Terex TR60 User Manual

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TABLE OF

CONTENTS

TR60

Off-Highway Truck

Maintenance Manual

SM 1564 Rev 3 02-02

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TECHNICAL PUBLICATIONS DEPARTMENT

TEREX EQUIPMENT LIMITED,

MOTHERWELL, SCOTLAND, ML1 5RY

REF. NO. SM750/782

Service

The information contained within this Alert must not be made available to third parties not authorised to receive it.

Information

Alert

DATE: April 1994 B168

MODEL: General

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

PURPOSE:

To advise potentially hazardous condition.

DETAIL:

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

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

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

a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky. b. If this is affirmed - Do Not Touch c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)

should be considered dangerous but natural rubber and nitrile are non-hazardous.

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

undertaking further work.

e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by

washing thoroughly with Limewater (Calcium Hydroxide solution). f. Any cloths, residue and gloves used MUST be safely discarded after use. Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process

where the gaseous products are treated by alkaline scrubbing.

TEREX SERVICE DEPARTMENT

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

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IMPORTANT SAFETY NOTICE

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

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

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

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

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

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

SM 222 Rev 1 9-93

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TABLE OF CONTENTS

Section No. Description SM No.

000 GENERAL INFORMATION

0000 TR60 Off-Highway Truck 1566 0010 Welding Procedure 2172

100 CHASSIS

0010 Chassis, Hood and Fenders 1570

110 ENGINE

0030 Engine and Mounting 1571 0050 Air Cleaner 1572 0130 Power Takeoff 1573

120 TRANSMISSION

0010 Transmission and Mounting 1574 0070 Commercial Electronic Control (CEC) Shift System 1575 0090 Power Takeoff 1178 0100 Transmission Oil Filter 1576

13 0 DRIVELINE

0010 Front Driveline - Pre June 1998 Production 1180 0010 Front Driveline - From June 1998 Production 1577 0020 Rear Driveline - Pre June 1998 Production 1181 0020 Rear Driveline - From June 1998 Production 1578

14 0 FRONT AXLE

0040 Wheel, Rim and Tyre 1579

16 0 REAR AXLE

0020 Differential 1580 0030 Axle Group 1184 0050 Wheel, Rim and Tyre 1582

165 BRAKE PARTS

0020 Brake Parts - Front Axle 1186

` 0030 Brake Parts - Rear Axle 1583

18 0 SUSPENSION SYSTEM

0030 Ride Cylinder - Front 1584 0050 Ride Cylinder - Rear 1189

190 CIRCUIT DIAGRAMS

0000 Circuit Diagrams 1585 0270 Switches and Sensors 1586

200 FUEL SYSTEM

0010 Fuel Tank and Mounting 1587 0040 Fuel Lines 1195 0051 Electronic Foot Pedal 1196

21 0 COOLING SYSTEM

0000 Cooling System 1197 0040 Radiator, Header Tank and Mounting 1588 0050 Disc Brake Oil Cooler 1589 0060 Transmission Oil Cooler 1590

SM 1565 12-98

1

TABLE OF CONTENTS

Section No. Description SM No.

22 0 STEERING SYSTEM

0000 Steering System Schematic 1591 0040 Steering and Brake Control Tank 1592 0050 Steering Pump 1204 0080 Accumulator 1205 0090 Steering Valve 1206 Rev 1 0110 Double Relief Valve 1208 0120 Steering Cylinder and Linkage - Pre October 1999 Production 1207 Rev 1 0120 Steering Cylinder and Linkage - From October 1999 Production 1908 0130 Accumulator Valve 1209 0150 Steering Filter 1593

23 0 BODY SYSTEM

0000 Body System Schematic 1594 Rev 2 0040 Body and Disc Brake Cooling Tank 1595 0050 Tandem Pump 1213 0060 Body Control Valve 1596 Rev 1 0081 Body Control Joystick 1597 0090 Kick-over Valve 1218 0120 Relief Valve 1598 0121 Pilot Supply Valve 1599 0130 Body Cylinder 1221

25 0 BRAKING SYSTEM

0000 Braking System Schematic 1222 Rev 1 0050 Brake Manifold Valve 1223 0060 Accumulator 1600 0070 Treadle Valve 1225 Rev 1 0090 Directional Control Valve 1226 0100 Monoblock Brake Valve 1227 Rev 2 0110 Pressure Reducing Valve (Optional) 1820 0130 Retarder Control Valve 1601 Rev 1 0140 Shuttle Valve 1229

260 OPERATORS COMPARTMENT

0010 Cab and Mounting 1602 Rev 1 0090 Driver Seat and Mounting 1901 0110 Passenger Seat and Mounting - Pre January 2000 Production 1603 0110 Passenger Seat and Mounting - From January 2000 Production 1902 0130 Air Conditioning and Mounting 1620 Rev 1

270 BODY

0010 Body and Mounting 1604

300 MISCELLANEOUS

0020 Lubrication System 1605 Rev 1 0070 Service Tools 1237 Rev 1 0080 Standard Bolt and Nut Torque Specifications 1238 0090 Unit Storage 1239

* * * *

2

SM 1565 Rev 3 02-02

GENERAL INFORMATION - TR60 Off-Highway Truck

Section 000-0000

SM - 1957

Max Body Depth

Optional

Spillguard

4 820

(15-10)

1 425

(4-8)

4 440 (14-7)

600

950

(2-0)

(3-1)

1 380

(4-6)

2 900 (9-6)

4 450 (14-7)

4 980 (16-4) 4 630 (15-2)

660

(2-2)

2 580 (8-5)

3 320 (10-11)

4 060 (13-4)

Vehicle Clearance Diameter (SAE) 21 m (68-10)

3 970 (13-0)

2 360 (7-9)

7 750 (25-5)

6 000 (19-8)

4 170 (13-8)

9 130 (29-11)

5 050 (16-7)

58˚

15˚

580 (1-11)

2 600 (8-6)

4 470 (14-8)

4 270 (14-0)

3 950

(12-11)

8 050 (26-5)

500

(1-8)

3 680 (12-1)

Dimensions in mm (ft-in)

Fig. 1 - Machine Dimensions

ENGINE

Make/Model .................................... Cummins QSK19-C650

Type .................... 4 Cycle, Turbocharged/Low Temperature

Aftercooled. Electronic Management

Gross Power 1 500 through 2 100 rev/min...............485 kW

(650 hp, 659 PS)

Net Power 1 500 through 2 100 rev/min .................. 462 kW

(620 hp, 628 PS)

Note: Power ratings to SAE J1995 Jun 95. Engine emission meets USA EPA/CARB MOH 40 CFR 89 and EU NRMM (non-road mobile machinery directive).

Maximum Torque .............................. 3 084 Nm (2 275 lbf ft)

at 1 300 through 1 500 rev/min

Number of Cylinders/Configuration .........................6, in line

Bore x Stroke ........................ 159 x 159 mm (6.25 x 6.25 in)

Total Displacement .............................. 18.9 litres (1 150 in³)

Starting...................................................................... Electric

Maximum Speed, Full Load ............................ 2 100 rev/min

Maximum Speed, No Load ............................. 2 350 rev/min

Idle Speed.......................................................Self Adjusting

Safe Operating Angle .................................. 30°/60% Grade

SM 1566 12-98

TRANSMISSION

Make/Model .............................................. Allison M6600AR

automatic electronic control with soft shift feature. Remote mounted in the frame. Integral TC 682 torque converter and planetary gearing. Six speeds forward, two reverse. Automatic converter lockup action in all speed ranges. With body up, gear range is limited to 1st forward only. Downshift inhibitor. Intregal hydraulic retarder.

Speeds With 24.00 R 35 Tyres

Forward Gear 1 2 3 4 5 6 Ratio 4.00 2.68 2.01 1.35 1.00 0.67 km/h 9.5 14.2 18.9 28.2 38.1 57.0 mile/h 5.9 8.8 11.8 17.5 23.7 35.5

Reverse Gear 1 2 Ratio 5.12 3.46 km/h 7.4 11.0 mile/h 4.6 6.8

1

General Information - TR60 Off Highway Truck

Section 000-0000

DRIVE AXLE

Heavy duty axle with single reduction spiral bevel gear differential, full floating axle shafts, and planetary reduction at each wheel.

Ratios:

Differential...................................................................3.73:1

Planetary..................................................................... 5.80:1

Total Reduction......................................................... 21.63:1

SUSPENSION Front: King pin strut type independent front wheel

suspension by self-contained, variable rate, nitrogen/oil cylinders.

Rear: Variable rate nitrogen/oil cylinders with A-frame linkage and lateral stabilizer bar.

Maximum Strut Stroke

Front .........................................................251 mm (9.9 in)

Rear ..........................................................182 mm (7.2 in)

Maximum Rear Axle Oscillation..................... ± 6.5 Degrees

WHEELS AND TYRES

Wheel Rim Width .......................................................... 17 in

Standard Tyres (Front & Rear) ..............24.00 R 35** Radial

Note: It 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.

BRAKES Service

All hydraulic brake system. Transmission mounted pressure compensating pump provides hydraulic pressure for brakes and steering. Independent circuits front and rear. Each circuit incorporates a nitrogen accumulator which stores energy to provide consistent braking response.

Front Brake Circuit Pressure ............. 159 bar (2 300 lbf/in²)

Rear Brake Circuit Pressure ....................52 bar (750 lbf/in²)

Accumulators:

Nitrogen Precharge Pressure ...............55 bar (800 lbf/in²)

Front:

Type.............................. Dry Disc with 1 calliper per wheel

Disc Diameter ............................................ 710 mm (28 in)

Pad Area, Total.................................... 1 395 cm²

Rear:

Type...............................Oil cooled, multiple friction discs,

completely sealed from dirt and water.

Braking Surface, Total ....................47 151 cm² (7 308 in²)

(216 in²)

Parking

Application of rear brakes by springs in brake disc pack. Hydraulically released.

Hold-off Pressure ..................................83 bar (1 200 lbf/in²)

Retardation

Modulated lever control of rear disc pack. 510 kW (685 hp) continuous.

Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in²)

Emergency

Push button solenoid control applies service and parking brakes. Automatically applies when engine is switched off. Parking brake applies should system pressure fall below a predetermined level.

Brakes conform to ISO 3450, SAE J1473 OCT 90.

STEERING SYSTEM

Independent hydrostatic steering with closed-centre steering valve, accumulator and pressure compensating piston pump.

Accumulator provides uniform steering regardless of engine speed. In the event of loss of engine power it provides steering of approximately two lock-to-lock turns. A low pressure indicator light warns of system pressure below 83 bar (1 200 lbf/in²). Steering meets SAE J53.

System Pressure................................ 159 bar (2 300 lbf/in²)

Relief Pressure ...................................207 bar (3 000 lbf/in²)

Steering Cylinders ................... Double Acting, Single Stage

Accumulator:

Oil Capacity ................................. 14.0 litres (3.70 US gal)

Nitrogen Precharge Pressure ...............55 bar (800 lbf/in²)

Steering Angle (Left and Right) .......................................39°

Pump:

Type......................................................................... Piston

Capacity at 2 100 rev/min....... 1.4 litres/s (22 US gal/min)

BODY HYDRAULICS

Two body hoist cylinders are mounted between the frame rails. Cylinders are two-stage with power down in the second stage.

System Relief Pressure ..................... 190 bar (2 750 lbf/in²)

Pump:

Type........................................................................... Gear

Capacity at 2 100 rev/min.............................227 litres/min

(60 US gal/min)

Control Valve ...................... Servo Controlled, Open Centre

Body Raise Time................................................ 16 Seconds

Body Lower Time ............................................... 14 Seconds

ELECTRICAL

Type ............................................. 24 Volt, Negative Ground

Battery......... Two, 12 Volt, 165 Ah each, Maintenance Free

Accessories................................................................ 24 Volt

Alternator ..................................................................70 Amp

Starter ........................................................................8.9 kW

2

SM 1566 12-98

General Information - TR60 Off-Highway Truck

Section 000-0000

BODY

Longitudinal 'V' type floor with integral transverse boxsection stiffeners. The body is exhaust heated and rests on resilient impact absorption pads.

Body wear surfaces are high hardness (360-440 BHN) abrasion resistant steel. Yield strength of plates 1 000 MPa (145 000 lbf/in²).

Plate Thicknesses:

Floor ......................................................... 19 mm (0.75 in)

Side .......................................................... 10 mm (0.39 in)

Front, lower............................................... 10 mm (0.39 in)

ROPS Cabguard SAE J1040 Feb 86. ISO 3471 Volumes:

Struck (SAE)............................................... 26 m³ (34 yd³)

Heaped 2:1 (SAE) ...................................... 35 m³ (46 yd³)

SERVICE CAPACITIES

Engine Crankcase and Filters............ 66 litres (17.5 US gal)

Transmission and Filters.................... 85 litres (22.5 US gal)

Cooling System ................................ 157 litres (41.5 US gal)

Fuel Tank .......................................... 606 litres (160 US gal)

Steering Hydraulic Tank ....................... 61 litres (16 US gal)

Steering System.................................... 72 litres (19 US gal)

Body and Brake Cooling Tank ............ 216 litres (57 US gal)

Body and Brake Cooling System ........ 258 litres (68 US gal)

Planetaries (Total) ............................. 43 litres (11.4 US gal)

Differential.......................................... 52 litres (13.7 US gal)

Front Ride Strut (Each) ........................ 14 litres (3.7 US gal)

Rear Ride Strut (Each)......................... 17 litres (4.5 US gal)

Power Takeoff........................................... 4 litres (1 US gal)

Typical Noise Levels

Operator Ear (ISO 6394)............................................ 79 dbA

*Exterior Sound Rating (SAE J88 JUN 86)................89 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.

Vehicle Weights (Mass)

kg lb Chassis, with hoists 30 600 67 460 Body, standard 10 650 23 480 Net Weight 41 250 90 940 PAYLOAD, maximum 54 430 120 000 Maximum Gross Weight* 95 680 210 940 FOR UNIT EQIPPED WITH OPTIONAL HARD ROCK BODY: Chassis, with hoists 30 600 67 460 Body, with wear plates 13 200 29 100 Net Weight 43 800 96 560 PAYLOAD, maximum 51 880 114 380 Maximum Gross Weight* 95 680 210 940 * Maximum permissable gross vehicle weight with options, attachments, full tank and payload. WEIGHT DISTRIBUTION Front Axle Rear Axle

Empty % 48 52

Loaded % 34 66

SM 1566 12-98

* * * *

3

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CHASSIS - Chassis, Hood and Fenders

Section 100-0010

2

1

9

8

7

6

4

3

5

8

7

6

10

SM - 1785

11

15

14

12

13

1 - Frame Assembly 2 - Bushing 3 - Engine Guard

4 - Channel 5 - Bolt 6 - Nut 7 - Lockwasher

Fig. 1 - Exploded View of Chassis and Guards

REMOVAL

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

To remove any of the components shown in Figs. 1, 2, 3, 4 or 5 (or similar components) the following procedures should be carried out.

1. Position the vehicle in a level work area, apply the parking brake and switch off the engine.

2. Turn steering wheel in both directions several times to relieve pressure in the steering circuit. Block all road wheels.

8 - Washer

9 - Bolt 10 - Transmission Guard 11 - Bolt

12 - Hardened Washer 13 - Locknut 14 - Spring Disc 15 - Washer

3. Attach a suitable lifting device to the component and remove mounting hardware. Remove the component from the vehicle.

INSTALLATION

Note: Tighten all fasteners to standard torques listed in

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

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

Using a suitable lifting device, align the component to be installed in position on the chassis. Secure the component securely to the chassis with mounting hardware removed during removal.

SM 1570 12-98

1

Chassis - Chassis, Hood and Fenders

Section 100-0010

Inspection

Inspect the frame and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending/twisting of the frame. Any defects found should be repaired before they progress into major failures. Contact your dealer for recommended weld and repair instructions.

SM - 1958MAINTENANCE

8

7

6

1

Welding

Note: It is important that the electrical connections are

disconnected in the following order to prevent damage to the electrical components:

a. Disconnect battery equalizer ground cables. b. Disconnect battery cables from terminal posts

(ground cable first). c. Disconnect battery equalizer positive cables. d. Disconnect electrical connections at the ECU.

After welding, reconnect all of the above in the reverse order.

WARNING Welding and flame cutting cadmium plated metals produce odourless fumes which are toxic. Recommended industrial hygiene practice for protection of the welding operator from the cadmium fumes and metallic oxides requires enclosure ventilation specifically designed for the welding process. A respiratory protective device such as the M.S.A. 'Gasfoe' respirator with G.M.A. cartridge will provide protection against cadmium, fumes and metallic oxides. The 'Gasfoe' respirator has been approved by the U.S. Bureau of Mines: Approval number 23B-10, and is designed to protect against gases, vapours, and/or metal fumes.

Electric arc welding is recommended for all chassis welding. Since the nature and extent of damage to the frame cannot be predetermined, no definite repair procedure can be established. As a general rule however, if parts are twisted, bent or pulled apart, or a frame is bent or twisted, no welding should be done until the parts are straightened or realigned.

5

4

2

5

4

3

1 - Hood Assembly 2 - Plate 3 - Bolt 4 - Hardened Washer

Fig. 2 - Exploded View of Hood and Mounting

5 - Nut 6 - Baffle 7 - Baffle 8 - Beading

and the ability of the welder. The Service Department can be consulted regarding the feasibility of welding repairs.

Painting

A check of the condition of the paint should be made approximately twice a year and chassis repainted if necessary.

WARNING Welding, burning, heating or dressing surfaces previously painted using polyurethane paint produces fumes which are toxic. Surfaces must be prepared using paint stripper prior to area being reworked. Recommended Industrial Hygiene and Safety Rules should be be followed for protection of the welding operator from fumes.

If painting of the actual frame of the unit is required, thoroughly clean the areas to be painted. Apply a primer coat of red oxide and then a finish coat of polyurethane enamel.

3

Successfully welded repairs will depend to a great extent upon the use of the proper equipment, materials

2

To keep rust and corrosion to a minimum, periodic painting of abrasions and other exposed metal areas on the frame is highly recommended.

SM 1570 12-98

32

23

18

DETAIL A

20

Chassis - Chassis, Hood and Fenders

Section 100-0010

SM - 1959

22

10

28

19

3

49

50

51

34

A

22

10

7

35

27 25

24

38 37

36

22

10

18

17

48

33

13

26 25

24

17

19

18

14

19

18

28

19

30

18

17

19 18

4

31 19

12

11

1

15

16

6

44

5

41

42

39

42

43

45

29

18

45

260-0010

17

19

SEC.

46

40

17

19

18

2

41 42

42 43

22

19

10

8

9

21

22

10

50

51

49

47

1 - LH Fender Assembly 2 - LH Platform Assembly 3 - RH Fender Assembly 4 - RH Platform Assembly

5 - Crossmember 6 - Support 7 - Support

8 - Bolt

9 - Lockwire 10 - Hardened Washer 11 - Bolt 12 - Washer

13 - Engine Access Cover 14 - Bolt 15 - Locknut 16 - Hardened Washer 17 - Bolt 18 - Locknut 19 - Hardened Washer 20 - Mirror 21 - LH Handrail 22 - Bolt 23 - Mirror Wide Angle 24 - Nut 25 - Washer

26 - Bolt 27 - Bolt 28 - Bolt 29 - Mudguard 30 - Mudguard 31 - Bolt 32 - Bolt 33 - Fender Extension RH 34 - RH Handrail 35 - Mirror Bracket 36 - Bolt 37 - Lockwasher 38 - Washer

Fig. 3 - Exploded View of Fenders and Mounting

39 - Plate Bent 40 - Plate bent 41 - Bolt

42 - Washer 43 - Nut 44 - Bolt

45 - Washer

46 - Nut 47 - Kick Plate

48 - Kick Plate 49 - Bolt 50 - Hardened Washer 51 - Nut

SM 1570 12-98

3

Chassis - Chassis, Hood and Fenders

Section 100-0010

13

14

6

10

12

3

11

4

14

4

11

12

10

SM - 1960

13

14

6

3

4

14

4

11 12

12 10

9

7

8

1 - LH Step Assembly 2 - RH Step Assembly 3 - Plate

11 12

2

12 10

5

7 - Washer 4 - 'U' Bolt 5 - Step 6 - Bolt

8 - Bolt

9 - Locknut

10 - Nut

Fig. 4 - Exploded View of Ladders and Handrails

9

7

8

11 - Bolt 12 - Hardened Washer 13 - Nut 14 - Hardened Washer

1

5

4

SM 1570 12-98

Chassis - Chassis, Hood and Fenders

Section 100-0010

SM - 1961

1

9

12

6

10

11

12

5

12 12

6

7

12

13

8

11

3

4

2

1 - Radiator Guard 2 - Cover Plate 3 - Washer

4 - Bolt 5 - Bolt

6 - Nut

7 - Bolt 8 - Grille 9 - Bolt

Fig. 5 - Radiator Guard and Mounting

* * * *

10 - Bracket 11 - Bolt 12 - Hardened Washer 13 - Plate

SM 1570 12-98

5

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GENERAL INFORMATION - Welding Procedure

Welding

WARNINGS Before any welding is done on a machine equipped with any electronic systems, disconnect the following (if applicable) in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables and electrical connections at the engine ECM, transmission ECU, body control lever, hydraulics ECU and cab bulkhead to avoid damage to electrical components. Turn off battery master switch to isolate the batteries before disconnecting any components. After welding connect all of the above in the reverse order.

Before any welding is done ensure all paint has been removed from the area to be welded. Failure to do so may result in hazardous fumes being given off from the paint.

Note: Always fasten the welding machines ground

cable to the piece/frame being welded if possible.

Section 000-0010

WARNING Welding and flame cutting cadmium plated metals produce odourless fumes which are toxic. Recommended industrial hygiene practice for protection of the welding operator from the cadmium fumes and metallic oxides requires enclosure ventilation specifically designed for the welding process. A respiratory protective device such as the M.S.A. 'Gasfoe' respirator with G.M.A. cartridge will provide protection against cadmium, fumes and metallic oxides. The 'Gasfoe' respirator has been approved by the U.S. Bureau of Mines: Approval number 23B-10, and is designed to protect against gases, vapours, and/or metal fumes.

Note: The current from the welding rod always follows

the path of least resistance. If, for example, the ground clamp is attached to the rear frame when welding is performed on the front frame, the current must pass a frame connection to return to the welding machine. Since the pivot coupling offers the least resistance but not a sound electrical connection, small electric arcs may be set up across the moving parts which may cause welding blotches on their wearing surfaces and increase the wear rate of these components.

Electric arc welding is recommended for all welded frame repairs. Since the nature and extent of damage to the frame cannot be predetermined, no definite repair procedure can be established. As a general rule however, if parts are twisted, bent or pulled apart, or a frame is bent or out of alignment, no welding should be done until the parts are straightened or realigned.

Successfully welded repairs will depend to a great extent upon the use of the proper equipment, materials and the ability of the welder. The Customer Support Department can be consulted regarding the feasibility of welding repairs.

General Welding Procedure

The following general procedure should be used for the repair of defects outwith the vicinity of alloy steel castings.

1. Completely ARC-AIR gouge or grind out the crack until sound metal is reached. If ARC-AIR method is employed, pre-heat area to 100° C (212° F), measure 3 - 4" either side of repair prior to gouging. On completion of gouging grind to remove thin carbon layer.

2. Apply dye-penetrant check to ensure crack has been completely removed.

SM 2172 10-02

1

General Information - Welding Procedure

Section 000-0010

3. Pre-heat area to 100° C (212° F), measured 3 - 4" either side of repair. Avoid local overheating.

4. Weld completely using E-7016 electrodes. Care must be taken to ensure electrodes are protected from moisture pick-ups at all times.

5. Allow repair weld to cool slowly.

6. Grind and blend repair to original contour. Paint heat damaged areas.

The following general procedure should be used for the repair of defects in alloy steel castings and in the welds joining steel castings.

1. Completely ARC-AIR gouge or grind out the crack until sound metal is reached. If ARC-AIR method is employed, pre-heat area to 200° C (392° F), measure

* * * *

3 - 4" either side of repair prior to gouging. On completion of gouging grind to remove thin carbon layer.

2. Apply dye-penetrant check to ensure crack has been completely removed.

3. Pre-heat area to 200° C (392° F), measured 3 - 4" either side of repair. Avoid local overheating.

4. Weld completely using E-7016 electrodes. Care must be taken to ensure electrodes are protected from moisture pick-ups at all times.

5. On completion of welding, post-heat repair area to 400° C (752° F), measure 3 - 4" either side of repair.

6. If welding has to be interrupted for any reason, e.g. overnight, post-heat immediately as in Step 5.

2

SM 2172 10-02

CHASSIS - Chassis, Hood and Fenders

Section 100-0010

SM - 2395

2

1

11

15

16

12

14

17

13

9

8

7 6

4

3

5

8

7

6

10

13

16

12 14

17

11

1 - Frame Assembly 2 - Bushing 3 - Engine Guard 4 - Channel

5 - Bolt 6 - Nut 7 - Lockwasher 8 - Washer

Fig. 1 - Exploded View of Chassis and Guards

REMOVAL

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

To remove any of the components shown in Figs. 1, 2, 3, 4 or 5 (or similar components) the following procedures should be carried out.

1. Position the vehicle in a level work area, apply the parking brake and switch off the engine.

2. Turn steering wheel in both directions several times to relieve pressure in the steering circuit. Block all road wheels.

13 - Locknut

9 - Bolt 10 - Transmission Guard 11 - Bolt 12 - Hardened Washer

14 - Spring Disc 15 - Washer 16 - Spacer 17 - Washer

3. Attach a suitable lifting device to the component and remove mounting hardware. Remove the component from the vehicle.

INSTALLATION

Note: Tighten all fasteners to standard torques listed

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

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

Using a suitable lifting device, align the component to be installed in position on the chassis. Secure the component securely to the chassis with mounting hardware removed during removal.

SM 1904 1-00

1

Chassis - Chassis, Hood and Fenders

Section 100-0010

Inspection

Inspect the frame and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending/twisting of the frame. Any defects found should be repaired before they progress into major failures. Contact your dealer for recommended weld and repair instructions.

SM - 2396MAINTENANCE

8

7

6

1

Welding

Note: It is important that the electrical connections are

disconnected in the following order to prevent damage to the electrical components:

a. Disconnect battery equalizer ground cables. b. Disconnect battery cables from terminal posts

(ground cable first). c. Disconnect battery equalizer positive cables. d. Disconnect electrical connections at the ECU.

After welding, reconnect all of the above in the reverse order.

WARNING Welding and flame cutting cadmium plated metals produce odourless fumes which are toxic. Recommended industrial hygiene practice for protection of the welding operator from the cadmium fumes and metallic oxides requires enclosure ventilation specifically designed for the welding process. A respiratory protective device such as the M.S.A. 'Gasfoe' respirator with G.M.A. cartridge will provide protection against cadmium, fumes and metallic oxides. The 'Gasfoe' respirator has been approved by the U.S. Bureau of Mines: Approval number 23B-10, and is designed to protect against gases, vapours, and/or metal fumes.

Electric arc welding is recommended for all chassis welding. Since the nature and extent of damage to the frame cannot be predetermined, no definite repair procedure can be established. As a general rule however, if parts are twisted, bent or pulled apart, or a frame is bent or twisted, no welding should be done until the parts are straightened or realigned.

5

4

3

2

5

4

3

1 - Hood Assembly 2 - Plate 3 - Bolt 4 - Hardened Washer

Fig. 2 - Exploded View of Hood and Mounting

5 - Nut 6 - Baffle 7 - Baffle 8 - Beading

and the ability of the welder. The Service Department can be consulted regarding the feasibility of welding repairs.

Painting

A check of the condition of the paint should be made approximately twice a year and chassis repainted if necessary.

WARNING Welding, burning, heating or dressing surfaces previously painted using polyurethane paint produces fumes which are toxic. Surfaces must be prepared using paint stripper prior to area being reworked. Recommended Industrial Hygiene and Safety Rules should be be followed for protection of the welding operator from fumes.

If painting of the actual frame of the unit is required, thoroughly clean the areas to be painted. Apply a primer coat of red oxide and then a finish coat of polyurethane enamel.

Successfully welded repairs will depend to a great extent upon the use of the proper equipment, materials

2

To keep rust and corrosion to a minimum, periodic painting of abrasions and other exposed metal areas on the frame is highly recommended.

SM 1904 1-00

Chassis - Chassis, Hood and Fenders

Section 100-0010

SM - 2397

22

32

10

42

23

28

19

18

3

A

22

10

7

27

25

24

22

10

18

33

13

26 25

24

17

19

18

14

17

19

18

28

19

30

18

17

19

18

4

31 19

12

11

1

15

16

6

36

41

34 39

38

37

34

35

37

29

5

17

19

18

41

40

34

34 35

17

19

18

2

21

22

19

10

8

9

22

10

20

45 48

47

55

1 - LH Fender Assembly 2 - LH Platform Assembly 3 - RH Fender Assembly 4 - RH Platform Assembly 5 - Crossmember 6 - Support 7 - Support 8 - Bolt

9 - Lockwire 10 - Hardened Washer 11 - Bolt 12 - Washer 13 - Engine Access Cover 14 - Bolt

43,46,57

56

51 50

49

54

53

52

DETAIL A

44

57

43

44

57

43

A

43 - Nut 15 - Locknut 16 - Hardened Washer 17 - Bolt 18 - Locknut 19 - Hardened Washer 20 - Mirror 21 - LH Handrail 22 - Bolt 23 - Mirror Wide Angle 24 - Nut 25 - Washer 26 - Bolt 27 - Bolt 28 - Bolt

29 - Mudguard 30 - Mudguard 31 - Bolt 32 - Bolt 33 - Fender Extension RH 34 - Washer 35 - Nut 36 - Bolt 37 - Washer 38 - Nut 39 - Plate Bent 40 - Plate bent 41 - Bolt 42 - RH Handrail

44 - Plate

45 - Mirror Arm Assembly

46 - Bar

47 - Rod Assembly

48 - Bracket Assembly

49 - Bolt

50 - Lockwasher

51 - Washer

52 - Nut

53 - Lockwasher

54 - Washer

55 - Bolt

56 - 'U' Bolt

57 - Hardened Washer

SM 1904 1-00

Fig. 3 - Exploded View of Fenders and Mounting

3

Chassis - Chassis, Hood and Fenders

Section 100-0010

13

14

6

10

12

3

11

4

14

4

11

12

10

SM - 1960

13

14

6

3

4

14

4

11 12

12 10

9

7

8

1 - LH Step Assembly 2 - RH Step Assembly 3 - Plate

11 12

2

12 10

5

7 - Washer 4 - 'U' Bolt & Nut 5 - Step 6 - Bolt

8 - Bolt

9 - Locknut

10 - Nut

Fig. 4 - Exploded View of Ladders and Handrails

1

9

7

8

11 - Bolt 12 - Hardened Washer 13 - Nut 14 - Hardened Washer

5

4

SM 1904 1-00

Chassis - Chassis, Hood and Fenders

Section 100-0010

SM - 2398

8

1

7

11

6

10

5

11

2

9

7

11

3

4

11 11

12

1 - Radiator Guard 2 - Cover Plate 3 - Washer

7

11

13

4 - Bolt 5 - Bolt 6 - Nut

7 - Bolt 8 - Grille 9 - Bolt

Fig. 5 - Radiator Guard and Mounting

* * * *

10 - Bracket 11 - Hardened Washer 12 - Nut 13 - Bracket

SM 1904 1-00

5

THIS PAGE IS INTENTIONALLY LEFT BLANK

ENGINE - Engine and Mounting

Section 110-0030

52

51

29

26

4

15

22,23

POSITION A

46

42

47

48

45

43

30

31

44

POSITION B

32

35

1 - Engine 2 - Locknut 3 - Bolt 4 - Alternator Guard 5 - Rear Mount 6 - Front Mount 7 - Bolt 8 - Lockwasher

9 - Support Bracket 10 - Bolt 11 - Snubbing Washer 12 - Isolation Mount 13 - Bolt 14 - Locknut 15 - Plate Support 16 - Damper

53

9

26

11

12

11

25

24

50

56

55

54

62

38

13

3

2

57

59

58

21

60

61

1

6

14

17 - Lockwasher 18 - Bolt 19 - Flange Coupling 20 - Bolt 21 - Clamp 22 - Bolt 23 - Lockwasher 24 - Washer 25 - Bolt 26 - Washer 27 - Padlock 28 - Key 29 - Bolt 30 - P-Clip 31 - P-Clip 32 - Bracket 33 - Latch Assembly

39

A

21

37

SECURITY KIT ENGINE DIPSTICK

34

27

28

34 - Latch Assembly 35 - Bolt 36 - Oil Filter 37 - Fuel Filter 38 - Coolant Filter 39 - Breather Line 40 - Filler Hose 41 - Clamp 42 - Lockwasher 43 - Locknut 44 - Plate 45 - P-Clip 46 - Bolt 47 - Lockwasher 48 - Locknut 49 - Filler Assembly 50 - Alternator

BB

S.W.E.

66

65

63

65

39

49

64

5

36

41

40

51 - Bolt 52 - Lockwasher 53 - Eye Bolt 54 - Jam Nut 55 - Link 56 - Nut 57 - Eye Bolt 58 - Lockwasher 59 - Bolt 60 - Locknut 61 - Lockwasher

62 - Bolt

63 - Bracket

64 - Bolt

65 - Washer

66 - Locknut

8

41

16

7

SM - 1962

17

18

19

20

10

12

11

24

2

SECURITY KIT ENGINE OIL FILL

33

27

11

28

Fig. 1 - Engine and Mounting

DESCRIPTION

Numbers in parentheses refer to Fig. 1. For engine make, model and specification, refer to

Section 000-0000, GENERAL INFORMATION. For engine servicing and repair data refer to the engine manufacturers service manual.

The engine is mounted to the frame at three points by a mounting bracket (6) at the front of engine (1) and two rear mounts (5). Rubber isolation mounts (12)

SM 1571 12-98

through engine mounts provide sufficient flexibility to absorb varying engine vibration and torsional loads.

There are two full-flow oil filters (36) mounted on the left hand side of engine (1) in a downward position. The filters are of the throw away, spin-on type. Oil supplied by the engine oil pump passes through oil filters (36) before reaching the various moving parts of engine (1). The oil is forced by pump pressure through a passage in the filter adaptor and into the elements. Impurities are filtered out as the oil passes through the

1

Engine - Engine and Mounting

Section 110-0030 elements and out through another passage in the filter

adaptor. Engine coolant filter (38) and conditioner is a compact

bypass type unit with a replaceable spin-on type element mounted on the gear case cover at the front right hand side of engine (1). Refer to Section 210-0000, COOLING SYSTEM.

There are two spin-on type fuel filters (37) mounted on the left hand side of engine (1). The primary fuel filter is in the fuel flow and acts as a strainer and the secondary fuel filter filters the fuel after having passed through the primary fuel filter.

QUANTUM ELECTRONIC FUEL CONTROL SYSTEM

Description

Refer to Fig. 2.

WARNING Before any welding is done on a machine equipped with the Quantum Electronic Fuel System, disconnect the following in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables, transmission black box connector, ECM interface harness connector (30 pin RHS), ECM power harness connector (5 pin RHS) and ECM sensor harness connector (30 pin LHS). Turn off ignition key switch to isolate the batteries before disconnecting any components.

After welding connect all of the above in the reverse order.

The engine is equipped with Quantum Electronic Fuel System which controls the timing and amount of fuel injection by the electronic fuel system injectors. The system also monitors several engine functions using electrical sensors which send 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.

The Quantum Electronic Fuel System also takes action to prevent damage to the engine and, provides the serviceman with diagnostic capabilities so that problems can be corrected quickly and easily.

1. Electronic Control Module (ECM) - Receives electronic inputs from the driver as well as from mounted sensors that provide information electronically, such as oil pressure and temperature and intake manifold pressure. This information is used to control both the quantity of fuel injected and injection timing.

2. Programmable Read Only Memory (PROM) -

Located in the ECM and encoded with the operating software. Additional information is programmed into the EEPROM. This information controls the horsepower rating, torque curve, maximum engine speed and engine protection devices. The ECM processes this information and sends electronic signals to the Electronic Fuel System Injectors where the precise amount of fuel is injected into the engine.

3. Electronic Fuel System Injectors - The injector is a lightweight, compact unit that injects diesel fuel directly into the combustion chamber. The amount of fuel injected and the beginning of injection timing is determined by the ECM. The ECM sends a command pulse which activates the injector solenoid.

The injector performs four functions: a - Creates the high fuel pressure required for efficient

injection. b - Meters and injects the exact amount of fuel required to handle the load. c - Atomizes the fuel for mixing with the air in the combustion chamber. d - Permits continuous fuel flow for component cooling.

Electronic fuel system injectors are self compensating and virtually eliminate engine tune-ups.

Note: Never apply 12 V directly to terminals on the injector as it will burn out. Before removing injectors, the fuel passages must be blown out to prevent fuel flow from entering the cylinder head.

4. Batteries - Two 12 volt maintenance free batteries supply the machine with electrical power to operate all electrical components.

5. Electronic Foot Pedal - The electronic foot pedal provides an electrical signal to the engine's fuel control system in proportion to the degree of pedal actuation.

Note: The electronically controlled engine will override the electronic foot pedal position until the engine is

2

SM 1571 12-98

Engine - Engine and Mounting

Section 110-0030

SM - 1791

4

1,2

1 - Electronic Control Module (ECM) 2 - Programmable Read Only Memory (PROM) 3 - Electronic Fuel System Injectors 4 - Batteries 5 - Electronic Foot Pedal

3

9

5

6 - Engine 'Stop' Light 7 - Engine 'Warning' Light 8 - Engine 'Fluid' Light

9 - Diagnostic Test Point 10 - Diagnostic Request Switch 11 - Diagnostic Search Switch

STOP

6

7 8

10 11

Fig. 2 - Quantum Electronic Fuel System Components

warmed up to the correct operating temperature. The engine MUST be started with foot 'OFF' the electronic foot pedal.

6. Engine Stop Light (Red) - When the engine 'Stop' light comes on, the computer has detected a major malfunction in the engine that requires immediate attention. It is the operators responsibility to shut down the engine to avoid serious damage.

7. Engine Warning Light (Yellow) - When the engine 'Warning' light comes on, the computer has detected a fault in the engine which may result in power loss. The fault should be diagnosed and corrected at the earliest opportunity.

8. Engine Protection Fluid Light (Amber) - When the engine 'Fluid' light comes on, the computer has detected a fault in the engine. The light will remain on as long as the fault is occuring. The fault should be diagnosed and corrected at the earliest opportunity. If the fault continues to get worse the light will flash. Stop the machine and do not operate until the fault is corrected.

9. Diagnostic Test Point - Plug in connector for diagnostic data reader (DDR).

10. Diagnostic Request Switch - To check for active codes:

a - turn the ignition key switch to the 'OFF' ('0') position.

b - press the diagnostic switch to the 'ON' position. c - turn the ignition key switch to position '1'.

If no active codes are recorded the 'Stop', 'Warning' and 'Fluid' lights will illuminate and stay on.

If active codes are recorded the 'Stop', 'Warning' and 'Fluid' lights will illuminate momentarily. The yellow 'Warning' and red 'Stop' lights will begin to flash the code of the recorded fault.

11. Diagnostic Search Switch - When the engine is in diagnostic mode this switch is used to search through a list of fault codes, ie. pressing the top of the switch momentarily will advance to the next active

SM 1571 12-98

3

Engine - Engine and Mounting

Section 110-0030 fault code, pressing the bottom of the will go back to

the previous code. On machines which have a Low Idle Adjustment

feature, this switch can also be used to increase or decrease (in increments of 25 RPM), the idle or intermediate speed of the engine.

Operation

Numbers in parentheses refer to Fig. 2. The machine is equipped with the Quantum engine

protection system which records fault codes in the ECM (1), when the engine malfunctions and when an out-of-range condition is found.

When the 'Stop' light (6) on the dash panel illuminates, the computer has detected a major malfunction in the engine that requires immediate attention. It is the operators responsibility to shut down the engine to avoid serious damage.

When an out-of-range conditions is found, the 'Fluid' light (8) illuminates and the engine protection system is initiated. The 'Fluid' light will start to flash if the outof-range condition continues to get worse. The operator MUST shut down the engine to avoid serious damage.

The engine should not be restarted after it has been shut down after activation of the engine protection system unless the problem has been diagnosed and corrected.

Conditions that will cause the amber 'Fluid' light (8) to come on are; Low coolant level, High coolant temperature, Idle validation/throttle pedal switch mismatch, High intake manifold temperature, Low oil pressure and High fuel rail pressure.

Whenever the 'Stop' light (6), 'Warning' light (7) or 'Fluid' light (8) come on, the Electronic Fuel System 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.

A special diagnostic data reader (INSITE) is available that can be plugged into the engine computer memory via the onboard diagnostic test point (9). The reader is used to extract information related to the cause of the problem. Once the malfunction has been corrected, the Electronic Fuel System will return the engine to normal operation. The data reader can now distinguish between active codes and those stored in the historic code memory (inactive codes). Inactive codes can only be viewed using the data reader. The fault code recorded in the ECM memory will remain until it is erased by a technician.

WARNINGS The operator of a Quantum-equipped vehicle must not attempt to use or read a data reader of any kind while the vehicle is operating. Doing so can result in loss of control, which may cause vehicle damage and may result in personal injury.

The operator can check for active faults by turning the ignition key switch to the 'OFF' position, switching the diagnostic switch 'ON' and then turning the ignition key switch to position '1'.

If no active fault codes are recorded, all three ('Stop', 'Warning' & 'Fluid') lights will come on and stay on. If active codes are recorded, all three lights will come on momentarily. The yellow ('Warning') and red ('Stop') lights will begin to flash the code of the recorded fault. The fault codes flash in the following sequence: the yellow light flashes once, then there is a pause where both lights are off. Then the numbers of the recorded fault code flash in red. There is a pause between each number. When the number is done, the yellow light flashes again. e.g. yellow flashes once - pause - red flashes twice - pause - red flashes three times - pause

- red flashes five times - pause - yellow flashes once, indicates fault code 235. The number will repeat in the same sequence until the the system is advanced to the next active fault code or the diagnostic switch is switched to the 'OFF' position. Refer to 'Electronic Fuel System Diagnostic Codes' table for fault code descriptions.

4

SM 1571 12-98

Engine - Engine and Mounting

Section 110-0030

ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES Error Code Description Fault Lamp

111 ECM Hardware Internal Failure - Mission disabling Red 112 Timing Actuator - Mechanically stuck Red 113 Timing Actuator - Component shorted high Yellow 114 Timing Actuator - Component shorted low Yellow 115 Engine Speed Sensor - Both signals lost Red 116 Fuel Timing Pressure Sensor - Component shorted high Red 117 Fuel Timing Pressure Sensor - Component shorted low Red 118 Fuel Pump Pressure Sensor - Component shorted high Yellow 119 Fuel Pump Pressure Sensor - Component shorted low Yellow 121 Engine Speed Sensor - One signal lost Yellow 122 Boost Pressure Sensor - Component shorted high Yellow 123 Boost Pressure Sensor - Component shorted low Yellow 131 Throttle Position Sensor - Component shorted high Red 132 Throttle Position Sensor - Component shorted low Red 135 Oil Pressure Sensor - Component shorted high Yellow 141 Oil Pressure Sensor - Component shorted low Yellow 143 Oil Pressure Sensor - Data below normal range Amber 144 Engine Coolant Temperature Sensor - Component shorted high Yellow 145 Engine Coolant Temperature Sensor - Component shorted low Yellow 151 Engine Coolant Temperature Sensor - Data above normal range Amber 153 Intake Manifold Temperature Sensor - Component shorted high Yellow 154 Intake Manifold Temperature Sensor - Component shorted low Yellow 155 Intake Manifold Temperature Sensor - Data above normal range Amber 221 Ambient Air Pressure Sensor - Component shorted high Yellow 222 Ambient Air Pressure Sensor - Component shorted low Yellow 231 Coolant Pressure Sensor - Component shorted high Yellow 232 Coolant Pressure Sensor - Component shorted low Yellow 233 Coolant Pressure, Engine Protection - Low coolant pressure Amber 234 Engine Speed - Data above normal range Red 235 Engine Coolant Level - Data below normal range Amber 254 Fuel Shutoff Value - Component shorted low Red 259 Fuel Shutoff Solenoid - Fuel shutoff valve stuck open Red 261 Fuel Temperature, Engine Protection - Fuel temperature high Amber 263 Fuel Temperature Sensor - Component shorted high Yellow 265 Fuel Temperature Sensor - Component shorted low Yellow 316 Fuel Pump Actuator - Component shorted high or low Yellow 318 Fuel Pump Flow - Mismatch between estimated and desired pressures Yellow 342 ECM Not Calibrated - ECM software mission disabling failure Red 343 ECM Hardware Failure - Warning non mission disabling Yellow 346 ECM Software - Read/write, checksum error - Non mission disabling Yellow 415 Oil Pressure Sensor - Data indicates very low oil pressure Amber 422 Engine Coolant Level Sensor Signals - Data invalid Yellow 423 Fuel Timing Pressure Sensor - In-range failure Yellow 431 Throttle Position Idle Validation Switch - Invalid Yellow 432 Throttle Position Idle Validation Switch - Switch position & throttle percent mismatch Amber 441 Battery Voltage, Unswitched - Data below normal engine range Yellow 442 Battery Voltage, Unswitched - Data above normal engine range Yellow 451 Fuel Pressure Sensor - Component shorted high Red 452 Fuel Pressure Sensor - Component shorted low Red 455 Fuel Control Valve - Component shorted high or open Red 467 Timing Fueling Flow - Mismatch between estimated and desired timing Yellow 468 Fueling Rail Flow - Mismatch between estimated and desired rail pressure Yellow 511 Fuel Control Valve - Component shorted low Red 514 Fuel Control Valve - Actuator mechanically stuck open Red 524 Alternate Droop Switch Fault Yellow 551 Idle Validation Circuit - No voltage detected on both off-idle and idle pins Red 553 Engine Fueling Pressure Exceeded - Data above normal range Red 554 Fuel Pressure Sensor - In-range failure Yellow 555 Blowby Pressure, Engine Protection - Blowby pressure high Amber 719 Blowby Pressure Sensor - Component shorted high Yellow 729 Blowby Pressure Sensor - Component shorted low Yellow 753 Engine Speed Sensor - Engine speed signals do not match Off

SM 1571 12-98

5

Engine - Engine and Mounting

Section 110-0030

REMOVAL

Numbers in parentheses refer to Fig. 1. Note: Tag all cables, harnesses, lines and pipes

disconnected during removal to aid in installation.

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

High electrical current can cause sparks and personal injury from burns. Turn ignition key switch to the 'Off' position before removing any components. Remove battery ground cable first, and reconnect last, to avoid damaging electrical components.

1. Position the vehicle in a level work area, ensure the body is fully lowered, apply the parking brake and switch off the engine.

2. Turn steering wheel several times to relieve pressure in the steering circuit. Block all road wheels.

3. Disconnect battery cables from battery terminal ports before starting removal procedures. Disconnect ground cable first.

7. If the truck is equipped with an air conditioning system, evacuate refrigerant from the system and disconnect lines at the compressor. Refer to Section 260-0130, AIR CONDITIONING.

8. With suitable containers in position, open drain cocks and drain coolant from the radiator and engine (1) assembly. Close all drain cocks after draining.

9. Identify cooling lines for ease of installation and with suitable containers in position, disconnect cooling lines from engine (1). Cap open line ends and fittings.

10. Using suitable lifting equipment, carefully remove the radiator assembly from the vehicle. Refer to Section 210-0040, RADIATOR AND MOUNTING.

11. Disconnect and remove air cleaner intake pipe from the engine turbocharger and air cleaner.

12. Disconnect and remove exhaust tube from the engine turbocharger.

13. Identify heater lines for ease of installation and, with a suitable container in position, disconnect heater lines from engine (1). Cap open line ends and fittings.

14. Close fuel shutoff valve at filter head, identify fuel lines for ease of installation and, with a suitable container in position, disconnect fuel lines from engine (1). Cap open line ends and fittings.

4. Remove mounting hardware securing the hood on the vehicle. Remove hood assembly from the vehicle.

5. Disconnect electrical connections from the radiator guard and remove mounting hardware securing the radiator guard on the vehicle. Remove radiator guard from the vehicle.

6. Place a suitable container under the engine drain port, remove drain plug and drain the oil. After draining, reinstall drain plug in the engine sump and tighten securely.

WARNING Harmful gas. Before disconnecting any air conditioner lines refer to Section 260-0130, AIR CONDITIONING. Refrigerant will rapidly freeze all objects with which it comes into contact, and it can cause serious damage to the skin and eyes.

15. Identify all electrical harnesses and cables attached to engine (1) for ease of installation and disconnect from engine (1).

16. Disconnect driveline from engine coupling and secure clear of engine (1). Refer to Section 130-0010, FRONT DRIVELINE.

17. Remove tandem pump from the engine power takeoff. Refer to Section 230-0050, TANDEM PUMP.

Note: The hydraulic lines can be left attached to the tandem pump.

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

6

SM 1571 12-98

Engine - Engine and Mounting

Section 110-0030

18. Attach suitable lifting equipment to the lifting brackets on engine (1) assembly and raise lifting equipment to take up the slack.

19. Remove locknuts (14) and bolts (13) securing engine (1) assembly to front mounting (6). Remove locknuts (2), washers (24), snubbing washers (11) and bolts (10) securing rear mounting brackets (5) to the frame.

20. Check to make certain that all necessary line and electrical disconnections have been made before lifting engine (1).

21. Carefully lift engine (1) assembly clear of the frame and move to a clean work area. Securely mount engine (1) assembly to a work stand.

DISASSEMBLY

Numbers in parentheses refer to Fig. 1.

1. If required, remove bolts (7) and lockwashers (8) securing rear mounts to engine (1). Remove rear mounts (5).

2. If required, remove rubber isolation mounts (12) from rear mounts (5).

Note: Adjuster screw and link assembly (53 thru 57)

will have been released when removing radiator

assembly from the vehicle.

8. Remove bolt (51) and lockwasher (52) securing

screw and link assembly (53 thru 57) to alternator (50).

Support alternator (50) and remove locknut (60),

lockwasher (61) and bolt (62). Remove alternator (50)

from engine (1).

9. If necessary, damper (16) can be removed from the

flywheel after the power takeoff assembly is removed.

Refer to Section 110-0130, POWER TAKEOFF.

10. With power takeoff assembly removed, remove

bolts (18) and washers (17). Remove damper (16)

from engine (1). If necessary, remove bolts (20) from

flange coupling (19). Remove flange coupling (19) from

damper (15).

11. If required, remove bolt (64), washers (65) and

locknut (66) securing filler assembly (49) to bracket

(63). Loosen bottom clamp (41) and remove filler

hose (40) and filler assembly (49) from engine (1).

12. Remove and discard filters (36, 37 & 38) from

engine (1), as described in 'Maintenance'. Cover

engine inlet ports to prevent entry of dirt.

3. Remove bolts (22) and lockwashers (23) securing fan to engine (1) then remove fan.

4. Loosen the fan hub mounting bolts and turn the adjusting rod anticlockwise enough to allow slack in poly 'V' belts. Remove poly 'V' belts.

5. If equipped with air conditioning, loosen compressor drive belt and remove compressor from engine (1). Refer to Section 260-0130, AIR CONDITIONING.

6. Remove bolts (25 & 29) and lockwashers (26) securing alternator guard (4) to engine (1). Remove alternator guard (4).

7. Loosen alternator mounting bolt (62) to allow slack in 'V' belts. Remove 'V' belts.

13. Refer to 'Engine Manufacturers Service Manual' if

engine service or repair is required.

INSPECTION

Numbers in parentheses refer to Fig. 1.

1. Inspect rubber isolation mounts (12) for damage and

replace if required.

2. Check rear mounts (5), front mounting bracket (6)

and mounting brackets on the front frame for cracks

and/or damage. Repair or replace as necessary.

3. Inspect engine damper (16) and flange coupling (19)

for damage and repair or replace as required.

SM 1571 12-98

7

Engine - Engine and Mounting

Section 110-0030

ASSEMBLY

Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners without special torques

specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.

1. Remove covers from engine filter ports and install new filters (36, 37 & 38) on engine (1), as described in 'Maintenance'.

2. If removed, secure filler hose (40) and filler assembly (49) to engine (1) with bottom clamp (41). Secure filler assembly (49) to bracket (63) using bolt (64), washers (65) and locknut (66).

3. Install damper (16) to rear of engine (1) and secure with bolts (18) and washers (17). Install flange coupling (19) to damper (16) and secure with bolts (20).

4. Position alternator (50) on engine mounting bracket and align the holes in the alternator mounting flanges with the tube in the bracket. Secure alternator (50) in position with bolt (62), lockwasher (61) and locknut (60). Tighten bolt (62) finger tight at this stage.

5. Install adjuster screw and link assembly (53 thru 57) to alternator (50) and secure with bolt (51) and lockwasher (52). Tighten bolt (51) finger tight at this stage.

Note: Replace all belts in a set when one is broken or replaced.

6. Install 'V' belts in the grooves of alternator (50) and accessory drive pulley.

Note: Alternator belt tension adjustment is made after installation of engine (1) and the radiator assembly.

7. If equipped with air conditioning, install air conditioner compressor and drive belt to engine (1). Refer to Section 260-0130, AIR CONDITIONING.

8. Install poly 'V' belts to the fan pulley and crankshaft pulley.

9. Adjust poly 'V' belts by turning the adjusting screw clockwise until the correct tension is obtained. Refer to 'Drive Belt Adjustments'. When correct tension is obtained tighten fan hub mounting bolts to a torque of 101 - 126 Nm (75 - 93 lbf ft).

10. Position fan to fan pulley on engine (1) and secure with bolts (22) and lockwashers (23). Tighten bolts (22) in a star shaped pattern to a torque of 34 Nm (25 lbf ft).

11. If removed, install rubber isolation mounts (12) to front mounting bracket (6).

12. Secure rear mounts (5) to engine (1) with bolts (7) and lockwashers (8) as identified at disassembly. Tighten bolts (7) to a torque of 150 Nm (110 lbf ft). If removed, install rubber isolation mounts (12) in rear mounts (5).

INSTALLATION

Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners without special torques

specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.

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

1. Attach suitable lifting equipment to engine (1) lifting brackets and carefully position engine (1) assembly in the frame.

2. Secure engine (1) assembly to rear mounts on the frame with bolts (10), snubbing washers (11) washers (24) and locknuts (2). Secure engine (1) assembly to front mounting bracket (6) with bolts (13) and locknuts (14).

3. Connect driveline to the engine coupling. Refer to Section 130-0010, FRONT DRIVELINES.

4. Install tandem pump on power takeoff assembly and secure with mounting hardware. Refer to Section 230-0050, TANDEM PUMP.

5. Using suitable lifting equipment, install the radiator assembly to the frame and secure with mounting hardware. Refer to Section 210-0040, RADIATOR AND MOUNTING.

6. Adjust 'V' belts by loosening locknut (54) and turning screw assembly (55) clockwise until the correct tension is obtained (refer to 'Drive Belt Adjustments'). When correct tension is obtained tighten locknut (54).

8

SM 1571 12-98

Engine - Engine and Mounting

Section 110-0030

7. Tighten bolt (62) securing alternator (50) to engine mounting bracket and bolt (51) securing link (53) assembly to alternator (50) to a torque of 81 - 95 Nm (60 - 70 lbf ft).

8. Remove caps from all cooling lines and connect lines to the radiator assembly and engine (1) assembly as identified at removal.

9. Install air cleaner intake pipe and exhaust piping to engine turbocharger. Tighten mounting clamps securely.

10. Remove caps from heater lines and fittings and connect heater lines to engine (1) as identified at removal.

11. Remove caps from fuel lines and fittings and connect fuel lines to engine (1) as identified at removal.

12. Connect all electrical harnesses and cables to engine (1) (with the exception of battery connections) as identified at removal.

13. If the vehicle is equipped with air conditioning, connect the 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 CONDITIONING.

19. Fill the engine with lube oil specified in Section

300-0020, LUBRICATION SYSTEM. Check oil level

as described under 'Maintenance'.

20. Start up the engine and bring the engine oil to

operating temperature. Check all lines and fittings for

leaks and tighten as required.

21. Ensure parking brake is applied and remove wheel

blocks from all road wheels.

MAINTENANCE

Numbers in parentheses refer to Fig. 1.

Note: Carry out the following maintenance procedures

in conjunction with additional procedures listed in

Section 300-0020, LUBRICATION SYSTEM.

Every 10 Hours (Daily)

Engine (1): Visually check engine for damage, loose

or frayed belts and listen for any unusual noises.

Check the turbocharger for leaks.

Engine (1) Oil Level: Check engine oil level and add

oil if low. To allow checking before starting as well as

immediately after shutting down the engine, the

dipstick is provided with two types of marks:

14. Using suitable lifting equipment, install radiator guard assembly to the frame. Secure with the required mounting hardware and connect electrical connections as identified at removal.

15. Using suitable lifting equipment, install hood assembly into position on the vehicle. Secure hood assembly with mounting hardware removed at removal.

16. Connect battery positive connections to battery terminal posts. Connect battery earth connections to battery terminal posts.

17. Ensure all lines, harnesses and cables are secured with clips and clamps as removed during removal. Ensure no lines are chaffing on sharp edges or resting against areas where heat will be evident. Ensure all drain plugs and cocks are secured tightly.

18. Fill the cooling system with coolant specified in Section 300-0020, LUBRICATION SYSTEM. Check the coolant level as described in Section 210-0000, COOLING SYSTEM.

1. Dot Marks - Before starting up after a major shut

down period the oil level should be up to the top dot

mark (cold level).

2. Dash Marks - Upon shutting down the engine at low

idling (wait 1 to 2 minutes) the oil level should be up to,

but not over, the top dash mark (hot level).

Every 250 Hours

Engine (1): Drain engine oil and refill. Refer to Section

300-0020, LUBRICATION SYSTEM for oil

specification.

Engine Water Pump: Inspect water pump drain hole

and clean if required.

Engine Oil Filters (36): Replace oil filters as follows:

1. Using filter wrench, remove and discard both oil

filters (36) from engine (1). Inspect the sealing

surface of the filter to ensure that the seal ring stayed

with the filter. If not, remove it from the filter adaptor.

2. Clean the filter adaptor with a clean, lint free cloth.

SM 1571 12-98

9

Engine - Engine and Mounting

Section 110-0030

3. Lightly coat new oil filter (36) seal with clean engine oil as specified in Section 300-0020, LUBRICATION SYSTEM.

4. Start a new oil filter (36) on the filter adaptor and tighten it by hand until the seal touches the adaptor filter head. Tighten an additional 2/3 of a turn after contact.

Note: Mechanical tightening of oil filters (36) is not necessary and will distort or crack the adaptor. Tighten oil filters by hand only.

5. Repeat steps 3 and 4 for second oil filter (36).

6. Start and run the engine for a short period and check for oil leaks. If any leaks are noted, have them corrected.

7. After the engine has been stopped long enough (approximately 20 minutes) for the oil from various parts of engine (1) to drain back to the crankcase, check oil level and add oil to bring it to the proper level on the dipstick. Refer to Section 300-0020, LUBRICATION SYSTEM for oil specification.

Fuel Filters (37): Replace primary and secondary fuel filters as follows:

Note: There is a fuel system shut off valve on the discharge side of secondary fuel filter. Closing this valve will prevent loss of fuel prime at time of filter replacement.

1. Close shut off valve at secondary fuel filter and, using filter wrench, remove and discard both fuel filters from engine (1).

2. Fill the replacement filters and coat the gaskets slightly with clean fuel oil as specified in Section 300-0020, LUBRICATION SYSTEM.

3. Start a new fuel filter on the filter adaptor and 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.

Note: Mechanical tightening of fuel filters is not recommended, and may result in seal and/or cartridge damage. Tighten fuel filters by hand only.

4. Repeat step 3 for second fuel filter.

Coolant Filter (38): Check condition of coolant inhibitor as described in Section 210-0000, COOLING SYSTEM. Replace coolant filter (38) as follows:

Note: There is a shut off valve at the coolant inlet and outlet lines of coolant filter (38). Closing these valves will enable coolant filter (38) to be replaced without an excessive loss of coolant.

1. Close shut off valves at coolant filter (38) inlet and outlet lines and, using filter wrench, remove and discard coolant filter (38) from engine (1).

2. Clean the filter adaptor with a clean, lint free cloth.

3. Lightly coat new coolant filter (38) seal with clean engine oil as specified in Section 300-0020, LUBRICATION SYSTEM.

4. Start coolant filter (38) on the filter adaptor and tighten it by hand until the seal touches the adaptor filter head. Tighten an additional 2/3 of a turn after contact.

Note: Mechanical tightening of coolant filter (38) is not necessary and will distort or crack the adaptor. Tighten oil filters by hand only.

5. Open shut off valves at coolant filter (38) inlet and outlet lines.

6. Start the engine and check for leaks. If any leaks are noted, have them corrected. Add coolant as required. Refer to Section 210-0000, COOLING SYSTEM.

Drive Belt Adjustments

Every 50 Hours: Check all drive belt tensions and

adjust if required. If vehicle is equipped with air conditioning, compressor belts should be checked and adjusted as described in Section 260-0130, AIR CONDITIONING.

Every 2 000 Hours: Replace all drive belts. Note: Replace all belts in a set when one is worn.

Single belts of similar size should not be used as a substitute for a matched belt set as premature belt wear can result due to belt length variation. All belts in a matched belt set are within 0.81 mm (0.032 in) of their specified centre distances.

5. Start the engine and check for leaks. If any leaks are noted, have them corrected.

10

SM 1571 12-98

Engine - Engine and Mounting

Section 110-0030

Using belt tension gauge, adjust the belt tension to the following values:

Fan - Poly 'V' Belt

Belt Tension 'New' - 3 340 N (750 lbf) Belt Tension 'Used' - 2 450 - 3 340 N (550 - 750 lbf)

Alternator - 'V' Belt

Belt Tension 'New' - 556 N (125 lbf) Belt Tension 'Used' - 445 N (100 lbf)

Note: A belt is considered 'Used' if it has been in service for 10 minutes or longer. If the used belt tension is less than the minimum value, tighten the belt to the maximum value.

Belts should be neither too tight nor too loose. Belts

that are too tight impose excess loads on the

crankshaft, fan and alternator bearings, shortening

both belt and bearing life. Excessively overtightened

belts can result in crankshaft breakage. A loose belt

will slip and may cause damage to accessory

components.

SPECIAL TOOLS

Refer to Section 300-0070, SERVICE TOOLS, for

part numbers of tools referenced in this section,

general service tools required, and service tools

which should be used in conjunction with procedures

oulined in the engine manufacturers service manual.

These tools are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE

FIG. NO. ITEM NO. ITEM NAME Nm lbf ft

1 7 Bolt 150 110 1 22 Bolt 34 25 1 51 Bolt 81 - 95 60 - 70 1 62 Bolt 81 - 95 60 - 70

- - Fan Hub Mounting Bolts 101 - 126 75 - 93

* * * *

SM 1571 12-98

11

THIS PAGE IS INTENTIONALLY LEFT BLANK

ENGINE - Air Cleaner

Section 110-0050

SM - 1532

1

4

2

5

1 - Air Cleaner Body 2 - Primary Element 3 - Safety Element 4 - Cover Assembly 5 - Latch 6 - Vacuator Valve

3

Fig. 1 - Exploded View of Air Cleaner

DESCRIPTION

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

There are two, dual dry element type air cleaner assemblies mounted on the platform to the right hand side of the cab. Air cleaner assemblies prolong engine life by removing grit, dust and water from the air as it enters the engine. Grit and dust combined with engine oil, forms a highly abrasive compound which can destroy the engine in a comparatively short period of time.

A rubber vacuator valve (6) attached to cover assembly (4) in a downward position, ejects grit, dust and water while the engine is running. Vacuator valve (6) minimizes the need for daily servicing. Even though vacuator valve (6) is normally under a slight vacuum when the engine is running, pulsing of the vacuum opens and closes vacuator valve (6) expelling grit, dust and water as they collect. When the engine is stopped, vacuator valve (6) opens and expels any accumulated grit, dust or water.

6

SM - 1964

STOP

Fig. 2 - Air Cleaner Restriction Indicator Light

the circuit closes and a restriction indicator light in

the dash panel (Fig. 2) illuminates. This light shows

at a glance when the system air flow is being

restricted indicating that primary element (2) should

be serviced. Air restriction gauge (14, Fig. 3) automatically

resets after each air cleaner assembly is serviced.

An electrical air restriction gauge (14, Fig. 3) indicates when air restriction levels reach the maximum allowable limit. When air restriction levels are reached,

SM 1572 12-98

While the indicator light indicates the need for

servicing, it does not give as precise a measurement

as a water manometer or vacuum gauge. Refer to

1

Engine - Air Cleaner

Section 110-0050

7

6

4

13

5

SM - 1701

15

14

22

17

19

22

4

10

9

8

3

1

12

2

10

18

17

16

20

10

21

5

1 - Bolt 2 - Hardened Washer 3 - Hardened Washer 4 - Bolt 5 - Locknut 6 - Mounting Band

3

10

7 - Cap Assembly 8 - Hump Hose

9 - Clamp 10 - Clamp 11 - Elbow

Fig. 3 - Exploded View of Air Cleaner Mounting

'Measuring Air Restriction'. Safety element (3) is installed in each air cleaner

assembly inside of primary element (2). This element increases the reliability of the air cleaner’s protection of the engine from airborne dirt. It protects the engine from dirt admitted by a damaged primary element (2), or dirt that might be dropped into the air cleaner assembly while servicing primary element (2).

MAINTENANCE

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

WARNING Always shutdown the engine before servicing air cleaner.

11

10

12 - Tube Assembly 13 - Bracket Assembly 14 - Air Restriction Gauge 15 - Protective Cap 16 - Tee

17 - Adaptor 18 - Nylon Tube 19 - Nipple 20 - Tube 21 - Hump Hose 22 - Elbow

over service. When restriction readings finally indicate a change, remove primary element (2) carefully and clean/replace as required. Refer to 'Primary Element'.

Never attempt to clean safety element (3). Change safety element (3) after every third primary element (2) service.

Make sure vacuator valve (6) is not damaged or plugged and that the joint with cover assembly (4) is not broken. If vacuator valve (6) is lost or damaged, replace it to maintain pre-cleaner efficiency and normal filter element service life.

Check condition of clamps (9 & 10, Fig. 3), hump hoses (8 & 21, Fig. 3), elbow (11, Fig. 3), tube assembly (12, Fig. 3) and tube (20, Fig. 3). Tighten/ replace as necessary.

The air cleaner elements should be serviced only when the maximum allowable restriction has been reached, as indicated by air cleaner restriction indicator light. The elements should not be serviced on the basis of visual observation as this would lead to

2

Air Cleaner Assembly

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

Note: Air cleaner body (1) should be thoroughly

SM 1572 12-98

Engine - Air Cleaner

Section 110-0050

cleaned twice a year. Do not apply heat in any form to

air cleaner body (1).

1. Release latches (5) on cover assembly (4) and

remove cover assembly from air cleaner body (1).

2. Remove primary element (2) and safety element (3)

from air cleaner body (1).

3. Slacken clamps (9, Fig. 3) and disconnect hump

hose (8, Fig. 3) from air cleaner body (1).

4. Remove locknuts (5, Fig. 3), hardened washers

(3, Fig. 3) and bolts (4, Fig. 3) securing the air cleaner

assembly to the platform.

5. Remove the air cleaner assembly from the platform

for cleaning.

6. Open clamps (6) and remove from air cleaner

body (1). Open clamp on cap assembly (7) and

remove cap assembly from air cleaner body (1).

7. Blank off air cleaner body (1) outlets with tape or

cardboard. Reach inside body with a compressed air

nozzle or brush and remove dust from the body.

8. Remove all loose dust from air cleaner body (1) and

remove tape or cardboard from body outlets.

Note: Assembly and installation of the air cleaner

assembly is the reverse of disassembly and removal.

2. Remove primary element (2) from air cleaner body (1).

3. Using a damp cloth and a suitable solvent, wipe out all excess dust from air cleaner body (1) and allow to dry.

4. If the major contaminant on primary element (2) is light dust, direct a jet of compressed air, not exceeding

6.9 bar (100 lbf/in2), against the pleats of the element. The air jet should be directed in the opposite direction of normal operating air flow. Move the air jet up and down the pleats, holding the air nozzle 25 mm (1.0 in) away from the pleats, to prevent rupturing the element with either the nozzle or air jet.

5. In cases where the dust cake on primary element (2) contains oil or carbon, air will not clean effectively. Using manufacturers recommended solution and warm water, not exceeding 48° C (120° F), soak primary element (2) for fifteen minutes. Element should be gently agitated to assist cleaning process.

Note: It is possible to modify an old agitator type washing machine for primary element (2) cleaning. Do not soak or agitate primary element (2) in the solution for more than fifteen minutes. Prolonged exposure softens vertical seams in the element.

6. Rinse washed element thoroughly with a low pressure stream of water, not exceeding 0.7 bar (10 lbf/in2), opposite from the normal air flow, until rinse water runs clear.

Primary Element

Numbers in parentheses refer to Fig. 1.

Although a paper primary element (2) is used, it is

possible to clean it so that it can be reused. The

number of times one element can be reused depends

on the type of dirt on the element and the care

exercised in cleaning.

The life of a properly cleaned element will be

approximately as long as that of a new element for the

first one or two cleanings. After that, the life of the

element will gradually decrease with each cleaning;

however, it should perform satisfactorily through

approximately six cleanings, providing it does not rupture.

Visually determine the condition of primary element (2)

and choose either the compressed air or washing

method.

1. Release latches (5) on cover assembly (4) and

remove cover assembly from air cleaner body (1).

SM 1572 12-98

7. Air dry primary element (2) thoroughly before returning it to service. Drying is a slow process which may be hastened by exposing element to slowly circulating heated air. Heated air temperature should not exceed 46o C (115o F). Drying time can be reduced to about three hours with heated air. DO NOT use a light bulb for drying. DO NOT use compressed air on a wet element.

Note: Replace paper elements after six cleanings or two years in service, whichever comes first. Mark each cleaned element to show total cleanings to date.

8. After primary element (2) is thoroughly dried, inspect for damage or ruptures, especially close to the end caps. To detect paper ruptures, place a bright light bulb inside the element and rotate element slowly. Inspection of element on the outside will disclose any holes where concentrated light shines through. Even the smallest hole will pass dust to the engine and may result in costly engine repairs.

9. Install primary element (2) in air cleaner body (1). 3

Engine - Air Cleaner

Section 110-0050

10. Install cover assembly (4) on air cleaner body (1) and secure with latches (5).

Secondary Element

Numbers in parentheses refer to Fig. 1. Since safety element (3) is protected from

contamination by primary element (2), it needs no periodic cleaning and should be replaced only after every third primary element (2) service.

1. With primary element (2) removed from air cleaner body (1), remove safety element (3).

2. Remove any dust dislodged into air cleaner body (1) outlet and, using a damp cloth and a suitable solvent, wipe out all excess dust from air cleaner body (1) and allow to dry.

3. Install new safety element (3) followed by primary element (2) in air cleaner body (1)

4. Install cover assembly (4) on air cleaner body (1) and secure with latches (5).

Recommendations

Numbers in parentheses refer to Fig. 3.

1. Under no condition should the vehicle be operated without both filter elements in each air cleaner assembly.

2. It is very important that hump hoses (8 & 21), tube assembly (12), tube (20) and elbow (11) from the air cleaner assembly to the engine be airtight or the purpose of the air cleaner will be completely defeated. All clamps (9 & 10) should be checked frequently and tightened to prevent leaks.

(air cleaner outlet) increases. This vacuum is generally measured as 'restriction in mm (inches) of water'.

The recommended maximum allowable intake restrictions at rated speed and load are as follows:

a. 380 mm-H2O (15 in-H2O) with clean filter elements. b. 635 mm-H2O (25 in-H2O) with dirty filter elements.

While the air restriction gauge sends a signal to indicate the need for servicing, it does not give as precise a measurement as a water manometer or vacuum gauge.

Water Manometer

a. Remove protective cap (15) and disconnect harness at air restriction gauge (14). Remove air restriction gauge (14) from tee (16).

b. Hold water manometer vertically and fill both legs approximately half full of water. Connect one of the upper ends to tee (16) by means of a flexible hose.

c. With the manometer held vertically and the engine drawing maximum air, the difference in height of the water columns in the two legs is measured as the air cleaner restriction.

d. If the restriction exceeds the levels indicated, engine performance will be affected. Primary filter element should be cleaned or replaced.

Vacuum Gauge

a. Remove protective cap (15) and disconnect harness at air restriction gauge (14). Remove air restriction gauge (14) from tee (16).

b. Connect the hose from the vacuum gauge to tee (16) and, with the engine drawing maximum air, take a note of the reading on the gauge.

3. Keep new or cleaned filter elements on hand for replacement to prevent unnecessary downtime of the vehicle.

MEASURING AIR RESTRICTION

Numbers in parentheses refer to Fig. 3. As a dry air cleaner element becomes loaded with

dust, the vacuum on the engine side of the air cleaner

* * * *

4

c. If the restriction exceeds the levels indicated, engine performance will be affected. Primary filter element should be cleaned or replaced.

SERVICE TOOLS

Refer to Section 300-0070, SERVICE TOOLS for part numbers of service tools referenced in this section and general service tools required. These tools are available from your dealer.

SM 1572 12-98

ENGINE - Power Takeoff

Section 110-0130

DESCRIPTION AND OPERATION

Numbers in parentheses refer to Fig. 1. The function of the power takeoff (PTO), as the name

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

The major components of the PTO assembly are; flywheel cover case (1), PTO cover (26), driveshaft (15), drive gear (14) and driven gear (12).

As driveshaft (15) is driven by the engine crankcase, drive gear (14) turns to drive driven gear (12). The tandem pump driveshaft, meshed in the hub of driven gear (12), turns with driven gear (12) to operate the tandem pump which, in turn, supplies hydraulic oil to the body hoist system and cooling oil to the disc brake assemblies. Refer to Section 230-0050, TANDEM PUMP.

SM - 1361

REMOVAL

Numbers in parentheses refer to Fig. 2.

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

1. Position the vehicle in a level work area, apply the parking brake and switch off the engine.

2. Turn the steering wheel in both directions to relieve pressure in the steering system. Block all road wheels.

3. Disconnect driveline from yoke (22) at the PTO assembly. Refer to Section 130-0010, FRONT DRIVELINE.

4. Drain oil from power takeoff housing by removing drain plug (6) from flywheel cover case (1). Reinstall drain plug (6) securely.

1 - Flywheel Cover Case 5 - Oil Seal 6 - Plug

9 - Oil Seal 10 - Bearing 11 - Bearing

Fig. 1 - Cutaway View of Power Takeoff Assembly

12 - Driven Gear 14 - Drive Gear 15 - Driveshaft 17 - Snap Ring 18 - Gasket 26 - PTO Cover

the pump before loosening attaching nuts. Remove nuts and lockwashers from pump mounting studs and secure pump clear of the PTO assembly.

7. Match mark engine flywheel housing and flywheel cover case (1) so that the PTO assembly can be installed in the same position at 'Installation'.

8. Attach a suitable lifting device to the PTO assembly and remove bolts (23 & 25) and lockwashers (24) securing PTO assembly to the engine flywheel housing. Carefully lower PTO assembly and spacer (27) from the flywheel housing and move to a clean work area for disassembly.

9. Remove spacer (27) from the PTO assembly.

5. Match mark tandem pump mounting flange and PTO cover (26) so that the pump can be installed in the same position at installation.

6. With suitable blocking or lifting equipment, support

SM 1573 Rev 1 1-00

DISASSEMBLY

Numbers in parentheses refer to Fig. 2.

1. Remove locknut (16) and hardened washer (19) from driveshaft (15). Pull yoke (22) from driveshaft (15).

1

Engine - Power Takeoff

Section 110-0130

18

SM - 2399

26

2

30

3

4

6

1

27

5

1 - Flywheel Cover Case 2 - Dowel Pin 3 - Bolt 4 - Lockwasher 5 - Oil Seal 6 - Plug 7 - Bolt

14

11

28

17

21

15

6

2

17

10

15 - Driveshaft 16 - Locknut 17 - Snap Ring 18 - Gasket 19 - Hardened Washer 20 - Breather 21 - Breather Cap 22 - Yoke

9

6

7

8

23 - Bolt 24 - Lockwasher 25 - Bolt 26 - PTO Cover 27 - Spacer 28 - Coupling 29 - Adaptor 30 - Plug

22

19

16

12

13

11

10

20

29

6

25,23

24

8 - Lockwasher

9 - Oil Seal 10 - Bearing 11 - Bearing 12 - Driven Gear 13 - Plug 14 - Drive Gear

Fig. 2 - Exploded View of Power Takeoff Assembly

2. Remove bolts (3 & 7) and lockwashers (4 & 8) from PTO cover (26). Pull PTO cover (26) and gasket (18) from flywheel cover case (1). Discard gasket (18).

3. Place PTO cover (26) yoke side up on a work bench. Pry oil seal (9) from PTO cover (26) and discard.

4. Remove snap rings (17) from pump and driveshaft bores. Drive bearings (10 & 11) from PTO cover (26) with a sleeve or soft steel drift. Drive on the outer race of bearings (10 & 11) taking care not to damage the bearings.

5. Slide drive gear (14) from driveshaft (15) and pull driven gear (12) from flywheel cover case (1).

6. Pull driveshaft (15) from flywheel cover case (1). Pry oil seal (5) from flywheel cover case (1).

7. Pull bearings (10 & 11) from flywheel cover case (1) with a suitable bearing puller.

8. If necessary, note locations and remove dowel pins (2) from flywheel cover case (1) and breather assembly (20, 21, 28 & 29) from PTO cover (26).

INSPECTION

Numbers in parentheses refer to Fig. 2.

1. Wash all parts thoroughly in a suitable solvent and dry all but bearings (10 & 11) with compressed air. Dry bearings (10 & 11) with a clean lint free cloth.

2. Check the condition of splines and teeth on gears (12 & 14), driveshaft (15) and yoke (22) for burrs or signs of wear.

3. Lubricate bearings (10 & 11) with oil and check operation by spinning bearings by hand. DO NOT spin bearings with compressed air. Inspect bearing bores for out of roundness. Replace bearings, if required.

4. Inspect flywheel cover case (1) and PTO cover (26) for cracks. If either flywheel cover case (1) or

2

SM 1573 Rev 1 1-00

Engine - Power Takeoff

Section 110-0130

PTO cover (26) are damaged, both parts must be replaced as an assembly.

5. Visually check oil seal lip contact surfaces on driveshaft (15) and yoke (22) for nicks, dents, scratches, wear, or corrosion. Replace as necessary.

ASSEMBLY

Numbers in parentheses refer to Figs. 2. Note: Prior to assembly, lubricate all seal lips and

surfaces with lubricant specified in Section 300-0020, LUBRICATION SYSTEM.

Note: Tighten all fasteners without special torques specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.

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

1. If removed, install dowel pins (2) in flywheel cover case (1) and breather assembly (20, 21, 28 & 29) in PTO cover (26), as noted at disassembly.

2. Install new oil seal (5) in centre bore of flywheel cover case (1) so that it is flush with flywheel cover case (1) face. See Fig. 1.

Note: When installing new oil seals, install them with the oil lip (larger of the two lips with the spring behind it) facing inward. Care should be taken to prevent damage to seal lips during assembly.

3. Press bearings (10 & 11) into their bores in flywheel cover case (1).

4. Press bearings (10 & 11) into their respective bores in PTO cover (26). Turn PTO cover (26) over and install snap rings (17).

5. Install new oil seal (9) into centre bore in PTO cover (26) so that it is flush with PTO cover (26) face. See Fig. 1.

6. Install driven gear (12) and driveshaft (15) into flywheel cover case (1). Slide drive gear (14) over driveshaft (15) to its proper location.

7. Install new gasket (18) on PTO cover (26) and assemble PTO cover (26) to flywheel cover case (1). Secure PTO cover (26) to flywheel cover case (1) with bolts (3 & 7) and lockwashers (4 & 8).

8. Install yoke (22), hardened washer (19) and locknut (16) on driveshaft (15) end. Tighten locknut (16) to a torque of 950 - 1 085 Nm (700 - 800 lbf ft).

INSTALLATION

Numbers in parentheses refer to Figs. 1 & 2. Note: When reassembling PTO assembly to engine

flywheel housing, and tandem pump to PTO assembly, be sure to align match marks inscribed during disassembly.

Note: Tighten all fasteners without special torques specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.

1. Install spacer (27) on PTO assembly and, using suitable lifting equipment, position PTO assembly on engine flywheel housing. Secure the PTO assembly and spacer (27) to the engine flywheel housing with bolts (23 & 25) and lockwashers (24).

2. Using suitable lifting equipment, position tandem pump over its mounting studs and secure with nuts and lockwashers removed during removal.

3. Reconnect driveline to yoke (22). Refer to Section 130-0010, FRONT DRIVELINE.

4. Remove oil level plug (6) from the front of PTO cover (26) and fill PTO assembly with lubricant specified in Section 300-0020, LUBRICATION SYSTEM, until oil flows from the oil level port. Install oil level plug (6) in PTO cover (26) and tighten securely.

5. Start the engine and bring oil to correct operating temperature. Check for leaks and correct as necessary.

6. Remove wheel blocks from all road wheels.

SM 1573 Rev 1 1-00

3

Engine - Power Takeoff

Section 110-0130

MAINTENANCE

Numbers in parentheses refer to Fig. 1. Note: Refer to Section 300-0020, LUBRICATION

SYSTEM for recommended check and drain intervals and lubricant specifications.

Oil Level Check

Remove oil level plug (6) from the front of PTO cover (6) and, if oil level is below the bottom of the filler hole, add lubricant until it flows from the filler hole. Reinstall oil level plug (6) and tighten securely.

Drain and Refill

To drain: Remove drain plug (6) from flywheel cover

case (1) and drain oil into a suitable container. Reinstall drain plug (6) securely when draining is complete.

To refill: Remove oil level plug (6) from the front of PTO cover (26) and fill PTO assembly with lubricant specified in Section 300-0020, LUBRICATION SYSTEM, until oil flows from the oil level port. Install oil level plug (6) in PTO cover (26) and tighten securely.

SPECIAL TOOLS

There are no special tools required for procedures outlined in this section. Refer to Section 300-0070, SERVICE TOOLS, for part numbers of general service tools required. These tools are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE

FIG. NO. ITEM NO. ITEM NAME Nm lbf ft

2 16 Locknut 950 - 1 085 700 - 800

* * * *

4

SM 1573 Rev 1 1-00

TRANSMISSION - Transmission and Mounting

Section 120-0010

13

14

25

51

50

*39 *38

1 - Transmission

2 - Trunnion

3 - Bolt

4 - Washer

5 - Locknut

6 - Bolt

7 - Hardened Washer

8 - Nut

9 - Mounting Bracket

10 - Bolt 11 - Lockwasher 12 - Isolation Mount 13 - Filler Cap

27

52

15

26

49

16

48

38

22

18

28

29

20

21

19

41

40

27 - Padlock 28 - Bolt 29 - Cover Plate 30 - Level Gauge 31 - Ring 32 - Bolt 33 - Strip 34 - Retainer 35 - Shim 36 - Shim 37 - Input Yoke 38 - Nut

*38 - Locknut

39 - Output Yoke

*39 - Output Flange

39

10

47

46

44

11

48

30

47

46

45

44

15

17

14 - Gasket 15 - Clamp 16 - Filler Hose 17 - Filler Tube 18 - Elbow 19 - Connector 20 - Nut 21 - Sleeve 22 - Nylon Tube 23 - Elbow 24 - Breather 25 - Adaptor 26 - Key

42

Fig. 1 - Exploded View of Transmission and Mounting

20

23

24

37

31

11

9

10

40 - Drain Cock 41 - Adaptor 42 - Adaptor 43 - Snubbing Washer 44 - P-clip 45 - Bracket 46 - Lockwasher 47 - Nut 48 - Bolt 49 - P-clip 50 - Bolt 51 - Hardened Washer 52 - Nut

* - Pre June 1998

Production

21

1

34

35,36

3

33

6

12

8

SM - 1965

32

4

7

12

43

5

2

DESCRIPTION

For transmission make, model and specification, refer to Section 000-0000, GENERAL INFORMATION. For transmission switches, sensors and instruments, refer to Section 190-0270, SWITCHES AND SENSORS. For transmission servicing and repair data, refer to the transmission manufacturers service manual.

The transmission is remote mounted in the frame and is supported by trunnion (2) assembly at the front and two mounting brackets (9) at the rear.

Integral with transmission (1) assembly are torque converter and planetary gearing. There are six forward gears and two reverse gears with automatic lockup in all speed ranges. Operation of the transmission is by the Commercial Electronic Control (CEC) Shift System,

SM 1574 12-98

(previously known as ATEC). A brief description and operation of the main

transmission components are as follows:

CEC Shift System

Refer to Section 120-0070, CEC SHIFT SYSTEM for description and operation, wiring diagrams and electrical troubleshooting of the CEC System.

Torque Converter

The torque converter consists of three elements pump, turbine, and stator. The pump is the input element and is driven directly by the engine. The turbine is the output element and is hydraulically driven by the pump. The stator is the reaction (torque multiplying) element.

1

Transmission - Transmission and Mounting

Section 120-0010 When the pump turns faster than the turbine, the torque

converter is multiplying torque. When the turbine approaches the speed of the pump the stator starts to rotate with the pump and turbine. When this occurs, torque multiplication stops and the torque converter functions as a fluid coupling.

Lockup Clutch

The lockup clutch is located inside the torque converter and consists of three elements - piston, clutch plate, and backplate. The piston and backplate are driven by the engine and the clutch plate, located between the piston and backplate, is splined to the converter turbine.

The lockup clutch is hydraulically engaged and released in response to electronic signals from the ECU. It engages when the vehicle reaches a predetermined speed. Engagement of the lockup clutch provides a direct drive from the engine to the transmission gearing. This eliminates converter slippage to provide maximum fuel economy. The lockup clutch releases at lower speeds (and momentarily during shifts). When the lockup clutch is released, drive from the engine is transmitted hydraulically through the converter to the transmission gearing. The lockup clutch also releases when the ECU detects certain undesirable conditions.

Planetary Gears and Clutches

A series of planetary gears and shafts provide the gear ratios and directions of travel for the vehicle. Power flow through the planetaries is controlled by multiple clutch packs. The clutches are applied and released hydraulically in response to electronic signals from the ECU.

Hydraulic Retarder

A vaned rotor and two vaned stators are the basic components of the retarder. Application of the retarder control valve fills the cavity around the rotor with oil when the vehicle must be slowed on steep downgrades. When the cavity is emptied, the rotor is free of drag. Refer to Section 250-0130, RETARDER CONTROL VALVE.

Maximum retarder effect occurs in the lowest gear range with foot off of the accelerator pedal. Long continuous use of the retarder will raise transmission oil temperature. Short periods of full release, to interrupt continuous application, will help prevent overheating.

During normal operation the dash mounted transmission oil temperature gauge should read in the green zone. However, during transmission retarder operation oil temperature can enter the yellow 'Retarder On' zone but should not enter the red zone.

Transmission Oil Cooler

The transmission oil is cooled by a separate oil cooler mounted between the radiator and transmission to maintain transmission oil within its required operating temperature range. Refer to Section 210-0060, TRANSMISSION OIL COOLER.

Transmission Oil Filter

The transmission oil filter is mounted off the frame at the front right hand side of the transmission. It is installed in the transmission oil lines to remove dirt and other contaminants from the transmission oil to minimise wear and provide maximum service life for the transmission. Refer to Section 120-0100, TRANSMISSION OIL FILTER.

REMOVAL

Numbers in parentheses refer to Fig. 1. Note: Tag all lines, pipes, electrical connections and

mechanical linkages disconnected during removal to aid in installation.

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

High electrical current can cause sparks and personal injury from burns. Switch circuit breakers to the 'Off' position before removing any electrical components. Remove battery ground cable first, and reconnect last, to prevent damaging electrical components.

Any time the battery equalizer is disconnected from the batteries, remove ground cable first, and reconnect last, to prevent damaging the component.

1. Position the vehicle in a level work area, raise the body and install the body prop pins. Refer to Section 270-0010, BODY AND MOUNTING.

2. Apply the parking brake and switch off the engine. Turn steering wheel several times to relieve pressure in the steering circuit. Depress and release brake pedal continuously to relieve pressure in the braking system (pressure in accumulator hydraulic line should be zero).

3. Block all road wheels.

2

SM 1574 12-98

Transmission - Transmission and Mounting

Section 120-0010

Note: It is important that the electrical connections are removed in the order listed in step 4 to prevent damage to the electrical components.

4. Disconnect battery equalizer ground connection from the batteries. Disconnect battery cables from terminal posts (ground cable first). Disconnect battery equalizer positive connection. Disconnect electrical connections at the ECU.

5. Using suitable lifting equipment, support transmission guard and remove mounting hardware securing the guard to the frame. Remove transmission guard.

6. Disconnect driveline from input yoke (37) at the front of transmission (1). Refer to Section 130-0010, FRONT DRIVELINE.

7. Disconnect driveline from output yoke/flange (39) at the rear of transmission (1). Refer to Section 130-0020, REAR DRIVELINE.

8. Place a suitable container under drain cock (40), loosen drain cock and drain oil from transmission (1). After draining, tighten drain cock (40) securely.

9. Disconnect the transmission retarder linkage at transmission (1).

10. Place a suitable container under the steering tank drain plug, remove drain plug and drain the oil from the steering tank. After draining, reinstall drain plug.

11. Disconnect steering lines from the steering pump and remove mounting hardware securing steering lines to transmission (1). Cap all open line ends and steering pump fittings to prevent entry of dirt.

12. Disconnect transmission oil cooler lines and oil filter lines from transmission (1). Cap all open lines and fittings to prevent entry of dirt.

13. Disconnect hydraulic line from lockup drop out valve at the front right hand side of transmission (1).

14. Disconnect all remaining hydraulic lines attached to transmission (1). Cap all open lines and fittings to prevent entry of dirt.

15. Disconnect all electrical connections and cables attached to transmission (1).

transmission (1) and move bracket and valve clear of

the transmission (1).

17. Remove mounting hardware supporting mounting

brackets for body hoist lines to the top of

transmission (1).

18. Remove mounting hardware securing kick-over

valve mounting bracket to the top of transmission (1).

19. Slacken nut (20) and move nut (20) and nylon

tube (22) assembly free from connector (19) in the

top of transmission (1).

20. Detach clamps (15) and remove filler hose (16)

from filler tube (17) and adaptor (25).

21. Install suitable lifting eyes into the holes provided

at the top of transmission (1) housing and secure a

suitable lifting device to the eyes. Take up slack in the

chain or cable.

22. Remove locknuts (5), bolts (3) and washers (4)

securing trunnion (2) to the frame.

23. Remove bolts (6), hardened washers (7), snubbing

washers (43) and nuts (8) securing mounting brackets

(9) to frame.

24. Check to make certain that all hydraulic lines and

electrical connections fitted to transmission (1) have

been disconnected before moving transmission (1).

25. Carefully manoeuvre transmission (1) out of the

frame mounting and lower onto a suitable dolly or pallet.

26. Move transmission (1) assembly to a suitable

work area or onto a work stand for further

disassembly, if necessary.

DISASSEMBLY

Numbers in parentheses refer to Fig. 1.

Note: Refer to the transmission manufacturers

Service Manual if transmission service or repair is

required.

1. Remove bolts (32), strip (33), retainer (34) and

shims (35 & 36) securing input yoke (37) on

transmission (1). Pull input yoke (37) from

transmission (1).

16. Remove mounting hardware securing accumulator valve mounting bracket to the front left hand side of

SM 1574 12-98

2. Pull trunnion (2) assembly from transmission (1)

and remove ring (31) from trunnion (2), if required.

3

Transmission - Transmission and Mounting

Section 120-0010

3. Remove nut/locknut (38) securing output yoke/ flange (39) on transmission (1). Pull output yoke/flange (39) from transmission (1).

4. Remove bolts (10) and lockwashers (11) securing mounting brackets (9) to transmission (1). Remove mounting brackets (9).

5. If necessary, remove isolation mounts (12) from mounting brackets (9).

ASSEMBLY

Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners without special torques

specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.

1. Secure mounting brackets (9) to transmission (1) assembly with bolts (10) and lockwashers (11). Tighten bolts (10) to a torque of 156 Nm (115 lbf ft). If removed, install isolation mounts (12) to mounting brackets (9).

2. If removed, fit new ring (31) to trunnion (2) and mount trunnion (2) to the front of transmission (1) with small leg to the top and facing away from transmission (1).

3. Make sure that transmission input shaft is in its most outward position and the bearing is seated against the shaft shoulder.

4. Coat input shaft splines and lip of oil seal with a thin layer of EP, NLGI molybdenum grease. Install input yoke (37) on input shaft by tapping lightly until the yoke is seated. If input yoke (37) is a tight fit, heat input flange (37) to 121° C (250° F) maximum prior to assembly. Two methods which may be employed are:

a. Heat in controlled temperature furnace for a minimum period of 45 minutes.

b. Submerge flange in heated oil for 15 minutes.

5. Use proper combination of shims (35 & 36) to obtain a 0.2 - 0.3 mm (0.008 - 0.012 in) gap between retainer face of input yoke (37) and end of input shaft. Fit retainer (34) and secure with bolts (32) and strip (33). Tighten bolts (32) to a torque of 130 - 156 Nm (96 - 115 lbf ft).

6. Coat output shaft splines and threads, and lip of oil seal with a thin layer of EP, NLGI molybdenum

grease. Install output yoke/flange (39) on output shaft by tapping lightly until the yoke is seated. If output yoke/flange (39) is a tight fit, heat output yoke/flange (39) to 121° C (250° F) maximum prior to assembly, using either of the methods described in step 3.

7. Secure output yoke/flange (39) on output shaft with nut/locknut (38). Tighten nut (38) to a torque of 950 - 1 355 Nm (700 - 1 000 lbf ft).

8. After assembly has cooled, check torque of bolts (32) and nut/locknut (38) and retighten to their required torques.

INSTALLATION

Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners without special torques

specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.

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

1. Position transmission (1) assembly under the vehicle and attach a suitable lifting device to the eye bolts on top of transmission (1).

2. Carefully lift transmission (1) assembly into its mounting position and lightly secure trunnion (2) to the frame (mounting face to the front of the frame mounting brackets) with bolts (3), washers (4) and locknuts (5). Install bolts (3) from the rear of the assembly.

3. Install bolts (6), hardened washers (7), snubbing washers (43) and nuts (8) securing mounting brackets (9) to frame mounting brackets. Securely tighten bolts (6) to a torque of 278 Nm (205 lbf ft).

4. Securely tighten bolts (3), securing trunnion (2) to frame mounting brackets, to a torque of 156 Nm (115 lbf ft).

5. Remove lifting device and lifting eye bolts from top of transmission (1).

6. Install filler hose (16) to filler tube (17) and adaptor (25) and secure with clamps (15).

4

SM 1574 12-98

Transmission - Transmission and Mounting

Section 120-0010

7. Secure accumulator valve mounting bracket to the front left hand side of transmission (1) assembly with mounting hardware removed during removal.

8. Secure kick-over valve mounting bracket to top of transmission (1) assembly with mounting hardware removed during removal.

9. Secure body hoist lines mounting brackets to the top of transmission (1) assembly with mounting hardware removed during removal.

10. Connect all electrical connections and cables to transmission (1) as tagged at removal.

11. Connect transmission oil cooler lines to transmission (1) and oil filter lines to transmission oil filter as tagged at removal.

12. Connect steering pump hydraulic lines as tagged at removal and secure lines to transmission (1) with mounting hardware removed during removal.

13. Connect hydraulic line from lockup drop out valve to front right hand side of transmission (1).

14. Connect any remaining hydraulic lines which were removed during removal. Ensure all hydraulic lines are securely tightened.

Note: It is important that the electrical connections are

made in the order listed in step 21 to prevent damage

to the electrical components.

21. Connect electrical connections at the ECU.

Connect battery equalizer positive connection.

Connect battery cables to battery terminal posts

(ground cable last). Connect battery equalizer ground

connection.

22. Start the engine and make an operational check

while the engine is running of all lines and

connections disconnected during removal of

transmission (1). Check for leaks and tighten lines

and fittings as required.

23. Ensure parking brake is applied, remove the body

prop pins and lower the body. Refer to Section

270-0010, BODY AND MOUNTING. Remove wheel

chocks from all road wheels.

MAINTENANCE

Periodic Inspections

For easier inspection, the transmission should be kept

clean. Make periodic checks for loose bolts and

leaking oil lines. Check the condition of electrical

harnesses and connections regularly.

15. Connect transmission retarder linkage at transmission (1).

16. Install rear driveline to output yoke/flange (39) at the rear of transmission (1) and secure with mounting hardware removed during removal. Refer to Section 130-0020, REAR DRIVELINE.

17. Install front driveline to input yoke (37) at the front of transmission (1) and secure with mounting hardware removed during removal. Refer to Section 130-0010, FRONT DRIVELINE.

18. Using suitable lifting equipment, support transmission guard and secure guard to the frame with mounting hardware removed during removal.

19. Fill transmission (1) assembly with oil specified in Section 300-0020, LUBRICATION SYSTEM, and check the oil level as described under 'Oil Level Check'.

20. Fill steering tank with oil specified in Section 300-0020, LUBRICATION SYSTEM, and check the oil level as described in Section 220-0040, STEERING AND BRAKE CONTROL TANK.

The transmission breather should be checked

regularly and as frequently as necessary, depending

on the operating conditions of the vehicle. A badly

corroded or plugged breather restricts proper

breathing and causes a buildup of condensation and

subsequent oil deterioration.

Oil Level Check

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

Check the transmission oil level and add oil if low, every 10 hours/daily. Use only oil of the type specified in Section 300-0020, LUBRICATION SYSTEM.

Because the transmission oil cools, lubricates and transmits hydraulic power it is important that the proper oil level be maintained at all times. If the oil level is too low, the converter and clutches will not receive an adequate supply of oil. If the oil level is too

SM 1574 12-98

5

Transmission - Transmission and Mounting

Section 120-0010 high, the oil will aerate and the transmission will

overheat. It is absolutely necessary that the oil put into the transmission be clean.

Oil must be handled in clean containers to prevent foreign material from entering the system.

Note: Containers or fillers that have been used for antifreeze or engine coolant solution must not be used for transmission oil.

Visual Level Indicator

A visual level indicator is mounted on the lower left side of the transmission main housing and provides a method of checking the oil level. Refer to Fig. 2.

Cold Oil Level Check

Before starting the engine, check the visual level indicator or remove the ADD (lower) plug. If oil is present in the indicator or if oil flows from the plug opening, the transmission has sufficient oil to permit safe starting of the engine. If no oil is present, add sufficient oil to bring the level within the indicator or to cause a flow from the plug opening. Replace the plug.

SAFE

OPERATIONAL

LEVEL AREA

SM - 1250

RED LINE

NO RED LINE VISIBLE (OVERFILL)

FULL MARK (CENTRE)

NO OIL VISIBLE (UNDERFILL)

Hot Oil Level Check Note: Observe the condition of the oil in the visual

level indicator or the type of flow from the plug opening. Foaming or spurting may indicate a false level.

A hot oil level check is made to determine if there is sufficient oil for working operation of the transmission. Select neutral on the transmission range selector and start the engine. Operate the vehicle until the transmission reaches a normal operating temperature of 82 - 103° C (180 - 220° F). Idle the engine, apply the parking brake and block all road wheels.

Check the visual level indicator or remove the FULL (upper) oil level check plug. The oil should be within the indicator limits shown in Fig. 2 or at or near the level of the plug opening. Add or drain oil as necessary to bring the oil level within these limits.

Note: The transmission may be operated safely as long as the oil level is above the ADD (lower) plug.

Oil and Filter Change

After the first 150 hours of operating a new or rebuilt transmission, the transmission oil and filters should be changed.

Fig. 2 - Visual Level Indicator

The transmission oil and filters should be changed at the intervals specified in Section 300-0020, LUBRICATION SYSTEM, or sooner, depending on operating conditions. Also, the oil must be changed whenever there are traces of dirt or evidence of high temperature indicated by discoloration or strong odour.

The screen and magnet assembly in the sump should be removed and cleaned with mineral spirits at each oil change. Metal particles in the oil (except for the minute particles normally trapped in the oil filters) indicate damage has occurred in the transmission When these particles are found in the filters, the cause must be established and rectified immediately to prevent damage to the transmission.

At each oil change, examine the used oil for evidence of dirt or water. A normal amount of condensation will emulsify in the oil during operation of the transmission. However, if there is evidence of water or engine coolant in the oil, the cause must be established and rectified immediately to prevent damage to the transmission.

6

SM 1574 12-98

Transmission - Transmission and Mounting

Welding on Vehicles Equipped With CEC

WARNINGS The ECU can be damaged by improper welding procedures.

Any time the battery equalizer is disconnected from the batteries, remove ground cable first, and reconnect last, to prevent damaging the component.

When frame or other welding is required, the following precautions are to be taken to protect the electronic components.

a. Disconnect battery equalizer ground connection from the batteries. Disconnect battery cables from terminal posts (ground cable first). Disconnect battery equalizer positive connection. Disconnect electrical connections at the ECU.

b. If additional system ground wires are connected to the frame, they must be disconnected also.

c. Cover electronic components and wiring to protect from damage.

d. Do not connect welding cables to electronic components. Do not weld on electronic components. If welding is to be done close to electronic components, the components should be removed prior to the welding process.

e. On completion of all welding reconnect electrical connections in the reverse order to step a.

TROUBLESHOOTING Converter Stall Test

A stall test should be conducted when the power package (engine and transmission) is not performing satisfactorily. The purpose of the test is to determine the engine power output and establish if the transmission is the malfunctioning component.

Section 120-0010

WARNING When conducting a stall test, the vehicle must be positively prevented from moving. The parking brake must be applied and the vehicle should be blocked to prevent movement forward or reverse. Keep people safely away from the vehicle path. Do not maintain the stalled condition longer than 30 seconds due to rapid heating of the transmission oil. With the transmission in neutral, run the engine at 1 200 - 1 500 rev/min for two minutes to cool the oil between tests. Do not allow the converter-out temperature to exceed 135° C (275° F). Keep a close check to prevent overheating of the engine cooling system.

1. Position the vehicle on a level area with room for movement all round.

2. Apply the parking brake and block all road wheels. Turn the manual mode key switch to the 'On' position and the mode selection switch to the 'Power' mode.

3. Apply the service brake, release the parking brake and select fifth gear on the transmission shift selector. The transmission will shift to fifth gear and deactivate the lockup clutch. Apply the parking brake and release the foot pedal.

4. Accelerate the engine to full throttle and, using a tachometer of known accuracy, note the maximum rev/min the engine will attain. Converter-out pressure should be 2 bar (30 lbf/in²).

Note: The stall speed of each vehicle is noted on the final inspection records prior to the vehicle leaving the factory. This can be used as a guide when checking the stall speed. It is recommended to keep a record of the stall speed after each major service and use the previous recorded value as a guide.

5. When the stall check is complete, return the accelerator to the idle position and move the shift selector to the neutral position.

Note: Engine power will decrease with an increase in elevation (altitude), becoming more pronounced at greater elevation. This will result in a lower engine speed under converter stall conditions.

SM 1574 12-98

7

Transmission - Transmission and Mounting

Section 120-0010

6. During the stall check the transmission oil temperature should rise while the engine is under load and drop when the transmission is returned to neutral. Should the temperature fail to drop it indicates that there is a problem with the converter.

7. After making allowances for elevation, a low engine speed may indicate the engine is not delivering full power. Refer to engine service manual for engine repair information.

Electronic Troubleshooting

Refer to Section 120-0070, CEC SHIFT SYSTEM for general electrical troubleshooting. For more detailed electrical troubleshooting refer to the Allison Transmission Commercial Electronic Control (CEC) Troubleshooting Manual SA2712A.

Mechanical Troubleshooting

It is recommended to follow the procedures laid down

for mechanical troubleshooting, as outlined in the 'Mechanical Trouble Shooting' charts, before carrying out electrical troubleshooting procedures.

WARNING Be sure to apply the parking brake, switch off the engine and block all road wheels before troubleshooting the vehicle. Should it be necessary to run the engine, it is imperative that an operator be present in the cab at all times, even at idle.

SPECIAL TOOLS

There are no special tools required for the procedures outlined in this section. Refer to Section 300-0070, SERVICE TOOLS for part numbers of service tools which should be used in conjunction with procedures outlined in the transmission manufacturers service manual, and general service tools required. These tools are available from your dealer.

MECHANICAL TROUBLESHOOTING CHART

CONDITION REASON REMEDY A - Transmission overheats High or low oil level Restore proper oil level

Aerated (foaming) oil Refer to condition 'B' Vehicle overloaded Reduce load Engine coolant overheated Correct engine overheating Transmission oil cooler or Clean or replace oil cooler or lines

lines kinked or clogged Low coolant level Add coolant, check for leaks Oil leaking Check transmission and lines for leaks Low main pressure Refer to condition 'V' Low converter-out pressure Refer to condition 'U' Vehicle brakes dragging Check parking and service brakes Torque converter stator locked Check for low top speed of vehicle. Check

torque converter components.

Clutch slipping Overhaul transmission. Replace worn piston seal rings or clutch plates.

B - Oil is aerated (foaming) Incorrect type of oil used Change oil. Use only oil specified in Section

300-0020, LUBRICATION SYSTEM.

High or low oil level Restore proper oil level Air entering suction side of Check oil pump bolts and gasket

oil pump Water in oil Check for source, clean system

8

SM 1574 12-98

Transmission - Transmission and Mounting

Section 120-0010

MECHANICAL TROUBLESHOOTING CHART

CONDITION REASON REMEDY C - Heavy metal debris found Transmission internal failure Completely disassemble, clean and repair

in oil transmission. Replace filters and clean lines

and oil cooler.

D - Coolant found in oil Transmission oil cooler leaking Completely disassemble and thoroughly clean

transmission. Replace all friction faced clutch plates. Repair or replace oil cooler. Replace filters and clean external lines.

E - Transmission will not Loss of electrical power Refer to Electronic Troubleshooting operate in any range regardless of selector position

F - Transmission continues in Loss of electrical power Refer to Electronic Troubleshooting the same forward gear regardless of selector position

Internal mechanical failure Overhaul transmission Driveline failure Check transmission input and output Low oil level Restore proper oil level Low main pressure Refer to condition 'V'

G - Shifting is erratic Refer to Electronic Troubleshooting H - Transmission operates only Refer to Electronic Troubleshooting

in first, neutral and reverse I - Transmission shifts to Refer to Electronic Troubleshooting

neutral during reverse operation, but will operate normally in all other ranges

J - Vehicle operates in reverse Reverse clutch has failed Overhaul transmission and moves backwards in (won't release) neutral when engine is accelerated, but stalls in all other gears when engine is accelerated - Electronic Troubleshooting OK

K - Vehicle operates in first First and second gear clutch Overhaul transmission and second gears and moves failed (won't release) forward in neutral when engine is accelerated, but stalls in all other gears when engine is accelerated - Electronic Troubleshooting OK

L - Vehicle operates in third Third and fourth gear clutch Overhaul transmission and fourth gears and moves failed (won't release) forward in neutral when engine is accelerated, but stalls in all other gears when engine is accelerated - Electronic Troubleshooting OK

SM 1574 12-98

9

Transmission - Transmission and Mounting

Section 120-0010

MECHANICAL TROUBLESHOOTING CHART

CONDITION REASON REMEDY M - Vehicle operates in fifth Fifth and sixth gear clutch Overhaul transmission

and sixth gears and moves failed (won't release) forward in neutral when engine is accelerated, but stalls in all other gears when engine is accelerated - Electronic Troubleshooting OK

N - No power is transmitted in Range clutch failed (won't Overhaul transmission. Check for worn piston any one range - Electronic apply, slipping) seals, broken piston housing, or worn clutch Troubleshooting OK plates in that range.

O - Vehicle will operate in Splitter-overdrive clutch won't Overhaul transmission. Check splitter clutches second, fourth, sixth and release or splitter-direct clutch for worn components. reverse gears but will not won't apply, slipping operate in all other gears Electronic Troubleshooting OK

P - Vehicle will operate in first, Splitter-direct clutch won't Overhaul transmission. Check splitter clutches third and fifth gears but will not release or splitter-overdrive for worn components. operate in all other gears - clutch won't apply, slipping Electronic Troubleshooting OK

Q - Slow clutch engagement Low oil level Add oil to proper level

Foaming oil Refer to condition 'B' Worn piston seals Overhaul transmission Low main pressure Refer to condition 'V'

R - Vehicle lacks power and Engine malfunction Check engine. Refer to engine service manual. acceleration

S - High engine speed at Low oil level Add oil to proper level converter stall

Aerated oil Refer to condition 'B' Low engine speed at converter Refer to condition 'T'

stall High engine speed at Refer to condition 'S'

converter stall Hydraulic retarder partially Check retarder linkage

applied Vehicle brakes dragging Check parking and service brakes Stator freewheel clutch failed Overhaul transmission

Low converter-out pressure Refer to condition 'U' High oil temperature (above Refer to condition 'A'

135° C; 275° F)

10

Clutch slipping, main pressure Overhaul transmission. Replace clutch piston normal seal rings or clutch plates.

Foaming oil Refer to condition 'B'

SM 1574 12-98

Transmission - Transmission and Mounting

MECHANICAL TROUBLESHOOTING CHART

CONDITION REASON REMEDY T - Low engine speed at Low engine output torque Tune engine and check output

converter stall

U - Low converter-out Low oil level Add oil to proper level pressure

V - Low main pressure Low oil level Add oil to proper level

Converter element Check for noise at stall; overhaul converter if interference necessary

Transmission oil not up to Warm up transmission to 82 - 103° C operating temperature (180 - 220° F)

Oil line leakage (oil cooler or Check for leaks, correct as required filter)

Plugged oil strainer Clean oil strainer Defective oil pump Rebuild/replace oil pump assembly High oil temperature Refer to condition 'A' Foaming oil Refer to condition 'B'

Section 120-0010

Leaks in hydraulic system Check all external points for leaks; check each

range for localizing internal leaks Failure in pressure regulator Overhaul valve assembly Worn input oil pump assembly Rebuild/replace pump assembly Clogged oil strainer Clean oil strainer Air leaks at suction side of Check input pump, correct as required

input pump

W - Downshift of transmission Refer to Electronic Troubleshooting is permitted during lockup operation

X - Shift quadrant not Failed light bulb Replace the light bulb illuminated

Y - Reverse signal not Refer to Electronic Troubleshooting energized

SPECIAL TORQUE SPECIFICATIONS

TORQUE

FIG. NO. ITEM NO. ITEM NAME Nm lbf ft

1 3 Bolt 156 115 1 6 Bolt 278 205 1 10 Bolt 156 115 1 32 Bolt 130 - 156 96 - 115 1 38 Nut/Locknut 950 - 1 355 700 - 1 000

SM 1574 12-98

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11

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TRANSMISSION - Transmission and Mounting

Section 120-0010

13

14

25

52

51

50

1 - Transmission 2 - Trunnion 3 - Bolt 4 - Washer 5 - Locknut 6 - Bolt 7 - Hardened Washer 8 - Nut

9 - Mounting Bracket 10 - Bolt 11 - Lockwasher 12 - Isolation Mount 13 - Filler Cap

27

15

26

49

16

48

38

39

20

21

22

18

28

29

20 19

21

40

41

1

27 - Padlock 28 - Bolt 29 - Cover Plate 30 - Level Gauge 31 - Ring 32 - Bolt 33 - Strip 34 - Retainer 35 - Shim 36 - Shim 37 - Input Yoke 38 - Nut 39 - Output Yoke

10

47

46

44

11

48

30

47

46

45

44

15

17

14 - Gasket 15 - Clamp 16 - Filler Hose 17 - Filler Tube 18 - Elbow 19 - Connector 20 - Nut 21 - Sleeve 22 - Nylon Tube 23 - Elbow 24 - Breather 25 - Adaptor 26 - Key

42

Fig. 1 - Exploded View of Transmission and Mounting

23

24

37

2

31

11

9

10

40 - Drain Cock 41 - Adaptor 42 - Adaptor 43 - Snubbing Washer 44 - P-clip 45 - Bracket 46 - Lockwasher 47 - Nut 48 - Bolt 49 - P-clip 50 - Bolt 51 - Hardened Washer 52 - Nut 53 - Isolation Mount

34

35,36

3 4

53

5

SM - 2400

32

33

6

7

12

12 43

8

DESCRIPTION

For transmission make, model and specification, refer to Section 000-0000, GENERAL INFORMATION. For transmission switches, sensors and instruments, refer to Section 190-0270, SWITCHES AND SENSORS. For transmission servicing and repair data, refer to the transmission manufacturers service manual.

The transmission is remote mounted in the frame and is supported by trunnion (2) assembly at the front and two mounting brackets (9) at the rear.

Integral with transmission (1) assembly are torque converter and planetary gearing. There are six forward gears and two reverse gears with automatic lockup in all speed ranges. Operation of the transmission is by the Commercial Electronic Control (CEC) Shift System,

SM 1905 1-00

(previously known as ATEC). A brief description and operation of the main

transmission components are as follows:

CEC Shift System

Refer to Section 120-0070, CEC SHIFT SYSTEM for description and operation, wiring diagrams and electrical troubleshooting of the CEC System.

Torque Converter

The torque converter consists of three elements pump, turbine, and stator. The pump is the input element and is driven directly by the engine. The turbine is the output element and is hydraulically driven by the pump. The stator is the reaction (torque multiplying) element.

1

Transmission - Transmission and Mounting

Section 120-0010 When the pump turns faster than the turbine, the

torque converter is multiplying torque. When the turbine approaches the speed of the pump the stator starts to rotate with the pump and turbine. When this occurs, torque multiplication stops and the torque converter functions as a fluid coupling.

Lockup Clutch

The lockup clutch is located inside the torque converter and consists of three elements - piston, clutch plate, and backplate. The piston and backplate are driven by the engine and the clutch plate, located between the piston and backplate, is splined to the converter turbine.

The lockup clutch is hydraulically engaged and released in response to electronic signals from the ECU. It engages when the vehicle reaches a predetermined speed. Engagement of the lockup clutch provides a direct drive from the engine to the transmission gearing. This eliminates converter slippage to provide maximum fuel economy. The lockup clutch releases at lower speeds (and momentarily during shifts). When the lockup clutch is released, drive from the engine is transmitted hydraulically through the converter to the transmission gearing. The lockup clutch also releases when the ECU detects certain undesirable conditions.

Planetary Gears and Clutches

A series of planetary gears and shafts provide the gear ratios and directions of travel for the vehicle. Power flow through the planetaries is controlled by multiple clutch packs. The clutches are applied and released hydraulically in response to electronic signals from the ECU.

Hydraulic Retarder

A vaned rotor and two vaned stators are the basic components of the retarder. Application of the retarder control valve fills the cavity around the rotor with oil when the vehicle must be slowed on steep downgrades. When the cavity is emptied, the rotor is free of drag. Refer to Section 250-0130, RETARDER CONTROL VALVE.

Maximum retarder effect occurs in the lowest gear range with foot off of the accelerator pedal. Long continuous use of the retarder will raise transmission oil temperature. Short periods of full release, to interrupt continuous application, will help prevent overheating.

During normal operation the dash mounted transmission oil temperature gauge should read in the green zone. However, during transmission retarder operation oil temperature can enter the yellow 'Retarder On' zone but should not enter the red zone.

Transmission Oil Cooler

The transmission oil is cooled by a separate oil cooler mounted between the radiator and transmission to maintain transmission oil within its required operating temperature range. Refer to Section 210-0060, TRANSMISSION OIL COOLER.

Transmission Oil Filter

The transmission oil filter is mounted off the frame at the front right hand side of the transmission. It is installed in the transmission oil lines to remove dirt and other contaminants from the transmission oil to minimise wear and provide maximum service life for the transmission. Refer to Section 120-0100, TRANSMISSION OIL FILTER.

REMOVAL

Numbers in parentheses refer to Fig. 1.

Note: Tag all lines, pipes, electrical connections and mechanical linkages disconnected during removal to aid in installation.

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

High electrical current can cause sparks and personal injury from burns. Switch circuit breakers to the 'Off' position before removing any electrical components. Remove battery ground cable first, and reconnect last, to prevent damaging electrical components.

Any time the battery equalizer is disconnected from the batteries, remove ground cable first, and reconnect last, to prevent damaging the component.

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

body and install the body prop pins. Refer to

Section 270-0010, BODY AND MOUNTING.

2. Apply the parking brake and switch off the engine. Turn steering wheel several times to relieve pressure in the steering circuit. Depress and release brake pedal continuously to relieve pressure in the braking system (pressure in accumulator hydraulic line should be zero).

3. Block all road wheels.

2

SM 1905 1-00

Transmission - Transmission and Mounting

Section 120-0010

Note: It is important that the electrical connections are removed in the order listed in step 4 to prevent damage to the electrical components.

4. Disconnect battery equalizer ground connection from the batteries. Disconnect battery cables from terminal posts (ground cable first). Disconnect battery equalizer positive connection. Disconnect electrical connections at the ECU.

5. Using suitable lifting equipment, support transmission guard and remove mounting hardware securing the guard to the frame. Remove transmission guard.

6. Disconnect driveline from input yoke (37) at the front of transmission (1). Refer to Section 130-0010, FRONT DRIVELINE.

7. Disconnect driveline from output yoke (39) at the rear of transmission (1). Refer to Section 130-0020, REAR DRIVELINE.