if low. Refer
8. Insert Screw grub (10) into piston (4) torque to a
to Section 230-0040, HYDRAULIC TANK, for correct fill
vaule of 49 Nm* * * *.Fully grease piston (4) OD
level. Refer to Section 300-0020, LUBRICATION
and 'O' rings (20 & 21) in end cap (3).
SYSTEM, for the type of oil used.
SM 2614 01-10 3
Section 230-0130

start the engine, operate the body and check cylinder lines SPECIAL TOOLS
for leaks. Tighten lines and fittings as required. Special tools can be fabricated as shown in Figs. 2 & 3.
Refer to Section 300-0070, SERVICE TOOLS, for part
8. Remove wheel blocks from road wheels. numbers of general service tools required. These tools are
MAINTENANCE
Every 250 hours: Lubricate cylinder pins as described
in Section 300-0020, LUBRICATION SYSTEM. Inspect
cylinders for leaks, if leaks are found, replace seals
with seals contained in the Service Repair Kit, as
specified in the parts book.

TORQUE
1 4 Piston 1 356 1 000
1 10 Grub Screw 49 36
1 25 Bolt 66 49
* * * *
4 SM 2614 01-10
BODY SYSTEM - Load Sense Control Valve
Section 230-0135
SM - 3875
C
T
2
1 - Valve Block 1
2 - Pressure Reducing Valve T
3 - Solenoid Valve
P
LS
DE
HCO
TC
BA
Fig. 1 - Load Sense Control Valve
Pilot hydraulic pressure, taken from an internal

DESCRIPTION connection on the main pump pressure gallery (P1)
within the main hydraulic valve, is fed to the input side
The load sense control valve is a composite valve
of the load sense control valve (port LSP, Figure 1),
assembly that uses a integral solenoid valve operating
where it divides into two distinct load sense cavities,
in conjunction with a pressure reducing valve to reduce
LSPF serving the forward main pump regulator and
the load sense pressure supplied to the rear main
LSPR connecting via the solenoid valve to the rear
hydraulic pump when a particular low engine speed
main pump regulator. When the engine speed is above
coincides with a high torque demand. Reducing the
900 rev/min, and the torque demand is less than 25%,
hydraulic demand in this circumstance reduces the risk
the front and rear pump regulators are both subject to
of the engine stalling.
the 240 bar pressure supplied to the load sense control
valve. When a low engine speed of 900 rev/min
The load sense control valve is mounted on a bracket
coincides with a torque demand of 25% or greater, a
on the front side of the left-hand vertical member of
signal from the hydraulic ECU energizes the solenoid
the exhaust cradle assembly. The load sense control
of the load sense control valve (3), which in turn
valve comprises a pressure reducing valve set at 160
redirects the LSPR pressure via the load sense
bar, a single acting solenoid valve, and internal porting
pressure reducing valve (2), which is set at 160 bar.
through the valve block.
Limiting the pressure to the rear pump regulator
OPERATION
SM 2615 Rev1 04-10 1

Body System - Load Sense Control Valve
Section 230-0135
SM3876
FROM PORT LSP

OF MAIN HYDRAULIC
VALVE
RETURN
TO TANK
LOAD SENSE PRESSURE

TO LOAD SENSE
TO FWD PUMP REGULATOR DIAGNOSTIC POINT
LOCAL ON LH FENDER
LOAD SENSE PRESSURE DIAGNOSTIC
TO REAR PUMP REGULATOR POINT
Fig. 2 - Load Sense Control Valve - Schematic
prevents the engine from stalling at low speed/high main hydraulic valve harness adjacent to the hydraulic
torque demand, by limiting the displacement of the proportional control valves CT22 and CT23 on the main
main hydraulic pump set. hydraulic valve. This signal cable in turn connects via
an intermediate cable at the IFM hydraulic controller
The torque signal is fed from the engine to the which plugs into socket 39 of the main 55 way
hydraulic ECU by CANBUS. electrical connector.
Pressure Reducing Valve REMOVAL

Numbers in parentheses refer to Fig. 2, except where
The pressure reducing valve (2) is mounted on the top identified otherwise.
of the load sense control valve body. A protective cap
covers the valve pressure adjustment screw on the top
of the valve body. Load sense pressure from the LSP WARNINGS
port of the main hydraulic valve enters the load sense Hydraulic fluid pressure will remain within the
valve block at port LSP. system after engine shut down. Operate the
treadle valve continuously until the pressure
Solenoid Valve has dissipated before carrying out any work on
the hydraulic system or serious injury could
The solenoid valve (3) is mounted on the bottom of the result.
load sense control valve body, and features a plug
connection to which the electrical cable harness is To prevent personal injury and property
fitted. The other end of this harness connects into the damage, be sure wheel blocks are properly
safely.
2 SM 2615 Rev1 04-10

Section 230-0135
1. Position the vehicle in a level work area, apply the INSTALLATION
Note: Tighten all fasteners to torques listed in
2. Operate the treadle valve continuously to relieve Note: Tighten all hydraulic lines fitted with ORFS
pressure in the braking system. Block all road wheels, connections, as described in Section 230-0000, BODY
place the steering lock bar in the 'Locked' position and the SYSTEM SCHEMATIC. Renew all 'O' rings where
battery master switch in the 'Off' position. used.
3. Remove and tag the electrical connection to the
1. Position load sense control valve assembly and the
solenoid valve (3, Figure 1).
bracket on the left-hand exhaust cradle, correctly
orientated, and secure.
4. Clean the load sense control valve assembly and
surrounding area with a suitable solvent. Ensure all
2. Remove blanking caps from hydraulic lines and
hydraulic lines connected to the load sense control
connect them to the load sense control valve as noted
valve are identified for ease of installation and, with
during removal.
suitable containers available to catch leakage,
disconnect hydraulic lines. Fit blanking caps to all open
3. Connect the electrical connection to the solenoid
lines.
valve as noted during removal.
5. Release and remove the mounting hardware
4. Check oil level in the hydraulic tank and add oil if
securing the load sense control valve to the exhaust
required. Refer to Section 230-0040, HYDRAULIC
cradle. Remove the assembly from the vehicle.
TANK for correct fill level, and, Section 300-0020,
DISASSEMBLY AND ASSEMBLY
Note: The load sense control valve is not a serviceable
remove wheel blocks, start the engine and bring
item, and will have to be be replaced as a complete
hydraulic oil to operating temperature.
unit if it fails in service.
SM3957
1 - Bolt
3 2 - Lockwasher
2 3 - Washer
1 4 - Exhaust Cradle
Fig. 3 - Load Sense Control Valve - Mounting Arrangements
SM 2615 Rev1 04-10 3

Section 230-0135
SM4002 on diagnostic plate on left hand fender at base of cab

door (16, Fig. 4), and to the rear load sense diagnostic
pressure point, local to the load sense control valve.
WARNING
Ensure that the pressure gauge for measuring
13 19 the rear load sense pressure is easily visible
1 7 from above the articulation area, with the cab
14 20
tilted upwards. Similarly, adjustments to the
2 8
15
load sense control valve must be carried out
21
from above. Performing these activities from
3 9
16 22 the articulation and oscillation pivot area would
4 10
introduce a danger of personal injury or
17 23 damage to equipment.
5 11
18
5. Run the engine at idle speed, with the transmission
6 12
engaged, the parking brake released and the footbrake
depressed. Articulate the steering on to its end stops
and observe the pressure readings. When against the
stops, the forward load sense pressure reading should
Fig. 4- Diagnostic Pressure Points, Left-hand Fender
be 240 bar and the rear load sense pressure should be
160 bar. Adjust the rear load sense pressure, if
necessary, by removing the yellow protective cap from
6. Check the load sense control valve and hydraulic the pressure reducing valve (2, Figure 1), then turn the
line connections for leaks and tighten as required. hexagonal head of the adjustment screw until the
required pressure is achieved. One half revolution of
the screw equates to approximately 29 bar of pressure
7. Shut off the engine and make sure that a full service
adjustment. Screwing in the adjustment screw
brake application is made followed by a parking brake
increases the pressure setting, screwing the
application.
adjustment screw out decreases the pressure setting.
8. Place steering lock bar in the 'Stowed' position.
Note: Pressure should always be adjusted on the
increase. Therefore, if for example the load sense
CHECKING LOAD SENSE PRESSURES pressure is too high, turn the screw anti-clockwise first
to lower the pressure below the required value, then
1. Position the vehicle in a level work area, apply the turn it clockwise until the reading is 160 bar.
wheel in both directions several times to relieve any 6. Refit the yellow protective cap once the correct
pressure in the steering circuit. pressure setting has been achieved.
2. Operate the brake treadle valve continuously to 7. Run the engine at idle speed, with the transmission
relieve pressure in the accumulators. Block all road disengaged, the park brake service switch and the
wheels, place the steering lock bar in the 'Locked' footbrake not depressed. Articulate the steering on to
position and the battery master switch in the 'Off' its end stops and observe the pressure readings. When
position. against the steering stops, both the forward and the
rear pressure gauge readings should be 240 bar.
3. Tilt the cab and fit the safety prop in accordance
with OPERATORS COMPARTMENT - CAB AND Note: The 240 bar (pump cut off) pressure is factory
MOUNTING , Section 260-0010. set and should not require adjustment. During start up,
as the pressure is building up, and when the engine is
4. This following procedure will check that the forward running at a low idle speed, the load sense pressure
and rear load sense pressures are properly set.
Connect hydraulic gauges, capable of recording a
pressure of 0 - 345 bar (0 - 5 000 lbf/in²), to the forward
load sense pressure diagnostic pressure point located
4 SM 2615 Rev1 04-10

Section 230-0135
will be 35 bar below the pump delivery pressure. This is
2. Install the fitting in the housing, hand tight, as shown
due to the differential pressure setting of the valves on
on Figure 6.
the main hydraulic pumps. If it is necessary to make
SM3894
adjustments to the pump cut off pressures, carry these
out in accordance with the procedure detailed in BODY
SYSTEM - MAIN HYDRAULIC PUMP (Section 230-
0050).
8.Switch off park brake service switch.
9. Engage the parking brake.
10. Shut off the engine and remove the pressure

gauges from the diagnostic check points.
Fig. 6 - Hydraulic Fitting Secured Hand Tight
11. Remove the safety prop and lower the cab in
accordance with OPERATORS COMPARTMENT - 3. Unscrew the fitting one full turn, while aligning the
CAB AND MOUNTING, Section 260-0010. elbow to the desired attitude to the appropriate angle
required by the connecting pipework, as shown on
MAINTENANCE Figure 7.
SM3895
Inspect the load sense control valve regularly for any
signs of leakage or damage and repair/replace as
required.
Note: The load sense control valve is not a serviceable

item, and will have to be be replaced as a complete
unit if it fails in service
ADJUSTABLE O-RING SEAL HYDRAULIC

PIPE FITTINGS Fig. 7 - Hydraulic Fitting Backed Off for Alignment
It is vital that anyhydraulic pipe fitting which has the 4. Tighten the lock-nut to the appropriate torque, as
facilityto be adjusted is correctly fitted, in order to itemized below. Figure 8 shows a cross-section of the
ensure that the male threaded stub of the fitting does fitting in its fully tightened position. Figure 9 illustrates
not extend too deeply into the tapped hole of the the complete hydraulic fitting in its installed condition.
housing where it is installed. Correct installation will
avoid the possibility of the fitting impinging on internal SM3896
components. The fitting procedure is itemized below.
1. Unscrew the lock-nut of the hydraulic fitting until is

fully backed off against the shoulder on the pipe, as
shown on Figure 5.
SM3893
Fig. 8 - Hydraulic Fitting Tightened to Correct Torque
Fig. 5 - Hydraulic Fitting with Lock-nut Backed Off
SM 2615 Rev1 04-10 5

Section 230-0135
SM3897
SPECIAL TOOLS
LOCKNUT outlined in this section. Refer to Section 300-0070,
BACK-UP tools and adhesives required. These tools, and
WASHER adhesives are available from your dealer.
O-RING
Fig. 9 - Hydraulic Fitting, Installed Condition
* * * *
6 SM 2615 Rev1 04-10

Braking System - Braking System Schematic
Section 250-0000
SM - 3613
D - Main Hydraulic Pump 13 - (CT13) Orifice PS1 - Steering Pressure Switch

E - Brake Treadle Valve 14 - (CT14) Cold Start Solenoid Valve PS2 - ACC2 Pressure Switch
15 - (CT15) Orifice PS3 - ACC1 Pressure Switch
7 - (CT7) Priority Valve 16 - (CT16) Shuttle Valve PS4 - Park Brake Pressure Switch
8 - (CT8) Check Valve 17 - (CT17) Shuttle Valve ACC1 - Front Brake Accumulator
9 - (CT9) Pressure Reducing Valve 19 - (CT19) Orifice ACC2 - Rear Brake Accumulator
10 - (CT10) Check valve 31 - (CT31) Park Brake Solenoid Valve ACC3 - Primary Accumulator
11 - (CT11) Check Valve 32 - (CT32) Directional Control Valve
12 - (CT12) Brake Charging Valve 33 - (CT33) Orifice
Fig. 1 - Brake System Schematic
DESCRIPTION Service Brakes

Numbers in parentheses refer to Figures 1, 2 and 9. The service brakes are of the enclosed, forced oil-
cooled multiple disc type. The service brakes are
The hydraulic braking system is a 'closed centre' actuated by hydraulic oil as specified in Section 300-
design, in which constant pressure is stored in 0020, Lubrication System. DO NOT USE BRAKE
accumulators and is regulated as required to retard or FLUID (J 1703). Multiple discs within the brake
stop the machine. assemblies are cooled by brake cooling oil as specified
in Section 300-0020, Lubrication System.
A brief description of the individual components used in
the braking system are listed below. Detailed service The brake assembly is bolted to the stub axle and
and operating instructions can be found in the relevant houses a sandwich of friction discs splined to a hub
component sections of this manual. rotor. There are four friction discs in each brake
assembly.
SM 2616 Rev1 04-10 1
Section 250-0000
When the treadle valve is actuated, hydraulic oil enters Brake Coolant / Hydraulic Tank
the brake assembly and forces the brake piston
Refer to Section 230-0040, Brake Coolant/Hydraulic
against the rotating friction discs, which in turn react
Tank.
with stationary reaction discs. The reaction discs are
retained by scalloped tangs at the outside diameter,
The brake coolant/hydraulic tank, as its name
which in turn transfers the reaction torque to the rigid
suggests,is a tank assembly comprising both the
outside housing, slowing or stopping the wheel rotation.
brake cooling oil tank and the hydraulic oil tank in one
integral unit fitted in the left-hand tractor frame rail.
In an emergency situation, application of the park/
Looking from the LHS of the tractor unit, the brake
emergency valve will actuate the service brakes and
cooling tank is to the left and the hydraulic tank is to
the right. The brake coolant tank supplies the brake
condition, a restriction in the 'Px' line from the brake
cooling circuit. The hydraulic tank is the common
manifold valve will slow oil flow from the parking brake
reservoir for the steering, braking, body hoist and fan
drive system.
ahead of the parking brake.
Integral with the brake coolant/hydraulic tank assembly
When the treadle valve or park/emergency brake is
are cap assemblies, a suction strainer, hydraulic filter
released, hydraulic pressure against piston is relieved
cover plates and drain valves. Located on the outboard
and cup springs force the piston to return to its original
face of the tank are level gauges and window nuts for
position, thus, relieving the pressure against the brake
checking the fluid levels of both the brake cooling oil
disc pack.
and hydraulic oil.
Parking Brake Main Hydraulic Pump (D)

Refer to Section 170-0010, Parking Brake and
Refer to Section 250-0000, Main Hydraulic Pump.
Mounting.
The hydraulic pump is mounted on the left-hand side of
The parking brake consists of a sliding calliper acting
the transmission PTO. It is an 'tandem' axial piston,
on a brake disc on a rear driveline and is of 'Inverted
variable displacement pump with load sense and
Design', which means that it requires pressure to hold
pressure regulator to match the flow and pressure to
it off.
the demand. 'Tandem' in the sense that it contains two
complete pump assemblies mated together to provide
Operation is by means of a spring applied/hydraulically
to desired output levels.
released actuator. A push control on the right hand dash
panel activates the park brake solenoid valve (31) on the
The tandem pump supplies hydraulic oil for the
main hydraulic valve assembly, controlling oil pressure
steering, braking and body hoist systems, as well as
from the rear brake circuit accumulator to the actuator.
the transmission and engine oil cooler fan drive
Application of the push control releases oil from the
system.
actuator allowing internal springs in the actuator to apply
the parking brake. Pulling out the push control directs oil Parking Brake Pressure Switch (PS4)
pressure from the rear brake circuit accumulator to the
Located on the main hydraulic valve assembly it
actuator, compressing internal springs, to release the
senses pressure in the parking brake (PB) line. The
parking brake.
pressure switch closes at a pressure of 4.8 bar (70 lb/
in²) and sends a signal to illuminate the parking brake
In an emergency situation, application of the park/
indicator light when the parking brake is applied.
emergency valve will actuate the service brakes and
condition, a restriction in the 'Px' line will slow oil flow Brake Circuit Pressure Switches (PS2 and
from the parking brake allowing the service brakes to PS3)
actuate momentarily ahead of the parking brake.
Front and rear brake circuit pressure switches are both
located on the main hydraulic valve assembly. The
pressure switches sense pressure in the front and rear
brake circuits and sends a signal to warning lights on
the dash (a buzzer also sounds) when the pressure
2 SM 2616 Rev1 04-10

Section 250-0000
drops below 122 bar (1769 lbf/in²). The warning lights Brake Treadle Valve (E)
will remain illuminated until the pressure rises above
135 bar (1958 lb/in2). Refer to Section 250-0070, Treadle Valve.
Brake Accumulators (ACC1,2 and 3) The treadle valve controls the level of hydraulic fluid
Refer to Section 250-0060, Accumulator. pressure applied to front and rear brakes and the
maximum pressure available to these circuits.The first
There are three accumulators mounted at the rear left few degrees movement of the brake pedal will acutate
hand side of the cab; one for the front brake system the brake lights on the rear of the vehicle. Continued
(ACC1) and one for the rear and park brake (ACC2) . movement will allow pressure to the service brakes. It
The front and rear brake accumulators are is operated by a foot pedal in the operator's cab and,
supplemented by a third (primary) accumulator (ACC3). with the engine running, is automatically applied by the
The primary accumulator supports the service brake park brake solenoid valve (31) through the directional
system and the body pilot pressure system. All three control valve (32) on the main hydraulic valve to the Px
accumulators are of the piston type and are precharged port on the treadle valve..
with nitrogen, ACC1 and ACC2 to 55 bar (797 lb/in²)
and ACC3 to 103 bar (1500 lb/in2). Each accumulator Valves 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
consists of a charging valve assembly, cylinder
19, 31, 32 and 33
SM - 3614 These valves form part of the brake cuircuit and are an
intregal part of the main hydraulic valve assembly,
mounted on the left-hand side of the tractor frame.
Refer to Section 215-0050, Main Hydraulic Valve
Assembly.
OPERATION
Numbers in parentheses refer to Figures 1, 2 and 3.
Brake Charging
The valves integral to the main hydraulic valve
assembly automatically maintain the brake
PS3 accumulator pressures between a lower and upper
limit.
PS4
Accumulators (ACC1 and ACC2) are charged from
PS2
accumulator (ACC3) via brake system relief valve (9),
to limit the pressure in these accumulators to 160 bar
PS2 - Rear Service Brake Circuit Pressure Switch
PS3 - Front Service Brake Circuit Pressure Switch (2320 lb/in2) and then via the check valves (10 and 11)
PS4 - Park Brake Pressure Switch respectively.
Fig. 2 - Brake System Pressure Switch Locations If the pressure in accumulator (ACC3) is below the
lower charge limit of 165 bar (2390 lbf/in2) the brake
assembly and piston. The charging valve will allow the system charge valve (12) spring closes the brake
precharge to be checked or accumulator charged. system charge valve (12). The pressure then builds up
in the load sense line from the brake system charge
The piston acts as a separator dividing the cylinder valve (12) to the shuttle valve (16) and on to the priority
assembly into two sections. The top section nearest valve (7) spring chamber where it helps this valve to
the charging valve contains the nitrogen precharge. close, ensuring flow priority is to the brake charging. At
Hydraulic oil from the main hydraulic pump flows the same time it also acts upon the main hydraulic
through check valves in the main hydraulic valve and pump load sense line via the shuttle valve (17) to
into the bottom section of the accumulators. supply enough flow to charge the accumulators.
Accumulator pressure is monitored by pressure
switches (PS2 and PS3) in the brake lines. As soon as the pressure in accumulator (ACC3)
SM 2616 Rev1 04-10 3

Section 250-0000
reaches the upper charge limit of 185 bar (2680 lbf/in2) valve assembly and the Px port on the brake treadle
the brake system charge valve (12) opens and unloads valve. This permits a flow of oil to either energize the
the load sense line to tank. This action unloads the Px port at the treadle valve, or, exhaust the Px port
main hydraulic pump back to its standby pressure of through the main hydraulic valve assembly to tank,
50 bar (725 lb/in2). dependant on the operation of the park brake solenoid
valve (31). The park brake solenoid valve (31) is
The accumulators (ACC1 and ACC2) are also controlled by the park/emergency control switch inside
automatically charged every time the pressure at the the operator's cab.
main hydraulic pump rises above the pressure in
accumulator (ACC3). It is therefore possible to achieve When the park/emergency control switch is activated
pressures up to the main hydraulic pump cut off (pushed in), the electrical signal between the switch
pressure of 240 bar (3 480 lb/in2) in this accumulator and park brake solenoid valve (31) is opened. This
(ACC3), for example when steering over the relief. The action de-energizes the park brake solenoid valve (31).
brake system relief valve (9) will still limit the pressure Oil flows through park brake solenoid valve (31) and
in accumulators ACC1 and ACC2 to 160 bar (2320 lb/ through the directional control valve (32). The oil
in2). travels through the directional control valve and into the
Px port in the treadle valve for an emergency brake
Orifice (35) would protect all three accumulators application.
against abnormally high pressure spikes. However,
accumulator (ACC3) can see system pressure if any of Return oil from the parking brake circuit enters the
the main hydraulic functions are held over relief for a main hydraulic valve assembly. The oil flows through
period of time. park brake solenoid valve (31) and exits the main
hydraulic valve assembly to the hydraulic tank. With no
Brake Apply pressure in the parking brake circuit to hold the parking
The minimum pressure required at the brake treadle brake off, the parking brake is applied by spring
valve is 48 bar (696 lb/in2). pressure.
The brake treadle valve controls the level of hydraulic When the emergency brake switch is deactivated
pressure applied to front and rear brakes and the (twisted and pulled out), the electrical signal between
maximum pressure to these circuits. It is operated by the switch and park brake solenoid valve (31) is
the foot pedal in the operators cab and in an closed, energizing the park brake solenoid valve (31).
emergency with the engine running, is automatically Oil flows through park brake solenoid valve (31) and
applied by the park brake solenoid valve (31) in the exits the main hydraulic valve assembly pressurizing
main hydraulic valve assembly (Ref. Park/Emergency the parking brake circuit to release the parking brake.
Brake Function).
Return oil from the Px port on the brake treadle valve
Mounted on the brake treadle valve is a microswitch. flows through the directional control valve (32), then
This microswitch, when activated, energizes K50, through the park brake solenoid cartridge (31) and exits
brake lamp relay. Relay is located in the fuse box in the main hydraulic valve assembly to the hydraulic
the operator's cab. When the relay is energized, an tank.
electrical circuit is completed to energize the brake
lights. When the engine is shut down, transmission pilot
pressure at directional control valve (32) is lost,
The first few degrees movement of the brake pedal causing the directional control valve (32) to move to
activates the rear brake lamps. the right under the influence of the compressed spring.
This movement links the Px port at the brake treadle
Park/Emergency Brake Function valve with the hydraulic tank through the main
The park/emergency brake function is designed to hydraulic valve assembly. This action results in a
electrically operate the park brake, and with the engine controlled bleed down of the applied service brakes to
running automatically actuates the service brakes also the hydraulic tank. This controlled bleed down permits
during this operation. a synchronized service brake release/mechanical park
brake application.
When the engine is running, a transmission hydraulic
pilot pressure acts against the spring at the directional When the engine is shutdown, the park brake solenoid
control valve (32). The directional control valve (32) valve (31) is automatically de-energized (fail safe).
creates an open circuit between the main hydraulic
4 SM 2616 Rev1 04-10

Section 250-0000
Park brake 'hold off' pressure is allowed to return to SM - 4002
tank through the park brake solenoid valve (31), 1 - Diff-lock Pressure 'TP1'
causing the park brake to apply (spring applied). The 2 - DropBox Lube Pressure
'TP3'
vehicle is now held with the park brake only. 3 - DropBox High Select 'TP2'
4 - DropBox Low Select 'TP2'
CHECKING SYSTEM PRESSURES 5 - Cross Axle Diff.Lock
Numbers in parentheses refer to Figs. 1, 2 and 9, 6 - CT21
7 - Body Hoist Raise
unless otherwise stated. 8 - Body Hoist Lower
13 19
9 - Raise Pilot
10 - Lower Pilot 1 7
11 - Transmission 14 20
WARNING
12 - Rear Axle Disconnect 2 8
To prevent personal injury and property 13 - Parking Brake Pressure 15 21
damage, be sure wheel blocks and blocking 14 - Main Pump (Front) 3 9
16 22
materials are properly secured and of adequate 15 - Main Pump (Rear)
capacity to perform the task safely. 16 - Front Pump LoadSense 4 10
17 23
Pressure
17 - Rear Pump LoadSense 5 11
18
Pressure
18 - Steering Pressure 6 12
19 - Front Brake Accumulator
20 - Rear Brake Accumulator
SM 3518 21 - Primary Accumulator
22 - Front Brakes
23 - Rear Brakes
A
Fig. 4 - Diagnostic Pressure Check Points, Left-hand
P
P2 Fender
A2
T T2
P1
P WARNING
T T1
A1
A within the system after engine shut down.
Operate the brake treadle pedal continuously
Px until the pressure has dissipated before
carrying out any work on the system or serious
Px
injury could result.

2. Operate the brake treadle valve continuously to

relieve pressure in the braking system. Block all road
wheels, place the steering lock bar in the 'Locked'
position and the battery master switch in the 'Off'
position.
3. Connect a hydraulic gauge, capable of recording a

pressure of 0 - 345 bar (0 - 5000 lb/in²), to the park
brake diagnostic pressure point (13, Figure 4), on the
left-hand fender outside the cab door.
P1- Pressure from Front Brake Accumulator
P2- Pressure from Middle and Rear Brake Accumulator
A1 - Pressure to/from Front Brakes 4. Place the battery master switch in the 'On' position,
A2- Pressure to/from Middle and Rear Brakes start the engine and release the park/emergency button
T1- Tank return, Front Brakes
T2- Tank return, Middle and Rear Brakes
(pull the button out), to energize the park brake line.
Px- Emergency/Park Pilot Pressure Monitor the system pressure gauge. Pressure setting
should be 160 bar (2320 lb/in²).This is the pressure at
Fig. 3 - Brake Treadle Valve Porting Arrangement the brake accumulators.
SM 2616 Rev1 04-10 5

Section 250-0000
SM - 1335
5. If necessary, pressure setting can be adjusted via
brake system relief valve (9) on the main hydraulic FITTING NUT
valve assembly. The operator cab will require to be TUBE
raised to access brake system relief valve (9). Refer to

pressure of 0 - 345 bar (0 - 5000 lb/in²), to the front
brake diagnostic pressure point (4, Figure 4) on the left-
hand fender. SLEEVE
O-RING O-RING

start the engine and apply the park/emergency brake
(push the button in), to apply service brakes. Monitor
system pressure gauge. Brake actuating pressure for vaseline.
the front brake circuit is 48 bar (696 lb/in²).
8. Repeat steps 6 and 7 at the rear brake diagnostic
pressure point (5, Figure 4). The brake actuating c. Where a hose is fitted, ensure that it is not twisted
pressure for the rear brake circuit is 48 bar (696 lb/in²). or kinked when the nuts are tightened so that it is
Note: When the brakes are released, a residual
pressure of no more than 0.2 bar (3 lbf/in²) should d. Where a tube is fitted, ensure that the connection is
remain. aligned correctly.
9. If pressure setting at front or rear brake system is

not to specification but pressure input to treadle valve
is ok (160 bar, 2320 lb/in2), then the treadle valve
should be investigated.
Note: There is no adjustment at the treadle valve.
10. Shut off the engine and remove the pressure gauge
from the diagnostic check point.
11. Remove wheel blocks, place the steering lock bar

in the 'Stowed' position, start the engine and check the
braking system for proper operation.
BLEEDING THE BRAKING SYSTEM

Refer to Section 165-0010, Brake Parts.
O-RING FACE SEALS (ORFS)

connections, the following procedure should be carried
out during 'Installation'. Refer to Figure 8.
a. Ensure that the O-ring/seal is in place and that the

joining surfaces are clean. If necessary, retain the O-
ring/seal in place with a light coating of grease or
6 SM 2616 Rev1 04-10

Section 250-0000
e. Tighten the nut a further 1/4 to 1/2 a turn using the
f. Check that a satisfactory hose or tube routing has

been achieved.
HYDRAULIC OIL
The braking system should be kept filled with hydraulic
oil as specified in Section 300-0020, Lubrication
System.
Whenever there is a hydraulic system failure, the oil

should be drained, the entire system flushed, oil filters
replaced, oil screens thoroughly cleaned and clean
hydraulic oil added to eliminate all metal particles or
foreign matter.
SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, Service
Tools, for part numbers of these tools.
Multi-Gauge
The multi-gauge, 15269784, is basically four pressure
gauges in one. Continuous system pressure readings
are indicated on one of three simultaneously reading
gauges through a pressure range of 30 in of vacuum to
5000 lbf/in².
The following items should be added to the multi-gauge

to enable the gauge to be used on the diagnostic
pressure check points;
15018226 Diagnostic Coupling
00118748 Connector (two)

The infrared thermometer, 15269785, can be used to
spot heat problems early in electrical, mechanical and
hydraulic systems. Hand held and easy to use, you
Since there is no need to touch what you are
measuring, temperatures of hard-to-reach or moving
components can be taken without getting burned or
shocked.
O-Ring Face Seals (ORFS) - Seal Kit

The braking system utilizes O-ring Face Seal (ORFS)
connectors. An ORFS kit, 15271082, is available. This
kit contains a minimum stock requirement of all sizes
of ORFS type seal.
SM 2616 Rev1 04-10 7

Section 250-0000
SM - 3616
9
15 14
33
16 11
32 13 31 12
17
Valve (14 & 31) Coil Rating

Ohms Amps Watts
41 0.6 14
Voltage: 24V
7 - Priority Valve
8 - Check Valve
9 - Pressure Reducing Valve
10 - Check valve
11 - Check Valve
12 - Brake Charging Valve
13 - Orifice
14 - Cold Start Solenoid Valve
15 - Orifice
16 - Shuttle Valve 10
17 - Shuttle Valve
19 - Orifice
31 - Park Brake Solenoid Valve
32 - Directional Control Valve 19
33 - Orifice
Fig. 6 - Brake System Valves Integral to Main Hydraulic Valve Assembly
8 SM 2616 Rev1 04-10

Section 250-0000
Braking System Trouble Shooting

Front and Rear Brake Accumulators Brake System Relief Valve (9) Re-set valve (9) to the correct
(ACC1 and 2) not reaching the not set correctly or faulty setting or replace if faulty
correct hydraulic charge pressure
Pressure at Primary Accumulator Set the Charge Valve (12) to the
(ACC3) not high enough due to Brake correct setting.
System Charging Valve (12) not being Replace valve (15)
set correctly
Pre-charge gas pressure in the Check Pre-charge gas pressure in

accumulator not at the correct level the accumulator. Refer to Section
250-0060, Accumulator
Front and Rear Brake Accumulators Check Valves (10) or (11) leaking Replace Check Valves (10) or (11)
(ACC1 and 2) do not hold their charge
pressure Pre-charge gas pressure in the Check Pre-charge gas pressure in
accumulator not at the correct level the accumulator. Refer to Section
250-0060, Accumulator
Faulty seal in the piston of the Replace the accumulator/seals.

accumulator
Brake Treadle Valve leaking Refer to Section 250-0070, Treadle

Valve
Brake Charging System Fails to Cold Start Solenoid Valve (14) Replace Valve (14). Refer to
charge at initial engine start up remains open Section 215-0050, Main Hydraulic
Valve Assembly
Faulty Brake System Charge Valve Replace valve (12)

(12)
Contamination in orifice (13) Replace orifice (13)
Air or contamination in the Load Lift the body of the truck up and
Sense System, especially when first down several times to purge the
running the truck after a new main system.
hydraulic valve has been fitted.
Primary Accumulator (ACC3) does Front and Rear Brake Accumulators See previous symptoms.
not hold its charge pressure. (ACC1 and 2) are not holding their
charge.
Check the pre-charge gas pressure
Pre-charge gas pressure in the in the accumulator. Refer to Section
accumulator not at the correct level 250-0060, Accumulator
Leakage across the Valves (8,12) is Replace each valve one at a time
too high. (in order stated) until the fault is
found.
Accumulator Piston Seal leaking Replace the accumulator
SM 2616 Rev1 04-10 9

Section 250-0000

Ineffective Park Brake Fault with Park Brake caliper Refer to Section 170-0010, Parking
and Mounting.
Park Brake Solenoid Valve (31) not Check if there is hydraulic pressure
functioning. Sticking in the selected at the Park Brake port. If there is
position pressure present, replace
Valve(31).
Park Brake fails to release. No voltage at Park Brake Solenoid Check park/emergency switch in
Valve (31) when the switch is operator's cab.
activated in the cab.
Check wiring between park/
emergency switch and park brake
solenoid (31).
Park Brake Solenoid Valve(31) fails Replace valve(31).

to operate due to fault.
Insufficient hydraulic charge pressure Check warning lights in cab and

in rear brake accumulator pressure at the Park Brake
diagnostic check point.
See trouble-shooting Brake
Accumulator Charging
Service brakes fail to come on when Faulty Brake Treadle Valve. Spool Refer to Section 250-0070, Treadle
Parking Brake is selected when the not stroking when pressure at port Px. Valve.
engine is running.
No transmission pressure at port TS Check piping and see instructions
on main hydraulic valve assembly. for the transmission.
Directional Control Valve (32) not Replace Valve (32)

selecting.
Fault with Park Brake System See previous trouble-shooting
Service Brakes come on when Directional Control Valve (32) Replace Valve (32)
Parking Brake is selected and Engine sticking in the selected position.
is not running.
Inadequate Braking. Low system pressure. Check hydraulic oil level.
Check oil condition.
Check for major leakage.
Check accumulator pressures.

Refer to Section 250-0060,
Accumulators
10 SM 2616 Rev1 04-10

Section 250-0000

Inadequate Braking (continued) Brake treadle valve delivery pressure Check front and rear brake pressure
below normal setting.
Check the brake treadle valve
operation. Refer to Section 250-
0070, Treadle Valve
Insufficient brake surfaces. Check brake disc/pads for wear.

Refer to Section 165-0010, Brake
Parts.
Replace seals and pistons as

required. Refer to Section 165-
0010, Brake Parts.
* * * *
SM 2616 Rev1 04-10 11

Section 250-0000
12 SM 2616 Rev1 04-10

BRAKING SYSTEM - Brake Coolant/Hydraulic Tank
Section 250-0026
SM3958
4 7,19 'B' 13 14
AT HEADER TANK
20
28 22
29 21
15 23
18 16 5
15
30 3 9 'A'
31 'B' 10
32 20
21
8
5 24
7,19
12
AT L.H.
RADIATOR GUARD
4
28
2 29
6
30
31
26 27
17 25
7,19
11
28 1
BREATHER LINES 'A'
1 - Brake Coolant / Hydraulic Tank 9 - Cap Assembly 19 - Bonded seal 27 - Element Assembly Kit
Assembly 10 - Gasket 20 - Bolt 28 - Bushing
2 - Spacer 11 - Connector 21 - Lockwasher 29 - Nipple
3 - Breather Valve 12 - Strainer 22 - Screw - Socket counter 30 - Bracket - Breather
4 - Breather 13 - Cover plate - Filter Sunk 31 - Connector
5 - Rubber Gasket 14 - Rubber Gasket 23 - Plate SWT - Float Switch 32 - Hose Assembly
6 - Guage - Fluid level 15 - Washer 24 - Guage - oil level
7 - Drain valve - Magnetic 16 - Bolt 25 - Filter Assembly - Return
8 - Top Cover Assembly - Cooling Tank 17 - Hose Assembly 26 - Filter Assembly Support Kit
18 - Locknut
Fig. 1 - Exploded View of Hydraulic Tank and Mounting
DESCRIPTION frame at the front left-hand side of the tractor.
Numbers in parentheses refer to Figure 1, except Integral with brake coolant/hydraulic tank assembly (1)
where indicated otherwise. is cap assembly (9), suction strainer (12), Filter
assembly (25) cover plates (8, 13) and drain valves (7).
The brake coolant/hydraulic tank assembly (1) Located on the outboard face of the tank are level
comprises both the brake cooling oil tank and the gauges for checking the fluid levels of both the brake
hydraulic oil tank in one integral unit. Looking from the cooling oil and hydraulic oil.
LHS of the tractor unit, the brake coolant tank is to the
left and the hydraulic tank is to the right. The brake Positive air pressure is provided to the hydraulic tank
coolant tank supplies the OCDB (oil cooled disc brake) from a connection on the engine air intake manifold,
cooling circuit. The hydraulic tank is the common via a check valve (8, Figure 2) and a precision
reservoir for the steering, braking, body hoist and fan regulator (7, Figure 2), set at 0.31 bar (4.5 lbf/in2).
drive system. The tank assembly is mounted on the
SM 2617 01-10 1
Section 250-0026
SM - 3888
4
6
8 1 - Hydraulic Tank
2 - Plastic Ball Check Valve
3 - Pressure Gauge
FROM ENGINE 4 - Relief Check Valve
INLET MANIFOLD
6 - Miniature Ball Valve
7 7 - Precision Regulator
8 - Check Valve
2
3
1
Fig. 2 - Hydraulic Tank Pressurization Circuit
Note:The tank pressurization pressure may drop to working range of between 228 litre and 250 litre. Refer
approximately 0.21 bar (3 lbf in2) as the body is raised, to Section 215-0050, Main Hydraulic Valve Assembly.
due to the volume of hydraulic fluid required to the
Raise end of the body cylinders. Similarly, during Emergency steering oil is drawn from the hydraulic
lowering of the body, the tank pressurization pressure tank section by an emergency pump, mounted off the
may rise to 0.62-0.69 bar (9-10 lbf in2) as the fluid in rear of the dropbox, and is also pumped to the main
the Raise ends of the body cylinders returns to the hydraulic valve. Should a failure occur at the main
tank. This pressure variation is perfectly normal. hydraulic pump the emergency pump will supply the
steering system with oil to enable the vehicle to be
brought to a safe halt. Refer to Section 220-0000,
OPERATION Steering System Schematic.
indicated otherwise. While the engine is running, a nominal air pressure is
supplied from the engine inlet manifold, through a
Oil is added to the hydraulic tank section through a connection on the hydraulic tank breather pipe, which
hose adaptor (7) on the top of the tank. The hose applies air pressure to the hydraulic fluid, to ensure
adaptor features a brass dust cap which must be that the main hydraulic pump is subject to a positive
removed to facilitate access to the adapter for oil fluid suction.
replenishment. A larger cap (9), fitted to a larger
diameter filling tube, is prevented from being removed Return oil from the hydraulic systems flows through the
by a lockable bracket that hinges over its top. hydraulic oil cooler and filter before entering the tank
storage area. The filter assembly has a by-pass valve
Note:It is recommended that the smaller, hose adaptor, which allows oil to by-pass the element (27) when it is
is used for replenishing the hydraulic tank, as this cold or when the filter element is plugged. A Hydraulic
method forces all introduced fluid via the hydraulic filter Oil Filter Change warning symbol will be displayed on
on entry to the tank. Refit the dust cap on completion. the VDU display on the main instrument panel to alert
the operator that it is time to replace the filter element
The hydraulic oil is drawn from the hydraulic tank by when the monitored pressure differential reaches 2.0
main hydraulic pump and pumped to the main hydraulic bar (29 lbf/in2). Should the filter remain restricted, the
valve to supply the various hydraulic systems. The by-pass valve will open at a pressure differential of 3.0
hydraulic tank has a capacity of 369 litre, and has a bar (43.5 lbf/in2).
2 SM 2617 01-10
Section 250-0026
Oil is added to the cooling tank section through a Note: Tighten all fasteners without special torques
cooling fill point, covered by a protective cap (9) during specified to standard torques listed in Section
normal operation. The cooling oil is drawn from the 300-0080, Standard Bolt and Nut Torque
cooling tank by the OCDB triple pump. Refer to Section Specifications.
250-0045, Motor/Triple Pump Assembly. Return oil
from the OCDB system flows through the disc brake oil
cooler before returning to the cooling tank section WARNING
through a common return line. Refer to Section 210- To prevent personal injury and property
0040, Radiator and Mounting. The brake coolant tank damage, be sure wheel blocks, blocking
has a capacity of 155 litre, and has a working range of materials and lifting equipment are properly
between 112 litre and 123 litre. secured and of adequate capacity to perform
the task safely.
MAINTENANCE
Checking The Hydraulic Tank Oil Level
Brake Coolant Tank 1. Operate the body hoist and steering systems
several times to bring the oil to the correct operating
Every 1000 Hours temperature.
Renew the brake coolant tank breather element.
2. Position the vehicle in a level work area. Ensure that
the body is fully lowered, then apply the parking brake
Every 1500 Hours and switch off the engine. Turn the steering wheel in
both directions several times to relieve any pressure in
Drain the OCDB cooling oil from the brake coolant tank,
the steering circuit. Operate the treadle valve
then replenish it with new oil. Refer to section 300-
continuously to discharge the accumulators.
0020, Lubrication System for specifications of oils to be
used. 3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in
Every 2000 Hours the 'Off' position.
Renew the OCDB (cooling oil) filter element. The filter is
mounted in the brake cooling line between the motor/ 4. Check the oil level from oil level guage and replenish
triple pump assembly and the front manifold block. The it if it is low. This alerts the operator that there is
filter is fitted with a visual indicator to show when the sufficient oil in the hydraulic tank end of the brake
filter is in by-pass mode. coolant/hydraulic tank assembly (1, Figure 1), to allow
the operator to run the vehicle to heat the oil up to
Clean and inspect the OCDB suction strainer (12, operating temperatures.
Figure 1). Refit the strainer if it is in a servicible
condition, or renew it if it is damaged. 5.Once the system is in operation, the operator should
check the oil level in the sight gauge (6, Figure 1)
Hydraulic Tank located on the lower deck, hydraulic tank end of the
brake coolant/hydraulic tank assembly (1). The oil
Every 10 Hours should be within the 'max' and 'min' marked lines.
Should more oil be required, relieve the air pressure by
Check the oil level, replenish the tank if it is low. Refer opening the miniature ball valve (6, Figure 2), then fill
to the Checking Hydraulic Oil Tank Level paragraph. the hydraulic tank with hydraulic oil specified in Section
300-0020, Lubrication System, through the hose
Check the status of the hydraulic filter, and renew the adaptor.The hose adaptor features a brass dust cap
element if required. which must be removed to facilitate access to the
adaptor for oil replenishment.
Every 2000 Hours Note:It is recommended that the smaller, hose adapter,
Drain the oil from the hydraulic tank and replenish it is used for replenishing the hydraulic tank, as this
with new oil. Refer to "Replacing Hydraulic Oil". method forces all introduced fluid via the hydraulic filter
on entry to the tank.
SM 2617 01-10 3
Section 250-0026
6. Refit the dust cap to the hose adaptor on the 1. Position the vehicle in a level work area, ensure the
hydraulic tank end of the brake coolant/hydraulic tank body is fully lowered, apply the parking brake and
assembly (1) and tighten it. switch off the engine. Turn the steering wheel in both
Replacing Hydraulic Oil steering circuit. Operate the treadle valve continuously
to discharge accumulators.
Hydraulic oil should be changed every 2000 hours.
Refer to Section 300-0020, Lubrication System, for 2. Block all road wheels, place the steering lock bar in
hydraulic oil used in the system. the 'Locked' position and the battery master switch in
the 'Off' position.
Note: When replacing the hydraulic oil due to a
hydraulic failure, or at recommended change interval, 3. Unscrew the breather (4) and remove it from the
the element of the filter (12, Figure 1) must be renewed brake cooling tank (1). If necessary, remove the hose
and the hydraulic tank end of the brake coolant/ (32) and constituent fittings from the breather line and
hydraulic tank assembly (1, Figure 1) cleaned tank.
thoroughly using a suitable solvent.
Replacing Hydraulic Filter Element

Checking Brake Coolant Tank Oil Level Every 2000 hours of operation, or when the Hydraulic
Oil Filter Change warning symbol displays on the
1. Operate the body hoist and steering systems several
instrument panel VDU warning screen, whichever
times to bring the oil to correct operating temperature.
comes first, remove the filter (25, Figure 1) and install
2. Position the vehicle in a level work area, ensure the a new element (26, Figure 1). Refit the filter (25) on
body is fully lowered, apply the parking brake and completion. This procedure is described below.
switch off the engine. Turn steering wheel in both
directions several times to relieve any pressure in the 1. Position the vehicle in a level work area, ensure the
steering circuit. Operate treadle valve continuously to body is fully lowered, apply the parking brake and
discharge accumulators. switch off the engine. Turn the steering wheel in both
3. Block all road wheels, place the steering lock bar in steering circuit. Operate the treadle valve continuously
the 'Locked' position and the battery master switch in to discharge the accumulators.
the 'Off' position.
4. Check oil level and replenish it if it is low. Oil should the 'Locked' position and the battery master switch in
be visible in the fluid level gauge (6) integral to the the 'Off' position.
brake coolant tank (1). This allows the operator to verify
that there is sufficient brake cooling oil in the system. 3. Remove the drain valve (7, Figure 1) on the bottom
of the hydraulic tank end of the brake coolant/hydraulic
tank assembly (1). Install a hose adaptor on drain
Replacing Brake Coolant Oil fitting, open the drain cock and drain hydraulic oil into a
Brake cooling oil should be changed every 15000 suitable container. Close the drain cock, remove the
hours. Refer to Section 300-0020, Lubrication System, hose and reinstall the drain valve (7, Figure 1).
for brake cooling oil used in the system.
4. Remove the bolts (16, Figure 1) and washers
Replacing Brake Coolant Tank Breather (15, Figure 1) securing the cover plate (13, Figure 1)
Every 1000 hours of operation, or sooner if the vehicle to the top of hydraulic tank .Discard the gasket (14).
is being operated in extremely dusty conditions, the
brake coolant tank breather (4, Figure 1) should be 5. Remove the filter assembly (25) from the hydraulic
replaced. tank end of the brake coolant/hydraulic tank assembly
(1).
4 SM 2617 01-10
Section 250-0026
6. Remove and discard the element (27) from the filter 14. Place the battery master switch in the 'On' position
assembly (26). and the steering lock bar in the 'Stowed' position,
remove all wheel blocks, start the engine and operate
7. Remove the bolts (20, Figure 1) and lock washers the steering, braking and body hoist systems to
(21, Figure 1) securing the float switch (23, Figure 1) to circulate the oil.
the hydraulic tank end of the brake cooling/hydraulic 15. Switch off the engine, check for leaks and check oil
tank assembly (1). Remove the cover plate (8) and level as described under 'Checking Oil Level'.
discard the gasket (15).
TANK ASSEMBLY
WARNING
Splashing liquid. Wear a suitable face shield Removal
when using compressed air to dry hydraulic Numbers in parentheses refer to Fig. 1.
tank and components.
WARNING
8. Clean out the inside of the hydraulic tank with a damage, verify that wheel blocks, blocking
suitable solvent and dry it with compressed air. materials and lifting equipment are properly
secured, and of adequate capacity to perform
9. Install a new element (24) in the filter assembly (26), the task safely.
ensuring that the Bracket (30) and nipple (29) are
installed correctly.
1. Position the vehicle in a level work area. Ensure that
the body is fully lowered, apply the parking brake and
10. Install the filter assembly (26) in the hydraulic tank
switch off the engine. Turn the steering wheel in both
end of the brake coolant/hydraulic tank assembly (1),
complete with a new 'gasket (5) and the cover plate
steering circuit. Operate the treadle valve continuously
(23).
to discharge the accumulators.
11. Secure the filter cover plate (23) and cover plate (8)
to the top of the tank with the bolts (20) and washers
the 'Locked' position and the battery master switch in
(21).
the 'Off' position.
12. Install a new gasket (5) prior to securing the cover
3. Ensure all lines connected to the tank assembly (1)
plate (38) in place.
are identified for ease of installation, and ensure that
there are suitable containers available to catch
13. Secure the cover plate (8) using the bolts (20) and
leakage. Fit blanking caps and plugs to all open lines
washers (21).
and fittings.
14. Remove the dust cap from the hose adaptor (7) on
the top of the hydraulic tank. Open the miniature ball
valve on the pressure regulator (5, Figure 3).
15. Fill the hydraulic tank with hydraulic oil specified in

Section 300-0020, Lubrication System. Fit the dust cap
on the hose adaptor (7) on the hydraulic tank (1) and
tighten it. Close the miniature ball valve on the
pressure regulator (5, Figure 3).When hydraulic
pipework has been separated for servicing activities, it
is vital that air is bled from the system on completion,
in accordance with Section 230-0050, Main Hydraulic
Pump.
* * * *
SM 2617 01-10 5
Section 250-0026
6 SM 2617 01-10
Braking System - Motor/Triple Pump Assembly
Section 250-0045
SM - 3527
15 22
2
15
5 16 18
17
5 7
4
18 16
13 20
24
11 13 12
9 14
14
19 8
14 21
23
14
8 3 23
6
6 10
14 21
14 24
8 25
10 6
6
24
6 3
6 10
1 - Motor / Triple Pump 8 - Drive Gear 15 - 'O'-ring 22 - Coupling 29 - Bolt

2 - Body 9 - Driven Gear 16 - Seal 23 - Plate - support 30 - Lockwasher
3 - Body 10 - Driven Gear 17 - Q-ring 24 - Dowel Pin 31 - Washer
4 - Rear Cover 11 - Screw 18 - Anti-estrusion 25 - Body 32 - Bolt
5 - Thrust Plate 12 - Nut 19 - Flange 26 - Special Adaptor
6 - Thrust Plate 13 - Washer 20 - Flange 27 - Lockwasher
7 - Drive Gear 14 - 'O'-ring 21 - Coupling 28 - Bracket
Fig. 4 - Motor/Triple Pump Exploded View
Note: Direction of rotation is clockwise as viewed from

shaft end, and is indicated by an arrow.
REMOVAL
switch in the 'Off' position. Place the steering lock bar
in the 'Locked' position.
WARNINGS
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the
has dissipated before carrying out any work on
the braking system or serious injury could
result.
blanking cap.
To prevent personal injury and property 4. Remove the blanking cap from remote drain line at
damage, ensure wheel blocks, blocking the bottom of the brake coolant tank. Install a length of
materials and lifting equipment are properly hose on the remote drain fitting, open the drain cock
secured and of adequate capacity to execute the and drain the brake cooling oil into a suitable container.
job safely. Close the drain cock, remove the hose and reinstall the
blanking cap.
2 SM 2618 01-10
Braking System - Motor/Triple Pump Assembly
Section 250-0045
6. Check the motor/triple pump and the hydraulic line If investigation shows that the relief valve (B) is in
connections for leaks and tighten them if required. good clean condition and fit for use, the seals should
be renewed, prior to re-assembly. Any damage to the
7. Remove all blocking from the road wheels and place motor section or to any of the pump elements would
the steering lock bar in the 'Stowed' position. necessitate renewal of the motor/triple pump
assembly.
FAULT DIAGNOSIS
Identifiers in parentheses refer to Figs. 2 and 3.
SPECIAL TOOLS
Refer to the following Fault Diagnosis chart. As stated There are no special tools required for the procedures
previously, it is not recommended that the relief valve outlined in this section. Refer to Section 300-0070,
(B) cartridge assembly is disassembled for SERVICE TOOLS, for part numbers of general service
maintenance purposes. Ensure that the motor/triple tools required. These tools are available from your
pump is cleaned off prior to removal of any dealer.
components and that no contaminant is allowed to
enter the internal galleries.
FAULT DIAGNOSIS
CONDITION REASON ACTION
Non rotation of shaft No oil supply. Check the pressure at the motor section of the triple
gear pump.
Pressure should be 26 bar (377 psi) at 2 100rpm,

when oil is at operating temperature.
Relief valve faulty. Check - refer to Section 250-0120, OCDB RELIEF

UNLOADER VALVE.
Brake packs overheating No brake cooling oil supply. Check oil level in brake cooling tank.
Pump elements damaged. Replace motor/triple pump.
* * * *
4 SM 2618 01-10
BRAKING SYSTEM - Brake Manifold Valve
Section 250-0050
SM3611
(XXX) - PORT DESIGNATIONS
(A1)
(PS)
7,8 (A2)
12 9,10
2,3 (TS2)
16 18,19
5 (B2) (TS1)
(C1)
13
(B1) 4,17
(B3)
20,21
2,3
1
(Y)
2,3
11
(CT1) 9 2,3 15
14 6
(X)
(T) (C2)
1 - Manifold Block 7 - O-ring 13 - Temperature Switch/Sender 19 - O-ring

2 - O-ring 8 - 45° Elbow 14 - Connector 20 - Plug
3 - 45° Elbow 9 - O-ring 15 - O-ring 21 - O-ring
4 - O-ring 10 - Elbow 16 - O-ring
5 - Connector 11 - Check Valve. 17 - Connector
6 - Connector 12 - Pressure Switch 18 - Plug
Fig. 1 - Exploded View of Front Axle Brake Manifold Valve Block
DESCRIPTION oil in the brake hubs reaches 50°C, a temperature

The brake manifold valve blocks can be identified as sender mounted on the front axle manifold valve block
items 11, 12 and 13 on Figure 2 in Section 210-0005, sends a signal to the IFM controller, which commands
Brake Cooling System Schematic. the OCDB relief unloader valve to de-energize, allowing
hydraulic oil to flow from port 'WB' on the main
hydraulic valve assembly, to supply the motor side of
There are three brake manifold valve blocks within the
the triple pump/motor unit. The three pumps will then
brake cooling circuit. Each is mounted on the
draw brake cooling oil from the brake coolant tank and
respective axle. The manifold valve blocks distribute
distribute it to the front,centre and rear hubs via the
hydraulic oil flow from the oil cooled disc brake (OCDB)
three manifold valve blocks.
motor/pump to the brake cooling circuit. Oil from the
accumulators passes through the treadle valve, and is
then distributed to the front,centre and rear brakes via Hydraulic oil from the motor/triple pump enters the
the three manifold valve blocks. brake manifold valve blocks at port 'A1'. Oil is
distributed to the six hubs via ports 'X' and 'B1' of each
manifold valve block (two per manifold).
OPERATION
Numbers in parentheses refer to Figures 1,4 and 6. Check Valve
At temperatures below 50°C, oil from the brake coolant An integral check valve (11, Figure 1; 5, Figures 4 and
tank is not drawn by the motor/triple pump. When the 6) set to relieve at 1 bar is contained within each
SM 2619 01-10 1
Braking System - Brake Manifold Valve
Section 250-0050
SM3612
TO/FROM TO FROM
SERVICE PRESS. BRAKE BRAKE
BRAKES SWITCH HUBS HUBS
C2 PS X Y
TO/FROM B3 CT1
TREADLE
TANK RELIEF
VALVE
TS2
BLANKED
TS1
TEMP. SW. / SENDER
D
BLANKED
C1 A1 B1 B2 A2
TO/FROM FROM TO FROM RETURN TO

SERVICE TRIPLE BRAKE BRAKE TANK VIA
BRAKES PUMP HUBS HUBS COOLER
Fig. 2 - Front Axle Brake Manifold Valve Block - Schematic
SM 3983
manifold valve block. Any excess pressure build up will
be relieved to the brake coolant tank via this valve. BRAKE
TEMPERATURE BRAKE PRESSURE
WARNING WARNING
Pressure Switch
Pressure switch 'PS1' is located on the 'PS' port on the

top of the front axle manifold valve block. PS1
monitors brake cooling oil pressure. Should the brake
pressure reach 1.5 bar (21.8 lbf/in²) a brake pressure
warning symbol will be displayed on the VDU screen to P
2 STOP
inform the operator of irregular pressure in the system. 1
Refer to Figure 3. 20
40
30
10
15
20
30 50
20 mph 60
10 40 r / min x100
km/h 5 25
Temperature Switch/Sender 10 70
80
0 0000000
0000 50 0 30
L H
The temperature switch/sender, mounted on the TS1 40
70
˚C 100
150 210
120 60
135˚C 165
275 320 200

105 ˚F 250 ˚F
port of the front axle manifold valve block, monitors the

140 390
brake cooling oil temperature. Three temperature

conditions will generate a response to the system. A Fig. 3 - VDU Warning Symbols
temperature of 50°C will signal the OCDB relief
unloader to allow flow to the triple pump/motor and
initiate starting of the engine cooling fan. A temperature
of 59°C will initiate starting of the transmission cooling
fan. A 60°C condition will signal a warning symbol to be
displayed on the VDU screen, refer to Figure 3.
2 SM 2619 01-10
Section 250-0050
SM3914
6,7,17 (B3)
2,3 8,16
(B2) 8,16
(A2)
2,3
(B1)
(A1)
15
(D)
(C1)
1 11,12
(Y)
5 13,14
(CT1)
(T) (C2)
9,10,19
11,12 (X)
1 - Manifold Block 8 - Connector 15 - Plug

2 - O-ring 9 - O-ring 16 - O-ring
3 - Elbow 10 - Elbow 17 - O-ring
4 - Not Used 11 - O-ring 18 - Not Used
5 - Check Valve 12 - Connector 19 - Tee
6 - Connector 13 - O-ring
7 - Tee 14 - Connector
Fig. 4 - Exploded View of Middle Axle Brake Manifold Valve Block
SM3912
TO/FROM TO FROM
SERVICE BRAKE BRAKE
BRAKES HUBS HUBS
C2 X Y
TO/FROM B3 CT1
TREADLE
TANK RELIEF
VALVE
D
BLANKED
C1 A1 B1 B2 A2

Fig. 5 - Middle Axle Brake Manifold Valve Block - Schematic
SM 2619 01-10 3
Section 250-0050
SM3915
(B3)
6,7
(A2)
2,3 (A1) 8,16
(E)
8,16
(B2) 17,19
2,3
(B1)
15
(D)
(C1)
(Y)
11,12
1
(C2)
13,14
5 (CT1)
9,10
(T) 11,12
(X)
1 - Manifold Block 8 - Connector 15 - Plug

2 - O-ring 9 - O-ring 16 - O-ring
3 - Elbow 10 - Elbow 17 - Elbow
4 - Not Used 11 - O-ring 18 - Not Used
5 - Check Valve 12 - Connector 19 - O-ring
6 - Connector 13 - O-ring
7 - O-ring 14 - Connector
Fig. 6 - Exploded View of Rear Axle Brake Manifold Valve Block
SM3913
TO/FROM TO FROM
SERVICE BRAKE BRAKE
BRAKES HUBS HUBS
C2 X Y
TO/FROM B3 CT1
TREADLE
TANK RELIEF
VALVE
E
TEST POINT
D (NOT USED AFTER
BLANKED MANUFACTURE)
C1 A1 B1 B2 A2

Fig. 7 - Rear Axle Brake Manifold Valve Block - Schematic
4 SM 2619 01-10
Section 250-0050
Renew any components which have failed.
REMOVAL
Numbers in parentheses refer to Fig. 1. 1. Clamp the manifold block (1) lightly in a soft jawed
vice. DO NOT overtighten the jaws. This will allow for
removal of any of the elbows (3,8 and 10, Figure 1; 3
WARNINGS and 10, Figure 4; 3, 10 and 17, Figure 6), the pressure
Hydraulic fluid pressure will remain within the switch (12, Figure 1) or the temperature switch/sender
system after engine shut down. Operate the (13, Figure 1).
has dissipated before carrying out any work on 2. Where any O-rings have been discarded, replace
the braking system or serious injury could them with new items at the assembly stage (2, 4, 7, 9,
result. 15, 16, 19 and 21, Figure 1; 2, 9, 11, 13, 16 and 17,
Figure 4; 2, 7, 9, 11, 13, 16 and 19, Figure 6) .
secured and of adequate capacity to perform ASSEMBLY
the task safely. Numbers in parentheses refer to Figure 1.
1. Position the vehicle in a level work area, apply the 1. Fit new O-ring(s) to any ports from which they have
parking brake, switch off the engine and turn the been removed.
relieve any pressure in the steering circuit. 2. Similarly renew any broken/failed component.
2. Operate the treadle valve continuously to relieve 3. Follow the torque values listed in 'special torques'.
pressure in the braking system. Block all road wheels,
place the steering lock bar in the 'Locked' position and the 4. If removed, install hydraulic line connectors in the
battery master switch in the 'Off' position. manifold block (1) as noted during disassembly.
3. If the front axle manifold valve block is to be INSTALLATION

removed, remove and tag the electrical connections to Note: Tighten all fasteners to torques listed in
the pressure switch (12, Figure 1) and to the Section 300-0080, Standard Bolt and Nut Torque
temperature switch/sender (13, Figure 1). Specifications.
4. Clean the brake manifold valve block assembly and Note: Tighten all hydraulic lines fitted with ORFS
surrounding area with a suitable solvent. Ensure all connections, as described in Section 250-0000,
hydraulic lines connected to the brake manifold valve Braking System Schematic. Renew all O-rings where
block are identified for ease of installation and, with used.
suitable containers available to catch leakage,
disconnect the hydraulic lines. Fit blanking caps to all 1. Position the brake manifold valve assembly on the
open lines. respective axle, and secure it.
5. Release and remove the mounting hardware 2. Remove blanking caps from hydraulic lines and
securing the brake manifold valve to the cradle connect them to brake manifold valve block as noted
respective axle. Remove the assembly from the during removal.
vehicle.
3. If the front axle manifold valve block is being
installed, connect the electrical connections to the
DISASSEMBLY
pressure switch (13) and to the temperature switch/
Numbers in parentheses refer to Figure 1. sender (13) as noted during removal.
Disassembly of a manifold assembly should only be 4. Check the oil level in the hydraulic tank and add oil if
carried out if there is the need to replace one of the required. Refer to Section 250-0025, Brake Coolant/
elements. In any case, remove the specific fitting/ Hydraulic Tank or 250-0026, Brake Coolant/Hydraulic
switch from the respective port and note this for the Tank (with Pressurization) for the correct fill level, and,
assembly stage. Section 300-0020, Lubrication System for the oil
specification.
SM 2619 01-10 5
Section 250-0050
5. Place the battery master switch in the 'On' position, 10. Place the steering lock bar in the 'Stowed' position.
remove the wheel blocks, start the engine and bring the
hydraulic oil to operating temperature.
MAINTENANCE
6. Check the brake manifold valve and hydraulic line Inspect the brake manifold valve regularly for any signs
connections for leaks and tighten them as required. of leakage or damage and repair/replace as required.
7. Shut off the engine and make sure a full service Note: Limited repair of the brake manifold valve is by
brake application is made followed by a parking brake replacement of parts only.
application.
8. Repeat all braking and engine shut down cycles SPECIAL TOOLS
several times and check for appropriate application/ There are no special tools required for procedures
release cycle several times. outlined in this section. Refer to Section 300-0070,
9. Check all connections again for leaks and tighten as tools and adhesives required. These tools, and
required. adhesives are available from your dealer.

TORQUE
1 3 Elbow (C1 port) 60 44
1 3 Elbow (B1 and B2 ports) 110 81
1 3 Elbow (X and Y ports) 110 81
1 6 Connector (C2 port) 60 44
1 8 Elbow (A1 port) 160 118
1 10 Elbow (A2 port) 160 118
1 12 Pressure Switch (PS) 30 22
1 13 Temperature Switch (TS1) 30 22
1 14 Connector (T port) 160 118
1 17 Connector (B3 port) 110 81
4 3 Elbow (B1 port) 110 81
4 7 Tee (B3 port) 51 38
4 8 Connector (A1 and A2 ports) 160 118
4 10 Elbow (T port) 160 118
4 12 Connector (X and Y ports) 110 81
4 19 Tee (T port) 150 111
6 3 Elbow (B1and B2 ports) 110 81
6 8 Connector (A1 and A2 ports) 160 118
6 10 Elbow (T port) 160 118
6 12 Connector (X and Y ports) 110 81
6 17 Elbow (E port) 20 15
* * * *
6 SM 2619 01-10
Braking System - Accumulator
Section 250-0060
SM - 3959
12 13
14
10 11
9
15
16
7 8 17
7
18 19 21 22 6
20
Charge Valve Assembly
4
3
2
5
1
1 - Charger Valve Assembly 7 - Wear Ring 13 - Bolt 19 - Valve Core

2 - Cyllinder Cap 8 - Seal Ring 14 - Elbow 20 - Locknut
3 - O-Ring 9 - Backup Ring 15 - Bolt 21 - 'O'-Ring
4 - Backup Ring 10 - 'O'-Ring 16 - Washer 22 - Valve Body
5 - Cylinder Body 11 - End Cap 17 - Nut
6 - Piston 12 - Mounting Bracket 18 - Cap
Fig. 1 - Exploded View of Accumulator Assembly
DESCRIPTION assembly (1), end cap (11), cylinder (5) and piston (6).
Charging valve (1) is equipped with a locking feature.
Loosening locknut (20) will open the valve so that the
precharge can be checked or the accumulator charged.
The accumulators can be identified as items
ACC1through ACC3 in Section 250-0000, BRAKING OPERATION
SYSTEM SCHEMATIC.
There are three accumulators mounted off exhaust
Piston (9) acts as a separator dividing cylinder (5) into
mounting cradle located at the rear of the cab; one for
two sections. The bottom section nearest charging
the front brake system and one for the rear. The front
valve (1) contains the nitrogen precharge. Hydraulic oil
and rear brake accumulators are supplemented by a
from the main hydraulic pump flows through check
third (primary) accumulator. Refer to Fig. 2.
valves in the main hydraulic valve and into the top
section of the accumulators.
The primary accumulator supports the service brake
system and the body pilot pressure system. All three
Accumulator pressure is monitored by pressure
accumulators are of the piston type and are precharged
switches located in the main hydraulic valve, which
with nitrogen. The primary accumulator (1, Fig 2) is
send a signal to illuminate warning lights in the dash
precharged to 103 bar (1494 Ibf/in²). The other two
panel when the pressure drops below 122 bar (1 769
accumulators (2,3 Fig.2) are precharged to 55 bar (798
lbf/in²). The warning lights will remain illuminated until
lbf/in²). Each accumulator consists of a charging valve
the pressure rises above 135 bar (1 958 lbf/in²).
SM 2620 01-10 1
Section 250-0060
SM - 3537
P - Primary Accumulator F
F - Front Brake Accumulator R 4
R - Rear Brake Accumulator 3
5
3
5
1
5
3
6
5
3 7
8
9
1 - U-bolt 6 - Locknut
2 - Accumulator Guard 7 - Washer
3 - Lockwasher 8 - Washer 1 P
4 - Partition Plate 9 - Bracket Cradle
5 - Bolt
Fig. 2 - Accumulator Mounting
TESTING Testing Charging Valve For Leakage

WARNINGS
To prevent personal injury and property 1. Remove cover plate from bottom of battery box.
damage, be sure wheel blocks are properly 2. Remove cap (18) from charging valve (1) and loosen
secured and of adequate capacity to do the job locknut (20). Coat open end of charging valve (1) with
safely. soapy water. Bubbles indicate leaky valve core (19).
3. Attempt to reseat the valve core by depressing and

Accumulators are charged with Nitrogen. releasing it quickly once or twice. Recheck for leakage.
The service pressure in the primary If leakage continues, discharge the accumulator as
accumulator is 103 bar (1494 lbf/in²) and in the described under 'Discharging Nitrogen' in this section.
Front and Rear Brake accumulators is 55 bar
(798 lbf/in²) at 20° C (68o F). To prevent personal 4. Replace valve core (19). Tighten locknut (20) to
injury and property damage do not attempt to 11 Nm (100 lbf in) and replace valve cap (18) finger
remove any valves or fittings until all nitrogen tight.
pressure is completely relieved.
Testing Precharge Pressure
Hydraulic fluid pressure will remain Numbers in parentheses refer to Fig. 3, unless
within the system after engine shut down. otherwise specified.
Operate the treadle pedal continuously until the
pressure has dissipated before carrying out any Note: The nitrogen pressure in an accumulator is
work on the braking system or serious injury directly affected by changes in nitrogen temperature.
could result. The cylinder pressure will increase or decrease
proportionally with temperature changes. An
accumulator pressure reading can vary about 4.3 bar
2 SM 2620 01-10
Section 250-0060
SM - 1273 5. Turn 'T' handle clockwise until charging valve core is

5 depressed. Be sure bleeder valve (10) is tight and does
6
not leak, and valves (4 & 6) are closed.
4 8 9
1
WARNING
Precharge values are different for the Primary
accumulator and front & rear brake
7 accumulators. Ensure pressures are correct to
10 the required value for each type!
2 6. To read accumulator precharge pressure, slowly

open cylinder valve (4). Pressure gauge (5) will register
precharge pressure, it should be 55 bar (798 lbf/in²) for
the front and rear accumulators; 103 bar (1494 lbf/in²)
for the Primary accumulator, all measured at 20° C (68°
3
F) ambient temperature. Refer to the table at the end of
this section for nitrogen pressures at ambient
temperatures of other than 20° C (68° F).
1 - Line 6 - Tank Valve
2 - Valve Chuck 7 - Gland Fitting 7. Close cylinder valve (4) and open bleeder valve (10)
3 - Valve Extension 8 - Gland Nut to dissipate gauge pressure. Close bleeder valve (10)
4 - Cylinder Valve 9 - Cylinder Adaptor after pressure is relieved. If the accumulator needs
5 - Pressure Gauge 10 - Bleeder Valve charged, leave line (1) and valve chuck (2) attached to
Fig. 3 - Charging Assembly Kit charging valve (1 , Fig. 1)). Charge the accumulator as
described under 'Charging The Accumulator'.
(62 lbf/in²) with 22° C (72° F) temperature change. Such 8. If precharge pressure is correct, rotate 'T' handle
temperature changes could easily occur between noon anticlockwise until it stops. Tighten locknut (20, Fig. 1)
and midnight of the same day. Refer to the table at the on charging valve (1, Fig. 1) to 11 Nm (100 lbf in).
end of this section for nitrogen pressures at ambient Loosen the swivel nut and remove gauging head.
temperatures of other than 20° C (68° F).
9. Install cap (18, Fig. 1) on charging valve (1, Fig. 1)
To test accumulator precharge pressure or to charge and tighten finger tight.
the accumulator, a charging assembly kit can be used.
Refer to Fig. 3. 10. Remove wheel blocks and place the battery master
switch in the 'On' position.
wheel in both directions several times to relieve any CHARGING THE ACCUMULATORS
2. Operate the treadle valve continuously to relieve WARNING

pressure in the braking system. Block all road wheels Precharge values are different for the Primary
and place battery master switch in the 'Off' position. accumulator and front & rear brake
accumulators. Ensure pressures are correct to
3. Check accumulator mountings to be sure the the required value for each type!
accumulator is held tightly in position.
4. Remove cap (18, Fig. 1) from accumulator charging otherwise specified.
valve (1, Fig. 1). Attach charging line (1) to charging
valve by rotating 'T' handle of valve chuck (2) Note: Either oil or water pumped nitrogen can be used
anticlockwise until it stops then screw the swivel nut to charge the accumulator. Both types are readily
down on the valve. Loosen locknut (20, Fig. 1) by available from a local compressed gas dealer.
turning anticlockwise one to two turns.
SM 2620 01-10 3
Section 250-0060
soapy water. Reinstall valve cap (18, Fig. 1) and tighten

WARNINGS finger tight.
Do not use Oxygen or any gas other than
Nitrogen to charge an accumulator. Oxygen DISCHARGING NITROGEN
under pressure coming into contact with oil or
grease will cause a violent explosion. Always Numbers in parentheses refer to Fig. 1.
double check to make sure you are using
Nitrogen to prevent personal injury and Make sure charging valve (1) is closed internally by
property damage. turning locknut (20) clockwise. Remove cap (18) and
core (19) from charging valve (1). Slowly turn locknut
A high pressure nitrogen pressure (20) anticlockwise to open charging valve (1).
regulator must be used with the charging
assembly kit. Failure to use pressure regulator Do not remove charging valve (1) until all the gas has
could cause property damage, personal injury been completely evacuated.
or death.
1. Attach line (1) and the swivel nut to charging valve (1, WARNING
Fig. 1) as described in steps 1 through 4 under the Do not try to discharge the accumulator by
heading 'Testing Precharge Pressure'. Be sure valves depressing charging valve core (25).
(4 & 6) are closed.
REMOVAL
2. Attach gauging head to nitrogen bottle by screwing
down on gland nut (8).
WARNINGS
3. Open tank valve (6) slowly; pressure shown on To prevent personal injury and property
pressure gauge (5) is tank pressure. damage, be sure wheel blocks, blocking
4. Open cylinder valve (4) slowly and charge materials and lifting equipment are properly
accumulator to the desired value, depending on which secured and of adequate capacity to do the job
accumulator is being chearged. i.e. the Primary safely.
accumulator 103 bar (1 494 lbf/in2) or the front and rear
brake accumulators 55 bar (798 lbf/in2) at 20° C (68° F)
ambient temperature, closing valve occasionally. Refer Accumulators are charged with Nitrogen.
to the table at the end of this section for nitrogen The service pressure in the primary
pressures at ambient temperatures of other than 20° C accumulator is 103 bar (1494 lbf/in²) and in the
(68° F). Front and Rear Brake accumulators is 55 bar
(798 lbf/in²) at 20° C (68o F). To prevent personal
5. To check accumulator charge, close tank valve (6), injury and property damage do not attempt to
relieve pressure between tank and pressure gauge (5) remove any valves or fittings until all nitrogen
by opening bleeder valve (10) momentarily. This will pressure is completely relieved.
allow gauge needle to settle, thus giving correct
pressure reading of accumulator charge. Numbers in parentheses refer to Fig. 2. unless
otherwise stated.
6. When the correct pressure for the ambient
temperature has been reached, close valves (4 & 6) 1. Position the vehicle in a level work area, apply the
tightly. Bleed pressure off pressure gauge (5) by parking brake, switch off the engine and turn steering
opening bleeder valve (10). Close bleeder valve when wheel in both directions several times to relieve any
all pressure is bled off from the gauge and unscrew pressure in the steering circuit.
gland nut (8) from the nitrogen bottle.
7. Rotate 'T' handle of valve chuck (2) anticlockwise pressure in the braking system. Block all road wheels
until it stops, tighten locknut (20, Fig. 1) to 11 Nm (100 and place battery master switch in the 'Off' position.
lbf in), loosen the swivel nut and remove gauging head.
8. Check charging valve (1, Fig. 1) for leakage using 3. Remove accumulator guard (2) a nd partition plate
(4) if necessary to gain adequate access to remove the
4 SM 2620 01-10
Section 250-0060
accumulators; by removal of bolts and washers (5 & 3) INSPECTION

4. Discharge nitrogen from the accumulators as
described under 'Discharging Nitrogen'.
1. Wash metal components with a suitable solvent and
5. Disconnect hydraulic lines from bottom of
thoroughly air dry.
accumulators and plug accumulators to prevent oil
spillage. Cap open lines and fittings to prevent entry of
2. Inspect piston (6) for cracks or burrs. Replace piston
dirt.
(9) if excessively scored or worn.
3. Use an inspection lamp to check the bore of
6. Support accumulators with an adequate sling and
accumulator cylinder (8) for scratches or scoring.
lifting device. Remove bolts (13, Fig.1 ), u-bolts (1),
Minor nicks, scratches or light scoring of the bore can be
locknuts (6), lockwashers (7) and washers (8) securing
removed by using crocus cloth. Dress the bore until all
accumulators to the bracket (9). Remove accumulators
apparent imperfections have been removed. Replace
and drain oil from top section into a suitable container.
complete accumulator assembly if the inside of cylinder
(8) is excessively scored or worn.
7. Remove accumulators to a clean area for
disassembly.
4. Inspect threads in end cap (11) and threads in
cylinder (5) for damage. Replace all parts worn or
DISASSEMBLY damaged beyond repair.
ASSEMBLY
WARNING
Accumulators are charged with Nitrogen.
1. Lubricate ‘O’ ring (10), Backup rings (9), Seal rings
The service pressure in the primary (8) and inside of cylinder body (5) with hydraulic oil
accumulator is 103 bar (1494 lbf/in²) and in the prior to assembly.
Front and Rear Brake accumulators is 55 bar
(798 lbf/in²) at 20° C (68o F). To prevent personal 2. Install 'O'- ring (10) and Backup ring (9) on the End
injury and property damage do not attempt to cap (11).
remove any valves or fittings until all nitrogen
pressure is completely relieved. 3. Install End cap (11) on cylinder body (5).
1. Make sure all nitrogen gas has been released before 4. Install new Seal ring (8) and 'O'-Ring (10) on grooves
starting to disassemble the accumulator. Refer to of Piston (6).
section on 'Discharging Nitrogen'.
5. Insert Piston (6) into bore of Cylinder body (5) with
2. Remove charging valve assembly (1) from end cap the cupped end facing the open end of the cylinder
(11). body (5). Taking care not to damage any components
on the threadfs of the Cylinder body (5) on insertion.
3. With accumulator lying horizontal, hold accumulator Use a hammer and wood block to carefully tap the
cylinder (5) with a strap wrench. Piston (6) into place until the Piston (6) is 50.8mm (2.0
in) below the beginning of the honed bore. Keep
4. Install pins in three equally spaced holes in end cap pressure against the Piston (6) while tapping into place
(11), then use a long bar working against the pins to to ensure the Piston (6) does not resist movement and
remove end cap from cylinder (5). Remove and discard force its way back.
Backup ring (4) and 'O' ring (3).
6. Install 'O'-ring (3) and Backup ring (4) onto the
5. Grip cast web of piston (6) with pliers and, while Cylinder cap (2) and install the Cylinder cap into the
rotating, pull piston from cylinder (5). Remove and bore of the Cylinder body (5). Tighten the Cap so that it
discard Seal rings (8). is flush with the end of the Cylinder body (5), within 1.6-
2.4mm (0.062 - 0.094in) above or below.
SM 2620 01-10 5
Section 250-0060
lockwashers (7) and locknuts (6).
7. Install the Chargin valve assembly (1). Torque tighten
Locnut (20) clockwise to 11Nm (100 Ibf in) to close the 3. Remove caps installed at removal and install
Charging valve (1). Insert Valve core (19) and torque to hydraulic lines securely to the oil inlet ports at the
0.5 Nm ( 5 Ibf in), replace Valve cap (18) and tighten bottom of the accumulators.
hand tight.
4. Charge the accumulator with Nitrogen gas as
described under 'Charging the Accumulator' in this
INSTALLATION section.
specified to torques listed in Section 300-0080, 5. If removed install partition plate (4) with washers (3 )
STANDARD BOLT AND NUT TORQUE and bolts (5).
SPECIFICATIONS.
6. Install accumulator guard (2) securely with bolts (5)
Note: Tighten all hydraulic lines fitted with ORFS and washers (3).
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings 7. Check oil level in hydraulic tank and add oil as
where used. required. Refer to Section 230-0040, HYDRAULIC
TANK, for correct fill level and Section 300-0020,
LUBRICATION SYSTEM, for oil specification.
WARNING
To prevent personal injury and property 7. Place the battery master switch in the 'On' position,
damage, be sure lifting equipment is properly start the engine and check for leaks. Tighten lines and
secured and of adequate capacity to do the job fittings as required. Remove wheel blocks.
safely.
MAINTENANCE
Numbers in parentheses refer to Fig. 2. unless Inspect accumulator assembly for leaks. If leaks are
otherwise stated. found, disassemble and replace all 'O' rings and seals.
Inspect hydraulic lines for wear and leaks. Replace/
1. Position accumulators onto their respective tighten lines as required.
mounting brackets (12, Fig. 1) and secure in place
using bolts (19).
SPECIAL TOOLS
2. Attach u-bolts (1) securely with washers (8), Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the charging assembly kit and other
general service tools required. These tools are
6 SM 2620 01-10
Section 250-0060

TORQUE
FIG. NO. ITEM NO. Nm Ibf in
1 26 11 100
AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE

AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE
o o
C F bar lbf/in2
-20 -4 81.9 1188
-10 14 85.6 1241
0 32 88.8 1288
10 50 91.3 1324
20 68 95 1380
30 86 97.9 1420
40 104 101 1465
50 122 104.4 1514
60 140 107.9 1565
70 158 111.8 1621
80 176 114.5 1661
90 194 117.3 1701
100 212 120.2 1743
110 230 123.4 1789
120 248 126.6 1836
WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the vehicle or cylinders by any method while
cylinders are charged. For shipment, contact the appropriate agency in the country involved. Consult
your dealer for further permit information.
* * * *
SM 2620 01-10 7
Section 250-0060
8 SM 2620 01-10
Braking System - Treadle Valve
Section 250-0070
SM - 3517
50 39
13
49 14
48
46 29
47 38 28 16
27 15 10
45
44 12
37
26 11 12
42 43 36
35 25
24 51,52
34 22 9
33 23 12
41 11
32 20
12 8
40
31 22 19
9 12
6
20 21 5
30 7 4
3
19
18
2
17 12
1
1 - Pedal 14 - Bolt 27 - O-ring 40 - Spool

2 - Pin 15 - Clevis 28 - Back Up Ring 41 - O-ring
3 - Push Rod 16 - Cam 29 - Piston 42 - Plug
4 - Boot 17 - Boot 30 - Spring 43 - O-ring
5 - Spring 18 - Push Rod 31 - Spring 44 - Valve Housing
6 - Retainer 19 - Cap Screw 32 - Spring 45 - Washer
7 - Cap Scew 20 - Washer 33 - Shim 46 - Cap Screw
8 - Washer 21 - Spring 34 - Retainer 47 - Spool
9 - Pin 22 - Cap Screw 35 - Cup 48 - Spring
10 - Base 23 - Pilot Housing 36 - Seal 49 - O-ring
11 - Pin 24 - Back Up Ring 37 - O-ring 50 - End Plug
12 - 'e'-ring 25 - O-ring 38 - Valve Housing 51 - Cap Screw
13 - Spring Washer 26 - Piston 39 - O-ring 52 - Nut
Fig. 1 - Exploded View of Treadle Valve Assembly
DESCRIPTION brake solenoid valve within the main hydraulic valve.

Numbers in parentheses refer to Figure 1. Refer to Section 215-0050, Main Hydraulic Valve
Assembly.
Note: The treadle valve can be identified as item E in
Section 250-0000, Braking System Schematic. In the normal position, brake pedal assembly is in the
up position. In this condition, the regulated pressure
The tandem circuit modulating treadle valve is a closed outlet ports of the valve (A1 and A2) are directly linked
centre controller which controls the level of hydraulic oil to the hydraulic tank ports (T1 and T2). While the pedal
pressure applied to the front and rear brakes and the is in this position the brakes are released.
maximum pressure available to these circuits. It is
operated by a foot pedal in the operator's cab, and with
the engine running, is automatically applied by the park
SM 2621 Rev1 01-10 1

Section 250-0070
SM2875 SM2876
9
9
PP
PP
SUPPLY
SUPPLY FROM FROM
FROM FRONT P1
TO FRONT P1 A1 MAIN HYDRAULIC
A1 MAIN HYDRAULIC BRAKES
BRAKES VALVE, PORT ACC1
VALVE, PORT ACC1 T1
T1
SUPPLY
SUPPLY FROM MIDDLE
TO MIDDLE FROM
FROM AND REAR P2
AND REAR P2 A2 MAIN HYDRAULIC
A2 MAIN HYDRAULIC BRAKES
BRAKES VALVE, PORT ACC2
VALVE, PORT ACC2 T2
T2
Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release
OPERATION Normal Service Brake Release

Numbers in parentheses refer to Figure 1. Refer to Figure 3. When the operator releases the
pedal (1) assembly, the spools (40 and 47) will become
Normal Service Brake Application unbalanced and move downwards, opening outlet ports
Refer to Figure 2. When the operator depresses pedal (A1 and A2) to tank. At this point, oil in the A1 and A2
assembly, push rod (18) is moved up and pushes on lines is released to tank through the tank ports (T1 and
pistons (26 and 29) which in turn, pushes spools (40 T2), in turn releasing the brakes.
and 47) up. As spools (40 and 47) move up, the
metering notches move out of the tank cavity and Emergency Stop Brake Application/
close the outlet ports (A1 and A2) off from the tank
ports (T1 and T2). The spools (40 and 47) continue to
Release
move upwards until the metering notches become Refer to Figure 4. Pushing in the park/emergency
exposed to the inlet pressure ports. This movement control results in the de-energization of the park brake
opens the inlet ports (P1 and P2) to the outlet ports solenoid valve within the main hydraulic valve. This
(A1 and A2) respectively. As hydraulic pressure builds allows full pressure to enter the PP port in the treadle
in the brakes, oil flows through the small orifices in the valve, simulating a full and immediate depression of
spools (40 and 47), and into the cavities above the pedal (1) assembly, therefore pushing spools (40 and
spools. As pressure rises in the brakes, it will thus 47) upwards and thereby applying maximum braking
also rise in the cavities above the treadle valve spools action.
(40 and 47), forcing them downwards and thus closing
the outlet ports (A1 and A2). The spools (40 and 47) Refer to Figure 5. Pulling out the park/emergency
are now balanced between the brake pressure and the control will energize the park brake solenoid valve
pressure of springs (30, 31 and 32) generated by the within the main hydraulic valve, allowing the pressure
operator's force on the pedal (1) assembly. Spools (40 in the PP line to fall via the return to tank port opened
and 47) have closed off the inlet ports, outlet ports and within the park brake solenoid valve. Outlet ports A1
the tank ports and will remain in this position as long and A2 are opened to tank ports T1 and T2 allowing oil
as the pedal (1) assembly is not moved. If the in the A1 and A2 lines to return to tank, releasing the
operator further depresses the pedal (1) assembly, brakes.
spools (40 and 47) will move up and build more
pressure in the brake until it balances the pedal force.
2 SM 2621 Rev1 01-10

Section 250-0070
SM2877 SM2878
9 9
SUPPLY
PP FROM PP TO TANK VIA
MAIN HYDRAULIC MAIN HYDRAULIC
VALVE, PORT PBP VALVE, PORT PBP
SUPPLY FROM SUPPLY

TO FRONT P1 FRONT P1
A1 FROM A1 FROM
BRAKES MAIN HYDRAULIC BRAKES MAIN HYDRAULIC
T1 VALVE, PORT ACC1 T1 VALVE, PORT ACC1
SUPPLY SUPPLY
TO MIDDLE FROM MIDDLE
FROM FROM
AND REAR A2 P2 AND REAR A2 P2
MAIN HYDRAULIC MAIN HYDRAULIC
BRAKES BRAKES
VALVE, PORT ACC2 VALVE, PORT ACC2
T2 T2
Fig. 4 - Park/Emergency Brake Application Fig. 5 - Park/Emergency Brake Release
REBUILD CRITERIA REMOVAL

Inspect the valve regularly for any signs of leakage or
damage and replace components if necessary.
WARNINGS
The treadle valve should be rebuilt if one or more of the To prevent personal injury and property
following conditions exist: damage, be sure wheel blocks are properly
secured and of adequate capacity to perform
1. Any sign of external leakage. the task safely.
Note: Check all hydraulic lines and fittings to identify Hydraulic oil pressure will remain
whether or not leakage is occurring at any of these within the system after engine shut down.
locations. Operate the treadle pedal continuously until the
2. Failure of the pedal to return to full upright position. work on the braking system or serious injury
could result.
3. Treadle valve holds pressure when in the neutral
position. 1. Position the vehicle in a level work area, apply the
4. Varying output pressure with the pedal fully wheel in both directions several times to relieve any
depressed. pressure in the steering circuit.
5. Output pressure does not remain constant between 2. Operate the treadle valve continuously to relieve
circuits. pressure in the braking system. Block all road wheels
and place battery master switch in the 'Off' position.
3. Pull on the handle to release the hood catch and lift

up the hood.
SM 2621 Rev1 01-10 3

Section 250-0070
SM - 3518
50
49
48 A
P2
P
P2 T
A2 T2
44
P
P1
T2
T T1
47 A1
A
41 39
P1
Px
40 Px
T1
34
33
30
38
36 37
35
32
46
29
31
28
27
21 23
26
25
24
18 17
P1 - Pressure from main hydraulic valve, port ACC1 T1 - Tank return, front brakes
P2 - Pressure from main hydraulic valve, port ACC2 T2 - Tank return, middle and rear brakes
A1 - Pressure to front brakes Px - Emergency Stop pressure (PP)
A2 - Pressure to middle and rear brakes
Fig. 6 - Treadle Valve Porting/ External View Detail

WARNING at the bottom of the hydraulic tank. Install a length of
If this vehicle is fitted with a pressurized hose on remote drain fitting, open drain cock and drain
hydraulic tank, the hydraulic tank remains the hydraulic oil into a suitable container. Close the
pressurized for 1-2 hours after the engine is drain cock, remove the hose and reinstall the blanking
stopped. Before carrying out any maintenance cap.
work on the tank, relieve the tank pressure by
opening the miniature ball valve (refer to 5. If necessary remove the engine air intake tube to
Section 250-0026, Brake Coolant/Hydraulic Tank gain access to the treadle valve on the front of the cab.
[with Pressurization]). Close this valve after the Alternatively, tilt the cab to gain access. Refer to
pressure has been relieved. Section 260-0010, Cab and Mounting.
4 SM 2621 Rev1 01-10

Section 250-0070
6. Clean the treadle valve assembly and surrounding The piston must be removed through the bottom end of
area with a suitable solvent. Ensure that all hydraulic the housing.
lines connected to the treadle valve are identified for
ease of re-installation and, with suitable containers Note: Be careful not to scratch or otherwise damage
available to catch leakage, disconnect the hydraulic the housing bore. A wooden dowel can be used to help
lines. Fit blanking caps to all open lines and treadle wuth this procedure.
valve ports.
7. Remove the O-rings (25 and 27) and back up rings
7. Disconnect the electrical connection from the brake (24 and 28) from the piston (26), being careful not to
pedal potentiometer. damage the O-ring and back up ring grooves.
8. Separate the pedal (1) from the base (10), by 8. Remove the piston (29), springs (30, 31 and 32) and
removing one 'e'-ring (12) from each pin (9 and11) and shim(s) (33) from the valve housing bore.
sliding the pin (11) from the clevis (15) and the pin (9)
from the base (10). Note: Take account of the number of shim(s) being
removed from housing.
9. Remove the boot (4) and the spring (5) from the
base (10). 9. Carefully remove the cup (35) and seal (36) from
valve housing half (44) bore.
10. Inspect the pin (2) and push rod (3), check that the
push rod is in good working order and moving freely. Note: Be careful not to scratch or otherwise damage
the housing bore.
11. Inspect the pins (9 and 11), the clevis (15) and the
cam (16) to check that the clevis (15) and cam (16) are 10. Remove the end plug (50) and the spring (48) from
in good working order and moving freely. the valve housing half (44). Remove the O-ring (49)
from the end plug (50).
12. Any further disassembly is unneccessary unless
there is damage to the assembly. 11. Remove the plug (42) from the valve housing half
(44). Remove the O-ring (43) from the plug (42).
13. Separate ther valve assembly from the base (10),
by removing the cap screws (7) and the washers (8). 12. Separate the housing halves (38 and 44) by
removing the cap screws (46) and washers (45).
Remove the O-rings (39 and 41) from the housing
DISASSEMBLY halves.
13. Carefully remove the spools (40 and 47) from
1. Remove the blanking caps from the treadle valve housing halves (38 and 44).
ports and drain all oil from the valve body ports, by
rotating the valve over a suitable container. Note: Be careful not to damage the spools or the
housing bores.
2. Remove the treadle valve from the mounting plate
and secure the valve assembly upright in a table vice.
WARNING
3. Remove the circlips to allow the cam assembly to Do not intermix spools and housings. Spools
be disassembled. and housings are matched sets.
4. Remove the boot (17) from the push rod (18), then
remove the push rod (18) and the spring (21) from the ASSEMBLY
pilot housing (23) bore. Numbers in parentheses refer to Figure 1.
5. Separate the pilot housing (23) and the valve Lubricate all new rubber components with clean
housing half (44) by removing the screws (37). Remove hydraulic oil used in the braking system. Refer to
the O-ring (37) from the valve housing (38). Section 300-0020, Lubrication System.
6. Remove the piston (26) from the pilot housing (23). 1. Clean all parts thoroughly before assembly.
SM 2621 Rev1 01-10 5

Section 250-0070
2. Install new O-rings (39 and 41) in their respective bore of the bottom end. Be sure to install piston as far
pockets on the housings (38 and 44). as it will go into pilot housing bore.
3. Lubricate the spool (40) with hydraulic oil used in the 12. Install new 'O'-Ring (37) on valve housing half (38).
braking system. Carefully slide it into the bottom end of
the valve housing half (38) bore. Ensure the correct 13. Carefully attach pilot housing (23) to valve housing
orientation of the spool. half (38) using cap screws (22). Torque cap screws to
a value of 27.1 - 33.9 Nm (20 -25 Ibf ft).
Note: The spool must slide easily into the bore. If
either part is damaged, a new spool/housing assembly 14. Install spring (21) and push rod (18) into pilot
may be required. housing (23) bore.
4. Re-assemble the valve housing halves (38 and 44) 15. Install new boot (17) on push rod (18) and over pilot
using ther cap screws (46) and the washers (45). Use housing (23).
Loctite 242™ (thread locking agent) on the cap screws
and torque them equally to a value of 29.8 - 33.9 Nm 16. When reinstalling pdeal actuated valve, use hex
(22 - 25 Ibf ft). cap screws (7). Torque cap screws to a value of 24.4 -
29.8 Nm (18 - 22 Ibf ft).
Note: Ensure that the valve housing halves (38 and 44)
line up correctly, and that the O-rings (39 and 41)
remain in their pockets during assembly. INSTALLATION
5. Install a new O-ring (49) on the plug (50) and install a
new spring (48) and the end plug (50) with O-ring in the Note: Tighten all fasteners to standard torques listed in
valve housing half (44). Tighten the plug securely to a Section 300-0080, Standard Bolt and Nut Torque
torque of 47.5 - 54.2 Nm (35-40 Ibf ft). Specifications.
6. Lubricate the spool (47) with hydraulic oil used in the Note: Tighten all hydraulic lines fitted with ORFS
braking system. Carefully slide the spool (47) into the connections, as described in Section 250-0000,
valve housing half (44) bore. Ensure the correct Braking System Schematic. Renew all O-rings where
orientation of the spool (47). used.
Note: Spool must slide easily into the bore. If either 1. Secure treadle valve and mounting plate assembly
part is damaged, a new spool/housing assembly may to front of cab using four bolts removed previously.
be required.
2. Connect electrical connection to the brake pedal
7. Carefully install new seal (36) and new cup (35) into potentiometer.
the valve housing half (38) bore.
3. Remove blanking caps and connect hydraulic lines
Note: Check the direction and order of the cup (35) and to the treadle valve assembly as noted at 'Removal'.
the seal (36). Be careful not to scratch or otherwise
damage the bore. 4. If previously removed install engine air intake tube,
or if applicable, lower the cab. Refer to Section 260-
8. Assemble the springs (30, 31 and 32), shim(s) (33) 0010, Cab and Mounting.
and retainer (34) in the piston (29).
5. Fill hydraulic tank with oil specified in Section
9. Carefully install the piston (29) assembly into the 300-0020, Lubrication System.
valve housing half (38) bore.
10. Install new O-rings (25 and 27) and new back-up start the engine and bring hydraulic oil to operating
rings (24 & 28) on piston (26). temperature.
Note: Ensure that O-rings and back-up rings are 7. Apply the brakes and check for oil leaks. Tighten
assembled in the correct order. line connections and fittings as necessary.
11. Install piston (26) into pilot housing (23) through the
6 SM 2621 Rev1 01-10

Section 250-0070
Note: When performing Step 8, make sure that parking 1. Position the vehicle in a level work area, apply the
brake applies and releases appropriately. parking brake, switch off the engine and turn the
8. Check the brake operations by actuating the pedal relieve any pressure in the steering circuit.
and the park/emergency control. Ensure that the pedal
assembly is free to operate. 2. Operate the treadle valve continuously to relieve
pressure in the braking system. Block all road wheels,
9. Shut off the engine and check the hydraulic tank oil place the steering lock bar in the 'Locked' position and
level. Replenish as necessary. the battery master switch in the 'Off' position.

CHECKING SYSTEM PRESSURES pressure of 0 - 345 bar (0 - 5000 lb/in²), to the front
brake diagnostic pressure point (22, Fig. 7) located on
the left hand fender directly outside the cab door.
WARNINGS
To prevent personal injury and property 4. Place the battery master switch in the 'On' position,
damage, be sure wheel blocks and blocking start the engine and apply park/emergency brake (push
materials are properly secured and of adequate button in), to apply service brakes. Monitor system
capacity to perform the task safely. pressure gauge. Brake actuating pressure for the front
brake circuit is specific to particular Serial Numbers,
Hydraulic fluid pressure will remain detailed below.
Truck Serial No. Pressure Tolerance
Operate the brake treadle pedal continuously
A8651010 to 48 bar +
/- 2.4 bar
A8651237 (700 lbf/in²) (+/- 35 lbf/in²)
carrying out any work on the system or serious
A9171011 to
injury could result.
A9171027
From:
SM4002
A8651238 58 bar +2 bar, -5 bar
A9171028 (841 lbf/in²) (+28 lbf/in², -
A9461011 72.5 lbf/in²)
Note: When the brakes are released, a residual

13 19
pressure of 0.3 bar (5 lb/in²) will remain.
1 7
14 20
2 8 5. Repeat steps 1 through 4 at the rear brake

15 21
diagnostic pressure point (23, Fig. 7) located outside
3 9
16 22 the cab door. The rear brake pressure is typically 3 bar
4 10
17 23
(45 lb/in2) lower than the front brake pressure quoted
5 11
above, and also specific to particular Serial
18
Numbers,detailed below.
6 12
Truck Serial No. Pressure Tolerance

A8651010 to 45 bar +
/- 2.4 bar
1 - Diff-lock Pressure 'TP1' 13 - Parking Brake Pressure A8651237
2 - DropBox Lube Pressure 14 - Main Pump (Front) (653 lbf/in²) (+/- 35 lbf/in²)
'TP3' 15 - Main Pump (Rear)
A9171011 to
3 - DropBox High Select 'TP2' 16 - Front Pump LoadSense A9171027
4 - DropBox Low Select 'TP2' Pressure From:
5 - Cross Axle Diff.Lock 17 - Rear Pump LoadSense A8651238
6 - CT21 Pressure 55 bar +2 bar, -5 bar
7 - Body Hoist Raise 18 - Steering Pressure A9171028 (798 lbf/in²) (+28 lbf/in², -
8 - Body Hoist Lower 19 - Front Brake Accumulator A9461011 72.5 lbf/in²)
12 - Rear Axle Disconnect 23 - Rear Brakes
Fig. 7 - Diagnostic Pressure Check Points Left Hand Fender
SM 2621 Rev1 01-10 7

Section 250-0070
Note: Actuating pressure for the front and rear brake Every 1 000 Hours
circuits is 48 bar/45 bar or 58 bar/55 bar respectively
Check front and rear brake pressures at remote
(as detailed above, subject to the tolerances stated).
diagnostic test points. If the pressures are not within
However, the system pressure is 240 bar (3 480 lbf/in²)
the specified pressure ranges, refer to the
and can be checked at the steering diagnostic pressure
Troubleshooting table for the treadle valve and to
point (18, Fig. 7) located on the left hand fender directly
Section 250-0000, Braking System Schematic.
outside the cab door . System pressure is checked
against steering pressure as this is the highest SPECIAL TOOLS
pressure requirement in the hydraulic circuit. Refer to
There are no special tools required for the procedures
Section 230-0050, Main Hydraulic Pump.
6. If the pressures to the brake circuits have been
determined as high or low, refer to the Troubleshooting
table for the treadle valve and to Section 250-0000,
Braking System Schematic.
MAINTENANCE
General
Check all hydraulic brake lines and fittings at treadle
valve for leaks and damage. Tighten/replace as
required.
TREADLE VALVE TROUBLESHOOTING

Brakes slow to apply No or improper accumulator Check accumulator pre-charge pressure.

pre-charge pressure Refer to Section 250-0060,
Accumulator
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
Brake Parts
Inoperative brakes Check brakes. Refer to Section 165-0010,
Brake Parts
Hydraulic lines/fittings leaking Check for leaks and repair
Damaged hydraulic brake lines Check lines for restrictions
Air in system Bleed air from system. Refer to Section
165-0010, Brake Parts
Brakes will not release Pedal angle out of adjustment Check for proper pedal angle
Brake Parts
Inoperative treadle valve. Replace treadle valve
Binding spools (40 and 47),
pistons (26 and 29) binding
8 SM 2621 Rev1 01-10

Section 250-0070

Insufficient brakes Low hydraulic oil level Top up hydraulic oil

Brake Parts
Oil or grease on brake pads Clean or replace brake pads. Refer to
Section 165-0010, Brake Parts
Hydraulic lines damaged Check hydraulic lines
No or improper accumulator Check accumulator pre-charge pressure.
Accumulator
Brake Parts
Broken spring (31). Boot (17)
cut, allowing dirt under piston
(29) flange.
Excessive braking Inoperative brakes Check brakes. Refer to Section 165-0010,

Brake Parts
Excessive shims (33) fitted
Brakes will not release Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
completely Brake Parts
Brake Parts
Pedal angle out of adjustment Check for proper pedal angle
Air in system Bleed air from system. Refer to Section
165-0010, Brake Parts
Piston (29) sticking, spring
(32) broken
Back pressure on return line Remove restriction
excessive
SM 2621 Rev1 01-10 9

Section 250-0070

No brakes No oil in hydraulic system Add oil to tank
Broken/damaged hydraulic line Replace broken/damaged line
Brake Parts
No accumulator Check accumulator pre-charge pressure.
Accumulator
No pump pressure Check pump operation
Worn brakes Replace brake pads and discs
Piston (29) binding, broken
spring (32)
Pedal kickback when brakes Air in system Bleed air from system. Refer to Section
are applied 165-0010, Brake Parts

TORQUE
1 7 Cap Screw 24.4 - 29.8 18 - 22
1 22 Cap Screw 27.1 - 33.9 20 -25
1 46 Cap Screw 29.8 - 33.9 22 - 25
1 50 End Plug 47.5 - 54.2 35 - 40
* * * *
10 SM 2621 Rev1 01-10

Braking System - OCDB Relief Unloader Valve
Section 250-0075
SM - 3609
6 6
1
2
8
7
11 12
10 5
4 3 13 14
6 6
1 - Valve Body 5 - Spool 10 - O-ring

2 - Relief valve 6 - O-ring 11 - O-ring
3 - Flow regulator 7 - O-ring 12 - O-ring
4 - Solenoid Coil 8 - O-ring 13 - O-ring
9 - O-ring 14 - O-ring
Fig. 1 - OCDB Relief Unloader Valve Exploded View
DESCRIPTION SM - 3516
The OCDB relief unloader valve can be identified as TO MOTOR /

TRIPLE PUMP
item 2 in Section 210-0005, BRAKE COOLING
SYSTEM SCHEMATIC. Numbers in parentheses refer RETURN FROM
to Fig. 1. MOTOR /
TRIPLE PUMP
Located on the left hand side of the hydraulic tank, the

P1 T
relief unloader valve comprises of an aluminium valve
body (1) with relief valve (2), flow regulator (3) and
solenoid valve (5).
The OCDB relief unloader valve receives hydraulic (B)
supply pressure from the 'WB' port of the integrated

(A)
control valve Refer to Section 215-0050, MAIN
HYDRAULIC VALVE ASSEMBLY. This is then fed to
the inlet side of the motor part of the motor/ triple (C)
pump assembly and back to tank via a return line filter.

Refer to Section 250-0045 MOTOR / TRIPLE PUMP
ASSEMBLY. P T
FROM HYD RETURN

VALVE ASSY. TO TANK
OPERATION
Fig. 2 - Relief Unloader Valve Schematic
The OCDB relief unloader valve forms part of the brake
cooling circuit. Main hydraulic supply pressure is The relief unloader connects to the inlet side of the
delivered from the main hydraulic valve assembly, via motor unit and drives the motor, which in turn drives
the 'WB' port. the three individual pump elements which supply
cooling oil to the brake packs.
The relief valve (B) within the unloader valve assembly
limits the supply pressure to the motor section of the When there is limited OCDB cooling demands, the
motor/ triple pump assembly to 26 bar (377 Ibf/in ²). solenoid of valve A is energized and in this condition
SM 2622 01-10 1
Braking System - OCDB Relief Unloader Valve
Section 250-0075
DISASSEMBLY
It is not recommended that any of the cartridge
where used.
assemblies (2 & 3)are disassembled for maintenance
purposes. Ensure that valve assembly is cleaned off
1. Secure priority unloader valve to hydraulic cradle
prior to removal of any components and that no
with bolts and lockwashers.
contaminant is allowed to enter the internal galleries.
2. Remove blanking caps from hydraulic lines and
1. Note location and position of all hydraulic connectors
and adaptors prior to removing them from valve body install lines to the priority unloader valve as identified
(1). during removal.
3. Fill hydraulic oil tank with hydraulic oil as specified

2. Remove unloader relief valve. Check for wear,
in Section 300-0020, LUBRICATION SYSTEM. Refer
scoring or contamination.
to Section 230-0040, HYDRAULIC TANK, for hydraulic
oil levels. Install filler cap on hydraulic tank filler neck.
3. Remove relief valve (2). Check for wear, scoring or
contamination.
4. If necessary, remove solenoid valve assembly.
temperature.
Check for wear, scoring or contamination.
5. Check priority unloader valve and hydraulic line
5. If necessary, remove flow regulator (3). Check for
connections for leaks and tighten as required.
wear, scoring or contamination.
6. Remove all blocking from road wheels and place
6. Ensure all O-Rings are checked and replaced when
steering lock bar in the stowed position.
re-assembly is carried out. Check parts book for
relevant kit information.
FAULT DIAGNOSIS
ASSEMBLY Refer to following fault diagnosis chart. As stated
previously, it is not recommended that any of the
cartridge assemblies are disassembled for
maintenance purposes. Ensure that valve assembly is
1. Replace all 'O' Rings on hydraulic connectors and
cleaned off prior to removal of any components and
adaptors.
that no contaminant is allowed to enter the internal
galleries.
2. Replace all seals on unloader relief valve body (1),
relief valve (2), solenoid coil/spool (4 &5) and flow
If investigation shows that the cartridge assemblies
regulator (3) valve prior to assembly.
are in good clean condition and fit for use, the seals
should be replaced prior to re-assembly. Damage to
3. Install hydraulic connectors (15) and adaptors to
the cartridge assemblies or valve body would
correct ports and orientation. Torque each to 35Nm
necessitate a new priority unloader valve assembly.
(25.8 Ibf-ft)
4. Fit relief valve (2), flow regulator (3) and solenoid SPECIAL TOOLS
valve assembly to valve body (1) at correct ports.
INSTALLATION SERVICE TOOLS, for part numbers of general service
dealer.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
SM 2622 01-10 3
OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010
SM - 3960
13 11 11 12 20,21
42,43
44,45
12 19
14,18
20,21
15 3, 35
36, 37
17 16 13
CAB - 43 42
R.H.S. 23, 24
44,45 44,45 LH 25, 26 RH
31 RH- LH
32
HINGED 22
34
38 1 6
4
33
5 40
27
29 41
5 28
2 39 10
29 LH
39 39
39 9 7 8
30
RH 30
1 - Locating Pin 13 - Mirror - Wide Angle 25 - Mat (right rear) 34 - Washer

2 - Hinge Pin 14 - Ball 26 - Mat (under seat) 35 - Heat Shield
3 - Nut 15 - Washer 24 - Cab Pin 36 - Bolt
4 - Bushing 16 - Spring 25 - Bolt 37 - Washer
5 - Spring Pin 17 - Locknut 26 - Locknut 38 - Lockwasher
6 - Bolt 18 - Grease (EMS19014) 27 - Support Block 39 - Washer
7 - Cab Safety Prop 19 - Window Guard 28 - Isolation Mount 40 - Support Block
8 - Pin Assembly 20 - Bolt 29 - Bolt 41 - Isolation Mount
9 - Bolt 21 - Washer 30 - Locknut 42 - Bar Clamp
10 - Nut 22 - Storage Box 31 - Mud flap (cab RHS) 43 - Bar Mirror Mounting
11 - Mirror Arm 23 - Mat (front floor) 32 - Bolt 44 - Bolt
12 - Mirror - Exterior 24 - Mat (left rear) 33 - Bolt 45 - Lockwasher
Fig. 1 - Cab and Mounting
DESCRIPTION The cab assembly can be tilted to improve accessibilty

Numbers in parentheses refer to Fig. 1. to components below the cab, including transmission
and main hydraulic valve. A hydraulic hand pump
The cab is fully insulated and mounted on cab supports (1, Fig. 2), located under the hood on the left hand
(23) to damp structure-borne noise and vibration. It fender side of the tractor frame and a cab raise cylinder
conforms with ISO/SAE, ROPS (Roll Over Protective (7, Fig. 2) are used to raise the cab.
Structure) and FOPS (Falling Object Protective
Structure) requirements as standard.
WARNING
ROPS - ISO 3471, SAE J1040 APR 88 Never operate the machine while the cab is
FOPS - ISO 3449, SAE J231 tilted. Always ensure the cab is fully lowered
and properly secured before operating the
machine.
WARNING
The protection offered by the roll over and Cab assembly is spacious and offers outstanding
falling object protective structure may be visibility through large areas of tinted safety glass.
impaired if it has been subjected to any Access to cab assembly is from the left hand side with
modification or damage. open tread steps, platform and handrail.
SM 2623 01-10 1
Operators Compartment - Cab and Mounting
Section 260-0010
SM - 2882
11
9
8 CAB BRACKET
10 5
13
3 9 12
6
BRACKET IN 11
1 BATTERY BOX
FRAME BRACKET
12 13
16
2
15
14
1 - Hand Pump 6 - Lever 11 - Bolt

2 - Hydraulic Tank 7 - Cab Raise Cylinder 12 - Washer
3 - Elbow 8 - Hose Assy 13 - Nut
4 - Flow Control Valve 9 - Elbow 14 - Bolt
5 - Adaptor 10 - Clamp 15 - Washer
16 - Nut
Fig. 2 - Cab Tilt Mechanism
The cab interior, trimmed with noise-absorbent material,

is extensively thermally insulated and a heater/filter/ WARNINGS
pressurizer and demisting unit keeps internal air fresh To prevent personal injury and property
and dust free. Sliding windows provide additional damage, be sure wheel chocks, blocking
ventilation. Air conditioning is fitted as standard. Refer materials and lifting equipment are properly
to Section 260-0130, AIR CONDITIONING. secured and of adequate capacity to do the job
safely.
Note: Access from the cab, in the case of an emergency,
can be gained by breaking any of the windows using the Hydraulic fluid pressure will remain within
hammer provided (mounted on back pillar). the system after engine shutdown. Operate the
brake pedal continuously until the pressure has
REMOVAL dissipated before disconnecting any hoses.
Numbers in parentheses refer to Fig. 1. 1. Position the vehicle in a level work area, apply the
Note: Identify and tag all cables, harnesses, lines and
linkages disconnected from cab assembly during 2. Operate the brake pedal continuously to relieve
removal to aid in installation. pressure in the system.
3. Block all road wheels, place the battery master

switch in the 'Off' position and lift the hood assembly.
2 SM 2623 01-10
Section 260-0010
4. Disconnect the electrical cables in the following Disconnect earth strap at rear right hand cab support
order to prevent damage to the electrical components: (40).
a. Battery earth cable. 11. Lower cab safety prop (7) and place in the stowed
b. Battery supply cable. position, then using lifting equipment, slowly lower cab
c. Alternator earth cables. until horizontal.
d. Alternator supply cables.
e. Electrical harnesses at cab bulkhead. 12. Remove spring pins (5) to allow right hand pins (2)
to be driven out using a suitable driver.
WARNING 13. Check to make certain that all necessary

Before disconnecting any air conditioner lines, disconnections have been made, before lifting cab
refer to Section 260-0130, AIR CONDITIONING. assembly. Taking care to prevent damaging the
Refrigerant will rapidly freeze all objects with insulating material, lift cab assembly from the frame
which it comes into contact. It can cause and place on suitable stands.
serious and permanent damage to the eyes and
skin.
INSTALLATION
5. Evacuate the refrigerant from the air conditioning Numbers in parentheses refer to Fig. 1.
system and disconnect the lines. Refer to Section
260-0130, AIR CONDITIONING. Fit blanking caps to all Note: Tighten all fasteners without special torques
open lines and fittings. specified to standard torques listed in
6. Ensure heater lines are identified for ease of TORQUE SPECIFICATIONS.
installation and with suitable containers available to
catch leakage, disconnect heater lines. Fit blanking
caps to open line ends and fittings. WARNING
7. Remove the front right hand tyre and rim assembly damage, be sure blocking materials and lifting
for access. Refer to Section 160-0050, WHEEL RIM equipment are properly secured and of
AND TYRE. adequate capacity to do the job safely.
1. Inspect cab supports (27 & 40) for damage and

WARNINGS replace if necessary.
To prevent damage, always ensure hood is
raised before tilting or lowering the cab. 2. Attach suitable slings to the cab lifting points and
raise and position cab on frame.
Never work near or under an unblocked
or unsupported cab. Always use the cab safety 3. Secure cab assembly to right hand cab supports
prop. (23) with pins (2) and spring pins (5), as shown in
Fig. 1.
8. Tilt cab to allow access to steering valve below cab,
and secure with cab safety prop (7). Ensure lines are 4. Using lifting equipment, raise cab and secure cab
identified for ease of installation and with suitable raise cylinder (7, Fig. 2) to bracket on cab floor using
containers available to catch leakage, disconnect and bolt (11, Fig. 2), washer (12, Fig. 2) and nut
remove steering valve hoses. Fit blanking caps to open (13, Fig. 2). Secure cab in raised position with cab
line ends and fittings. safety prop (7).
9. Attach suitable slings to the cab lifting points and 5. Install and connect steering valve hoses as noted on
raise lifting equipment to take up the slack. Disconnect removal. Connect earth strap at rear right hand cab
cab raise cylinder (7, Fig. 2) from cab floor by removing support.
bolt (11, Fig. 2), washer (12, Fig. 2) and nut
(13, Fig. 2). 6. Connect and secure any other harnesses and hoses
that were previously removed.
10. Tag and disconnect any other harnesses and
hoses that may be affected by cab removal. 7. Place cab safety prop (7) in the stowed position.
SM 2623 01-10 3
Section 260-0010
Using hand pump (1, Fig. 2) to control lowering of cab, SM - 3572
gently lower cab until cab brackets align with cab
supports (40). Install pins (1) and secure with bushes
(4) and bolts (6).
8. Install front right hand tyre and rim assembly. Refer

to Section 160-0050, WHEEL RIM AND TYRE.
9. Secure the heater hoses to the front of the cab as

identified at removal.
10. Connect air conditioning lines and charge air 1

conditioning system. Refer to Section 260-0130, AIR
CONDITIONING.
3
11. Connect electrical harnesses at cab bulkhead as
identified at removal.
12. Connect cables to alternator (earth cable last).
13. Connect cables to battery terminal posts (earth

cable last). 2
start the engine and check for leaks. Tighten fittings if
necessary. Allow engine to warm up and recheck all
1 - Cab Safety Prop 3 - Cab Raise Cylinder
connections for leaks. Ensure electrical systems and 2 - Cab Support
gear shift are functioning properly.
Fig. 3 - Cab Secured In Raised Position
15. Ensure parking brake is applied and remove wheel
blocks from all road wheels. 4. Insert lever (6), located under the hood on the left
hand fender side of the tractor frame, into cab hand
pump (1).
TILTING THE CAB
Numbers in parentheses refer to Fig. 2, unless 5. Using hand pump (1), charge the cab raise cylinder
otherwise stated. (7) sufficiently to allow left hand pins (1, Fig. 1) to be
removed. Hold cylinder (7) in this position by locking
hand valve on hand pump (1).
WARNINGS
To prevent damage, always ensure hood is 6. Remove bolts and bushes (6 & 4 Fig. 1), then drive
raised before tilting or lowering the cab. out pins (1, Fig. 1). Carefully raise or lower the cab as
necessary to facilitate removal of pins (1, Fig. 1).
Never work near or under an unblocked
or unsupported cab. Always use the cab safety 7. Once pins (1, Fig. 1) have been safely removed,
prop. continue to raise the cab using hand pump (1) until the
cab safety prop (1, Fig. 3) can be fitted.
parking brake and switch off the engine. 8. Remove pin assembly (8, Fig. 1) to allow cab safety
prop (1, Fig. 3) to swing down to a vertical position on
2. Operate the brake pedal continuously to relieve top of the front left hand cab leg.
pressure in the hydraulic system.
9. Lock the cab safety prop (1, Fig. 3) in position using
3. Block all road wheels, place the battery master pin assembly (8, Fig. 1), locating through holes on
switch in the 'Off' position and lift the hood assembly. bracket at front left hand cab leg.
4 SM 2623 01-10
Section 260-0010
10. Lock off hand valve on hand pump (1). Remove lever (17), hardened washers (15) and springs (16) securing
(6) from pump (1) and place in the stowed position. mirror arm assembly to mounting brackets.
2. Remove mirror arm bracket (11) and ball bearings

LOWERING THE CAB (14) from mounting brackets.
otherwise stated. 3. Repeat steps 1 and 2 for other mirror arm bracket
(11).
WARNINGS
To prevent damage, always ensure hood is MIRROR ARMS
raised before tilting or lowering the cab.
Installation
Never work near or under an unblocked Numbers in parentheses refer to Fig. 1.
or unsupported cab. Always use the cab safety
prop. Note: Tighten all fasteners without special torques
specified to standard torques listed in
1. Remove pin assembly (8, Fig. 1) from bracket at Section 300-0080, STANDARD BOLT AND NUT
front left hand cab leg. Place cab safety prop (1, Fig. 3) TORQUE SPECIFICATIONS.
in stowed position by locating pin assembly (8, Fig. 1)
in bracket under cab.
WARNING
2. Slowly open hand valve on hand pump (1) to allow To prevent personal injury and property
cab to gently lower. Rate of descent is controlled by damage, be sure blocking materials and lifting
the hand valve on pump (1). equipment are properly secured and of
3. Lower cab until holes in cab brackets line up with
holes in cab supports (2, Fig. 3). Hold cylinder (7) in 1. Coat ball bearings (14) with grease (18) and locate in
this position by locking hand valve on hand pump (1). mounting brackets.
4. Install pins (1, Fig. 1) through cab brackets and cab 2. Locate mirror arm bracket (11) to mounting brackets
supports (2, Fig. 3). Secure pins in position with bush and install hardened washers (15), springs (16) and
(4, Fig. 1) and bolts (6, Fig. 1). locknuts (17) as shown in Fig. 1.
5. Lower the hood and place the battery master switch 3. Set mirror bracket spring (16) pressure as follows;
in the 'On' position before closing the battery box.
a. rotate mirror arm (11) until ball bearings (14) are
6. Ensure parking brake is applied and remove wheel out of their detent.
blocks from all road wheels. b. tighten locknut (17) until spring (16) is almost
completely compressed (typical two places).
c. swing arm until it seats in detent.
MIRROR ARMS d. check the other two detent positions
Removal 4. Repeat steps 1, 2 and 3 for other mirror arm bracket
Numbers in parentheses refer to Fig. 1. (11).
WARNING REPLACING GLASS

To prevent personal injury and property Note: When replacing broken glass, it is the user’s
damage, be sure blocking materials and lifting responsibility to ensure that the replacement glass
equipment are properly secured and of meets the required specifications. Replacement glass
adequate capacity to do the job safely. can be purchased from your dealer.
1. Support mirror arm bracket (11) and remove locknuts The rear glass, left and right hand side glasses and
front windscreen are held in place by a bonding
adhesive.
SM 2623 01-10 5
Section 260-0010
To replace a glass assembly, proceed as follows: 8. Ensuring the glass is adequately supported, allow
the sealing adhesive to set properly.
Note: Ensure the glass is supported adequately before
starting to cut the adhesive seal. 9. Clean off any excess adhesive using a suitable
solvent.
1. Using a pointed tool, pierce a hole in the adhesive
seal, it is advisable to start at the top edge of the
glass. Unscrew one handle of the special tool and feed Water Leaks
the wire through the opening. Pierce a second hole in Test for leaks by directing a stream of water along the
the adhesive on the side directly opposite the first. adhesive seal, while an assistant marks the spot of
leakage inside the cab. Care should be taken to note
2. From inside the cab pull the wire through and feed it whether the leak is between adhesive and glass. Then
back out through the second hole. apply a sealing compound from the outside. Start from
a point near the leak and continue applying the sealer
3. Re-fit the handle on the special tool. Pull both until well beyond the suspected point of entry.
handles outwards until wire is taut.
This should stop the leak immediately, but since some
4. Manoeuvre the special tool around the edge of the sealing compounds should be allowed to set before
glass, keeping the wire taut, to cut the adhesive seal. getting wet, wait a few minutes before testing.
Ensure the glass is supported adequately before
completing the cut.
MAINTENANCE
5. Clean the remains of the adhesive from the edge of
the panel opening using a suitable solvent.
General
Ensure that hand pump hydraulic tank (2, Fig. 2) is
6. Coat the edge of the replacement glass with primer filled with clean hydraulic oil as specified in Section
and apply adhesive around the lip of the window 300-0020, LUBRICATION SYSTEM. Capacity is 0.75
aperture, as per the manufacturers recommendations. litre (0.2 US gallon).
7. Position glass onto panel opening, pressing firmly

so that adhesive bonds sufficiently to allow the glass
SERVICE TOOLS
to be moved or straightened up as required. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the glass removal tool, adhesive bonding
kit and other general service tools required. These
tools are available from your dealer.
* * * *
6 SM 2623 01-10
OPERATORS COMPARTMENT - Driver Seat and Mounting
Section 260-0090
SM - 3961
36 31 50 36
32
4 1 36
5 47
27
44
51
6 46
15
28 33
8
54 34
48
53 41
11
12 7 52 43
17 26 45
13
9 10 35
41
18 19 55 40
14 49
16 23 29 42
22
25 2
NSS-PART OF ITEM 37
20
24
36
21 22
30
39
24
38 37,56
3 36
36
1 - Seat Assembly - Driver 20 - Resilient Sheet 39 - Bellows - Complete

2 - Backrest 21 - Bracket Kit 40 - Compressor - Complete
3 - Cushion 22 - Side Cover Kit 41 - Shock Absorber - Complete
4 - Head Rest 23 - Adjuster - Seat Depth 42 - Air Reservoir - Complete
5 - Bushing 24 - Adjustment - Rail Set 43 - DA. Adjuster - Complete
6 - Lumber Support 25 - Fixing Part - Rail Set 44 - DA. Handle - Complete
7 - Actuator - Front Lumber 26 - Cable 45 - HV. Handle - Complete
8 - Handle Kit - Lumber Support 27 - Seat Belt 46 - Adapter Cable - Complete
9 - Handle - Complete 28 - Arm Rest Assembly - RH 47 - Secondary Belt - Complete
10 - Actuator - Front/Back rest 29 - Arm Rest Assembly - LH 48 - Bowden Cable
11 - Backrest - Bearing Kit 30 - Cushion Set 49 - Inner Tube - Complete
12 - Stop 31 - Cover Complete 50 - Bowden Cable
13 - Glide 32 - Lever Control - Complete 51 - Bowden Cable
14 - Seat Pan 33 - Suspension Upper - Complete 52 - Operation Unit
15 - Back Rest 34 - Harness - Complete 53 - Cover
16 - Actuator - Front Cushion 35 - Air Spring - Complete 54 - Adjustment - Complete
17 - Kit Resilient Sheet 36 - Kit - Wear Parts 55 - Longitudinal Horizon
18 - Adjuster - Seat Angle 37 - Suspension Assembly - Complete 56 - Mounting Parts - Suspension Assembly
19 - Lever 38 - Suspension Lower - Complete
Fig. 1 - Exploded View of Driver Seat
DESCRIPTION base by means of a suspension assembly (37). The air

Numbers in parentheses refer to Fig. 1. seat only reacts when the driver sits on the seat. When
unoccupied, the seat sinks to the lowest position to
allow easier access.
WARNING
By Law, seat belts must be provided. Always A retractable seat belt (27) is secured to the seat
wear seat belts when travelling in the vehicle. assembly using nuts and spacers. A push button
allows quick release of seat belt (27).
The seat assembly consists of a seat cushion (3) and
backrest cushion (2) mounted to back rest (15) and
seat pan (14). Seat pan (14) is attached to a cab seat
SM 2624 01-10 1
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
SM - 2885 height setting - 'bounce' lightly until a 'click' is heard,

34 - Bolt (x4) the seat position in now engaged properly.
35 - Washer (x4) 6
36 - Lock Washer (x4) 3. Pull up horizontal adjustment handle (2) and move
37 - Nut (x4)
seat forwards or backwards, release handle when
required position is achieved.
4. Pull up (or push down) height and weight adjustment
10 (1) handle and hold until the require height position is
achieved, release handle - 'bounce' lightly until a 'click'
is heard, the seat position in now engaged properly.
4 5. Pull handle (8) to adjust seat cushion fore and aft
11
position. Hold and pull handle (8) until desired position
5
8
is achieved.
9
7 6. Pull handle (9) to adjust seat cushion rake angle,
2 hold and pull until desired angle is achieved. Ensure
34
1 3 35 cushion is locked into position. This procedure is better
36 performed when operator is off seat.
37
7. Pull up handle (5) and adjust backrest to the required
Fig. 2 - Operator Seat Controls angle, release handle when required position is
achieved.
The following is the list of controls to adjust the seat: 8. Pull up (or push down) backrest (6) to the required
1. Height and weight adjustment. height.
2. Horizontal adjustment (sliderails). 9. Turn lumber support adjustment (10) until desired
3. Fore/aft isolator (forward position - unlocked, pressure if felt on operators back.
rearmost position - locked). 10. Set damper adjustment (7) position to suit driving
4. Seat belt. conditions, (4 positions; forward position - hardest
5. Backrest angle adjustment. setting, rearmost position - softest setting).
6. Backrest height adjustment. 11. Set fore/aft isolator (3) position to suit driving
7. Damper adjustment (4 positions; forward position - conditions, (forward position - unlocked, rearmost
hardest setting, rearmost position - softest setting). position - locked).
8. Seat cushion - Fore/aft adjustment. 12. Turning armrest adjustment (11) alters the height of
9. Seat cushion - Rake adjustment armrests.
10.Lumber support adjustment 13. Engage seat belt (4).
11.Armrest adjustment.
NOTE: All controls should be set to operators own
WARNING personal comfort.
Do not attempt to adjust the seat or seat belt
while the machine is moving. Loss of control
may result. Stop the machine; apply the REMOVAL
brakes; then adjust. Numbers in parentheses refer to Fig. 2.
OPERATION
WARNINGS
To achieve the most comfortable driving position, To prevent personal injury and property
adjust the seat as follows; damage, be sure wheel chocks, blocking
1. Sit in seat. materials and lifting equipment are properly
2. Pull up and release height and weight adjustment (1) job safely.
handle - this will reset the seat to the predetermined
2 SM 2624 01-10
Section 260-0090
1. Position the vehicle in a level work area, apply the Horizontal Shock Absorber
Note: Remove seat assembly as described in
'Disassembly'
3. Disconnect harness connector at the rear of the
1. Remove pop-out buttons (1) and remove access
seat.
cover (2) to allow access to suspension assembly.
4. Push down height and weight adjustment (1) handle
2. Unclip hooked end of shock absorber (4) from
to release the air from the seat air suspension system.
horizontal spring assembly.
5. Remove bolts (34), washers (35), lock washers (36)
3. Remove circlip (3) and lever out shock absorber (4)
and nuts (37) securing complete seat assembly to the
from rocker shaft and slide off of mounting pin.
cab seat base. Remove seat assembly from vehicle
using suitable lifting equipment.
4. Remove spacer (5) from mounting pin.
DISASSEMBLY 5. Reassembly is done in the reverse order.

SM - 2487
Note: The disassembly and assembly procedures will

cover only basic sub-assemblies due to the multitude
of parts. If a sub-assembly must be disassembled, use
the exploded view in Fig. 1 for reference.
1. Remove cover (31) from seat assembly. Remove

nuts and spacers securing lap belt (27) to seat
assembly. Remove lap belt (27).
2. Pull up and remove headrest (4) from seat frame (1).
3. Remove screws securing backrest cushion (2) to

seat frame (1). Remove backrest cushion (2).
4. Remove screws securing seat cushion (3) to seat

Fig. 3 - Exploded View of Horizontal Shock Absorber
frame (1). Remove seat cushion (3).
Vertical Shock Absorber
5. Pull up horizontal adjustment (2, Fig. 2.) lever and
slide seat assembly rearwards. Hold captive nuts using Numbers in parentheses refer to Fig. 4.
a suitable spanner and remove front allen screws.
Note: Remove seat assembly as described in
6. Pull up horizontal adjustment (2, Fig. 2.) lever and 'Disassembly'
slide seat assembly forwards. Hold captive nuts using a
suitable spanner and remove rear allen screws. 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly.
7. Remove seat assembly from suspension base.
2. Unhook Bowden wire (5) and damper adjuster (6)
assembly from the top of shock absorber (7).
3. Remove circlips (3) and lever out shock absorber (7)

from mounting pins (4).
4. Remove spacers (8) from lower mounting pin (4).
5. Reassembly is done in the reverse order.
SM 2624 01-10 3
Section 260-0090
Note: Inscription must face upwards when assembling 3. Remove pressurised airline (5) from compressor (6).
shock absorber (7).
4. Identify and tag and disconnect electrical plug
SM - 2488
connections (7 & 8). Unfasten cable tie on the rocker.
5. Pull suspension assembly up to its highest position

and block securely.
6. Unscrew lower nut (9) and remove micro

encapsulated cylinder screw (10) and retaining clamp
(11).
7. Remove compressor (6) and felt mat (12) from

suspension base.
8. Reassembly is done in the reverse order.
Note: Replace micro encapsulated cylinder screw (10).
Fig. 4 - Exploded View of Vertical Shock Absorber Note: Centralise compressor (6) and felt mat (12)
between rocker arms.
SM - 2489
SM - 2490
Fig. 5 - Exploded View of Compressor and Mounting

Fig. 6- Exploded View of Level Controller and Mounting
Compressor Level Controller

Note: Remove seat assembly as described in Note: Remove seat assembly as described in
'Disassembly' 'Disassembly'
1. Remove pop-out buttons (1) and remove access 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly. cover (2) to allow access to suspension assembly.
2. Remove pop-out buttons (3) and push down 2. Remove pop-out buttons (3) and push down
suspension skirt (4) to allow further access to suspension skirt (4) to allow further access to
suspension assembly. suspension assembly.
4 SM 2624 01-10
Section 260-0090
3. Pull suspension assembly up to its highest position slide seat assembly rearwards. Hold captive nuts using
and block securely. a suitable spanner and install front allen screws.
Tighten allen screws to a torque of 25 Nm (18 lbf ft).
4. Unhook bowden wires (5 & 6) from level controller (7).
3. Install seat cushion (3) to seat frame (1) and secure
5. Identify and tag and disconnect electrical plug using screws.
connections (8 & 9).
4. Install backrest cushion (2) to seat frame (1) and
6. Identify and tag and disconnect pressurised airlines secure using screws.
(10) from air suspension unit (11). Unfasten cable tie on
the rocker. 5. Refit headrest (4) to seat frame (1).
7. Remove screw (12), push out pin (13) and release 6. Position lap belt (27) to seat assembly and secure
roll up belt (17). using nuts and spacers as removed at 'Disassembly'.
Tighten nuts to a torque of 50 Nm (36 lbf ft). Refit cover
8. Remove nuts (14) and manoeuvre level controller (7) (31).
until studs are free from mounting holes.
9. Remove screws (15) and remove bowden wire (16) INSTALLATION

retainer from level controller (7). Numbers in parentheses refer to Fig. 2.
10. Remove level controller (7) from suspension base. Note: Tighten all fasteners without special torques
11. Reassembly is done in the reverse order. STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Note: Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).
WARNING
INSPECTION To prevent personal injury and property
Numbers in parentheses refer to Fig. 1. damage, be sure wheel chocks, blocking
1. Inspect air lines, shock absorber (41), compressor secured and of adequate capacity to do the
(40), level controller (32) and air spring (35) for leaks job safely.
and damage and replace if required.
2. Check all brackets and frame for cracks and/or 1. Using suitable lifting equipment, position seat
damage. Repair or replace as necessary. assembly on the cab seat base and secure using bolts
(34), washers (35), nuts (37) and lock washers (36).
3. Check springs for fatigue or damage and replace as
required. 2. Reconnect harness at the rear of the seat.
3. Place battery master switch in the 'On' position, start

ASSEMBLY the engine and charge the air system. Check seat for
Numbers in parentheses refer to Fig. 1. proper operation, refer to 'Operation'.
Note: Tighten all fasteners without special torques 4. Remove wheel chocks from road wheels.
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. Position seat assembly onto suspension base. Hold

captive nuts using a suitable spanner and install rear
allen screws. Tighten allen screws to a torque of 25
Nm (18 lbf ft).
2. Pull up horizontal adjustment (2, Fig. 2) lever and
SM 2624 01-10 5
Section 260-0090

TORQUE
1 # Nut 50 36
1 # Allen Screw 25 18
5 14 Nut 25 18
MAINTENANCE
The care of the upholstery on seat cushion (3) and

backrest cushion (2) is a relatively simple, but
important matter. Accumulation of dirt on the surface
eventually turns into a hard gritty substance which cuts
into the surface of the upholstery.
To clean seat cushion (3) and backrest cushion (2),

use warm water and a mild soap, such as Castile.
Work up thin soap suds on a piece of soft cloth and
rub the upholstery briskly. Remove the suds with a
damp cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.
Lap belt (27) assembly should be inspected by the user

on a regular basis. Replace lap belt (9) immediately if
hardware is worn or damage, straps are nicked or
frayed, buckle is not functioning correctly, loose
stitching is found, or if the strap material has lost
strength due to the effects of ultraviolet rays.
Note: Regardless of appearance, lap belt (27) must be

removed and replaced at least once every three years.
* * * *
6 SM 2624 01-10
OPERATOR'S COMPARTMENT - Instructor Seat and Mounting
Section 260-0110
SM3903
4
5
3 1
1 - Instructor Seat Assembly

2 - Seat Belt
3 - Bolt
4 - Washer
5 - Lockwasher
Fig. 1 - Exploded View of Instructor Seat
DESCRIPTION electrical harnesses, the transmission ECU, the

Hydraulic ECU, the wash/wipe relay, the CPU and the
Numbers in parentheses refer to Figure 1. busbar assembly, all of which are described elsewhere.
Access to the equipment below the seat requires
pivoting of the base cushion into a vertical attitude,
WARNING then securing it to the back rest by means of the strap
By Law, seat belts must be provided. Always provided, as shown on steps 1 and 2 on Figure 2
wear seat belts when travelling in the vehicle. below. The back rest can be pivoted to the horizontal
position when not in use, by first unlocking the release
The instructor seat is located adjacent to the left-hand catch on the right-hand side, then rotating it down as
side of the driver's seat, and is secured to tapped shown on steps 3 and 4 of Figure 2.
bosses on the rear wall of the cab with bolts (3),
washers (4) and lockwashers (5). The seat assembly The diagnostic interface socket and the hood control
(1) comprises a seat cushion and back cushion switch are both fitted adjacent to the right-hand side of
mounted to a seat frame. Seat frame (2) is attached to the instructor seat.
seat base (8) by means of a hinge (9) at the front end
and locked at the rear by a spring loaded latch A retractable lap seat belt (2) is secured to drilled lugs
arrangement. Located below the seat base is a storage on the rear wall of the cab. A release button allows
box, below which is a cavity containing a number of quick release of the seat belt (2).
SM3904
1 2 3 4
Fig. 2 - Instructor Seat, Hinged Back and Base Operations
SM2572 01-10 1
Operator's Compartment - Instructor Seat and Mounting
Section 260-0110
h. Disconnect the body control lever
REMOVAL AND DISASSEMBLY
i. Disconnect the Hydraulic ECU
Numbers in parentheses refer to Figure 1. j. Disconnect the instrument panel (VDU) ECU.
WARNINGS
To prevent personal injury and property ASSEMBLY AND INSTALLATION
damage, be sure wheel chocks, blocking Numbers in parentheses refer to Figure 1.
secured and of adequate capacity to perform the Note: Tighten all fasteners without special torques
task safely. specified to torques listed in Section 300-0080,
Standard Bolt and Nut Torque Specifications.
High electrical current. Turn the ignition key 1. Carry out the procedures itemized below in the order
switch 'Off' before disconnecting any electrical given to prevent damage to the electrical components.
components. Disconnect electrical connections
in the correct order given to prevent damage to a. Connect the instrument panel (VDU) ECU
the electrical components. b. Connect the Hydraulic ECU
c. Connect the body control lever
1. Position the vehicle in a level work area, apply the d. Connect the Transmission TCM
parking brake and shut down the engine. e. Connect the electrical connections at the engine
ECM
2. Turn the steering wheel in both directions several f. Connect the alternator supply cable
times to relieve any pressure in the steering system. g. Connect the alternator earth cable
Block all road wheels. h. Connect the battery supply cable
i. Connect the battery earth cable
3. Pivot the base cushion to the vetical position, then j. Switch on the battery master switch.
secure it to the back rest using the strap provided, thus
allowing access to the seat mounting hardware. 2. Position the instructor seat assembly (1) against the
internal rear wall of the cab, correctly orientated such
4. Undo and remove the bolts (3), lockwashers (5) and that the three holes in the rear of the seat frame align
washers (4) securing the seat assembly to the rear wall with the tapped holes in the bosses of the rear cab
of the cab. wall.
5. Lift the entire seat assembly (1) out of the cab and 3. Secure the instructor seat to the rear wall of the cab
remove it to a prepared area. using the bolts (3), lockwashers (5) and washers (4),
tightened evenly and securely.
6. If access is required to the electrical equipment in
the space underneath the seat mounting position, firstly 4. Support the base cushion, then undo the strap
undo and remove the screws securing the storage box, holding it in a vertical attitude. Carefully pivot the base
then remove the storage box and the screws to a cushion to the horizontal position.
prepared area.
5. Remove the wheel chocks from the road wheels.
7. Before working on any of the electrical items beneath
the instructor seat, carry out the procedures itemized
below in the order given to prevent damage to the
electrical components.
a. Turn off the battery master switch

b. Disconnect the battery earth cable
c. Disconnect the battery supply cable
d. Disconnect the alternator earth cable
e. Disconnect the alternator supply cable
f. Disconnect the electrical connections at the engine
ECM
g. Disconnect the Transmission TCM
2 SM2572 01-10
Section 260-0110
MAINTENANCE strap material has lost strength due to the effects of

Numbers in parentheses refer to Fig. 1. ultraviolet rays.
The care of the upholstery on the base cushion and Note: Regardless of appearance, the seat belt (2) must
back rest is relatively simple, but an important matter. be removed and replaced at least once every three
Accumulation of dirt on the surface eventually turns years.
into a hard gritty substance which cuts into the surface
of the upholstery.
To clean the base cushion and back rest, use warm

water and a mild soap, such as Castile. Work up thin
soap suds on a piece of soft cloth and rub the
upholstery briskly. Remove the suds with a damp
cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.
The seat belt (2) assembly should be inspected by the

user on a regular basis. Replace the seat belt (2)
immediately if the hardware is worn or damage, straps
are nicked or frayed, release mechanism is not
functioning correctly, loose stitching is found, or if the
* * * *
SM2572 01-10 3
Section 260-0110
4 SM2572 01-10
Operators Compartment - Air Conditioning
Section 260-0130
SM - 2430
1 3 IN
D
S OUT
4
5
1 - Compressor 3 - Receiver Drier 5 - Evaporator

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

The R-134a compressor systems use an electronically
Temperature Control Switch actuated clutch to engage and disengage drive to the
A thermostat switch senses the temperature of the compressor. The drive belt pulley is mounted on a bearing
evaporator and engages or disengages the and is free to rotate without turning the compressor
compressor clutch. The control for this switch is crankshaft any time electrical power is disconnected. The
located in the cab. compressor is not operating when the pulley is
freewheeling. The field coil is energized by supplying
electrical current to the exposed wire. The other end of the
Compressor coil winding is grounded to the compressor and equipment
The compressor is designed to compress vapour and frame. Energizing the coil creates a magnetic force that
can be damaged by non-compressibles such as dirt, locks the driven disk to the pulley and drives the
moisture, liquid refrigerant (R-134a), etc. The compressor.
compressor draws vaporized R-134a from the
evaporator (which maintains the low pressure
necessary for proper evaporation) and compresses Condenser
the vapour to a high pressure, which is necessary for The purpose of the condenser is to radiate enough heat
condensation. The high pressure vapour then moves energy from the compressed high pressure vaporized
into the condenser where heat can be radiated to R-134a so that the R-134a changes from vapour to
change the R-134a back to liquid. liquid. During normal operation all the high pressure
section of the system will be warm or hot, but large
Note: R-134a designates the type of refrigerant used quantities of heat should be radiating from the
in heavy duty vehicle air conditioning systems. condenser. Nothing should be permitted to stop or slow
SM 2625 01-10 1
Section 260-0130
down this radiation of heat. Cooling fins are located on Thermostatic Expansion Valve
the condenser tubes and fans are used to circulate
An expansion valve is installed in the system to lower
cool air around the condenser tubes. Keep all leaves,
the pressure before the R-134a enters the
paper, dirt, etc. clear from the condenser and
evaporator. The reduction in pressure is done by
condenser filter. The cooling fins should be straight to
passing the R-134a through a small hole (orifice).
permit free flow of air. The condenser is sometimes
The size of the orifice must be controlled to
located ahead of the engine radiator and blockage of air
compensate for changes in pressure and
flow through the radiator also affects the condenser.
temperature. The temperature of R-134a leaving the
Bent fan blades, slipping fan drive, inoperable
evaporator is sensed by a thermostatic sensor that
condenser fan motors, or any other fault that lessens
moves the valve seat via a diaphragm and actuating
the amount of cool air circulated through the
pin.
condenser, should be corrected. The oil, dirt, or
antifreeze will act as an insulator that will inhibit the
radiation of heat. Evaporator - Heat/Cool
The evaporator is the low pressure, low temperature
Since the purpose of the condenser is to radiate heat
component where liquid R-134a absorbs heat from
energy, anything that prevents or inhibits this action
surrounding air. The expansion valve bleeds high
may affect cooling, but the temperature and pressure
pressure R-134a into the low pressure evaporator.
of the R-134a raise and lower together. Heat energy
The R-134a expands rapidly in the evaporator and its
that has not been radiated will remain in the R-134a
temperature is quickly reduced. The R-134a absorbs
and the result will be pressure that is too high. The
heat from the air when the blower fan circulates air
condenser, hoses, connections and seals can be
over the evaporator coil fins. The exchange of heat
damaged by the high pressure. Pressure sensing
from the air to the R-134a depends upon the
safety switches may be activated by the high
difference in temperature. During high heat load, such
pressure caused by the condenser not radiating
as usually encountered when the system is first
enough heat.
turned on, the temperature difference is great and the
R-134a will absorb heat quickly. The blower fan can
Receiver Drier be set at its highest setting to circulate large
quantities of warm air around the evaporator. After
The high pressure liquid R-134a moves from the
the cab has cooled, the fan speed should be reduced
condenser to the receiver drier, where the R-134a is
so that the already cool air will have a longer time to
stored and filtered. Moisture is the major enemy of
yield heat to the R-134a as it passes the evaporator
the air conditioning system and the desiccant inside
coils. The heater circuits utilize engine coolant at
the receiver drier will absorb only a small amount.
approximately 82° C (180° F).
The container of desiccant inside the receiver drier
may break open and contaminate the system if any
attempt is made to dry the desiccant, or, if more High Pressure and Low Pressure Switches
moisture is inside the system than the desiccant can
The pressure switches are electric switches that
absorb.
monitor air conditioner operation. The high pressure
and low pressure switches are activated at preset
Every effort should be made to remove all moisture
pressures and engage and disengage the compressor
from the system and install a new receiver drier if its
clutch.
condition is questionable. Installation of a new
receiver drier is recommended each time any part of
the R-134a system is open to the atmosphere.
Bubbles are observed in the sight glass on top of the
receiver drier during the charging procedure.
A filter screen is located in the receiver drier to stop

solid contaminates from leaving the unit. Blockage of
the filter will result in a drop in pressure that will be
indicated by a drop in temperature. Connections of
the new receiver drier should be securely capped
before installation to prevent the entrance of moisture
(air) while in storage.
2 SM 2625 01-10
Section 260-0130
REMOVAL 5. When satisfied that the system is completely

discharged, tag refrigerant hoses (2 &3) to aid in
installation and carefully disconnect hoses from cab
otherwise stated.
firewall. Cap fittings at front of cab and refrigerant
hoses (2 &3) to prevent foreign matter from entering
the system.
WARNINGS
Always wear goggles or glasses to protect your
6. Remove screws (3, Fig. 3) securing front cover (34,
eyes when working around R-134a.
Fig. 3) to main weldment (35, Fig. 3).
R-134a boils at sea level temperatures of
-29.8° C (-21.6° F), which means that direct
7. Remove heater hoses from front of cab, which
contact with your skin will produce frostbite.
connect to water inlet manifold (22, Fig. 3) and water
Exercise extreme care when handling R-134a. If
outlet manifold (23, Fig. 3). Cap open ports and hoses
R-134a contacts your skin, wash immediately
to prevent foreign matter from entering the system.
with plenty of warm water. Remove any
contaminated clothing with caution as it may
8.If necessary to remove main weldment (35, Fig. 3)
adhere to the skin. If blistering or continued
from cab, be sure to disconnect harness (24) and any
irritation occurs obtain immediate medical
remaining hoses or ducting before withdrawing main
attention.
weldment (35, Fig. 3) from cab.
If you get the slightest trace of R-134a in
Note: The blower assembly mounting (25, Fig. 3),
your eye, flood the eye immediately with cool
thermostat (23, Fig. 3) and heat exchanger (19, Fig. 3)
water; then treat with mineral oil or clear
can be accessed without removing the main weldment
petroleum jelly followed by boric acid rinse.
(35, Fig. 3) from cab.
Report to a hospital or doctor as soon as
possible.
10. Tag refrigerant hoses (1 & 4) to aid in installation
and carefully disconnect hoses from receiver/drier (12).
The chemicals of R-134a when burned
produce gases that will damage the respiratory Cap receiver/drier (12) fittings and refrigerant hoses (1
system if inhaled. NEVER SMOKE in an area & 4) to prevent foreign matter from entering the
where R-134a is used or stored. Use hot water system.
or an approved heated charge cylinder as a heat
source if required to force R-134a into the 11. Support receiver/drier (12) and remove clamps
system. If using water, do not exceed 52° C securing receiver/drier (12) to mounting bracket (11).
(125° F). Never use direct flame or electric
heaters in direct contact with the R-134a 12. Tag refrigerant hoses (1 & 4) to aid in installation
container. High temperatures may result in and carefully disconnect hoses at condenser (10). Cap
raising the pressure to a dangerous level. condenser (10) fittings and refrigerant hoses to prevent
ingress of foreign matter.
13. If required, support air conditioner condenser (23)
securing condenser (10) to radiator assembly. Remove
condenser (23) from vehicle.
safely.
14. Tag refrigerant hoses (3 &4) to aid in installation
and carefully disconnect hoses from compressor (10).
Cap compressor (10) fittings and refrigerant hoses (3 &
4) to prevent foreign matter from entering the system.
2. Toggle the hood switch located beneath the
15. Disconnect electrical connection from compressor
passenger seat to raise the hood.
(10) clutch.
18. Support compressor (10) and remove bolts (17) and
washers (17) securing compressor (1) to engine.
Remove compressor (10) from the vehicle.
4. Discharge the air conditioning system as described
under 'Discharging The System'.
SM 2625 01-10 3
Section 260-0130
SM - 3636
21 5
9 19
CAB 3
6 9
FIREWALL 20 18
16
24
7 17
8
10
8
23
14 18
21
T 23
OU
IN 15
11 7
4 7
14
7 12 22
1 - Refrigerant Hose 7 - 'O'-Ring 13 - P-Clip 19 - P-Clip

2 - Refrigerant Hose 8 - 'O'-Ring 14 - Lockwasher 20 - P-Clip
3 - Refrigerant Hose 9 - 'O'-Ring 15 - lamp 21 - Bolt
4 - Refrigerant Hose 10 - Compressor 16 - Bolt 22 - Bolt
5 - P- clip 11 - Bracket 17 - Washer 23 - Condenser
6 - Nut 12 - Receiver/Drier 18 - Clamp 24 - Bracket
Fig. 2 - Air Conditioner Lines and Mounting
INSTALLATION 1. If main weldment (35, Fig. 3) was removed, install in

cab and reconnect harnesses, hoses and air ducting as
noted during removal.
otherwise stated.
2. Reconnect heater hoses to front of cab and connect
Note: Tighten all fasteners to standard torques
to water inlet manifold (22, Fig. 3) and water outlet
specified in Section 300-0080, STANDARD BOLT AND
manifold (21, Fig. 3), as identified at removal.
NUT TORQUE SPECIFICATIONS.
4. Once all necessary connections have been made,
Note: Renew all 'O' rings where necessary (7, 8 & 9).
secure front cover (34, Fig. 3) to main weldment (35,
Fig. 3) using fasteners previously removed.
WARNING
5. Remove caps from end of refrigerant hoses (2 & 3)
and ports at front of cab and connect hoses to ports as
tagged at removal.
6. Route refrigerant hoses (2 & 3) along the LH side of
safely.
the engine securing with clamps removed during
removal.
4 SM 2625 01-10
Section 260-0130
SM - 3637
24
4
23
7 20
10 22
2
12
17
13 21
11
65 15
16 25
18
9
14 26
19
27 1
28,30
31,32
2 3
1 28,30
31,33
28,29,30,31
1 - Filter Assembly 10 - Binary Switch 19 - Coil Assembly 28 - Knob

2 - Grommet 11 - Screw 20 - Top Seal 29 - Potentiometer Assy
3 - Screw 12 - Bolt 21 - Manifold 30 - Nut
4 - Grommet 13 - Plate 22 - Manifold 31 - Washer
5 - 'O'-Ring 14 - Water Hose 23 - Thermostat 32 - Air Con Switch
6 - 'O'-Ring 15 - Plate 24 - Harness 33 - Blower Switch
7 - Grommet 16 - Water Outlet Pipe 25 - Blower Assy Mounting
8 - Vent 17 - Valve 26 - Water Valve Assy
9 - Clamp 18 - Water Hose 27 - Drain Tube Assy
Fig. 3 - Air Conditioner Lines and Mounting
7. If removed, install receiver/drier (12) to mounting Note: If fan guard and compressor drive belt were
bracket (11) and secure with clamps. removed, proceed with steps 12 & 13.
8. Remove caps from end of refrigerant hoses (1 & 2) 12. Install new drive belt onto engine pulley and fit to
and ports on receiver/drier (12) and connect hoses to groove on compressor (10).
ports as tagged at removal.
13. Adjust tension of compressor drive belt with nut on
9. If removed, install condenser (23) to radiator adjuster bolt until there is approximately an inward
assembly and secure. deflection of 10 mm (0.4 in) at the centre of drive belt
(3). Fully tighten all mounting hardware.
10. Remove caps and connect refrigerant hoses
(1 & 8) to condenser (23) ports as tagged at removal. 14. Remove caps from end of refrigerant hoses (3 & 4)
and ports on compressor (10) and connect hoses to
11. Fit compressor (10) to engine and secure with bolts ports as tagged at removal.
(16) and washers (17). Do not fully tighten at this
stage. 15. Connect electrical connection to compressor (10)
clutch.
SM 2625 01-10 5
Section 260-0130
16. Secure all lines with clips and clamps as removed 2. If the system has a heater in the same location as
during removal. Ensure no lines are chaffing on sharp the air conditioning evaporator core, heater valves
edges or resting against areas where heat will be should be closed.
evident.
3. To check the refrigerant level, run the engine at
17. Charge the air conditioning system as described 1 200 rev/min with fans on high speed and thermostat
under 'Charging Procedure'. fully open for a minimum of five minutes. If the clutch
is engaged in this situation, there should be very few
18. Switch the battery master switch to the 'On' bubbles visible in the receiver-drier sight glass.
position, start up the engine and check for correct
operation of the air conditioning system. Note: Unit can operate with some bubbles visible, but
not milky looking.
19. Lower hood and remove wheel blocks from all road
wheels. 4. Ensure all hoses and hose clamps are free from
contact with sharp metal, moving parts or near to
manifolds.
MAINTENANCE
5. Inspect condensation drain lines for debris, sharp
bends or breaks.
WARNINGS
Always wear goggles or glasses to protect your 6. Inspect the clutch wire from the thermostat for bare
eyes when working around R-134a. R-134a boils spots.
at sea level temperatures of -29.8° C (-21.6° F),
which means that direct contact with your skin 7. Inspect bolts and nuts on the compressor and
will produce frostbite. Exercise extreme care mounting bracket for proper tightness.
when handling R-134a. If R-134a contacts your
skin, wash immediately with plenty of warm 8. Check for any air blockages within the system.
water. Remove any contaminated clothing with Clean recirculation filter periodically, by shaking off
caution as it may adhere to the skin. If blistering dust or by washing in soapy water.
or continued irritation occurs obtain immediate
medical attention. 9. If the refrigerant system is broken into following gas
loss due to mechanical damage or there is any other
If you get the slightest trace of R-134a in reason to suspect foreign material ingress, then the
your eye, flood the eye immediately with cool receiver/drier should be replaced.
water; then treat with mineral oil or clear
petroleum jelly followed by boric acid rinse. 10. Every 4 000 hours, drain, flush and refill the
Report to a hospital or doctor as soon as compressor with refrigerant oil specified in Section
possible. 300-0020, LUBRICATION SYSTEM. Also see
'Refrigerant Oil'.
The chemicals of R-134a when burned
produce gases that will damage the respiratory
system if inhaled. NEVER SMOKE in an area
where R-134a is used or stored. Use hot water or
an approved heated charge cylinder as a heat
source if required to force R-134a into the
system. If using water, do not exceed 52° C
(125° F). Never use direct flame or electric
heaters in direct contact with the R-134a
container. High temperatures may result in
raising the pressure to a dangerous level.
1. Periodically clean the condenser coil of debris and

dirt using water or air pressure. A partially blocked
condenser coil can reduce the life of the compressor
belt and/or clutch.
6 SM 2625 01-10
Section 260-0130
Maintenance of drive belts Refrigerant Oil

1. Listen for 'ticking' sound - they mean interference
with the belts. Visually inspect for bent or damaged
belt guards. WARNINGS
To prevent personal injury always wear rubber
2. Replace all belts in a mismatched set at one time to gloves when handling refrigerant oils.
ensure even load distribution.
Too much refrigerant oil will dampen the
3. Periodically check tension and keep belts tight. cooling effect and too little refrigerant oil may
lead to compressor failure. If in doubt flush the
- The ideal tension is the lowest tension at which the system.
belt will not slip under peak load conditions.
- Check belt tension frequently during the first 24 - 48 Oil is required to lubricate the compressor. The oil
hours of run-in operation. mixes with the refrigerant and is carried around the
- Initial belt tension should be 533 N (120 lbf) system. The compressor is supplied with an oil
dropping to 422 N (95 lbf) after the first 48 hours. charge. However, additional oil is required, the
- There should be a freeplay of 10 mm in the belt. amount depending on the length of refrigerant hose
- 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 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 If any component is replaced the following amount of
edge tool while tensioning belts. oil should be added to the system;
4. Never attempt to correct belt slippage by using a Condenser add 1 fl oz (28.4 ml)
belt dressing. The dressing may cause softening and Drier add 1 fl oz (28.4 ml)
deterioration. Evaporator add 3 fl oz (85.2 ml)
Compressor add 4.4 fl oz (125 ml)
5. If belt slips, even when properly tensioned, check for
overload, worn sheave grooves or oil or grease on the The oil should be added to the oil filling port of the
belts. compressor before the evacuation procedure is started
or by using an oil injector when the system is being
6. Never pry a drive belt or force it into the sheave charged, observing the following good practises:
groove. Loosen the drive belt tightener prior to
installation. a. Only pour the amount required from the container
straight into a CLEAN measuring jug and
7. A belt that has operated while rolled over in the immediately pour the oil into the compressor.
sheave groove may be damaged - replace it. b. Re-cap container tightly as soon as the required
amount has been taken (never leave an oil container
8. Store belts in a cool, dry place. If stored on a open).
machine, relieve all belt tension by loosening the c. Do not mix different oils.
drive belt tightener.
Only new oil should be used, because oil that has
9. Never attempt to check or adjust belts while they are been exposed to the air will have absorbed water
running. (hygroscopic).
Use only refrigerant oil as specified in Section

SM 2625 01-10 7
Section 260-0130
System Leak Testing system is empty before connecting the vacuum so that
refrigerant does not enter the pump.
Recommended Equipment Required:
Electronic Leak Detector
5. Tighten down (turn clockwise) both high and low side
valves on the gauge manifold to the closed position.
Switch off the engine and check all connections
Remove protective caps from the service ports on the
throughout the system for leaks. A large leak point will
compressor.
have an oily or greasy appearance. The refrigerant
carries compressor oil with it and deposits it around the
6. Connect both service hoses from the two fittings (2
leak area. Check all such points for loose connections
& 3) in the bottom of the manifold to the two service
and tighten.
ports on the compressor. High side (red) to compressor
discharge valve, low side (blue) to compressor suction
Using a suitable leak detector, search for leaks around
valve.
all joints, connections, seals and control devices. If a
leak is located, purge the system of refrigerant and
7. Switch vacuum pump on, open vacuum pressure
repair. Fully evacuate and charge the system to make
valve (1) until less than 6 mb is reached on vacuum
it operational.
gauge (A). The vacuum gauge (A) should remain at
this value when vacuum pressure valve (1) is closed
DISCHARGING THE SYSTEM to indicate that there are no leaks.
Note: Refer to all WARNINGS listed under
8. Open the low side hand valve on the manifold and
'Maintenance' prior to discharging the system.
vacuum pressure valve (1) and watch that the
gauges start to register that a vacuum is being drawn.
Recommended Equipment Required:
If the gauges do not register the vacuum thena
Portable High Vacuum Charging Station
blockage is present. Open the high side and pump
Suitable Canister
down until a vacuum of 10 mb is achieved.
or Standard Service Manifold (Refer to Fig. 4)
To eliminate system contaminants from an air
9. After 10 - 15 minutes close vacuum pressure valve
conditioning system requires discharging the entire
(1) and allow the system to settle, vacuum gauge (A)
system. This means removing all of the refrigerant
should not alter. If the vacuum is held, no leaks or
and cleansing all contamination (air and moisture) from
refrigerant contaminated oil is present. If not, open the
the system components. If any of the major system
vacuum pressure valve (1) and continue pumping,
components are to be repaired or replaced, the system
checking at regular intervals. If there is a leak, check
must also be completely discharged.
all fittings and tighten if necessary.
WARNING 10. Tighten down (turn clockwise) both high and low
The vehicle must not be running during this side valves on the gauge manifold to the closed
procedure. Be sure to have adequate ventilation position, remove the service hose (yellow) from the
during this operation. Do not discharge vacuum connection (6) on vacuum pump and switch
refrigerant near an open flame. the pump 'Off'.
Numbers and letters in parentheses refer to Fig. 4. 11. Connect the service hose (yellow) to the R-134a
cylinder. Open the cylinder valve and then purge air
1. Position the vehicle in a level work area, apply the from the hose at the manifold connection.
12. Open the low side hand valve on the manifold
2. Block all road wheels and place the battery master slowly, until low pressure gauge (B) is at bottle
switch in the 'Off' position. pressure. Watch the high side manifold gauge (C) rise
to ensure that no blockage is present. Close the
3. Pull on handle to release hood catch and raise the manifold valve and cylinder, then disconnect the hose
hood. from the cylinder.
4. Connect the service hose (yellow) to the centre 13. Connect the service hose (yellow) to the Nitrogen
access port on the manifold gauge and to the vacuum cylinder. Open the neck valve on the cylinder and set
connection (6) on vacuum pump. Ensure that the the regulator pressure such that it is higher than the
8 SM 2625 01-10
Section 260-0130
system pressure then purge the hose. Open the low 9. Run vacuum pump for approximately 30 minutes.
side hand valve on the manifold, as the pressure rises Ideal gauge readings should be 29.92 inches of
open the high side hand valve on the manifold and mercury. The pressure will vary with altitude; it will be
allow a system pressure of 10 bar (150 psig) to be approximately 0.03 bar (0.5 lbf/in²) less for each 305 m
reached. Close all the valves. Using a suitable (1 000 ft) of elevation.
electronic leak detector, check all joints in the air
conditioning system for leaks. Tighten any loose 10. Before disconnecting power supply from vacuum
joints and re-test if necessary. pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
14. Vent the refrigerant mix to atmosphere by R-134a source.
removing the service hose (yellow) from the Nitrogen
cylinder and opening the low side hand valve on the 11. Open R-134a source. Loosen, but do not remove,
manifold. Re-evacuate the system to below 6 mb yellow supply hose at manifold on gauges to remove all
(steps 7 to 10). air in the yellow supply hose, replacing the air with R-
134a. This is done in a few seconds. Tighten yellow
15. Lower hood assembly and remove wheel blocks. supply hose.
12. Open low side of R-134a gauges slowly. When

CHARGING THE SYSTEM gauge reads zero open both sides completely. Vacuum
Note: Refer to all WARNINGS listed under in the system will draw R-134a gas into the system.
'Maintenance' prior to charging the system. Hold until both gauge readings equalize.
Recommended Equipment Required: Note: Never charge with liquid R-134a. Charge on the
Portable High Vacuum Charging Station low pressure side only.
Electronic Leak Detector
or Standard Service Manifold (Refer to Fig. 4)
Final Charging Of The System
For New Or Completely Empty System 1. Start the engine and run at engine idle speed.
Note: The charging procedure must be done in ambient
temperatures above 15.5° C (60° F) with the R-134a 2. Turn the air conditioning system on with the
canister temperature equal to the outside ambient thermostat set on maximum cooling and fan on high
temperature. speed.
1. Shut off engine and block all road wheels. 3. At this point a visual inspection must be made of
the sight glass on top of the receiver-drier. Allow
2. Pull on handle to release hood catch and raise the charging to continue until 1.1 kg (2.43 lbs) of refrigerant
hood. has been added. The charging process can be speeded
up by running the engine at a fast idle.
3. Remove protective caps from 'quick coupler' valves
on rear of compressor. 4. The sight glass on top of the receiver/drier will be
substantially free of bubbles.
4. Connect low pressure gauge hose (blue hose and
gauge) to suction side or low side fitting on Note: It is normal for bubbles to increase during clutch
compressor. The suction side can be identified by the cycling or system start-up.
size of the hose connected to the fitting. This will be
the largest diameter hose of the system. 5. With the system completely charged, shut off the
engine. Close the valve on the R-134a canister and
5. Connect the high pressure gauge hose (red hose and remove the yellow supply hose. Remove both the low
gauge) to discharge or high side fitting on compressor. pressure (blue) hose and high pressure (red) hose from
6. Connect yellow supply hose to suction port on the filling ports on the compressor.
vacuum pump.
Note: Some R-134a will escape as the hoses are being
7. Open both sides of gauges, low and high, completely. removed.
8. Start vacuum pump to evacuate the complete air
conditioning system.
SM 2625 01-10 9
Section 260-0130
The system is completely charged when; is at a normal operating temperature of 80°C (176°F)
a. the suction pressure on the gauge is approx.
2. Turn the blower control to setting 1.
20 - 30 psig at 25° C ambient.
3. Turn on the air conditioning unit on for 5 seconds
b. the correct weight of refrigerant has been added i.e.
then off for 5 seconds.
1.1 kg (2.43 lbs).
c. the correct sub-cooling can be measured at the 4. Repeatedly switch the air conditioning on and off for
condenser, approx. 5 - 7° C. at least 1 minute. This should be at least 12
repetitions.
6. Replace protective caps on hoses and valve fittings.
5. Commissioning the air conditioning unit is complete
7. Lower hood assembly and remove wheel blocks. and ready for use.
Air Condition Commissioning Procedure THIS PAGE IS INTENTIONALLY

BLANKTROUBLESHOOTING
If the machine has been idle overnight or for an
extended period of time, the refrigerant in the air Preliminary Checks
conditioning unit converts from a gas to a liquid. This Before any checks are carried out on the refrigerant
puts the compressor unit is under a great deal of strain circuit the following checks should be made:
trying to compress a liquid instead of a gas and could
cause a failure in the air conditioning unit. The following 1. Check the compressor drive belt is serviceable and
commissioning procedure allows the air conditioning correctly tensioned.
unit to achieve normal operating parameters.
2. Check the condenser and engine radiator are not
1. Start the machine and allow it to run until the engine blocked by debris. Clean with compressed air or water
SM - 2424
if necessary.
B C D
3. Check that the condenser fins are not flattened or
damaged, the fins must allow air to pass freely.
4. Check the cab fresh air inlet filter for blockage.
4
2 3
5. Check that, with the ignition switch on (engine not
SUC DIS R running), the blower operates over whole speed range
ACCESS E
F
PORT R 6. Check that, with the ignition switch on (engine not
I
G running), the blower and air conditioning switched on,
E the compressor clutch engages.
A R
A
N Charge level:
T
Note: It is not possible to check refrigerant charge
level with R134a systems. Any bubbles seen at the
VACUUM PUMP sight glass on the receiver drier may be bubbles of oil
and are perfectly normal.
6
1 5 Fault finding:
Refer to Troubleshooting table
Gauges: Valves: Important: Refer to appropriate removal and installation
A - Vacuum Gauge 1 - Vacuum Pressure procedures before working on any system component.
B - Low Pressure Gauge 2 - Suction Line
C - High Pressure Gauge 3 - Discharge Line
D - Charging Cylinder 4 - Refrigerant Gas
Pressure Gauge 5 - Refrigerant Liquid SPECIAL TOOLS
Port: Refer to Section 300-0070, SERVICE TOOLS, for part
6 - Vacuum Connection
numbers of special tools referenced in this section and
Fig. 4 - Standard Service Manifold general service tools and sealants required. These
tools and sealants are available from your dealer.
10 SM 2625 01-10
Section 260-0130
AIR CONDITIONING TROUBLESHOOTING

CONDITION PROBLEM REMEDY
1. Belt Trouble
Slipping Loose Adjust belt to 10 mm (0.39 in)

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

disengaged
Noise Clutch rubbing field coil Align clutch
Faulty belt Replace belt
Compressor oil level low Add oil
Chatter/Knock Valve plate broken Repair or replace
3. Noise - Evaporator
Rubbing/scraping Fan blade or blower Repair or replace
Hissing Low charge/leak Correct charge/repair leak
Chatter/Knocking Expansion valve Replace
Noisy case Loose brackets/screws Tighten
Motor squeal Dry bearings Replace
SM 2625 01-10 11
Section 260-0130
AIR CONDITIONING TROUBLESHOOTING (CONTINUED)

4. Air Conditioning Inadequate
After Short Period Of Operation
Cooling quits Loss of refrigerant Charge system/check for leaks
Moisture in system Replace drier
Thermostat Replace thermostat
Clutch Check pull-in of clutch or replace
Cooling intermittent Moisture in system Replace drier
5. Electrical Trouble
Blower motor or condenser fan Defective circuit breaker or bad Replace. Clean and tighten
motor inoperable wiring connections connections
Tight motor bearing Repair or replace motor
Switch open or shorted Repair or replace switch
Blown fuse Check fuse, replace if necessary
Motor seized Check rotors are free to turn
Loose wire/connection Check connectors at blower. Check

there is power across terminals
Motor failure Remove and replace blower
Faulty control Check system with replacement
Module damaged Check system with replacement

module inside main weldment
Slow running blower Shaft binding Replace motor - worn bearings
Wheel misaligned Replace
Bad blower switch Replace blower
Insufficient current Install larger alternator
Clutch inoperable Defective relay Replace
Loose connection Clean and tighten connection
Broken wire - ground Repair wire
Shorted or open field Replace field
Blown fuse Check fuse, replace if necessary
Faulty freeze protection thermostat When temperature is above cut-off

temp, thermostat should be closed.
If faulty, replace thermostat
12 SM 2625 01-10
Section 260-0130
AIR CONDITIONING TROUBLESHOOTING (CONTINUED)

Clutch inoperable (continued) Faulty compressor If compressor clutch is being fed
power then it should be engaged. If
not, check wiring. Replace
compressor if faulty
Faulty pressure switch If the binary pressure switch

detects pressure within range,
circuit should be closed. If switch
is not closed circuit, indicates
incorrect pressure or faulty switch.
6. Air Conditioning System

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

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

repair or replace
* * * *
SM 2625 01-10 13
Section 260-0130
14 SM 2625 01-10
Body - Body and Mounting
Section 270-0010
SM - 3962
14
1 37 7
1 4
15
16 3
6 1
5
25
26 11
27 13
18 20 21
12
24
32
23 9
28 34
29 30
31
33 10
36 17
19
22 29 2
35
38
1 - Body 10 - Grease Fitting 20 - Washer 20 - Washer

2 - Bushing 11 - Towing Pin Assembly 21 - Locknut 30 - Bolt
3 - Shim, 10 SWG 12 - Chain 22 - Pin Assembly 31 - Plate
4 - Shim, 18 SWG 13 - Spring Pin 23 - Nut 32 - Plate
5 - Bolt 14 - Guide Plate 24 - Bolt 33 - Switch Assembly
6 - Washer 15 - Washer 25 - Cover Plate 34 - Bent Plate
7 - Locknut 16 - Bolt 26 - Bolt 35 - Bolt
8 - Body Pad 17 - Shim 27 - Hardened Washer 36 - Washer
9 - Body HingePin Assembly 18 - Body Prop 28 - Locknut 37 - Spacer
19 - Bolt 29 - Washer 38 - Bolt
Fig. 1 - Body and Mounting
DESCRIPTION OPERATION
The standard body is an all welded construction with all The body control joystick is mounted on the right hand
wear plates fabricated from high hardness side dash panel, adjacent to the transmission shift
(min. 360 BHN) 10150 bar (145000 lbf/in²) yield controller.
strength material. Angled lower body sides reduce
body impacts when loading and a tail chute angle of When the body control lever is operated, a volatge is
25° provides good load retention when travelling without sent to the hydraulic ECU, which converts voltage to
a tailgate. Refer to Section 000-0000, General current. This current controls the body raise and lower
Information for body capacities. proportional pressure control valves, producing a pilot
pressure to shift the control spool in the main hydraulic
The body is pivoted at the rear of the trailer frame and valve. This allows the flow of oil to reach the body
is operated by two single stage, double acting body cylinders, to either raise or lower the body. Refer to
cylinders which are cushioned at both ends of the Section 230-0000, Body System Schematic and
stroke to reduce impact shocks. The body cylinders Section 215-0050, Main Hydraulic Valve.
raise the body to a tipping angle of 65° in 16 seconds
and power down the body in 12 seconds.
SM 2626 12-09 1
Section 270-0010
The three operating positions of the joystick from front
to rear are as follows: WARNINGS
Power Down - The joystick should be moved to this damage, be sure wheel chocks and lifting
position while the body is lowering by gravity and equipment are properly secured and of
should remain in this position until the body is required adequate capacity to perform the task safely.
to be be operated again. The control joystick should
always be kept in 'FLOAT' while the machine is in Exercise extreme caution when lowering
motion. the cylinders from the body. The cylinders will
swing out sharply as they leave their
'LOWER' - Pushing the lever forward propvides mountings.
hydraulic force to power down the body. Pushing the
lever fully forward will engage the electric detent. When 1. Position the vehicle in a level work area, ensure the
the body reaches the body proximity switch, the lever body is fully lowered, apply the parking brake and
springs back to 'NEUTRAL' and the power down action switch off the engine. Turn steering wheel several
is ramped back to allow the body to float down on to times to relieve any pressure in the steering circuit.
the chassis.
'NEUTRAL' - If the body is above the body proximity switch the 'Off' position.
switch, moving the lever to this position will stop and
hold the body at any desired height. If the body is 3. Remove the upper pins securing the body cylinders
below the proximity switch, the hydraulic ECU defaults to the body (1) and secure the body cylinders clear of
the control spool in the main hydraulic valve to the the body (1). Refer to Section 230-0130, Body Cylinder.
NEUTRAL position, and energizes a float solenoid,
allowing the body to float down on to the chassis. The 4. Using suitable lifting equipment, sling the body (1)
body should be fully lowered and in the NEUTRAL assembly at the four lifting points and take an initial
position while the machine is in motion. The lever will strain.
remain in the NEUTRAL position when released.
Note: The approximate weight of the body (1)
'RAISE' - Pulling the joystick back and holding it in this assembly is 5400 kg (11905 lb).
position directs oil to extend the body hoists and raise
the body. When released, the joystick spring back to 5. Remove the bolts (35) and washers (36) securing the
the NEUTRAL position. body hinge pins (9) through the body (1) and pin
mounting bores (via bushing, 2).
In the event of an engine, hydraulic or hydraulic ECU
failure, the body can be lowered using a manual 6. Remove the body hinge pins (9) and shims (17) from
release on the float valve solenoid, which is locatead the body (1) and remove the body (1) assembly from
on the main valve block. the vehicle. If necessary, remove the bushing (2) from
the pin mounting bores.
Note: The body control lever must remain in the
'NEUTRAL ' position until it is necessary to operate the Note: Do not remove body pads (8) and shims (3 and
body again. Failure to comply to this could result in 4) unless the body pads are being renewed.
overheating the hydraulic oil and failure of the
hydraulic system components. 7. If required, remove the locknuts (7), washers (6) and
Note: A proximity sensor (33) prevents the body (1) bolts (5) securing the body pads (8) and shims (3 and
being fully powered down on to the chassis. At a 4) to the body (1) assembly. Remove and discard the
predetermined height, the sensor automatically body pads (8) and shims (3 and 4).
defaults the body control valve to the 'FLOAT'
condition. INSTALLATION
REMOVAL Note: Tighten all fasteners to standard torques listed in

Numbers in parentheses refer to Figure 1. Section 300-0080, Standard Bolt and Nut Torque
Specifications.
2 SM 2626 12-09
Section 270-0010
WARNING 1. Raise the body (1) clear of the trailer frame and lay
To prevent personal injury and property the body pads (8) (metal face down), roughly in position
damage, be sure wheel chocks and lifting on the frame.
adequate capacity to perform the task safely. 2. Lower the body (1) on to the body pads (8).
1. If removed, install the bushings (2) in the pin 3. Centralize the body (1) to the frame and place shims
mounting bores. (3 and 4) under the front two body pads (8) until all
other pads are clear of the body (1).
2. Using suitable lifting equipment, sling the body (1)
assembly and position it over the trailer frame. 4. Slide shims (3 and 4) under the other body pads (8)
until they just make contact with the body (1).
Note: The approximate weight of the body (1)
assembly is 5400 kg (11905 lb). 5. Raise the body (1) and install the body pads (8) and
shim packs (3 and 4) to their relative brackets on the
3. Align the body hinge pin (9) shafts in the body (1) with body (1) securing them with bolts (5), washers (6) and
bushing (2) bores in the trailer frame. Install the body hinge locknuts (7).
pins (9) and shims (17), and secure them with the bolts
(35) and washers (36). 6. Lower the body (1) and check the shimming.
4. Secure the body cylinders to body (1) assembly with 7. Install the body guide plates (14) with spacers (37)
pins and mounting hardware removed during removal. to the mounting brackets on the body (1) setting the
Refer to Section 230-0130, Body Cylinder. gap between plates (14) and the frame at 5 - 10 mm
(0.2 - 0.4 in). Secure the plates (14) and spacers (37)
5. Lubricate the body hinge pins (9) and body cylinder to the mounting brackets with the bolts (16) and
pins with lubricant specified in Section 300-0020, washers (15).
Lubrication System. Lubricate slowly until excess
lubricant is observed.
MAINTENANCE
6. If removed, install body pads (8) and body guide Every 50 Hours: Lubricate the body hinge pins and
plates (14) on the body (1) as described under 'Body body cylinder pins with lubricant specified in Section
Shimming Procedure'. 300-0020, Lubrication System. Lubricate slowly until
excess lubricant is observed.
7. Remove the lifting equipment from the body (1) and
the wheel chocks from all road wheels. CHAIN OPERATED TAILGATE OPTION
8. Start the engine and check for correct operation of
the body (1) assembly. The chain operated tailgate, when fitted features a rear
tailgate (3), two tailgate side arms (1 and 2), trunnion
BODY SHIMMING PROCEDURE mounted to the stub shafts (5) on the sides of the
body, and side chain assemblies that connect the front
Numbers in parentheses refer to Figure 1. ends of the side arms (1 and 2) to support assemblies
(22) bolted to the suspension equalization frames. As
Note: Tighten all fasteners to standard torques listed in the body is lifted, the chains rotate the side arms (1
Section 300-0080, Standard Bolt and Nut Torque and 2) about the axes of the stub shafts (5), thus
Specifications. maintaining the side arms in an approximately
horizontal attitude, and opening up a gap between the
Note: When it becomes necessary, body pads (8) tailgate (3) and the rear end of the body.
should be replaced as a set to maintain load
distribution along the chassis. Existing body pads will
have taken a compression 'set' and a new pad
shimmed to match existing pads will not carry its share
of the load, resulting in uneven load distribution along
the chassis.
SM 2626 12-09 3
Section 270-0010
SM - 3963
11 6 7 28 26
12 25
24
17 20 10 22 26
1 15
21 9
25
A 27
4 23
16
8
7 6 15
5
19
15
5 16,19
9
13
18 14
2 15
3
4 12
21 11
10
20 29 30
31
14 A
18 13
32
17
1 - Left-hand Tailgate Arm Assembly 9- Bush 17 - Grease Fitting 25 - Washer
2 - Right-hand Tailgate Arm Assembly 10 - Thrust Plate 18 - Washer 26 - Nut
3 - Tailgate 11 - Bolt 19 - Spiral Wrap 27 - Bolt
4 - Locking Plate 12 - Washer 20 - Bolt Locking Plate 28 - Lifting Lug
5 - Stub Shaft 13 - Bolt 21 - Shim 29 - Adapator
6 - Bolt 14 - Locknut 22 - Support Assembly 30 - Elbow
7 - Lockwasher 15 - Shackle 23 - Tie Plate 31 - Hose Assembly
8 - Shim 16 - Chain 24 - Bolt 32 - Coupling
Fig. 2 - Chain Operated Tailgate Assembly (Option)
TAILGATE REMOVAL side arms (1 and 2) and tailgate (3) together, and
remove the locking plates (4), if necessary. The side
arms (1 and 2) are applied with a retaining compound
WARNING (Loctite™ 648) on assembly to the tailgate (3), and
To prevent personal injury and property may not readily be separated from the tailgate (3).
equipment are properly secured and of 5. Remove the tailgate (3) to a prepared area.
adequate capacity to perform the task safely.
6. Transfer the lifting tackle to one of the tailgate side
1. Position the vehicle in a level work area, ensure the arms (1 or 2) and take up the slack.
switch off the engine. Turn steering wheel several 7. Disconnect the shackle (15) at the lower end of the
times to relieve any pressure in the steering circuit. respective chain (16) from the location on the
respective support assembly (22).
switch the 'Off' position. 8. Bend down the corners of the locking plate (20) to
allow the bolts (11) and washers (12) to be removed.
3. Attach lifting tackle to the attachment point on the Remove the adapter (29) from the locking plate. Undo
top of the tailgate (3) and take up the slack. and remove elbow (30), hose (31) and coupling
(32).Undo and remove the bolts (11), washers (12),
4. Undo and remove the bolts (13) with nuts (14) and locking plate (20), thrust plate (10) and the shim (21),
washers (18) securing the locking plates (4), tailgate if fitted. Discard the locking plate (20) and fit a new
one on assembly.
4 SM 2626 12-09
Section 270-0010
9. Carefully manipulate the tailgate side arm (1 or 2) off prepared area. Repeat this step for the stub shaft on
the stub shaft (5), and remove it to a prepared area. the other side arm (2 or 1 respectively).
10. Remove the bush (9) from the aperture of the
tailgate side arm (1 or 2), if required. The bush is an TAILGATE INSTALLATION
interference fit in the arm and therefore it will be Numbers in parentheses refer to Figure 2.
necessary to use a bearing puller to assist in the
removal process. Note: Tighten all fasteners to standard torques listed in
Section 300-0080, Standard Bolt and Nut Torque
11. Transfer the lifting tackle to the other tailgate side Specifications.
arm (2 or 1) and take up the slack.
12. Disconnect the shackle (15) at the lower end of the WARNING
respective chain (16) from the location on the To prevent personal injury and property
respective support assembly (22). damage, be sure wheel chocks and lifting
13. Bend down the corners of the locking plate (20) to adequate capacity to perform the task safely.
allow the bolts (11) and washers (12) to be removed.
Undo and remove the bolts (11), washers (12), locking 1. Apply Loctite™ 243 (anaerobic threadlock) to bolts
plate (20), thrust plate (10) and the shim (21), if fitted. (6), then secure both stub shafts (5) to the side walls of
Discard the locking plate (20) and fit a new one on the body using the bolts (6) and lockwashers (7).
assembly.
Note: Ensure that the stub shaft is fitted with the radial
14. Carefully manipulate the tailgate side arm (2 or 1) grease aperture uppermost.
off the stub shaft (5), and remove it to a prepared area.
2. Attach the support assemblies (22) to the lugs on
15. Remove the bush (9) from the aperture of the the top of the left-hand and right-hand equalization
tailgate side arm (2 or 1), if required. The bush is an beams using the bolts (24), washers (22) and nuts (23).
interference fit in the arm and therefore it will be
necessary to use a bearing puller to assist in the
removal process.
SM 3907
16. Undo and remove the bolt (24) with nut (26) and
washer (25) securing one of the tie plates (23) to the
lug on the bottom of the respetive equalization beam.
17. Support the weight of the tie plate (23), then undo
3 374 CHECK SIZE
and remove the bolt (27) with nut (26) and washer (25)
securing the tie plate (23) to the support assembly (22).
Remove the tie plate (23) to a prepared area.
18. Support the weight of the support assembly (22),

then undo and remove the bolts (24) with nuts (26) and
washers (25) securing the support assembly (22) to the
lugs on thetop of the equalization beam. Remove the
support assembly (22) to a prepared area. Repeat
steps 16-18 for the other support assembly (22) and tie
plate (23).
Fig. 3 - Side Arm Check Size
19. Undo and remove the four bolts (6) with
lockwashers (7) securing one of the stub shafts (5) to
the side of the body. Remove the stub shaft to a
SM 2626 12-09 5
Section 270-0010
3. Attach the tie plates (23) to the support assemblies 6. Refer to Figure 4. Fit the two grease lubrication
(22) and to the lugs on the bottom of the equalization hoses (3) complete with elbows (2) and adapters (1) to
beams. the stub shafts (5, Figure 2). Fit the couplings and
grease nipples (17, Figure 2) to the bottom of the
3. Install a bush (9) to each of the two tailgate side hoses (3).
arms (1 and 2 respectively).
7. Apply retaining compound (Loctite™ 638) to the
Note: The bushes (9) may be a tight fit in the side areas of the tailgate (3) identified on Figure 5 below, at
arms (1 and 2). Take care not to damage the bushes if BOTH ENDS of the tailgate (3).
using mechanical assistance during the installation
process. SM 3910
4. Lift both tailgate side arms (1 and 2) into position on

their respective stub shafts (5), correctly orientated. mm
200
Measure the linear distance between the two side arms
(1 and 2), which should be in accordance with the
reference dimension identified on Figure 3. If
necessary, remove the side arms (1 and 2) and insert
sufficient shims (8) over the stub shafts (5), in order to
achieve the reference dimension of 3374 mm, then re- mm
200
fit the side arms (1 and 2) and check the dimension
again.
5. Fit a thrust plate (10) to each stub shaft (5), Fig. 5 - Retaining Compound Application Areas
orientated as shown on Figure 4 below, securing them
with the locking plates (20), bolts (11) and washers 8. Transfer the lifting tackle to the tailgate (3) and lift it
(12). Ensure that the thrust plates (10) are secured to into position at the rear of the body. Loosely assemble
the stub shafts (5) and NOT to the side arms (1 and 2 the tailgate (3) with the side arms (1 and 2) and the
respectively). If a thrust plate is impinging on a side locking plates (4), using the bolts (13), washers (18)
arm, undo the bolts (11), remove the bolts (11), and lock-nuts (14).
washers (12), locking plate (20) and thrust plate (10),
then fit a shim (21), and finally re-fit the thrust plate, 9. Manipulate the tailgate (3) until it makes contact with
(10), locking plate (20), bolts (11) and washers (12). the rear lip of the body. Tighten the bolts (13) with
There must be a clearance between each side arm (1 washers (18) and lock-nuts (14), in accordance with
and 2) and their respective thrust plate (10) of 0.3-1.3 Section 300-0080, Standard Bolt and Nut Torque
mm. Bend up the corners of the locking plates (20) Specifications.
against the flats of the bolts (11) on completion.
10. Manually operate the side arms (1 and 2) to ensure
that the tailgate (3) operates correctly, and does not
impinge on the top of the body in its lifted position.
SM 3909
11. Lubricate the tailgate (3) via the grease nipples

(17), until excess lubricant can be observed exiting the
pivot bushes (9).
12. Fit the support assemblies (22) to the respective

equalization beams using the bolts (24), washers (25)
and nuts (26).
1
2 13. Attach the tie plates (23) to the equalization beams
3
LEFT-HAND RIGHT-HAND
using the bolts (24), washers (25) and nuts (26).
14. Attach the other ends of the tie plates (23) to the
Fig. 4 - Orientation of Thrust Plates
support assemblies (22) using the bolts (27), washers
(25) and nuts (26).
6 SM 2626 12-09
Section 270-0010
15. Fit the chains (16) with shackles (15) to the drilled
lugs at the forward end of the side arms (1 and 2) and
to the corresponding drilled lugs on the top of the
support assemblies (22).
Note: The tailgate (3) should begin to open when the

body has tlited 2° from the horizontal. If necessary,
remove chain links to achieve this action. DO NOT
remove sufficient links to allow the axis of either chain
(16) to coincide with an imaginary axis between the
respective tailgate pivot point and the chain location
point on the associated support assembly (22), when
the body is fully open.
16. When the chains (16) have been adjusted to their

required length, cut appropriate lengths of spiral wrap
(19) to cover as much of the chains (16) as possible.
TAILGATE MAINTENANCE
Every 50 Hours: Lubricate the tailgate stub shafts (5)
with lubricant specified in Section 300-0020,
Lubrication System. Lubricate slowly until excess
lubricant is observed.
* * * *
SM 2626 12-09 7
Section 270-0010
8 SM 2626 12-09
Miscellaneous - Lubrication System
Section 300-0020
LUBRICATION AND SERVICE

SAFETY PRECAUTIONS
Do not allow unauthorised 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 at
safety precautions detailed throughout this manual. maximum gradeability as designated in the
'Performance Data' section of the relevant Sales
Always attach a DO NOT OPERATE or similar warning Specification Sheet.
sign to the ignition switch or a prominent control before
cleaning, lubricating or servicing the vehicle. Lubrication is an essential part of preventive
maintenance. It is important that the instructions
Never allow anyone to work on the vehicle while it is regarding lubricant specifications, and the frequency of
moving. Make sure there is no one on the vehicle their application, be followed to prolong the useful life
before working on it. of the vehicle. Periodic lubrication of moving parts
reduces to a minimum the possibility of mechanical
Do not work under or near an unblocked or unsupported failures.
body. Always use the body prop. The body prop must only
be used when the body is empty. All change periods are recommendations based on average
operating conditions. Lubricants showing evidence of
Always install the steering lock bar before making excessive heat, oxidation or dirt should be changed more
adjustments or servicing the vehicle with the engine frequently to prevent these conditions.
running.
Lubricant change and service periods must be
Do not work under or near any unblocked or established on the basis of individual job conditions
unsupported linkage, part or vehicle. utilizing oil sampling and recommendations from
lubricant suppliers.
Always relieve pressure before servicing any
pressurized system. Follow the procedures and safety Thoroughly clean all fittings, caps and plugs, to prevent
precautions detailed in the relevant Maintenance dirt from entering any system while carrying out
Manual section. servicing procedures. Lubricants must be at normal
operating temperature when draining.
When changing oil in the engine, transmission and
hydraulic system, or removing hydraulic lines, Note: Do not operate any system unless oil level is
remember that the oil may be hot and can cause burns within the recommended operating levels as indicated
to unprotected skin. on oil level dipstick, sight gauge or level plug.
When working on or around exhaust components, Small circles on the following illustration represent
remember that the components may be hot and can points at which lubrication and/or servicing must take
cause burns to unprotected skin. place, at the intervals indicated on the left hand side of
the lubrication and service chart.
Always deflate the tyre before trying to remove any
embedded objects or removing the tyre and rim The numbers on the illustration contain reference
assembly from the vehicle. numbers which correspond to the reference numbers in
the 'Ref. Points' column of the lubrication and service
Always use a self-attaching chuck with a long airline, chart.
and stand to one side while inflating the tyre. Refer to
Section 160-0050, Wheel Rim and Tyre.
SM 2627 01-10 1
Section 300-0020
1795
13 29 11 9 12 18 19 25 17 16 10
28
35
24
31
5
7
33 32 30 15 2 12 21 34 22 26 17 20 8 27 23
4 3 14
Lubrication and Servicing Points
LUBRICATION AND SERVICE CHART

Interval Ref. No. of Lubricant or Service
Hours Points Identification Service Instructions Points Coolant Quantities
1 Engine Check oil level. Add oil if low. 1 EO As required.
1 Engine Crankcase Breather Inspect and clean if required. 1
10 2 Transmission Check oil level. Add oil if low. 1 TranSynd /
TES295* See note 2.
(Daily) 3 Hydraulic Tank Check oil level. Add oil if low. 1 HO As required.
4 Radiator Expansion Tank Check coolant level. Add if low 1 Ethylene Glycol As required.
5 Primary Fuel Filter / Check. Drain as required. 1 -
Water Separator
14 Dropbox Check oil level. Add oil if low. 1 EO See note 7.
32 OCDB Tank Check oil level. Add oil if low. 1 Textran TDH As required.
Premium
11 Engine Air Cleaner Check. Renew element if required
6 Drive Belt Visual inspection for damage. 1
27 Tyres Check condition and pressure. 6
7 Battery Electrolyte Check level. Add electrolyte if low. 2 As required.

8 Wheel rim nuts Check Torque. 114 600 Nm / 442 Ibf ft
50 9 Cab fresh air Filter Inspect and clean if required. 1
(Weekly) 10 Panhard Rod Bearings Lubricate 4 EP, NLGI See Note 3.
19 Oscillation Bush Lubricate 2 EP, NLGI See Note 3.
20 Suspension Beam Bushings Lubricate 2 EP, NLGI See Note 3.
21 Steering Cylinder Pins Lubricate 4 EP, NLGI See Note 3.
22 Body Cylinder Pins Lubricate 4 EP, NLGI See Note 3.
23 Body Hinge / Tailgate Pins Lubricate 2 EP, NLGI See Note 3.
2 Transmission Breather Clean if required. 1

5 Primary Fuel Filter/Water
250 Separator Renew 1
(Monthly) 15 Secondary Fuel Filter Renew 1
16 Differentials Check oil level. Add oil if low 3 EPL & LZ As required.
17 Wheel planetaries Check oil level. Add oil if low 6 EPL As required.
18 Articulation Bearings Lubricate 2 EP LI COMP See Notes 3 and 4.
19 Oscillation Pivot Check end float. Adjust if required. 1
25 Parking Brake Pads Check wear. Replace if required. 2
6 Drive Belt Check tension. Tighten if required 1
2 SM 2627 Rev1 12-10

Section 300-0020
LUBRICATION AND SERVICE CHART (Continued)

Interval Ref. No. of Lubricant or Service
Hours Points Identification Service Instructions Points Coolant Quantities
1 Engine Drain oil and refill with new oil. 1 EO 32 Litres / 8.4 US
Gal.
500 (3 13 Engine Oil Filters Renew 2
Monthly) 14 Drop box Drain oil and refill with new oil. 1 EO 13 Litres / 3.4 US
Gal.
14 Dropbox Oil Filter Renew 1
1000 (6 11 Engine Air Cleaner Renew Element

Monthly) 28 Coolant Additive Renew
9 Cab Fresh Air Filter Renew 1
29 Fuel Tank Breather Renew 1
30 Hydraulic Tank Breather Renew 1
31 OCDB Tank Breather Renew 1
26 Driveshaft Bearing Check oil level. Add if low. 1 EPL See note 6.
32 OCDB Tank Drain oil and refill with new oil. 1 Textran TDH 115 Litres / 30.5 US
Premium Gal.
16 Differentials Drain oil and refill with new oil. 3 EPL and LZ See Note 5
1500 (9 17 Wheel Planetaries Drain oil and refill with new oil. 6 EPL 9 Litres / 2.4 US Gal.
Monthly) 33 OCDB Filter Renew 1
33 OCDB Strainer Clean 1
3 Hydraulic Tank Drain oil and refill with new oil. 1 HO 298 Litres / 79 US Gal.
3 Hydraulic Oil Filter Renew 1
2000 6 Drive Belt Renew belt 1
(Annu- 24 Cooling System Check concentration, add booster. 1 Ethylene 67 Litres / 18 US Gal.
ally) Glycol
34 Articulation Pivot Nut Check Torque (Torque seal). 1 1425 Nm / 1050 lbf ft.
2 Transmission Mtg. Bolts Check Torque (Torque Seal). 2 921 Nm / 680 Ibf ft.
1 Turbocharger Mtg. Nuts Check Torque (Torque Seal). 2 921 Nm / 680 Ibf ft.
1 Engine Mtg. Bolts Check Torque (Torque seal). 2 330 Nm / 239 Ibf ft.
3000 12 Transmission Oil Filters Renew 2
4000 35 Air Conditioning Compressor Drain flush and refill with new oil 1 PAG Oil 0.125 Litres
6000 2 Transmission Drain oil and refill with new oil. 1 TranSynd / 61 Litres / 16 US Gal.
TES 295*
* - When determining whether a fluid is TES 295 approved or not look and/or ask for one of two things - The Allison
TES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on Page 7. If
uncertain if a fluid is approved, consult Allison Transmission for confirmation.
Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and
'Miscellaneous Servicing' contained on the following pages.
SM 2627 Rev1 12-10 3

Section 300-0020
Notes on 'Lubrication and Service Chart' PAG Oil - Polyalklene Glycol (PAG)
Compressor Lubricating Oil - Low
Note 1 - Capacities given are approximate - work to
Viscosity (ISO46).
dipstick, sight gauges or level plugs.
Note 2 - Check with the engine idling and the

transmission at its normal operating MISCELLANEOUS SERVICING
temperature.
WHEN REQUIRED
Note 3 - Lubricate slowly until excess lube is seen. Seat Belts - Inspect for damage and replace if
required.
Note 4 - Remove plugs and fit lube fittings.
Lubricate slowly until excess lube is seen. Note: Replace seat belts at least once every three
Remove fittings and refit plugs. years, regardless of appearance.
Note 5 - Capacity of front and rear differentials Windscreen Wipers and Washers - Inspect wiper
33 Litre (8.7 US Gal.) capacity of centre blades and replace if damaged. Top up washer
differential 34 Litre (9 US Gal.) plus 1 Litre (2 reservoir.
Pints) for priming the 3rd differential unit (36
Litre EPL + 2 Litre LZ 6178). Wheel Rim Nuts - After first 10 hours of operation
re-torque nuts to 600 Nm (442 lbf ft).
Note 6 - Remove plug from the port on underside of
the oscillation hub. Plug is removed to drain Note: Torque should be applied in 3 stages. Nuts to
the cavity of any oil that enters the cavity be torqued crosswise (i.e. opposing pairs). Check
when filling. Remove grommet and level plug torque every 50 hours (weekly) thereafter.
on the side of the oscillation hub. Add oil if
required. Refit all plugs. Engine - Steam clean the engine prior to performing
any repair or service work on it, and if heavily
Note 7 - Check Dropbox level cold with engine running contaminated due to prevailing site conditions.
CAUTION
Electrical and electronic connections, the
Engine ECM and harness connections should
EO - Engine Oil. Refer to 'Recommended be protected or not directly steam cleaned when
Lubricants'. on or removed from the engine.
*- Refer to chart under 'Recommended
Lubricants'.
Note: The engine and its components that are
HO - Hydraulic Oil. Refer to 'Recommended scheduled to be checked, serviced or replaced must
Lubricants'. be cleaned in accordance with the manufacturer's
recommendations.
EPL - Extreme Pressure Lubricant
specification MIL-L21058. EVERY 10 HOURS OF OPERATION (DAILY)
EP, NLGI - Extreme Pressure, Lithium No. 2 Walk Around Inspection - Inspect the vehicle as
Grease (without Molybdenum), Ref. described in Section 4 of the Operator's Handbook.
EEMS 19014
Engine - Visually check engine for damage, loose or
EP LI COMP - Extreme Pressure Lithium Complex frayed belts and listen for any unusual noises.
Grease. Ref. EEMS 19057
Engine Air Cleaner - Change air cleaner element
LZ - Lubrizol 6178 only when the yellow band of the air restriction gauge
locks up in the orange. Service vacuator valve daily.
Inspect and remove any obstructions from the
vacuator valve lips which should be open and pliable
with the engine stopped.
4 SM 2627 Rev1 12-10

Section 300-0020
Note: Service air cleaners more often when operating vehicle, particularly the chassis, for cracks or broken
under extremely dusty conditions. welds. Repair where necessary.
Engine Crankcase - Check oil level and replenish it if Parking Brake - Check pads and disc for wear.
low. A cold level check should always be done prior to Adjust or replace if required. Test for proper function.
starting the vehicle, to ensure that sufficient oil is in the Thickness of pad friction material should never be
system to allow the unit to be run to operating temp to allowed to wear below 3 mm (0.12 in).
perform a hot level check.
Note: This service interval applies to normal driving.
Transmission - Check the oil level and replenish it if Check the pads more frequently under more severe
low. Refer to Section 120-0010, Transmission and conditions. Thickness of pad friction material should
Mounting, for correct oil level check procedure. never be allowed to wear below 3 mm (0.12 in).
Hydraulic Tank - Check the oil level and replenish it Oil Can Points - Oil working parts with engine oil.
if low.
Brake Coolant Tank - Check the oil level and EVERY 500 HOURS OF OPERATION
replenish it if low. Dropbox Oil Filter - Remove and renew.
Radiator - Check coolant level and replenish it if low. Dropbox - Drain oil and refill with new oil.
Fill the radiator header tank with coolant until coolant
EVERY 1000 HOURS OF OPERATION (6 MONTHS)
reaches the bottom of the filler neck and holds at
that level. Hydraulic Oil Filter - Clean filter housing and install
new element when indicated, or after 1000 hours of
Note: Any time a significant amount of coolant is operation, whichever comes first.
concentration is low, engine damage will result. Brake Coolant Tank - Replace breather.
Conversely, over-inhibiting antifreeze solutions can
result in silicate dropout. Refer to Section Articulation Vertical Bearings - Remove plugs and
210-0000, Cooling System. fit lube fittings. Lubricate slowly until excess lube is
seen. Remove lube fittings and refit plugs.
AFTER FIRST 100 HOURS OF OPERATING NEW OR
REBUILT COMPONENTS Driveshaft Bearings - Remove the plug from the port on
the underside of the oscillation hub. The plug is removed
Hydraulic Oil Filter - Clean filter housing and install
to drain the cavity of any oil that enters the cavity when
new element at 100 hours of operation, or when
filling. Remove grommet and level plug on side of
indicated, whichever occurs first.
oscillation hub. Add oil if required. Refit all plugs.
Note: A 6 µm filter is used to flush the system. This
Grease Points - Grease door hinges.
is replaced with a 12 µm filter for normal use. See
vehicle Parts Book for filter part numbers. EVERY 1500 HOURS
Axles - Drain lubricant and refill to level plugs.
Brake Cooling Oil Filter - Clean the filter within the
brake coolant tank after 100 hours of operation. Note: When refilling centre axle ensure that 3rd
differential unit is primed with 1 l (1.75 UK pints) of oil
AFTER FIRST 250 HOURS OF OPERATING NEW OR before filling drive head.
REBUILT COMPONENTS
EVERY 2000 HOURS
Front Suspension - Check ithat the pre- Drivelines - Visually check Low Maintenance
compressed length of the rubber mounts is 203 drivelines for leaking or damaged seals.
mm.
Note: Low Maintenance drivelines can be identified
EVERY 250 HOURS OF OPERATION by having plugs fitted to the spiders, not grease
nipples.
General Inspection - Check entire vehicle for leaks,
loose bolts and nuts or damaged parts. Examine the
SM 2627 01-10 5
Section 300-0020
Note: When service is required, remove the plug and ENGINES AND TRANSMISSIONS
fit a grease nipple. Grease the spider and refit the
plug when finished. Use Type K lubricating grease in All information contained in the 'Lubrication and Service
accordance with DIN 51825-KP2-K-40. Chart' was extracted from the relevant manufacturer's
Operators Manual and was correct at time of publication.
Hydraulic Oil Tank - Drain oil, remove and clean Users should ensure that information contained in this
suction screens and strainers. Reinstall suction chart, regarding Engines and Transmissions, reflects the
screens and strainers and refill hydraulic oil tank. information shown in the relevant manufacturer's
Operator's Manuals supplied with the vehicle.
EVERY 3000 HOURS Maintenance procedures should be carried out in
Transmission - Replace oil filter and lube oil filter. conjunction with any additional procedures contained in
the relevant manufacturer's 'Operation and Maintenance
EVERY 6000 HOURS Manual', at the intervals specified.
Transmission - Drain oil and refill to level.
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS
Engine Engine Oil with 1.00% 32 l See Engine Approved Fluids and Lubricants
(Including Filters) sulphated ash limit is (9.8 US gal) Chart.
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission 61 l See TranSynd / TES 295 Oil Table.
(Including Filters) TranSynd / TES 295 (16.1 US gal)
(Dry Fill)
Hydraulic System Hydraulic Transmission Oil 330 l See Hydraulic Oil Table (Including Lines)
(87 US gal) (See Note 1)
Cooling System Anti-freeze, Ethylene 67 l

Glycol (18 US gal)
Differential Extreme Pressure 33 l each
(Front) Gear Lubricant (8.7 US gal)
Differential Extreme Pressure 34 l
(Centre) Gear Lubricant (8.9 US gal)
Differential Extreme Pressure 33 l
(Rear) Gear Lubricant (8.7 US gal)
Planetaries - Extreme Pressure 9 l each
Gear Lubricant (2.4 US gal)
Dropbox EO 13 l
(3.4 US gal)
Fuel Tank Diesel Fuel Oil with 481 l DIN EN590
max. sulphur 0.5% (127 US gal)
Grease Nipples** Extreme Pressure
Lithium Grease
Driveshaft Through Extreme Pressure 1.50 l MIL-L-2105 D
Bearings Gear Lubricant (0.40 US gal)
Articulation Extreme Pressure EMS 19057
Bearings Lithium Complex
Air Conditioning Polyalklene Glycol (PAG) 0.125 l ISO46
Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10
Low Viscosity
Brake Cooling Hydraulic Transmission Oil 175 l See Brake Cooling System Approved Lubricants
System (42.6 US gal)
6 SM 2627 01-10
Section 300-0020
TES295 APPROVED OILS

Approval Number Approved Maker Product Brand Name
AN-011001 Castrol Heavy Duty Lubricants Transynd
AN-031002 BP Autran Syn 295
AN-031003 Cognis Corporation Emgard 2805
AN-031004 International Truck & Engine Co. Fleetrite Synthetic ATF
AN-031005 Exxon Mobile Lubricants Mobile Delvac Synthetic ATF
and Petroleum Specialities Co.
* - When determining whether a fluid is TES 295 approved or not look and/or ask for one of two things - The Allison
TES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on the following
page. If uncertain if a fluid is approved, consult Allison Transmission for confirmation.
Recommended Lubricant notes
* - Capacities given are approximate, work to dipstick, Note 2 - Hydraulic Transmission Oil meeting
sight gauges or level plugs. Specification EMS19058 is also suitable for use in the
hydraulic system.
** - Refer to the 'Lubrication and Service Chart' for the
different applications. DO NOT use on the Articulation Note 3 - Axles have limited slip differentials. If use of a
bearings. standard SAE 90 oil results in very loud noise and
jerking of the wheels when driving slowly round sharp
Note 1 - Operation below the minimum temperatures corners, an EP oil with limited slip additives should be
listed for the oil used without proper pre-heat or used.
warm-up results in greatly reduced transmission life.
Proper warm-up requires 20 minutes minimum
operation in neutral (with engine at part throttle) before
operating the transmission in gear.
LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) TEMPERATURE

SM - 637
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
Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.
SM 2627 01-10 7
Section 300-0020
DIFERENTIAL AND PLANETARY APPROVED LUBRICANTS

ZF Lubricant class 05C Gear oil with limited-slip-additives
Viscosity grades: SAE 75W-90 / 75W-110 / 75W-140 / 80W-90 / 80W-110 / 80W-140 / 85W-90 / 85W-110 / 85W-140 / 90
Manufacturer (05C) Trade name (05C)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GH 80W-90 LS
ADDINOL GETRIEBEÖL GH 85W-90 LS
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP ROTRA MP/S
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL HYP LS 90
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA HYPOID 90 LS
AVIA HYPOID 90 LS, 85W-90
BAYWA AG, MÜNCHEN/D BAYWA GETRIEBEÖL HYPOID LS 90
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH GETRIEBEÖL LS 85W90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR LIMSLIP 90
FRONTOL GETRIEBEÖL LS 90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL UNIVERSAL LS 80W/90
CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM GEAR OIL LS 90
CASTROL INTERNATIONAL. PANGBOURNE READING/GB CASTROL HYPOY LS 90
CASTROL LSX
CHEVRON BRASIL LTDA, RIO DE JANEIRO/BRAZIL GEARTEX LS 85W140
CHEVRONTEXACO, GHENT/B GEARTEX LS 80W-90
GEARTEX LS 85W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX GEAR OIL ZF SAE 80W-90
CLAAS KGAA MBH, HARSEWINKEL/D CLAAS AGRISHIFT BLS 90
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR T ( 90 )
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR SUPER GEAR OIL LS 80W90
ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENGEN GEARLUBE EP 90 LS - SAE 80W-90
ENI S.P.A. REFINING & MARKETING DIVISIO, POME/I AGIP ROTRA MP/S 85W-90
EXXON MOBIL CORPOATION,FAIRFAX, VIRGINIA/USA ESSO GEAR OIL LSA 85W-90
MOBILUBE LS 85W-90
FINKE MINERALÖLWERK GMBH, VISSELHÖVED/D AVIATICON HYPOID LS 90
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA AXLEPOWER (80W90)
AMBRA AXF 80W90
AMBRA STF (80W90)
TUTELA W990/LS (SAE 80W-90)
FUCHS PETROLUB AG, MANNHEIM/D TITAN GEAR LS 90
GINOUVES GEORGES SA, LA FARLEDE/F YORK 698 LS
GRUPA LOTOS SA, GDANSK/PL LOTOS TITANIS LS GL-5 SAE 85W/140
LOTOS TITANIS LS GL-5 SAE 80W/90
GS CALTEX CORPORATIION, SEOUL/ROK DIC LS GEAR OIL 80W/90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR LS 90
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENDALL SPECIAL LIMITED SLIP AXLE GEAR LUBE 80W/90
HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 90 GL
IGOL FRANCE SA., AMIENS/F HYPOID BPA SAE 90
KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KOMPRESSOL-HYPOID LS SAE 90
KROON-OIL B.V.,ALMELO/NL GEAR OIL LS 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 45 SAE 90
LIQUI MLLY GMBH, ULM/D HYPOID GETRIEBEÖL GL 5 SAE 85W-90 LS
IMAZIVA ZAGREB D.O.O., ZAGREB/HR INA HIPENOL GTL LS 90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 LS
MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL SPERRDIFFERENTIAL HYPOID GETRIEBEOEL LS90
MOL-LUB KFT., ALMÿSFÜZITÖ/H MOL HYKOMOL LS 85W-90
NORTHLAND PRODUCTS COMPANY, WATERLOO/USA POSI-GRIP JDZF 80W90
NOVA STILMOIL SPA, MODENA/I GEARING WONDER LS SAE 85W90
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST GETRIEBEÖL HYPOID LS 90
OK NEDERLAND, STAPHORST/NL OK CARDAN OIL MP-B-LS SAE 80W/90
QUINTOL CARDAN OIL LS-90
PAKELO MOTOR OIL S.R.L., SAN BONIFACIO (VR)/I PAKELO UNIVERSAL GEAR EP/LS SAE 85W/140
PAKELO UNIVERSAL GEAR EP/LS SAE 80W/90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY LS 90
PETROLGAL SA., LISBOA/P GALP LS 90
PTT PUBLIC COMPANY LIMITED, BANGKOK/TH PTT LIMITED SLIP (SAE 80W-90)
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SPERRDIFF.-GETR.-OEL LS 90
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E CS EP AUTOBLOCANTE SAE 85W140
S.A.E.L., MADRID/E GULF LS REAR AXLE OIL 80W-90
SRSA SCHMIERSTOFF VERTRIEB GMBH. SALZBERGEN/D WINTERSHALL WIOLIN RSH
SUOMEN PETROOLI OY, HAMINA/FIN TEBOIL HYPOID LS SAE 80W-90
TOTAL LUBRIFANTS S.A., PARIS/F ANTAR BLS 90
ELF TRACTELF BLS 90
TOTAL LUBRIFANTS S.A., PARIS/F FINA TRANSFLUID LS 80W-90
TOTAL DYNATRANS DA 80W-90
UNIL OPAL, SAUMUR CEDEX/F UNIL OPAL GEAR AB-EP SAE 85W90
YACCO, ST PIERRE LES ELBEUF/F BVX LS 200
ZF Lubricant class 05D Gear oil with limited-slip-additives

Manufacturer (05D) Trade name (05D)
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP HLZ, SAE 75W-140
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR SHX-ZR 75W-140
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL GEARLUBE VS 500
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL GETRIEBFLUID BMS PLUS
TOTAL LUBRIFANTS S.A., PARIS/F FINA PONTONIC MLX 75W-140
TOTAL TRANSMISSION LS 75W-140
8 SM 2627 01-10
Section 300-0020
BRAKE COOLING SYSTEM APPROVED LUBRICANTS

ZF Lubricant class 05F Universal Tractor Transmission Oil (UTTO)
Manufacturer (05F) Trade name (05F)

76 LUBRICANTS (CON0C0PHILLIPS COMP.), HOUSTON/USA 76 HYDRAULIC/TRACTOR FLUID
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL UTTO SAE 10W30
ARAL AG, BOCHUM/D ARAL FLUID HGS 10W-30
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA HYDROFLUID DLZ
BAYWA AG, MÜNCHEN/D BAYWA HYDRA HYDRAULIKFLUID
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER TRANSMISSION 10W-30
BP TERRAC SUPER TRANSMISSION CVT 10W-30
BP TRACTRAN TF 10 10W-30
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX POLYFARM 304
CASTROL INTERNATIONAL, PANGBOURNE, READING/GB CASTROL AGRI TRANS PLUS 10W-30
CASTROL AGRI TRANS PLUS CVT 10W-30
CATERPILLAR INC. PEORIA/USA CATERPILLAR MULTIPURPOSE TRACTOR OIL (MTO) 10W-30
CEPSA LUBRICANTS S.A., MADRID/E CEPSA AURIGA TE 55 (SAE 10W-30)
CHEVRONTEXACO, GHENT/B TEXTRAN TDH
TEXTRAN TDH PREMIUM
CLAAS KGAA MBH, HARSEWINKEL/D CLAAS AGRISHIFT GA 12
CNH, BURR RIDGE/USA CASE TRANSAXLE FLUID 80W-140
NEW HOLLAND TRX FLUID 80W-140
ENGEN PETROLEUM LTD.,CAPE TOWN/ZA ENGEN AGRIFLUID
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL AGRIFLUID 424
MOBIL FLUID 424
MOBIL FLUID 426
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA NEXPLORE (SAE 10W-30)
AKCELA TRANSAXLE FLUID (SAE 89W-140)
AMBRA MULTI G
AMBRA TRX 20W-40
AMBRA TRX 80W-140
FUCHS PETROLUB AG, MANNHEIM/D AGRIFARM UTTO MP
TITAN UTTO HYDRA
TITAN UTTO J20C
TITAN UTTO ZF SAE 20W-40
GINOUVES GEORGES SA, LA FARLEDE/F YORK 6766 10W30
IGOL FRANCE SA, AMIENS/F TICMA FLUID MU SAE 80W
JOHN DEERE, MANNHEIM/D JOHN DEERE HY-GARD
KENDALL MOTOR OIL (CONOCOPHILLIPS C.) HOUSTON/USA KENDALL HYKEN 052
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NI Q8 T 2000
Q8 T 2200
LURICANT OIL COMPANY, SINOPEC, BEIJING/CN HYDRAULIC-TRANSMISSION MULTIFUNCTIONAL FLUID 10W30
MAZIVA ZAGREB D.O.O., ZAGREB/HR INA TRANSHIDROL JD 50
INA TRANSHIDROL ZF 20W-40
OMV REFINING & MARKETING GMBH, WIEN/A OMV AUSTROMATIC IGB SAE 10W-30
PAKELO MOTOR OIL S.R.L., SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 10W/30
PAKELO UTTO FLUID 4D SAE 20W/40
PANOLIN AG, MADETSWIL/CH PANOLIN JD 303
PETROGAL SA.,LISBOA/P GALP TRALUB 807S
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL UTTO
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E AGRO ORION SAE 10W30
SAVITA CHEMICALS LTD., MUMBAI/IND SAVSOL 315 HAT
SHELL INTERNATIONAL PETROLEUM COMP LTD., LONDON/GB SHELL DONAX TD 10W-30
SHELL DONAX TD 5W-30
SHELL DONAX TDS 10W-30
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL HYDROFLUID N
STRUB + CO AG, REIDEN/CH VULCOTRAC UTTO SAE 20W-40
SUOMEN PETROOLI OY, HAMINA/FIN TEBOIL WETOL
TOTAL LUBRIFANTS S.A., PARIS/F ANTAR TRANSAGRIA THF 16
ELF TRACTELF BF 16
TOTAL DYNATRANS LS 20W-40
TOTAL DYNATRANS MPV
WOLF OIL CORPORATION N.V., HEMIKSEM/B WOLF UTTO 170 VOLVO BM SAE 10W30
ZF Lubricant class 05G Universal construction- machinery oil
Manufacturer (05G) Trade name (05G)

ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-POWERFLUID
ZF Lubricant class 05H Biodegradable lubricants

Viscosity grade: SAE 75W-80
Instructions on the use of biodegradable lubricants:
The oil manufacturer's change-over directives included in the product description are to be observed when change-over to
biodegradable lubricants is effected.
Manufacturer (05H) Trade name (05H)

PANOLIN AG, MADETSWIL/CH PANOLIN BIOFLUID LS
SM 2627 01-10 9
Section 300-0020
ENGINE APPROVED FLUIDS AND LUBRICANTS
Multigrade Oils - Category 2, SAE-grades 10W-40, 15W-40 for Diesel Engines
Manufacturer Brand Name SAE Viscosity

Class
Addinol Lube Oil Addinol Diesel Long life MD 1047 10W-40

Addinol Diesel Long life MD 1548 15W-40
Anomina Petroli Italiana IP Taurus Turbo Plus 15W-40
API D Multi Diesel Turbo 15W-40
Arabi Enertech KSC Burgan Diesel CH-4 15W-40
BP p.l.c BP Vanellus C6 Global 15W-40

BP Vanellus E6
BP Vanellus C7 Global
BP Vanellus Multi-Fleet
BP Mine Multi 15W-40
Castrol Ltd. Castrol Diesel X 15W-40

Castrol Tection T 15W-40
Castrol Tection Plus 15W-40
Cepsa Cepsa Euromax 15W-40
Chevron Caltex Delo Gold [ISOSYN] 15W-40

Chevron RPM Heavy Duty Motor Oil 15W-40
Chevron Delo 400 Multigrade 15W-40
Texaco Usr a Super Plus 15W-40
Texaco Usr a Super TD 10W-40
Texaco Usr a Super TDS 15W-40
Exxon Mobil Essoluble XT 4 15W-40

Fuchs Fuchs Titan Truck Plus 15W-40
Fuchs Titan HPE 15W-40
Fuchs Titan Cargo LD 10W-40
Gulf Oil International Gulf Super fleet LE 15W-40

Gulf Super fleet Supreme 15W-40
Huiles Berleit S.A RTO Maxima RD 15W-40

RTO Maxima RLD 15W-40
Igol, France Trans Turbo 7X 15W-40

Trans Turbo 9X 15W-40
Protruck 100 X 15W-40
Imperial Oil Esso XD-3 Extra 15W-40
Indy Oil SA Indy Super Turbo Diesel 15W-40
10 SM 2627 01-10
Section 300-0020
Manufacturer Brand Name SAE Viscosity

Class
Indian Oil Corp. Servo Premium (N) 15W-40
Kuwait Petroleum Q8 T 720 10W-40

Q8 T 750 15W-40
Lotos Oil Turdus Powertec CI-4 15W-40 15W-40
Mauran SAS Turbo land 15W-40
OMV AG OMV truck LD 15W-40
Pennzoil Products Penn zoil Long. Life Gold 15W-40
Pertamina Meditran SMX 15W-40
Petro-Canada Lubricants Duron 15W-40
Duron XL Synthetic Blend 15W-40
Petrol Ofisi PO Turbo Dizel Extra 15W-40

Petro limex Petrochemical
Joint-Stock Company PLC Diesel SHPD 15W-40 15W-40
Prista Oil AD Prista SHPD 15W-40
Ravensberger
Schmierstoffvertrieb GmbH RAVENOL Mineralo I Turbo Plus SHPD 15W-40
Shanghai HIRI Lubricants HIRI 245 15W-40
Shell Shell DEO Super 15W-40
Shell Rimula MV 15W-40
Shell Rimula R3 X 15W-40
Shell Rimula R4 L 15W-40
Shell Rimula R T 4 L 15W-40
Shell Rimula Super 15W-40
Shell Rotella T 15W-40
Shell Rotella T Multigrade 15W-40
Rimula X CH-4 15W-40
Singapore Petroleum
Company SDM 900, SAE 15W40 15W-40
Sinopec Corp. Great Wall Jinpai Zunlong 15W-40
SRS Schmierstoff Vertrieb

GmbH Winter shall Multi-Rekord top 15W-40
Winter shall Turbo Diesel Plus 15W-40
Winter shall TFX 10W-40
Statoil Turbo synt 15W-40
Svenska Statoil MaxWay 15W-40
Total Antar Milantar PH 15W-40
Antar Milantar PX 15W-40
Elf Performance Trophy DX 15W-40
Elf Performance Victory 15W-40
Fina Kappa Optima 15W-40
Total Caprano TDH 15W-40
Total Caprano TDI 15W-40
Total Rubia TIR 7400 15W-40
Unil Opal Medos 700 15W-40

Yacco Inboard 100 4 T Diesel 15W-40
* * * *
SM 2627 01-10 11
Section 300-0020
12 SM 2627 01-10
MISCELLANEOUS - Service Tools
Section 300-0070
INTRODUCTION Hood
Contained in this section are recommended service For manual wind of the linear actuator a 6mm Ball End
tools and equipment required for maintenance, overhaul Allen key with extension is necessary to gain sufficient
and troubleshooting. In certain instances, both Metric access.
and Imperial equivalents of the same tools are listed.
SERIES 60 ENGINE
Note: The Company reserves the right to make General
changes in the design or construction of tools and
equipment without obligation to incorporate such See 'Fabricated tools' detail at end of this section for
changes in tools and equipment previously sold. details of engine support brackets.
Note: A tool may be of one piece construction or

DDEC V Electronic Diagnostic
consist of a number of parts.
15501306 - DDDL Complete kit; includes software,
General Cables & translator box.
Spares
*15269784 - Multi-Gauge - Pressure range of 30 in of
vacuum to 5 000 lbf/in² 15501455 - Translator Box
15269785 - Non-contact Infrared Thermometer 15501458 - PC to Translatore Box Cable
15268968 - Strap Type Filter Wrench 15501460 - Translator Box to Vehicle Cable
15268969 - Socket Type Filter Wrench 15501457 - Vehicle Cable
15268970 - Universal Belt Tension Gauge 15501454 - ExtensionCable
15270180 - Belt Tension Gauge - Poly 'V' Belt 15501379 - 6 to 9 Pin adaptor Cable - DDEC V
15269858 - Digital Tachometer engines only!
15269859 - Multimeter 15502457 - DDEC V Card
15269813 - Water Manometer
15269802 - Dial Indicator Gauge - Metric 15275098 - Detroit Diesel Multi Kit, consisting of PRO-
15269803 - Dial Indicator Gauge - Imperial LINK Diagnostic Data Reader and cables,
15269804 - Magnetic Base for Dial Indicator Gauge Detroit Diesel 6 pin Adaptor Cable and
15269805 - Micrometer - 0 to 25 mm Multi-Cartridge.
15269806 - Micrometer - 0 to 1 in 15273793 - Detroit Diesel Diagnostic Link (Diskette)
15269809 - Internal Micrometer - 50 to 210 mm 15273794 - Detroit Diesel Diagnostic Link (CD)
15269810 - Internal Micrometer - 2 to 8 in 15269239 - High Impedance Digital Multimeter Kit
15269860 - 92 Piece Heavy Equipment Tool Kit 15270271 - Diagnostic Jumper Wire Kit
15269861 - Torque Wrench - 3/8 in drive, 15273795 - DDEC Repair Kit
20 - 100 Nm (15 - 80 lbf ft) range 15270310 - Detroit Diesel 6 pin Adaptor Cable
15269862 - Torque Wrench - 1/2 in drive, 15269038 - Portable Printer for use with DDR,
60 - 330 Nm (45 - 250 lbf ft) range complete with 110 V AC Adaptor
15269863 - Torque Wrench - 3/8 in drive, 15269039 - Portable Printer for use with DDR,
4 - 20 Nm (40 - 180 lbf in) range complete with 220 V AC Adaptor
15269864 - Torque Wrench - 3/4 in drive, 15269040 - Printer Paper for use in above
300 - 1 000 Nm (200 - 750 lbf ft) range printers - 5 rolls
15269865 - Torque Wrench - 3/4 in drive, 15273084 - Multi-Cartridge
700 - 1 500 Nm (500 - 1 000 lbf ft) range 15268971 - PRO-LINK Diagnostic Data Reader and
15269866 - Torque Multiplier - 1/2 in to 1 in drive, cables
25:1 Ratio, 3 000 Nm (2 200 lbf ft) range
For a list of service maintenance tools for overhaul of
* - The following items should be added to the the engine, refer to relevant series 60 engine operation
multi-gauge to enable the gauge to be used on and overhaul manual. Overhaul should only be carried
diagnostic test points: out by approved Detroit Diesel trained service
personnel.
15018226 - Diagnostic Coupling
00118748 - Connector (2 off)
15004085 - Hose Assembly (-4 HP, 84 in long)
SM 2567 01-10 1
Miscellaneous - Service Tools
Section 300-0070
Transmission 15500894 - Shims.

15269934 - Measuring Shaft.
The following tools are recommended for Transmission
15500895 - Torque Spanner.
Maintenance Procedures. These tools should be used
15500896 - Driver.
in conjunction with procedures outlined in the
15500909 - Driver.
transmission manufacturers service manual.
15270121 - Handle.
15500910 - Compressed Air Connection.
4th Gen Electronic Diagnostic 15500911 - Indicator.
15500897 - Magnetic Stand.
15502613 - Allison DOC V 5.0 PC service tool (New 15500898 - Dial Indicator.
user). 15500899 - Micrometer.
15502614 - Allison DOc V 5.0 PC service tool 15500912 - Driver.
(Currrent user). 15502331 - Adjusting Screw.
15502615 - Translator Device (Kit). Includes all 15501178 - Lifting equipment.
relevant cables to interface laptop with the 15271107 - Extractor Tool.
transmission and DPA box. 15500882 - Socket.
15502616 - 9-Pin to DB15 Cable. 15500883 - Centering Bracket.
15502617 - USB cable for laptop to DPA box. 15270131 - Pry Bar.
15501177 - Mounting Tool.
General 15269888 - Handle.
15502336 - Inner Installer.
15502618 - Valve Body spring compression tool. 15501178 - Chain.
15502404 - Bock Gauge.
Transmission PTO 15502405 - Lifting Tackle.
15501231 - Lifting Tackle.
Stud mounting kit 15502084 is required for installation 15501169 - Spring Balance
of the PTO to the transmission. 15269088 - Helical Gear Tool
15500012 - Large Face Seal Insertion Tool
15500013 - Small Face Seal Insertion Tool
Articulation and Oscillation Pivot 15500014 - Plate Centralising Tool
15269101 - Thrust Nut Tool 15500015 - Ring Gear Alignment Tool
15270104 - Driver
OCDB / Wheel Hub
Axles and Differentials
15502331 - Adjusting Screws.
15271101 - Backup Tool. 15501178 - Lifting Eye.
15500905 - Extractor. 15270145 - Pliers.
15269929 - Lifting Pliers. 15500882 - Socket.
15272560 - Bearing Puller. 15500883 - Centering Bracket.
15500887 - Gripping Insert. 15501170 - Lifting Tackle.
15500888 - Gripping Insert. 15270131 - Pry Bar.
15500889 - Reducer. 15502336 - Inner Installer (Seal locator).
15500890 - Socket. 15269899 - Hot Air Blower (220V).
15270120 - Clamping Yoke. 15269900 - Hot Air Blower (110V).
15500906 - Puller. 15269948 - Straight edge.
15500907 - Fixture. 15270114 - Digital Depth Gauge.
15500908 - Socket. 15502404 - Block Gauges.
15269946 - Puller Set. 15502405 - Lifting Tackle.
15500891 - Socket. 15501167 - Adjusting Screws
15500892 - Gripping Insert. 15270132 - Pry bar
15272560 - Bearing Puller. 15270115 - Eyebolts
15270113 - Gauge Blocks. 15501175 - Clamping Pliers
15269948 - Straight Edge. 15502408 - Assembly Fixture
15270114 - Digital Depth Gauge. 15501168 - Lifting Straps
15500893 - Shims. 15500884 - Wheel Bolt Puller
2 SM 2567 01-10
Section 300-0070
15269895 - Inserts 09379518 - Loctite 574 (160 ml)
15269898 - Driver and Handle 15269106 - Loctite 577 (Superflex)
15503978 - Fixing Device 15270244 - Loctite 592 - Pipe Sealer with Teflon
15501174 - Assembly Fixture 15023696 - Loctite 635
15501176 - Spline Mandrel 09371048 - Loctite 638
15269107 - Loctite 641
Front Suspension 15269108 - Loctite Superclean Safety Solvent 706
15269095 - Hydraulic Jack 15229541 - Loctite Activator 'N'
15269096 - Power Press 09243825 - Loctite Activator 'T'
15269097 - Press Tool 09175039 - General Adhesive
15269114 - Tectyl 280 Wax Based Rust Preventive
09380475 - Hylosil RTV Silicone Compound
15303808 - Silicon Grease (Dielectric)
Nitrogen Charging
09359489 - Charging Assembly Fabricated Tools
The service tools shown on the following pages can be
fabricated as detailed in the Figures.
Cooling and Air Conditioning
15270181 - Coolant Test Strips
15500709 - Pro Cool Test Strips
15269816 - Refractometer - °C Scale
15269817 - Refractometer - °F Scale
15269844 - Portable High Vacuum Charging
Station - R-134a Gas
15269845 - Halogen Leak Tester
Cab
15271016 - Glass Removal Tool
15271017 - Bonding Kit (Quick Dry)
Adhesives and Sealants

15269103 -Loctite 221
09362529 -Loctite 225
09029849 -Loctite 243
15500690 -Loctite 262
09244598 -Loctite 270
09985300 -Loctite 271
15269104 -Loctite 275
15269245 -Loctite 277
15233715 -Loctite Prism 406
15269111 -Loctite Prism 410
15503981 - Loctite 415
15269105 -Loctite 515
09007209 -Loctite 574 (50 ml)
SM 2567 01-10 3
Section 300-0070
140 SM 3529
ENGINE SUPPORT BRACKET (LHS)
85 43 90
25
" "
50 10 100 Ø 20 4 POS'N
332 245
210 12
75
¾"unc
10 100 50
190
(mm)
Fig. 1 - Engine Support Bracket LHS (Section 110-0030, ENGINE AND MOUNTING)
SM 3530
140 ENGINE SUPPORT BRACKET (RHS)
10
25
"
43 90
"
5
" "
100 Ø 20
4 POS'N VIEW ON 'A'
"
377 280
50 "
155 70
10 80
'A'
12
5
5 ¾"unc
60
12
225 (mm)
Fig. 2 - Engine Support Bracket RHS (Section 110-0030, ENGINE AND MOUNTING)
4 SM 2567 01-10
MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
Section 300-0080
fasteners can be safely tightened, the following torque

WARNING tables have been compiled.
Some fasteners are important attaching parts
which could affect the performance of vital The torque values listed in the tables have been
components and systems, and/or, could result established over a period of years and cover all
in major repair expense. Fasteners should be conditions of assembly. The maximum torque values
replaced with parts of the same part number, or for standard bolts and nuts are based on 75% of the
with equivalent parts, if replacement becomes specified minimum proof strength of the bolt steel in
necessary. Do not use replacement parts of order to provide a safety factor to compensate for the
lesser quality or substitute design. The torque variation in the accuracy of torque wrenches, skill of
values shown in the following tables should be the assembler, and variance in fractional conditions.
used in all cases, unless otherwise specified All torque values are for lubricated threads. The
elsewhere in this manual, in order to avoid term 'lubricated' includes the application of thread
possible personal injury or property damage. lubricants, cadmium plating or the use of hardened
washers.
The following torque specification tables are based on
GM Standard Materials for bolts, nuts, studs and self- To provide a quick method for determining the GM
locking fasteners based on SAE bolt steel material classification of a particular standard bolt
classifications, or, prevailing torque specifications for or nut, compare the bolt head markings to those in
self-locking fasteners. the appropriate tables, then locate the maximum
torque value for that bolt size in the column under
To prevent the threaded bolts and nuts used on this that marking.
equipment from being overstressed during assembly,
and to establish a uniform value to which these
RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ±10% TABLE 144
SAE Symbol SAE Symbol SAE Symbol SAE Symbol 12 Point

GM 260-M GM 280-M GM 290-M GM 300-M Cap Screws
Size Steel Steel Steel
Steel
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8)
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
0.25 - 20 5 4 8 6 11 8 12 9 14 10
0.25 - 28 7 5 10 7 12 9 14 10 15 11
0.31 - 18 11 8 18 13 22 16 24 18 27 20
0.31 - 24 12 9 19 14 24 18 27 20 30 22
0.38 - 16 20 15 31 23 38 28 43 32 49 36
0.38 - 24 23 17 34 25 43 32 49 36 56 41
0.44 - 14 33 24 47 35 59 43 68 50 75 55
0.44 - 20 37 27 54 40 68 50 79 58 87 64
0.50 - 13 50 37 75 55 94 69 106 78 119 88
0.50 - 20 56 41 88 65 106 78 122 90 134 99
0.56 - 12 75 55 108 80 136 100 156 115 171 126
0.56 - 18 81 60 122 90 149 110 176 130 191 141
0.62 - 11 102 75 149 110 190 140 217 160 237 175
0.62 - 18 115 85 169 125 210 155 244 180 270 199
0.75 - 10 176 130 271 200 332 245 380 280 420 310
0.75 - 16 203 150 298 220 366 270 420 310 472 348
0.88 - 9 169 125 434 320 536 395 610 450 679 501
0.88 - 14 190 140 488 360 590 435 678 500 751 554
1.00 - 8 258 190 651 480 800 590 915 675 1021 753
1.00 - 12 285 210 719 530 881 650 1003 740 1119 825
1.00 - 14 285 210 732 540 902 665 1030 760 1148 847
SM 1238 01-10 1
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ±10% TABLE 145
Size SAE Symbol SAE Symbol SAE Symbol SAE Symbol 12 Point Cap Screws
GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8)
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft

1.12 - 7 366 270 800 590 1132 835 1302 960 1447 1067
1.12 - 12 407 300 902 665 1274 940 1451 1075 1624 1198
1.25 - 7 515 380 1132 835 1600 1180 1830 1350 2043 1507
1.25 - 12 569 420 1254 925 1776 1310 2034 1500 2267 1672
1.38 - 6 664 490 1478 1090 2095 1545 2400 1770 2676 1974
1.38 - 12 759 560 1688 1245 2393 1765 2739 2020 3056 2254
1.50 - 6 881 650 1966 1450 2786 2055 3186 2350 3556 2623
1.50 - 8 936 690 2088 1540 2962 2185 3390 2500 3781 2789
1.50 - 12 990 730 2217 1635 3145 2320 3593 2650 4010 2958
1.75 - 5 - - - - 4393 3240 5016 3700 5604 4133
1.75 - 12 - - - - 5091 3755 5830 4300 6497 4792
1.88 - 8 - - - - 6006 4430 6874 5070 7664 5653
1.88 - 12 - - - - 6304 4650 7213 5320 8048 5936
2.00 - 4.5 - - - - 6623 4885 7565 5580 8448 6231
2.00 - 8 - - - - 7342 5415 8406 6200 9367 6909
2.00 - 12 - - - - 7687 5670 8786 6480 9811 7236
2.25 - 4.5 - - - - 9701 7155 11090 8180 12377 9129
2.25 - 8 - - - - 10629 7840 12148 8960 13566 10006
2.25 - 12 - - - - 11050 8150 12636 9320 14102 10401
2.50 - 12 - - - - 15280 11270 17463 12880 19500 14383
Note: Where materials other than GM Standards are used, refer to the conversion table below.
Types of Steel Rockwell Hardness Applicable Torque SAE Bolt Head Symbols
Range Values
Plain Low Carbon Rockwell "B" 85-100 GM 260-M

(for example SAE 1018
or 1020)
Plain Medium Carbon Rockwell "C" 19-30 GM 280-M

(for example SAE 1035,
1038 and 1045)
Medium Carbon Alloy Rockwell "C" 28-34 GM 290-M

8642 and 5157)
Medium Carbon Alloy Rockwell "C" 32-38 GM 300-M

8642 and 5147)
2 SM 1238 01-10
Section 300-0080
RECOMMENDED MAXIMUM TORQUES (METRIC) ±10% TABLE 146

Class 8.8 Class 9.8 Class 10.9 Class 12.9
Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
M1.6 - 0.35 - - 0.20 0.15 - - 0.20 0.15
M1.6 - 0.20 - - 0.25 0.20 - - 0.40 0.30
M2.0 - 0.40 - - 0.25 0.20 - - 0.45 0.30
M2.0 - 0.25 - - 0.45 0.30 - - 0.45 0.30
M2.0 - 0.45 - - 0.25 0.20 - - 0.45 0.30
M2.5 - 0.35 - - 1 0.75 - - 1 0.75
M3.0 - 0.50 - - 1 0.75 - - 2 1.5
M3.0 - 0.35 - - 1 0.75 - - 2 1.5
M3.5 - 0.60 - - 2 1.5 - - 3 2
M4.0 - 0.70 - - 3 2 - - 4 3
M4.0 - 0.35 - - 3 2 - - 5 3
M5.0 - 0.80 - - 5 4 - - 8 6
M5.0 - 0.50 - - 6 4 - - 9 6
M6.0 - 1.00 - - 9 6 - - 13 10
M6.3 - 1.00 - - 10 8 13 10 16 11
M6.0 - 0.75 - - 10 7 12 9 14 10
M8.0 - 1.25 - - 21 15 27 20 32 23
M8.0 - 1.00 - - 23 17 29 21 34 25
M10.0 - 1.50 - - 42 31 54 39 63 46
M10.0 - 1.25 - - 45 32 57 41 67 48
M12.0 - 1.75 - - 74 53 94 68 110 80
M12.0 - 1.25 - - 81 58 103 74 121 87
M14.0 - 2.00 - - 118 85 151 109 176 127
M14.0 - 1.50 - - 128 92 163 118 190 137
M16.0 - 2.00 169 122 - - 234 169 274 197
M16.0 - 1.50 181 130 - - 250 180 292 211
M18.0 - 2.50 234 169 - - 323 234 378 273
M18.0 - 1.50 263 190 - - 363 262 425 307
M20.0 - 2.50 330 239 - - 457 330 531 386
M20.0 - 1.50 367 265 - - 507 366 593 423
M22.0 - 2.50 451 325 - - 623 450 728 526
M22.0 - 1.50 495 357 - - 684 494 800 577
M24.0 - 3.00 571 412 - - 790 570 923 667
M24.0 - 2.00 623 450 - - 861 622 1007 727
M27.0 - 3.00 837 605 - - 1158 836 1354 977
M27.0 - 2.00 903 652 - - 1250 902 1461 1055
M30.0 - 3.00 1135 820 - - 1570 1134 1835 1325
M30.0 - 2.00 1258 908 - - 1740 1256 2034 1468
M30.0 - 1.50 1300 939 - - 1799 1299 2102 1516
M36.0 - 4.00 1985 1433 - - 2745 1982 3208 2317
M36.0 - 3.00 2102 1517 - - 2907 2099 3398 2453
SM 1238 01-10 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 TABLE 537

Lock Screws Lock-nuts
SAE Grade 5 and 8, SAE Grade 5 SAE Grade 8
and ASTM A-574
Size Nm lbf in Nm lbf in Nm lbf in
0.25-20 0.3 3 0.4 3.5 0.5 4.5
0.25-28 0.3 3 0.4 3.5 0.5 4.5
0.31-18 0.6 5 0.6 5.5 0.9 7.5
0.31-24 0.6 5 0.6 5.5 0.9 7.5
0.38-16 1.0 9 1.0 8.5 1.3 11.5
0.38-24 1.0 9 1.0 8.5 1.3 11.5
0.44-14 1.4 12 1.4 12 1.8 16
0.44-20 1.4 12 1.4 12 1.8 16
0.50-13 1.8 16 1.7 15 2.3 20
0.50-20 1.8 16 1.7 15 2.3 20
0.56-12 2.5 22 2.4 21 3.2 28
0.56-18 2.5 22 2.4 21 3.2 28
0.62-11 3.4 30 3.1 27 4.1 36
0.62-18 3.4 30 3.1 27 4.1 36
0.75-10 5.1 45 4.6 41 6.1 54
0.75-16 5.1 45 4.6 41 6.1 54
0.88-9 7.3 65 7.0 62 9.3 82
0.88-14 7.3 65 7.0 62 9.3 82
1.00-8 9.6 85 9.5 84 12.7 112
1.00-12 9.6 85 9.5 84 12.7 112
1.00-14 - - 9.5 84 12.7 112
* * * *
4 SM 1238 01-10
MISCELLANEOUS - Unit Storage
Section 300-0090
GENERAL batteries where they will be protected from temperature

extremes. Coat the battery terminals and cable ends
The storage of machines for short periods of time or
with acid resistant petroleum jelly.
during the off-season is an important item if major
damage to components is to be avoided. Failure to take
9. TYRES - Remove all grease and oil. Inflate all tyres
the necessary steps to protect the various assemblies
to correct pressure. During storage, check inflation
while the machine is being stored can result in an
pressure approximately once every two weeks.
expensive overhaul job and delay in returning the
machine to work.
10. TRACKS - Check recoil cylinder pressure and track
adjustment. Remove all oil and grease (rubber tracks).
TEMPORARY STORAGE
11. EXHAUSTS - Cover exhaust stack openings with
When storing a machine for a period of 30 days or less,
plastic or waterproof paper and secure with adhesive
the following precautions must be taken:
tape.
1. INSPECTION AND REPAIR - Thoroughly inspect and
12. AIR INTAKES - Cover openings with plastic or
test the machine and make any necessary repairs or
waterproof paper and secure with adhesive tape.
adjustments which may be necessary to prepare the
machine for service. This will enable you to put the
13. SUSPENSION RIDE CYLINDERS - Release the
machine back into use immediately at the end of the
pressure in the cylinders to retract them for minimum
storage period.
piston rod exposure. Coat the remaining exposed
piston rod surface with a suitable oil or grease.
2. LUBRICATION - Lubricate the machine completely
according to the instructions given in Section
14. HYDRAULIC CONTROL VALVES - Where possible
300-0020, LUBRICATION SYSTEM of this manual.
position hydraulic controls for minimum exposure of
valve spools (spool inside valve body). Coat the
3. COOLING SYSTEM - Verify that the cooling system
remaining exposed spool surface with a suitable oil or
is adequately protected for the climatic conditions
grease.
expected at the storage locatin. Adjust if necessary.
15. HYDAULIC CYLINDERS - Where possible retract
4. PARKING - After thoroughly cleaning the entire
cylinders for minimum rod exposure. Coat the
machine, park it on a hard, dry, level surface that is free
remaining exposed piston rod surface with a suitable oil
from grease and oil. The oil and grease would cause
or grease.
tyre deterioration. Apply the parking brake.
16. AIR CYLINDERS - Coat the exposed piston rod
Note: If the machine is delivered from the Terex facility
surface with a suitable oil or grease.
with a wax coating to protect the paint-work, do not
remove it until the machine is removed from storage.
17. CONTROL CABLES & LINKAGE - All exposed
linkage, clevis ends, ball joints etc, wchich are not
5. FUEL TANK - Fill the fuel tank to prevent moisture
protected during "lubrication" should be protected by a
condensation within the tank. Coat filler neck and cap
suitable oil or grease.
threads with oil.
18. OPEN PORTS & HOSE ENDS - Plug or seal with
6. HYDRAULIC TANKS - Coat filler neck and cap
adhesive tape all open ports.
threads with oil. Fill the tank to operating level if
necessary.
19. MACHINED SURFACES - Coat any exposed
machined bores and surfaces with a suitable rust
7. AIR RESERVOIRS - Open all drain cocks at bottom
preventative.
of air tanks.
Note: Do not apply oil or grease to brake discs.
8. BATTERIES - Where moderate temperatures are
expected, the batteries may be left in the machine. Up
20. HINGES - Apply oil to all the hinges.
to 30 days, the batteries may require a boost at the
end of the storage period. Preferably place the batteries
21. SEAT SLIDE ADJUSTERS - Coat with grease.
in the shop where they can be inspected, brought up to
full charge and placed on a trickle charge to keep them
22. SEATS, ARMRESRTS & CUSHIONS - When
at full charge. In very cold or hot climates, store the
SM 2629 01-10 1
Miscellaneous - Unit Storage
Section 300-0090
machine is not equipped with a cab, cover these items Clean 8-19 mm (0.25-0.75 in) gravel under each tyre is
with plastic or waterproof barrier paper, and secure with desirable if the area is not paved. Storage should not be
adhesive tape. Provide an opening in the underside of permitted on blacktop or oil stabilised surfaces.
the protective materials to prevent condensation build
up. Except in very cold weather, stored machines should
be moved occasionally, at least once every six months,
23. CABS - All windows, doors and vents closed. so the same section of the tyre is not always under
strain from deflection.
24. HOODS, HOODSIDES, COVERS, PANELS, ETC -
Installed. Inflation in the tyres must be adjusted to the
recommended service pressure before shipping or
25. SECURITY PANELS AND SECURITY LOCKS - putting a stored machine into service.
Installed and locked.
EXTENDED STORAGE - Over Six Months
EXTENDED STORAGE - Under Six When a machine is to be stored for a period over SIX
Months MONTHS, the following procedure must be followed:
When storing a machine for periods of longer than 30
days, but less than six months, the following procedure Note: These steps are in addition to those given
must be followed, in addition to the procedure previously under 'Extended Storage - Under Six
described above: Months'.
1. ENGINE - Consult the relevant Engine Manual/Dealer 1. WHEEL BEARINGS - Remove, clean, inspect and
for storage procedure for periods longer than 30 days. repack all wheel bearings.
2. TRANSMISSION - Consult the relevant Transmission Note: The above steps must be repeated for every Six
Manual/Dealer for storage procedure for periods longer Month period the machine is in storage.
than 30 days.
3. BATTERIES - Remove the batteries from the REMOVAL FROM EXTENDED STORAGE
machine and store in shop. Protect batteries from
temperature extremes. Coat the terminals and cable The following procedure must be followed when a
ends with acid resistant petroleum jelly. machine is removed from storage.
4. VENTS AND BREATHERS - Remove all vents and 1. FUEL TANK - Drain off any condensation. Remove
breathers and plug all the openings with pipe plugs or covers from openings and re-install breather.
seal with adhesive waterproof tape.
2. HYDRAULIC TANKS - Remove covers from openings
5. BELTS - Release tension on all the belts. and re-install breathers. Fill tank to operating level if
necessary.
6. TYRES - When extended storage is anticipated, the
machines should be blocked up so weight does not 3. AIR RESERVOIRS - Close all drain cocks.
rest on the tyres, and inflation pressure reduced to 1
bar (15 lbf/in2). Storage of such machines should be 4. BATTERIES - Check batteries are fully charged and
under cover if possible; otherwise tyres should be re-install.
protected from the elements by an opaque waterproof
covering. 5. TYRES - Inflate to the recommended pressure.
If it is not possible to block up the machines, inflation 6. TRACKS - Check recoil cylinder pressure and track
pressure in the tyres should be increased to 25% above adjustment.
the rated pressure for the actual load on the tyre in
storage condition. 7. EXHAUSTS - Remove temporary storage covers from
exhaust stack openings.
The storage area surface should be firm, reasonably
level, well drained and free of all oil, fuel or grease. 8. AIR INTAKES - Remove temporary storage covers
from air intake openings.
2 SM 2629 01-10
Section 300-0090
9. SUSPENSION RIDE CYLINDERS - Remove

protective coating from piston rod surface. Charge with
Nitrogen.
10. HYDRAULIC CYLINDERS - Remove protective

coating from piston rod surface.
11. VENTS AND BREATHERS - Remove seals and

plugs from all breather openings, then install all
breathers and vents.
12. BELTS - Adjust tension on all belts.
13. ENGINES - Consult the relevant Maintenance

Manual/Dealer for instructions on removing an engine
from storage.
14. TRANSMISSION - Consult the relevant

Maintenance Manual/Dealer for instructions on
removing a transmission from storage.
15. PAINT - Check machine for rust. Remove all rust

spots and repaint rusted areas.
16. DECALS - Check condition of decals and replace if

necessary.
17. LUBRICATION - Completely lubricate the machine

according to the instructions in the "Lubricatin System"
section of the relevant Manual.
18. GENERAL - Check for fuel, hydraulic oil, coolant

and air leaks. Replace all leaking seals.
Field rework should always be implemented in

accordance with the appropriate instructions in
the Maintenance Manuals.
* * * *
SM 2629 01-10 3
Miscellaneous - Unit Storage
Section 300-0090
4 SM 2629 01-10

2010 TEREX TA350-TA400 Dump Truck Service Repair Manual

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Re-order Part Number

Revision: April 2010

Section No. Description SM No.

180 SUSPENSION SYSTEM

SM 2628 Rev1 04-10 1

Section No. Description SM No.

190 ELECTRICAL SYSTEM

200 FUEL SYSTEM

215 MAIN HYDRAULIC VALVE

220 STEERING SYSTEM

230 BODY SYSTEM

250 BRAKING SYSTEM

2 SM 2628 Rev1 04-10

Section No. Description SM No.

SM 2628 Rev1 04-10 3

4 SM 2628 Rev4 01-10

Safety Alert Symbol

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

WARNING indicates an potentially hazardous situation which, if not avoided, could

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

ENGINE Main ................................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

SM 2577 Rev1 04-10 1

SUSPENSION Braking surface (tractor) ....... 590240 mm2 (914.9 in2)/brake

2 SM 2577 Rev1 04-10

TYPICAL NOISE LEVELS

*Exterior Sound Rating (ISO 6395) ......................... 109 dbA

Note: Noise Level Exposure to the operator and bystander

SM 2577 Rev1 04-10 3

THIS PAGE IS INTENTIONALLY BLANK

4 SM 2577 Rev1 04-10

ENGINE Main Pressure ................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

SM 2578 Rev1 04-10 1

DROPBOX Inflation Pressures (Michelin):

2 SM 2578 Rev1 04-10

TYPICAL NOISE LEVELS

*Exterior Sound Rating (ISO 6395) ......................... 109 dbA

Note: Noise Level Exposure to the operator and bystander

SM 2578 Rev1 04-10 3

THIS PAGE IS INTENTIONALLY BLANK

4 SM 2578 Rev1 04-10

ENGINE Main ................................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

SM 2579 Rev1 04-10 1

SUSPENSION Braking surface (tractor) ........ 590240 mm2 (914.9 in2)/brake

Inflation Pressures (Good Year): ELECTRICAL SYSTEM

2 SM 2579 Rev1 04-10

TYPICAL NOISE LEVELS

*Exterior Sound Rating (ISO 6395) ......................... 109 dbA

Note: Noise Level Exposure to the operator and bystander

SM 2579 Rev1 04-10 3

THIS PAGE IS INTENTIONALLY LEFT BLANK

4 SM 2579 Rev1 04-10

Note: The current from the welding rod always follows