Terex TA40 OCDB Articulated Dump Truck Service Repair Manual

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TA40 OCDB (A820) Articulated Dumptruck Maintenance Manual

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CUSTOMER SUPPORT DEPARTMENT Part No. 15275763 SM 2345 06-05

TEREX EQUIPMENT LIMITED MOTHERWELL, SCOTLAND ML1 5RY REF. NO. SM820

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

Service Information Alert

DATE:

April 1994

MODEL:

General

SUBJECT:

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

B168

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.

WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly 1. 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

TABLE OF CONTENTS Section No. Description 000 0000 0010 100 0010 0020 0040 110 0030 0050 120 0010 130 0010 0020 140 0020 0040 0060 150 0020 160 0020 0030 0050 165 0015 170 0010 0030 180 0020 0040 0040 190 0000 0270 200 0040 0051

SM No.

GENERAL INFORMATION Technical Data - TA40 Welding Procedure

2110 Rev 4 2172

CHASSIS Frames Articulation and Oscillation Pivot Hood and Mounting

1372 Rev 1 1373 Rev 2 2120

ENGINE Engine and Mounting Air Cleaner

2121 Rev 1 2122 Rev 1

TRANSMISSION Transmission and Mounting

2124 Rev 3

DRIVELINES Front Drivelines Rear Drivelines

1378 Rev 2 1379 Rev 2

FRONT AXLE GROUP Axle Group (Hub) Wheel Rim and Tyre Differential Drive Head

(Refer to Section 160-0030) (Refer to Section 160-0050)

2148

CENTRE AXLE Differential Drive Head

2149

REAR AXLE GROUP Differential Drive Head Axle Group (Hub) Wheel Rim and Tyre

2151 2147 Rev 1 1382 Rev 1

BRAKE ASSEMBLY Oil Cooled Disc Brakes

2167 Rev 1

PARKING BRAKE Parking Brake and Mounting Actuator

2253 2166 Rev 1

SUSPENSION SYSTEM Front Suspension Rear Suspension Rear Suspension

From A8201011 to A8201230 From A8201231

2119 1384 Rev 2 2340

ELECTRICAL SYSTEM Circuit Diagrams (DDEC IV, 6WG 310 transmission) Switches and Sensors

2126 Rev 2 2252

FUEL SYSTEM Fuel System Electronic Foot Pedal

SM 2146 Rev 10 06-05

1398 Rev 1 1399

1

TABLE OF CONTENTS Section No. Description 210 0000 0005 0010 0040 0045 0046 0050 0060 0100 220 0000 0090 0100 0120 0140 230 0000 0040 0050 0060 0081 0121 0130 250

COOLING SYSTEM Cooling System (Series 60 Engine) Cooling System Schematic Cooling Fan and Motor Radiator and Mounting Low Temperature Unloader Valve Low Pressure Relief Valve Disc Brake Oil Cooler Transmission Oil Cooler Hydraulic Oil Cooler

Steering System Schematic Steering Valve Flow Amplifier Valve Steering Cylinder Emergency Valve

Body System Schematic Hydraulic Tank Main Hydraulic Pump Body Control Valve Body Control Joystick Pilot Supply Valve Body Cylinder

OPERATORS COMPARTMENT

300 0020 0070 0080 0090

1407 Rev 2 1913 Rev 2 1394 Rev 1 1410 Rev 2 1411 Rev 2 1448 Rev 1 1409 Rev 1

BRAKING SYSTEM

260

0010

1390 Rev 2 1391 1392 Rev 3 1393 Rev 1 1395 Rev 1

BODY SYSTEM

Braking System Schematic Brake Coolant Tank Triple Pump Motor/Triple Pump Assembly Brake Manifold Valve Accumulator Two Speed Control Valve Treadle Valve Priority Unloader Valve Directional Control Valve Relief Valve

270

2155 Rev 1 2156 2157 2162 2158 2160 2159 2165 Rev 1 2161 2254 2163

Cab and Mounting Driver Seat and Mounting Air Conditioning

1404 Rev 1 1981 1405 Rev 2

BODY Body and Mounting

1406 Rev 1

MISCELLANEOUS Lubrication System Service Tools Standard Bolt and Nut Torque Specifications Unit Storage *

2

2117 Rev 1 2154 Rev 1 2116 2118 Rev 1 2152 2164 Rev 1 2153 1922 Rev 2 1403 Rev 1

STEERING SYSTEM

0000 0025 0040 0045 0050 0060 0065 0070 0075 0090 0120

0010 0090 0130

SM No.

*

*

2129 Rev 4 1419 Rev 4 1238 1239 * SM 2146 Rev 10 06-05

GENERAL INFORMATION - Technical Data Section 000-0000 SM - 3303

Max 1 450 Body (4-9) Depth

3 220 ( 10-7 ) 3 020 (9-11)

45˚

Vehicle Clearance Turning Diameter 19.5m (64ft)

6 500 (21-4)

65˚ 3 720 (12-2) 5 700 (18-8) 5 370 (17-7)

3 670 (12-0) 3 450 (11-4)

25˚

3 100 (10-2) 2 240 (7-4)

560 (1-10) 1 810 (5-11) 2 640 (8-8) 3 430 (11-3)

28˚ 2 540 (8-4)

675 (2-3)

525 (1-9) 1 600 (5-3)

3 000 (9-10)

1 970 (6-6)

1 540 (5-0)

10 650 (34-11) Dimensions in mm (ft-in)

Fig. 1 - Machine Dimensions

ENGINE

TRANSMISSION

Make/Model .................................... Detroit Diesel Series 60 Type .............. Four cycle diesel, turbocharged with air-to-air charge cooling, water cooled. Electronic management.

Gross power at 2 200 rev/min ...... 332 kW (445 hp, 451 PS) Net power at 2 200 rev/min .......... 291 kW (390 hp, 395 PS)

Make/Model ..................................... ZF 6WG 310 Automatic with manual override. The transmission consists of a torque converter close-coupled to a 6 speed gearbox with integral output transfer gearing. Automatic shifting throughout the range, with kickdown feature. Lockup in all forward gears. A torque-proportioning output differential transmits drive permanently to front and rear axles. This differential may be locked by the driver for use in difficult traction conditions. Integral hydraulic retarder.

Note: Net power is after deductions for alternator. Engine emission meets Tier II USA EPA/CARB MOH 40 CFR 89 and EU NRMM (non-road mobile machinery) directive.

Maximum Torque .............................. 2 000 Nm (1 475 lbf ft) at 1 350 rev/min Number of cylinders/configuration ............ 6 cylinder, in line Bore and Stroke .................... 130 x 160 mm (5.12 x 6.30 in) Total Displacement ................................. 12.7 litres (774 in³) Air cleaner .................................... Dry type, double element Starting ..................................................................... Electric Maximum Speed (No load) ............................ 2 325 rev/min Maximum Speed (Full load) ........................... 2 200 rev/min Idle Speed ......................................................... 700 rev/min Maximum Operating Slope ........................ 30° (57% Grade)

Pressures: Main ....................................... 16 + 2 bar (232 + 30 lbf/in²) Lockup (Wk) ........................ 14 +/- 1 bar (190 +/- 15 lbf/in²) Converter 'IN' ........... 7.6 bar (110 lbf/in²) at 2 300 rev/min Converter 'OUT' .......... 4.8 bar (70 lbf/in²) at 2 300 rev/min Converter Relief Valve ....................... 8.5 bar (123 lbf/in²) Retarder ................................................... 6 bar (87 lbf/in²) Temperatures: Normal ................................... 80° - 110° C (176° - 230° F) Maximum .................................................. 120° C (248° F) Stall Speed ............................................. 1 835 ± 50 rev/min

SM 2110 Rev 4 03-05

1

General Information - Technical Data Section 000-0000 Ratios: Torque Converter .................................................... 1.84:1 Transmission .................................... Refer to table below.

Gear Ratio km/h mile/h Gear Ratio km/h mile/h

Forward 1 2 3 4 5.35 3.45 2.21 1.42 6.0 9.3 14.6 22.7 3.7 5.8 9.1 14.1 Reverse 1 2 3 5.35 2.21 0.97 6.0 14.6 33.3 3.7 9.1 20.7

5 0.97 33.3 20.7

6 0.62 51.7 32.1

Note: During reversing operations it is recommended to reduce engine speed, use only 1st or 2nd gear and never exceed 10 km/h (6.2 mile/h).

BRAKES Full hydraulic braking system with enclosed, forced oilcooled multiple discs on each wheel. Independent circuits for front and rear brake systems. Warning lights and audible alarm indicate low brake system pressure. Brake system conforms to ISO 3450, SAE J1473.

Actuating Pressure ........... 138 ± 6.2 bar (2 000 ± 90 lbf/in²) Pump Type ................................................ Triple stage gear Capacity at 2 200 rev/min ...... 2.02 litre/s (32 US gal/min) combined Braking surface (tractor) ..... 802837 mm2 (1244.4 in2)/brake Braking surface (trailer) ........ 535225 mm2 (829.6 in2)/brake Parking:

Spring-applied, hydraulic-released disc on rear driveline.

Emergency: Automatic application of driveline brake should pressure fall in main brake hydraulic system. Service brakes may also be applied using the parking-emergency brake control.

Retardation: Hydraulic retarder integral with transmission.

AXLES Three axles in permanent all-wheel drive with differential coupling between each axle to prevent driveline wind-up.

Heavy duty axles with fully-floating axle shafts and outboard planetary gearing.

Automatic limited slip differentials in each axle. Leading rear axle incorporates a through-drive differential to transmit drive to the rearmost axle. Locking of this differential is actuated simultaneously with the transmission output differential lock.

WHEELS AND TYRES Wheels ...... Five-piece Earthmover rims with 23 Stud Fixing Size: Standard ....................... 25 x 25.00 in for 29.5 R25** tyres Tyres: Standard ............................................... 29.5 R25** Radial Inflation Pressures (Bridgestone): Front 29.5 R25** 3.5 bar (51 lbf/in²)

Rear 4.25 bar (62 lbf/in²)

Ratios: Differential ............................................................... 4.86:1 Planetary ................................................................. 4.94:1 Total Reduction ....................................................... 24.0:1

Inflation Pressures (Continental): Front 29.5 R25** 3.5 bar (51 lbf/in²)

Rear 4.25 bar (62 lbf/in²)

SUSPENSION

Inflation Pressures (Michelin): Front 29.5 R25** 3.0 bar (44 lbf/in²)

Rear 3.65 bar (53 lbf/in²)

Front: Axle located by a leading A-frame permitting both vertical movement and oscillation. Rubber cone suspension medium with heavy duty hydraulic dampers.

Axle Vertical Travel .................................. 105 mm (4.2 in) Rear: Each axle is coupled to the frame by three rubberbushed links with lateral restraint by a transverse link.

Pivoting inter-axle balance beams equalise load on each rear axle. Suspension movement is cushioned by rubber/ metal laminated compression units between each axle and underside of balance beam ends. Pivot points on rear suspension linkages are rubber-bushed and maintenance-free.

Axle Vertical Travel ............................ ± 115 mm (± 4.5 in) Axle Oscillation ............................................................ ± 9°

Note: Tyre pressures should be regarded as nominal only.

It is recommended that for tyres both listed and unlisted, the user should consult the tyre manufacturer and evaluate all job conditions in order to make the proper selection.

HYDRAULIC SYSTEM Steering and Body Hoist The steering and body hydraulic systems are supplied with oil from a common tank by the main hydraulic gear pump. Pump is driven from power takeoff on transmission.

The components are protected by advanced full flow filtration to 5 micron particle size on the return line.

Pump capacity (at 2258 rpm)....................... 7.03 litre/s (111 US gal/min)

2

SM 2110 Rev 4 03-05

General Information - Technical Data Section 000-0000 Steering

SERVICE CAPACITIES

Hydrostatic power steering by two double-acting, cushioned steering cylinders. Actuating pressure for steering operation is supplied by the main hydraulic gear pump.

Fuel tank .......................................... 463 litres (122 US gal) Hydraulic System (Steering, Braking & Body) ................ 209 litres (55 US gal) Brake Cooling System .................... 199 litres (52.6 US gal) Cooling System ................................ 80 litres (21.1 US gal) Engine Crankcase (with filters) .......... 37 litres (9.8 US gal) Transmission (with filters) ................. 56 litres (14.8 US gal) Differential - Dana (Front) ................ 37.5 litres (9.9 US gal) Differential - Dana (Centre) ................. 38 litres (10 US gal) Differential - Dana (Rear) ................ 31.5 litres (8.3 US gal) Planetaries - Dana ............................ 8.5 litres (2.2 US gal) Driveshaft Bearings ........................... 1.5 litres (0.4 US gal) Air Conditioning Compressor .... 0.125 litres (0.033 US gal)

Emergency steering pressure is provided by a ground driven pump mounted on the transmission. An indicator lamp signals should the emergency system activate.

Conforms to SAE J53.

System pressure ................................. 206 bar (3000 lbf/in²) Steering Angle (left and right) ......................................... 45° Lock to Lock Turns, steering wheel .................................... 4 Clearance Turning Diameter (SAE) ................ 19.5 m (64 ft)

Body

VEHICLE WEIGHTS

Two single-stage, double-acting hoist cylinders, cushioned at both ends of stroke. Electro servo assisted hoist control.

Actuating pressure for body hoist is supplied by the main hydraulic gear pump.

Standard Vehicle

System pressure ................................. 172 bar (2500 lbf/in²) Control Valve .......................... Pilot Operated, Open Centre Body Raise Time (loaded) ......................................... 16 sec Body Lower Time (power down) ................................ 12 sec

kg

lb

Net Distribution Front Axle

15 275

33 675

Centre Axle

7 750

17 085

Rear Axle

7 705

16 985

Net Weight

30 730

67 745

Payload

36 500

80 470

Gross Distribution

ELECTRICAL SYSTEM

Front Axle

20 170

44 465

Type ............................................. 24 volt, Negative Ground.

Battery ......... Two, 12 Volt, 175 Ah each, Maintenance Free Accessories ............................................................... 24 Volt Alternator .................................................................. 70 Amp

Centre Axle

23 530

51 875

Rear Axle

23 530

51 875

Gross Weight

67 230

148 215

Bare Chassis

24 670

54 390

5 400

11 905

660

1 455

Body

BODY

Body Hoists (pair)

All welded construction, fabricated from high hardness (min. 360 BHN) 1 000 MPa (145 000 lbf/in²) yield strength steel. 25° tail chute angle provides good load retention without tailgate.

Ground Pressures

Plate Thicknesses: Floor and Tailchute ................................... 15.0 mm (0.59 in) Sides ......................................................... 12.0 mm (0.47 in) Front .......................................................... 10.0 mm (0.39 in) Volume: Struck (SAE) ............................................ 17.0 m³ (22.2 yd³) Heaped 2:1 (SAE) ................................... 22.0 m³ (28.8 yd³)

*

SM 2110 Rev 4 03-05

*

At 15% sinkage of unloaded radius and specified weights 29,5 R25 Net Loaded 102 kPa (14.8 psi) 135 kPa (19.6 psi) Front Rear 52 kPa (7.5 psi) 158 kPa (22.9 psi)

*

*

3

GENERAL INFORMATION - Welding Procedure Section 000-0010

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.

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.

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.

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.

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

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

5. Allow repair weld to cool slowly.

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

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

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

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

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

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

*

2

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

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

*

*

*

SM 2172 10-02

CHASSIS - Frames Section 100-0010 SM - 1859

Fig. 1 - General Arrangement of Frame Assemblies

DESCRIPTION

roller bearings.

The front and rear frames are all-welded high grade steel fabrications, with rectangular box section beams forming the main side and cross-members. These heavy duty structures are designed to withstand the severe loadings incurred when operating over rough terrain.

Note: For details on the articulation and oscillation pivot and procedures for separating the front and rear frames, refer to Section 100-0020, ARTICULATION AND OSCILLATION PIVOT.

The front frame houses engine, transmission, hydraulic and fuel tanks and carries the cab, front suspension and front drive axle. The rear frame carries the body, body cylinders, rear suspension system and the rear drive axles.

Inter-frame oscillation is provided by a robust cylindrical coupling, carried on large nylon bushes.

Steering is by frame articulation to 45 degrees either side by two widely spaced vertical pivot pins in taper

SM 1372 Rev 1 2-00

MAINTENANCE Note: This section covers maintenance of the front and rear frames only.

Inspection Inspect the frames and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending of the frame. Any defects found should be repaired before they progress into major failures.

1

Chassis - Frames Section 100-0010

Straightening If the frame is not too badly sprung or twisted, hydraulic straightening and aligning equipment can be used to straighten the frame without dismantling the machine. However, if the frame is severely damaged, it will be necessary to disassemble the machine in order to repair or replace the frame assembly.

All straightening operations should be performed without application of heat if possible. If heat must be applied, do not heat the metal beyond a dull cherry red colour, as it will result in serious weakening of the frame by decreasing the tensile strength of the steel.

When it is necessary to apply heat, apply it uniformly over the area to be straightened until the metal reaches a uniform colour. Protect the heated surface from drafts to prevent sudden cooling of the metal. If the frame or frame parts cannot be straightened they must be replaced.

Welding WARNINGS Before any welding is done on a machine equipped with the DDEC system, disconnect wiring harnesses at the ECM, connections at body hydraulics joystick, all battery connections at both positive and negative terminals and ground cable to alternator to avoid damage to electrical components. Turn battery master switch to the 'Off' position before disconnecting any components.

Remove battery ground cable first, and reconnect last, to avoid damaging electrical components.

Battery supply cables Alternator earth cables Alternator supply cables Body hydraulics joystick Transmission (Est-37) connector ECM interface harness connector (30 pin RHS) ECM power harness connector (5 pin RHS) ECM sensor harness connector (30 pin LHS) ECM engine to transmission datalink connector (6 pin RHS)

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

Note: Always fasten the welding machines ground cable to the piece/frame being welded if possible.

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 Service Department can be consulted regarding the feasibility of welding repairs.

Reinforcement Frame reinforcement can be made with channel, angle or flat structural stock. Whenever possible, the reinforcement should extend well beyond the bent, broken or cracked area. The reinforcement stock thickness should not exceed that of the frame stock and the material should be of the same tensile strength.

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.

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

Note: Prior to welding, switch off/disconnect the following in the order given. Failure to do so may seriously damage the machines electrical components.

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

a - Turn keyswitch off b - Turn battery master switch off c - Battery earth cables *

2

defghijkl-

*

*

*

SM 1372 Rev 1 2-00

CHASSIS - Articulation and Oscillation Pivot Section 100-0020 SM - 1896

29 16 51 19

52

25 56

50

5,6

56

55

7 20

14

53

27

17

54

56 DETAIL A

42

25

41 45,46,49

39 36,49 45,47,49 1

32 26,56 52,55

30 23 38

26,53 54,55 56

2,3,4

10,26 11

2,3,4

60

33

57,58,59 49,61,62

36,49

40

28

51

43

37,49

51

31

17 19 50 44,48,49

18

13

15 8,9

19 50 16

16

35

14

29

31

24

29

8,9

15

38 30,23

21,22 12

34 25

10,26 45,46,49

1 2 3 4 5 6 7 8 9 10 11 12 13

45,47,49

37,49

- Pivot Assembly - Nylon Bush - Loctite 648 - Loc Quick Primer - Gasket - Cover Plate - Bolt - Bearing Assy - Cup - Bearing Assy - Cone - 'V' Ring Seal - Thrust Nut - Locking Plate - Antiseize Comp

14 15 16 17 18 19 20 21 22 23

- Driveshaft - Seal - Thrust Washer - Front Yoke - Brake Yoke - Nut - Washer - Lockwasher - Bolt - Extreme Pressure Lithium No.2 Grease 24 - SAE 80W-90 EP Gear Oil

25 - Plug 26 - Extreme Pressure Multipurpose Grease 27 - Lube Fitting 28 - Plug 29 - 'O' Ring 30 - Bearing Assembly 31 - Retaining Ring 32 - Seal Housing 33 - Seal Housing 34 - Seal Housing 35 - Seal Housing 36 - Seal

37 38 39 40 41 42 43 44 45 46 47 48 49

- Seal - Shim - Spacer - Upper Pin - Washer - Nut - Lower Pin - Hardened Washer - Washer - Bolt - Bolt - Bolt - Loctite 243

50 51 52 53 54 55 56 57 58 59 60 61 62

- Lockwasher - 'O' Ring - Hose Assembly - Hose Assembly - Connector - Lube Fitting - Elbow - Adaptor - Connector - Elbow - Pipe Assembly - Washer - Bolt

Fig. 1 - Articulation and Oscillation Pivot

DESCRIPTION AND OPERATION The articulation and oscillation pivot allows the front and rear frames to rotate horizontally (articulation) and tilt laterally (oscillation) with respect to each other. It is also the main load bearing coupling between the two frames. The pivot assembly houses

SM 1373 Rev 2 8-03

the driveshaft connecting the drive between the front and rear frames.

Articulation bearings, oscillation bushes, pivot driveshaft bearing and associated parts can be removed, inspected and replaced or renewed by following the procedures outlined in this section.

1

Chassis - Articulation and Oscillation Pivot Section 100-0020

THRU-DRIVE DRIVESHAFT Numbers in parentheses refer to Fig. 1, unless otherwise specified.

9. Disconnect mounting hardware securing protective guard (if fitted), from beneath the parking brake disc, to the rear frame.

Note: The following procedures assume that only thru-drive components require repair.

10. Release the parking brake by turning the hex-head on the parking brake actuator fully anticlockwise.

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

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

When necessary to drive out or drive on components during disassembly/assembly, be sure to use a soft drift to prevent property damage and personal injury.

Removal and Disassembly

WARNING Tensioned spring on adjuster.

11. Remove mounting hardware securing parking brake assembly to mounting bracket on frame, then secure parking brake assembly clear of brake disc.

12. Identify the relationship of the driveline caps to brake yoke (18). Remove capscrews, disconnect driveline and secure clear of brake yoke.

13. Withdraw driveshaft assembly (14) from housing by pulling rearwards on parking brake disc/brake yoke assembly (18). If necessary, tap front end of driveshaft (14) to ease removal, take care to avoid damaging threads. Place driveshaft (14) assembly on work bench for further disassembly.

1. Position the vehicle on a level work area and apply parking brake.

14. Prise out and discard seal (15) from front of the housing.

2. Raise body and install body safety prop to secure body in partially raised position.

15. Lift out front bearing assembly cup (8) from front of the housing.

3. Shut down engine and block all wheels securely.

16. If bearing replacement is required, use a suitable puller to remove front and rear bearing assembly cups (8) from the housing.

4. Identify the relationship of the driveline caps to the transmission yoke and front yoke (17). Remove capscrews and remove driveline from vehicle.

Note: If either bearing assembly cup or cone (8 or 9) need replacing, they must be replaced as a set.

Note: Take extra care when handling drivelines as any deformity on a rotating mass creates vibration and excessive wear during any operation.

17. If retaining rings (31) need replacing, use a suitable drift or puller to remove them from the housing.

5. Remove wheel blocks, start engine and steer vehicle into a full left-hand lock. Shut down engine and block all wheels securely.

18. Remove front nut (19) then temporarily install front yoke (17) fully onto front of driveshaft (14) and suitably restrain to resist rotation.

6. Remove front nut (19), lockwasher (50) and thrust washer (16) from driveshaft (14). Reinstall nut (19) temporarily onto driveshaft (14) to protect the threads.

19. Remove mounting hardware securing parking brake disc to brake yoke (18) and remove brake disc.

7. Remove and discard 'O' rings (29 & 51) from thrust washer (16).

20. Remove rear nut (19), lockwasher (50), thrust washer (16), and brake yoke (18) from driveshaft (14).

Identify front and rear ends of driveshaft (14).

8. Place a suitable container under the front of the pivot and pull front yoke (17) from driveshaft (14).

21. Remove and discard 'O' rings (29 & 51) from thrust washer (16).

2

SM 1373 Rev 2 8-03

Chassis - Articulation and Oscillation Pivot Section 100-0020 22. Remove and discard seal (15) from driveshaft (14).

23. If bearing replacement is required, use a suitable puller or drift to remove rear bearing assembly cone (9) from driveshaft (14).

5. Remove nut (19), thrust washer (16) and brake yoke (18) from driveshaft (14). The distance from the end of the bearing cone (8) to the end of the spline should be approximately 57 mm.

6. Install driveshaft (14) through the housing.

24. Reinstall nuts (19) on driveshaft (14) to protect the threads.

Inspection 1. Clean all parts with a suitable solvent and let dry.

DO NOT spin bearings with compressed air. Place bearings on a clean surface, cover with a lint free cloth and allow to dry.

2. Check bearing assemblies cups and cones (8 & 9) for wear or damage. Renew as necessary.

Note: If either bearing assembly cup or cone (8 or 9) need replacing, they must be replaced as a set.

3. Inspect splines of driveshaft (14) and yokes (17 & 18) for nicks, burrs or excessive wear. Replace if wear is excessive or splines are nicked. Burrs may be removed with a fine file or medium India stone.

4. Check yokes (17 & 18) for damage in region polished by oil seal lip; even slight damage in this area can cause leakage. Very slight marks may be polished out with fine emery cloth but it is essential that polishing marks are parallel to the seal lip.

5. Replace all seals and 'O' rings with new parts.

Assembly and Installation

7. Using a suitable driver, install front bearing assembly cone (9) on driveshaft (14).

8. Using a suitable driver, install seals (15) into ends of housing, ensuring that they butt hard against abutment shoulders.

9. Install brake yoke (18) on rear of driveshaft (14) until it butts against bearing assembly cone (9).

10. Install front yoke (17) on driveshaft (14) until it butts against bearing assembly cone (9).

11. Install 'O' rings (29 & 51) to thrust washer (16) and install assembly on front of driveshaft (14).

12. Install front nut (19) temporarily on front of driveshaft (14).

13. Install 'O' rings (29 & 51) to thrust washer (16) and install assembly on rear of driveshaft (14).

14. Install nut (19) and lockwasher (50) to rear threads of driveshaft (14). Prevent driveshaft (14) from turning by restraining brake yoke (18).

15. Tighten nut (19) and bend at least one lockwasher (50) tab into nut (19). If required back off nut (19) until the first available tab lines up with a slot in the nut (19).

1. If removed, use a suitable driver and install retaining rings (31) into housing, ensuring that they butt hard against abutment shoulders.

16. Tighten nut (19) at front of driveshaft (14) to a torque of 250 Nm (180 lbf ft) to seat bearing cup and cone assemblies (9 & 8).

2. Using a suitable driver, install front and rear bearing assembly cups (8) into housing, ensuring that they butt hard against abutment shoulders.

17. Chap driveshaft (14) at both ends with a hide-faced hammer. Re-torque nut (19) to 250 Nm (180 lbf ft).

3. Lightly oil both bearing assembly cones (9) with SAE 80W - 90 E. P. gear oil (24).

4. Using a suitable driver, install rear bearing assembly cone (9) on rear end of driveshaft (14). Temporarily install brake yoke (18), thrust washer (16) and nut (19) to driveshaft (14). Tighten nut (19) until the yoke (18) bottoms out on the driveshaft (14).

SM 1373 Rev 2 8-03

18. Back off nut (19) four flats, and chap rear end of driveshaft (14) with a hide-faced hammer to remove pre-load from bearing cup and cone assemblies (9 & 8).

19. Remove nut (19) from front of driveshaft (14), install lockwasher (50) and reinstall nut (19).

20. Set up dial indicator with pointer positioned on end face of driveshaft (14). Push and pull on parking brake disc to move driveshaft (14) backwards and forwards, remembering to rotate shaft at the same time to obtain an accurate reading. Note dial indicator reading.

3

Chassis - Articulation and Oscillation Pivot Section 100-0020 21. Tighten nut (19) until end play on driveshaft (14) can just be felt. Take dial indicator reading of end play.

Tighten nut (19) until end play on driveshaft (14) is 0.05 - 0.15 mm (0.002 - 0.006 in).

Note: One flat on nut (19) turned is equivalent to 0.025 mm (0.001 in).

33. Install parking brake disc protective guard (if fitted) and secure with bolts, washers and nuts. Tighten nuts to a torque of 73 Nm (54 lbf ft).

34. Start engine, raise body, lower body safety prop and lower body.

35. Remove wheel blocks.

22. When correct end play is obtained, remove dial indicator and secure nut (19) by bending the first available lockwasher (50) tab into nut (19). Recheck end play.

ARTICULATION COMPONENTS

23. Install parking brake disc on brake yoke (18) and secure with bolts and washers. Tighten bolts to a torque of 73 Nm (54 lbf ft).

Note: The following procedures assume that only components associated with articulation require repair.

24. Install parking brake assembly to mounting brackets and secure with bolts, washers and nuts.

Refer to Section 170-0010, PARKING BRAKE AND MOUNTING.

Note: It is essential that the grease used for articulation components is Extreme Pressure Lithium Complex No. 2 (23), as specified in Section 300-0020, LUBRICATION SYSTEM.

25. Apply parking brake by turning the hex-head on the parking brake actuator fully clockwise.

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

26. Apply Loctite 638 to the threads of capscrews used to mount driveline to brake yoke (18). Align match marks and install driveline. Tighten capscrews to a torque of 153 Nm (113 lbf ft).

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

27. Apply Loctite 638 to the threads of capscrews used to mount driveline between transmission yoke and front yoke (17). Align match marks and install driveline.

Tighten capscrews to a torque of 153 Nm (113 lbf ft).

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.

28. Remove bolts (7), washers (20), gasket (5) and cover plate (6) from side of oscillation hub to gain access to filler/level hole plug (25) on pivot assembly (1). Remove filler/level plug (25).

When necessary to drive out or drive on components during disassembly/assembly, be sure to use a soft drift to prevent property damage and personal injury.

29. Add SAE 80W - 90 E. P. gear oil (24) through filler/ level hole in pivot assembly (1) until the oil is level with the bottom of filler/level hole.

30. Remove plug (25) from underside of oscillation hub to drain the cavity between the oscillation hub and pivot assembly (1) of any oil that entered while filling the driveshaft bearing housing.

31. Install plug (25) into filler/level hole on pivot assembly (1). Install gasket (5) and cover plate (6) on side of oscillation hub, secure with bolts (7) and washers (20).

Disconnecting Front and Rear Frames Note: The front and rear frames can be separated sufficiently to permit disassembly/assembly of the articulation components without disconnecting hydraulic lines or electrical wiring.

1. Position the vehicle on a level work area and apply parking brake.

2. Raise body and install body safety prop to secure body in partially raised position.

3. Shut down engine and block all wheels securely.

32. Install plug (25) into cavity drain port on underside of oscillation hub.

4

4. Identify the relationship of the driveline caps to the SM 1373 Rev 2 8-03

Chassis - Articulation and Oscillation Pivot Section 100-0020 transmission yoke and front yoke (17). Remove capscrews and remove driveline from vehicle.

5. Support tractor frame at front and rear with suitably placed stands or timbers so the frame will remain level during and after pin removal.

6. Remove bolts, washers and pins securing steering cylinders to pivot. Secure steering cylinders clear of pivot.

7. Release the parking brake by turning the hex-head on the parking brake actuator fully anticlockwise.

WARNING Tensioned spring on adjuster.

8. Attach suitable lifting equipment to pivot/rear frame assembly. Lifting equipment must prevent pivot from oscillating after separation, and, be capable of pulling pivot/rear frame assembly clear of front frame. Raise lifting equipment to support pivot/rear frame assembly.

9. Remove bolt (62), washer (61), large nut (42) and washer (41) securing upper pin (40).

10. Remove upper pin (40). If necessary tap upper pin (40) to ease removal taking care to avoid damaging the threads.

Note: It may be necessary to relieve binding between the pin and pin bores by raising or lowering the pivot/ rear frame assembly.

11. Remove bolt (48) and hardened washer (44) securing lower pin (43).

Disassembly 1. Identify seal housings (32, 33, 34 & 35) to ensure correct location on assembly/installation.

Note: Seal housings (32, 33, 34 & 35) are not interchangeable.

2. Remove bolts (46 & 47), washers (45), seal housings (32, 33, 34 & 35) and upper and lower shims (38).

3. Prise out and discard seals (36 & 37) from the housings.

4. Remove and tag all bearing assemblies (30) with spacers to ensure correct assembly/installation.

Note: Bearing assemblies (30) and spacers are a matched set, never interchange cups, cones or spacers between sets.

Inspection 1. Clean all parts with a suitable solvent and let dry.

DO NOT spin bearings with compressed air. Place bearings on a clean surface, cover with a lint free cloth and allow to dry.

2. Check bearing assemblies (30) and spacers, and pins (40 & 43) for wear or damage. Renew as necessary.

Note: Bearing assemblies (30) and spacers must be renewed as a matched set.

3. Replace all seals with new parts.

Assembly 12. Remove lower pin (43). If necessary tap lower pin (43) to ease removal taking care to avoid damaging the pin.

1. Apply Loctite 243 (49) sparingly to bore of seal housings (32, 33, 34 & 35).

Note: Only separate the frames sufficiently to permit removal of the articulation bearings or damage to hydraulic and electrical connections could result.

2. Using a suitable driver, install seals (36 & 37) into seal housings (32, 33, 34 & 35) ensuring that the metal ring on inside of the seals are not disturbed, and, that they are located towards the inside of seal housing.

13. Remove blocks from rear wheels and use lifting equipment to pull pivot/rear frame assembly clear of the front frame. After moving, block pivot/rear frame assembly and block the wheels.

14. Remove spacer (39) noting orientation to ensure correct installation.

SM 1373 Rev 2 8-03

3. Apply Loctite 243 (49) to threads of outer seal housing bolts (46).

4. Place outer seal housings (32 & 34) in position ensuring that grease relief hole in seal housings are directly opposite bearing grease port on pivot. Secure with bolts (46) and washers (45). Tighten bolts (46) to a torque of 94 Nm (68 lbf ft).

5

Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 008

4. Remove blocks from rear wheels and blocking from pivot/rear frame assembly. Using lifting equipment, pull pivot/rear frame assembly to align pivot bearing bores and front frame pin bores. Block wheels and block pivot/rear frame assembly to remain level and stationary.

5. Freeze upper and lower pins (40 & 43) to ease installation.

6. Smear lower pin (43) with Extreme Pressure Lithium Complex No. 2 grease (23) and install through front frame and bearing bores.

Fig. 2 - Determining Shim Thickness

Note: Bearing assemblies (30) and spacers are a matched set, never interchange cups, cones or spacers between sets.

5. Using Extreme Pressure Lithium Complex No. 2 grease (23), pack bearing assemblies (30), including end faces, and install bearings.

6. Place inner seal housings (33 & 35) temporarily in position and secure with bolts (47) and washers (45).

Tighten bolts (47) to a torque of 16 Nm (12 lbf ft).

Note: It may be necessary to relieve binding between the pin and pin bores by raising or lowering pivot/rear frame assembly.

7. Apply Loctite 243 (49) to threads of bolt (48) and secure lower pin (43) with bolt (48) and hardened washer (44). Tighten bolt (48) to a torque of 73 Nm (54 lbf ft).

8. Smear upper pin (40) with Extreme Pressure Lithium Complex No. 2 grease (23) and install through front frame and bearing bores.

9. Apply Loctite 243 (49) to threads of bolt (62). Secure upper pin (40) with bolt (62), washer (61), large nut (42) and washer (41). Tighten nut (42) to a torque of 1 425 Nm (1 050 lbf ft).

7. Using feeler gauges, as shown in Fig. 2, measure the dimension between the inner pivot faces and seal housings (33 & 35). Measure at 3 positions equally spaced around seal housings and determine average dimension, this is the size of shims (38) required.

Final Assembly

8. Remove bolts (47), washers (45) and inner seal housings (33 & 35).

1. Apply parking brake by turning the hex-head on the parking brake actuator fully clockwise.

9. Install shims (38) as calculated at Step 7, reinstall inner seal housings (33 & 35) and secure with bolts (47) and washers (45). Tighten bolts (47) to a torque of 94 Nm (68 lbf ft).

2. Remove lifting equipment from pivot/rear frame assembly.

Connecting Front and Rear Frames 1. Install spacer (39) in upper outer seal housing (32), as noted on removal.

2. Smear bearing and pin bores with Extreme Pressure Lithium Complex No. 2 grease (23).

3. Attach suitable lifting equipment to pivot/rear frame assembly. Lifting equipment must prevent pivot from oscillating and be capable of pulling pivot/rear frame assembly to align pivot bearing bores and front frame pin bores. Raise lifting equipment to support pivot/rear frame assembly.

6

3. Remove stands or timbers from front frame.

4. Apply Loctite 270 to the threads of capscrews used to mount driveline between transmission yoke and front yoke (17). Align match marks and install driveline. Tighten capscrews to a torque of 153 Nm (113 lbf ft).

5. Align steering cylinder bores and mounting pin bores on pivot, install pins and secure with bolts and washers. Tighten bolts to a torque of 73 Nm (54 lbf ft).

6. Remove plugs (28) from articulation bearing grease ports and replace with lube fittings (27).

Note: Lube fittings (27) are stored on pad on side of SM 1373 Rev 2 8-03

Chassis - Articulation and Oscillation Pivot Section 100-0020 pivot assembly (1).

7. Fill bearing housings with Extreme Pressure Lithium Complex No. 2 grease (23), through lube fittings (27), until excess grease starts to escape from seal housings (32 & 34).

8. Remove lube fittings (27) and reinstall plugs (28).

Store lube fittings (27) on pad on side of pivot assembly (1).

9. Start engine, raise body, lower body safety prop and lower body.

10. Remove wheel blocks.

Disconnecting Front and Rear Frames 1. Position the vehicle on a level work area and apply parking brake.

2. Raise body and install body safety prop to secure body in partially raised position.

3. Shut down engine and block all wheels securely.

4. Depress and release brake pedal continuously to relieve the pressure in the braking system.

5. Carefully loosen brake lines at base of both accumulators to check that the pressure has released. Re-tighten brake lines.

Note: The following procedure assumes that only components associated with oscillation require repair.

6. Tag all hydraulic lines and electrical wiring between front and rear frames to ensure correct assembly/ installation. Disconnect all hydraulic lines and plug openings to prevent ingress of dirt. Disconnect electrical wiring and any other attachments which could be damaged on separation of front and rear frames.

Note: It is necessary to disconnect the front and rear frames at the articulation point to service the oscillation components.

7. Identify the relationship of the driveline caps to the transmission yoke and front yoke (17). Remove capscrews and remove driveline from the vehicle.

Note: It is essential that the grease used for oscillation components is Extreme Pressure Multipurpose Grease (26), as specified in Section 3000020, LUBRICATION SYSTEM.

8. Support tractor frame at front and rear with suitably placed stands or timbers to keep the frame level during and after pin removal.

OSCILLATION COMPONENTS Numbers in parentheses refer to Fig. 1.

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

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.

When necessary to drive out or drive on components during disassembly/assembly, be sure to use a soft drift to prevent property damage and personal injury.

Hydraulic fluid pressure will remain within the braking system after engine shut down. Operate the treadle pedal continuously until the pressure has dissipated before carrying out any work on the braking system or serious injury could result.

9. Remove bolts, washers and pins securing steering cylinders to pivot. Secure steering cylinders clear of pivot.

10. Release the parking brake by turning the hexhead on the parking brake actuator fully anticlockwise.

WARNING Tensioned spring on adjuster.

11. Attach suitable lifting equipment to pivot/rear frame assembly. Lifting equipment must prevent pivot from oscillating after separation, and, be capable of pulling pivot/rear assembly clear of front frame. Raise lifting equipment to support pivot/rear frame assembly.

12. Remove bolt, washer, large nut (42) and washer (41) securing upper pin (40).

13. Remove upper pin (40). If necessary tap upper pin (40) to ease removal taking care to avoid damaging the threads.

Note: It may be necessary to relieve binding between

SM 1373 Rev 2 8-03

7

Chassis - Articulation and Oscillation Pivot Section 100-0020 the pin and pin bores by raising or lowering the pivot/ rear frame assembly.

SM - 038

14. Remove bolt (48) and hardened washer (44) securing lower pin (43).

15. Remove lower pin (43). If necessary tap lower pin (43) to ease removal taking care to avoid damaging the pin.

16. Remove blocks from rear wheels and use lifting equipment to pull pivot/rear frame assembly clear of the front frame. After moving, block pivot/rear frame assembly and block the wheels.

Fig. 3 - Preventing Pivot Assembly From Oscillating

17. Remove spacer (39) noting orientation to ensure correct installation. Cover articulation bearings to prevent ingress of dirt.

Disassembly 1. Remove protective guard (if fitted) from beneath parking brake disc by removing mounting hardware securing guard to the rear frame. Refer to Section 170-0010, PARKING BRAKE AND MOUNTING. 2. Remove mounting hardware securing parking brake assembly to mounting bracket on frame. Remove and secure parking brake assembly clear of brake disc.

3. Identify the relationship of the driveline caps to brake yoke (18). Remove capscrews, disconnect driveline and secure clear of brake yoke (18).

4. Remove mounting hardware securing parking brake disc to brake yoke (18) and remove brake disc.

5. Place a suitable container under rear brake yoke (18) to catch oil released when pulling brake yoke (18) from driveshaft (14).

6. Remove rear nut (19) and thrust washer (16) from driveshaft (14) and pull brake yoke (18) from driveshaft (14). Reinstall nut (19) on driveshaft (14) to protect the threads.

7. Remove adaptor (57), connector (58), elbow (59) and pipe assembly (60) from oscillation hub.

8. Remove bolts (22) and washers (21) securing locking plate (12). Remove locking plate (12).

9. Restrain pivot assembly (1) to prevent it oscillating, by placing a heavy bar between the steering cylinder mountings. Lock the bar in position using suitable 8

trestles or stands. See Fig. 3.

10. Using a suitable tool, remove thrust nut (11). If wear area of thrust nut (11) is damaged, replace thrust nut (11).

11. Insert an M20 eyebolt into tapped pad provided on top of pivot assembly (1) and attach suitable lifting equipment.

12. Remove pivot restraining bar.

13. Using lifting equipment, carefully pull pivot assembly (1) clear of oscillation hub. Place pivot assembly (1) in a suitable work area for further disassembly.

14. Reinstall thrust nut (11) on pivot assembly (1) to protect the threads.

15. Note position of front 'V' ring (10) to aid in 'Installation'. Remove and discard 'V' ring (10).

16. Inspect nylon oscillation bushes (2) as described in 'Inspection'. If bushes are to be renewed, proceed with step 17.

17. Remove nylon oscillation bushes (2) with hammer and chisel.

Note: The suggested method is to make an axial cut along the bush then to lever the bush in order to collapse it upon itself.

Inspection 1. Clean nylon oscillation bushes with a suitable solvent and allow to dry.

SM 1373 Rev 2 8-03

Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 011

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

PAINT DOT

6. Lightly coat 'V' ring (10) and machined surfaces of pivot with Extreme Pressure Multipurpose Grease (26) and, install 'V' ring (10), with lip towards rear, on front of oscillation hub.

7. Using suitable lifting equipment, and taking care to prevent damaging bushes (2) or pivot threads, install pivot assembly (1) into rear frame.

Fig. 4 - Installing Oscillation Bushes

2. Inspect nylon oscillation bushes for wear, scoring, erosion and 'out of round'. Pay particular attention to the thrust faces of the bushes which should also be inspected for cracking/splitting. Renew if required.

3. Replace all seals with new parts.

Assembly Numbers in parentheses refer to Fig. 1.

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

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

1. Wipe bush housing clean using a suitable solvent and allow to dry.

2. Apply Loctite 648 (3) and Loc Quick Primer (4) and align new bushes (2) to housing with grease holes aligned vertically and identification 'PAINT DOT' at Top Dead Centre. Refer to Fig. 4. Drift bushes (2) into housing using hammer with soft packing for protection.

3. Install plug (25) in filler/level hole on pivot assembly (1). Install gasket (5) and cover plate (6) on side of oscillation hub and secure with bolts (7) and washers (20).

4. Install plug (25) in cavity drain port on underside of oscillation hub.

SM 1373 Rev 2 8-03

8. Lightly coat 'V' ring (10) and machined surfaces of pivot with Extreme Pressure Multipurpose Grease (26) and, install 'V' ring (10), with lip towards front, on rear of oscillation hub.

9. Thread thrust nut (11) on pivot assembly (1) and tighten as follows: a) Restrain pivot assembly (1) to prevent it oscillating, by placing a heavy bar between the steering cylinder mountings. Lock the bar in position using suitable trestles or stands. See Fig. 3. b) Secure a suitable tool to pivot thrust nut (11) and tighten thrust nut (11) until there is no end float/ clearance at thrust face of either bush. Slacken thrust nut (11) until pin of the locking plate (12) can be inserted in the first available hole in the thrust nut (11). c) Secure locking plate (12) with bolts (22) and lockwashers (21). Torque tighten bolts (22) to 94 Nm (69 lbf ft).

10. Install adaptor (57), connector (58), elbow (59) and pipe assembly (60) to oscillation hub.

11. Install brake yoke (18) on driveshaft (14) until it butts against bearing assembly cup and cone (8 & 9).

12. Install parking brake disc on brake yoke (18) and secure with bolts, washers and nuts. Tighten bolts to a torque of 73 Nm (54 lbf ft).

13. Install thrust washer (16) on rear of driveshaft (14).

14. Install nut (19) at rear of driveshaft (14), and tighten nut (19) to a torque of 250 Nm (180 lbf ft) to seat bearing cup and cone (8 & 9) assemblies.

15. Chap driveshaft (14) at both ends with a hide-faced hammer. Re-torque nut (19) to 250 Nm (180 lbf ft).

16. Back off nut (19) four flats, and chap rear end of driveshaft (14) with a hide-faced hammer to remove 9

Chassis - Articulation and Oscillation Pivot Section 100-0020 pre-load from bearing cup and cone assemblies (8 & 9).

frame and bearing bores.

17. Remove nut (19) from rear of driveshaft (14), install lockwasher (50) and reinstall nut (19).

7. Apply Loctite 243 (49) to threads of bolt (48).

Secure lower pin (43) with bolt (48) and hardened washer (44). Tighten bolt (48) to a torque of 73 Nm (54 lbf ft).

18. Set up dial indicator with pointer positioned on rear end face of driveshaft (14). Push and pull on parking brake disc to move driveshaft (14) backwards and forwards, remembering to rotate shaft at the same time to obtain an accurate reading. Note dial indicator reading.

19. Tighten nut (19) until end play on driveshaft (14) can just be felt. Take dial indicator reading of end play.

Tighten nut (19) until end play on driveshaft (14) is 0.05 - 0.15 mm (0.002 - 0.006 in).

Note: One flat on nut (19) turned is equivalent to 0.025 mm (0.001 in) axial movement.

20. When correct end play is obtained, remove dial indicator and secure nut (19) by bending the first available lockwasher (50) tab into nut (19). Recheck end play.

8. Smear upper pin (40) with Extreme Pressure Lithium Complex No. 2 grease (23) and install through front frame and bearing bores.

9. Apply Loctite 243 (49) to threads of bolt (62). Secure upper pin (40) with bolt (62), washer (61), washer (41) and large nut (42). Tighten nut (42) to a torque of 1 425 Nm (1 050 lbf ft).

Final Assembly 1. Install parking brake assembly to mounting brackets and secure with bolts, washers and nuts.

Refer to Section 170-0010, PARKING BRAKE AND MOUNTING. 2. Apply parking brake by turning the hex-head on the parking brake actuator fully clockwise.

Connecting Front and Rear Frames 1. Install spacer (39) in upper bearing assembly (30) as noted on removal.

WARNING Tensioned spring on adjuster.

2. Smear bearing assembly (30) and pin bores with Extreme Pressure Lithium Complex No. 2 grease (23).

3. Remove lifting equipment from pivot/rear frame assembly.

3. Attach suitable lifting equipment to pivot/rear frame assembly. Lifting equipment must prevent pivot from oscillating and be capable of pulling pivot/rear frame assembly to align pivot bearing bores and front frame pin bores. Raise lifting equipment to support pivot/rear frame assembly.

4. Remove stands or timbers from front frame.

4. Remove blocks from rear wheels and blocking from pivot/rear frame assembly. Using lifting equipment, pull pivot/rear frame assembly to align pivot bearing bores and front frame pin bores. Block wheels and block pivot/rear frame assembly to remain level and stationary.

6. Align match marks and reconnect driveline to brake yoke (18). Tighten capscrews to a torque of 153 Nm (113 lbf ft).

5. Freeze upper and lower pins (40 & 43) to ease installation.

Note: It may be necessary to relieve binding between the pin and pin bores by raising or lowering pivot/rear frame assembly.

6. Smear lower pin (43) with Extreme Pressure Lithium Complex No. 2 grease (23) and install through front 10

5. Apply Loctite 270 to threads of capscrews used to mount driveline between transmission yoke and front yoke (17). Align match marks and install driveline.

Tighten capscrews to a torque of 153 Nm (113 lbf ft).

Note: Take extra care when handling drivelines as chips, dents, burrs or deformity on any rotating mass creates vibration and excessive wear during any operation.

7. Align steering cylinder bores and mounting pin bores on pivot. Install pins and secure with bolts and washers.

Tighten bolts to a torque of 73 Nm (54 lbf ft).

8. Connect hydraulic lines and electrical wiring as noted on disassembly.

SM 1373 Rev 2 8-03

Chassis - Articulation and Oscillation Pivot Section 100-0020 9. Remove bolts (7), washers (20), gasket (5) and cover plate (6) from side of oscillation hub to gain access to filler/level plug (25) on pivot assembly (1).

Remove filler/level plug (25).

10. Add SAE 80W - 90 E. P. gear oil (24) through filler/ level hole in pivot assembly (1) until the oil is level with the bottom of filler/level hole.

11. Remove plug (25) from underside of oscillation hub to drain the cavity between the oscillation hub and pivot assembly (1) of any oil that entered while filling the driveshaft bearing housing.

12. Install plug (25) in filler/level hole on pivot assembly (1). Install gasket (5) and cover plate (6) on side of oscillation hub, secure with bolts (7) and washers (20).

13. Install plug (25) in cavity drain port on underside of oscillation hub.

14. Remove plugs (28) from articulation bearing grease ports and replace with lube fittings (27).

Note: Lube fittings (27) are stored on pad on side of pivot assembly (1).

15. Fill bearing housings with Extreme Pressure Lithium Complex No. 2 grease (23) through lube fittings (27) until excess grease starts to escape from seal housings (32 & 34).

16. Remove lube fittings (27) and reinstall plugs (28).

Store grease fittings (27) on pad on side of pivot assembly (1).

17. Add Extreme Pressure Multipurpose grease (26) to oscillation bushing lube fittings (55) on top of oscillation hub. Lube until excess grease in seen.

18. Install parking brake disc protective guard (if fitted) and secure with bolts, washers and nuts. Tighten nuts to a torque of 73 Nm (54 lbf ft).

19. Start engine to charge hydraulic systems, raise body, lower body safety prop and lower the body.

20. Bleed the braking system as described in Section 165-0010, BRAKE PARTS. 21. Remove wheel blocks.

MAINTENANCE Numbers in parentheses refer to Fig. 1.

SM 1373 Rev 2 8-03

Every 250 hours, oscillation bushes must be lubricated. Add Extreme Pressure Multipurpose grease (26) to oscillation bushing lube fittings (55) on top of oscillation hub. Lube until excess grease in seen.

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

Every 250 hours, check the end float/clearance at the thrust face of the oscillation bushes. Any clearance found must be removed by adjustment of the thrust nut, as described in step 9 of 'Assembly' procedure.

Note: A practical method of establishing the effective adjustment of the thrust nut is to use movement of the machines body in the raised position. Move the body from fully raised to almost fully raised while watching the effect of this action on the frame and pivot arrangement. Any slackness between the thrust nut and thrust faces will be clearly visible movement of the frame.

Every 1 000 hours (6 months), follow the procedure given below to check the oil level in the driveshaft bearing housing, and, lubricate the articulation and oscillation bearings.

Note: It is essential that the grease used for articulation components is Extreme Pressure Lithium Complex No. 2 grease (23), as specified in Section 300-0020, LUBRICATION SYSTEM. 1. Position the vehicle on a level work area and apply parking brake.

2. Raise body and install body safety prop to secure body in partially raised position.

3. Shut down engine and block all wheels securely.

4. Remove protective guard (if fitted) from beneath parking brake disc by removing nuts, washers and bolts securing guard to rear frame.

5. Remove bolts (7), washers (20), gasket (5) and cover plate (6) from side of oscillation hub to gain access to filler/level plug (25) on pivot assembly (1).

Remove filler/level plug (25).

6. Add SAE 80W - 90 E. P. gear oil (24) through filler/ level hole in pivot assembly (1) until the oil is level with the bottom of filler/level hole.

11

Chassis - Articulation and Oscillation Pivot Section 100-0020 12. Remove lube fittings (27) and reinstall plugs (28).

Store grease fittings (27) on pad on side of pivot assembly (1).

7. Remove plug (25) from underside of oscillation hub to drain the cavity between the oscillation hub and pivot assembly (1) of any oil that entered while filling the driveshaft bearing housing.

13. Add Extreme Pressure Multipurpose grease (26) to oscillation bushing lube fittings (55) on top of oscillation hub. Lube until excess grease in seen.

8. Install plug (25) into filler/level hole on pivot assembly (1). Install gasket (5) and cover plate (6) on side of oscillation hub, secure with bolts (7) and washers (20).

9. Install plug (25) into cavity drain port on underside of oscillation hub.

10. Remove plugs (28) from articulation bearing grease ports and replace with lube fittings (27).

14. Install parking brake disc protective guard (if fitted) and secure with bolts, washers and nuts. Torque tighten nuts to 73 Nm (54 lbf ft).

15. Start engine, raise body, lower body safety prop and lower body.

16. Remove wheel blocks.

Note: Lube fittings (27) are stored on pad on side of pivot assembly (1).

SPECIAL TOOLS

11. Fill bearing housings with Extreme Pressure Lithium Complex No. 2 grease (23) through lube fittings (27) until excess grease starts to escape from seal housings (32 & 34).

Refer to Section 300-0070, SERVICE TOOLS, for part numbers of the thrust nut tool and general service tools and adhesives required for procedures outlined in this section. These tools and adhesives are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. No. 1 1 1 1 1 -

ITEM No. 19 22 42 46 & 47 48 -

ITEM NAME Nut (to seat bearing only) Bolt Nut Bolt Bolt Parking Brake Disc Bolts Parking Brake Brkt Mounting Nuts Driveline Mounting Capscrews Protective Guard Mounting Nuts Steering Cylinder Pin Bolts

*

12

*

*

Nm 250 94 1 425 94 73 73 680 153 73 73

lbf ft 180 69 1 050 68 54 54 490 113 54 54

*

SM 1373 Rev 2 8-03

CHASSIS - Hood and Mounting Section 100-0040 SM - 2675

17

18

24 41

19

16 15

1

20 21 23

16

42 43 44 45 14

22 4

3 25

30

2

31

5

9

36 37

8

HOOD

46

34 28

35

9 27

26

48

32

33

7

8

35 40 39 38

29

- Hood - Handle - LH - Bolt - Washer - Bolt - Washer - Grille Subframe - Hinge Assembly - Plate - Bolt - Locknut - Washer

12 13 13 12 11

6

10

1 2 3 4 5 6 7 8 9 10 11 12

2

13 14 15 16 17 18 19 20 21 22 23 24

- Washer - Hoodcatch Kit - Bolt - Locknut - Bolt - Washer - Hardened Washer - Hood Stop - Spring - Cable Assembly - Plate - Goalpost Assembly

25 26 27 28 29 30 31 32 33 34 35 36

36

34 47

37

- Bolt - Bolt - Washer - Locknut - Grille - Bolt - Lockwasher - Gas Strut - Hood Strap - Bolt - Hardened Washer - Tube

FRAME

37 38 39 40 41 42 43 44 45 46 47 48

- Tube - Washer - Lockwasher - Locknut - Hood Blanking Piece - Bolt - Washer - Hardened Washer - Locknut - Hood Safety Bar - Bolt - Locknut

Fig 1 - Hood and Mounting

HOOD Removal Numbers in parentheses refer to Fig. 1.

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

1. Position the machine on a level surface, apply the parking brake and switch off the engine.

SM 2120 2-02

2. Block all road wheels and place the battery master switch in the 'Off' position.

3. Remove bolts (30) and lockwashers (31) securing grille (29) to grille subframe (7). Secure grille (29) clear of hood (1).

4. Pull cable assembly (22), handle inside cab, to release hood catch and lift up hood (1). Secure hood (1) in raised position using suitable lifting equipment.

5. Carefully remove bolts (34), hardened washers (35), tubes (36 & 37), washers (38), lockwashers (39) and nuts (40).

1

Chassis - Hood and Mounting Section 100-0040 6. Remove hood straps (33) and gas struts (32) from hood.

GOALPOST ASSEMBLY

7. Remove bolts (26), washers (27) and nuts (28) securing hinges (8) to frame and lift hood (1) assembly from the machine.

Numbers in parentheses refer to Fig. 1.

8. If required, remove bolts (3) and washers (4) securing grille subframe (7) to hood (1). Secure grille subframe (7) clear of hood.

9. If required, remove mounting hardware (5 & 6) securing handle (2) to hood (1). Secure handle (2) clear of hood (1).

Installation Numbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners to torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.

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

1. If removed, secure handle (2) to hood (1) using mounting hardware (5 & 6) as removed at 'Removal'.

Removal

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

1. Position the machine on a level surface, apply the parking brake and switch off the engine.

2. Block all road wheels and place the battery master switch in the off position.

3. Pull cable assembly (22), handle inside cab, to release hood catch and lift up hood (1).

4. Remove mounting hardware securing washer bottle to mounting bracket on the left hand side of goalpost assembly (24). Secure washer bottle clear of goalpost assembly (24).

5. With a suitable container available to catch leakage, remove drain plug from radiator header tank and drain coolant. Apply Loctite 225 to drain plug and reinstall in header tank.

2. If removed, secure grille subframe (7) to hood (1) with bolts (3) and washers (4).

6. Ensure all cooling lines connected to header tank are identified for ease of installation and with suitable containers available to catch leakage, disconnect cooling lines. Fit blanking caps to all open lines.

3. Using suitable lifting equipment, lift and position hood (1) on the machine and align holes in hinges (8) with mounting holes on frame. Secure hood (1) using bolts (26), washers (27) and locknuts (28).

7. Note routing of all hoses and harnesses attached to goalpost assembly (24) and disconnect.

4. Carefully install hood straps (33) and gas struts (32) using mounting hardware (34 - 40) as removed at 'Removal'.

5. Remove lifting equipment and lower hood (1) to match with goalpost assembly (24).

6. Install grille (29) to hood (1) and secure using bolts (30) and lockwashers (31).

7. Remove wheel blocks.

2

8. Disconnect ball joint from cam assembly in hoodcatch kit (14) and secure cable assembly (22) clear of lock mechanism.

9. Check to make certain that all necessary line and cable disconnections have been made, before lifting goalpost assembly (24).

10. Attach suitable lifting equipment to goalpost assembly (24). Remove bolts (25), washers (12), washers (13) and locknuts (11) securing goalpost assembly (24) to its mounting. Lift goalpost assembly (24) from the machine.

SM 2120 2-02

Chassis - Hood and Mounting Section 100-0040 11. If required, remove locknuts (16), bolts (15), hood stops (20) and springs (21) from goalpost assembly (24).

6. Install washer bottle to mounting bracket on the left hand side of goalpost assembly (24) and secure using mounting hardware as removed during 'Removal'.

12. If required, remove mounting hardware securing hood blanking piece (41) to right hand fender. Remove hood blanking piece (41) from the machine.

7. Remove blanking caps from all cooling lines and connect cooling lines to radiator header tank as tagged at 'Removal'.

Installation

8. Secure all hoses and harnesses to goalpost assembly (24) following routing as noted at 'Removal'.

Numbers in parentheses refer to Fig. 1.

9. Fill radiator header tank with coolant as specified in Section 210-0000, COOLING SYSTEM.

Note: Tighten all fasteners to torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.

10. Lubricate hood catch mechanism. Use grease as specified in Section 300-0020, LUBRICATION SYSTEM.

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

11. Lower hood assembly and check for correct alignment between hood (1) and goalpost assembly (24) and for operation of hood catch mechanism.

12. Remove wheel blocks.

1. If removed, secure hood blanking piece (41) to right hand fender with mounting hardware as removed at 'Removal'.

MAINTENANCE Periodically check bolts (26), washers (27) and locknuts (28) and tighten when necessary.

2. If removed, secure hood stops (20) and springs (21) to goalpost assembly (24) with bolts (15) and locknuts (16).

Periodically check condition of lock mechanism and adjust and lubricate when necessary.

3. Using suitable lifting equipment, lift and position goalpost assembly (24) on the machine. Secure goalpost assembly (24) to its mounting with bolts (25), washers (12), washers (13) and locknuts (11).

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 and adhesives required. These tools and adhesives are available from your dealer.

4. Remove lifting equipment.

5. Connect ball joint to cam assembly in hoodcatch kit (14) and secure cable assembly (22) using clips removed during 'Removal'. *

SM 2120 2-02

*

*

*

3

ENGINE - Engine and Mounting Section 110-0030 SM - 2676

26 27

43

24 34 17

14

1

16

35 33 12

41 37 40

39

20

36 13

15

38

9 8

28 7

8 2 10

29

23 22

21 25

8

31 32

3 28 ON ENGINE LHS

18 LH 19 RH 9 10

30 31 4

1 2 3 4 5 6 7 8 9 10 11

- Engine - Oil Filter - Coolant Filter - Primary Fuel Filter - Secondary Fuel Filter - Dipstick - Engine Coupling - Snubbing Washer - Washer - Nut - Bolt

12 13 14 15 16 17 18 19 20 21 22

- Bolt - Bolt - 'V' Belt - Bolt - Plate - Screw Assembly - Rear LH Mount - Rear RH Mount - Link - Bolt - Bushing

23 24 25 26 27 28 29 30 31 32 33

- Connector - Link - Washer - Bolt - Lockwasher - Isolation Mount - Bolt - Step - Lockwasher - Bolt - Washer

6

5

34 35 36 37 38 39 40 41 42 43

42

32

- Nut - Pin - Bolt - Washer - Bolt - Washer - Locknut - Locknut - Clip - Alternator

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 tractor frame at three points by a mounting bracket at the front of engine (1) and two rear mounts (18 & 19). Rubber isolation mounts (28) through engine mounts provide sufficient flexibility to absorb varying engine vibration and torsional loads.

SM 2121 Rev 1 11-03

There are two full-flow oil filters (2) mounted on the right 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 (2) 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 elements and out through another passage in the filter adaptor.

Engine coolant filter (3) 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 1

Engine - Engine and Mounting Section 110-0030 210-0000, COOLING SYSTEM. There are two spin-on type fuel filters mounted on the left hand side of engine (1). Primary fuel filter (4) is in the fuel flow and acts as a strainer and secondary fuel filter (5) filters the fuel after having passed through primary fuel filter (4). The word 'Primary' or 'Secondary is cast into the top of the respective adaptor to prevent mismatching.

DETROIT DIESEL ELECTRONIC CONTROL (DDEC) Description Refer to Fig. 2.

WARNING Before any welding is done on a machine equipped with the DDEC system, disconnect the following in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables, body hydraulics joystick, transmission (Est-37) connector, ECM interface harness connector (30 pin RHS), ECM sensor harness connector (30 pin LHS) and ECM engine to transmission datalink connector (6 pin RHS).

Turn off battery master switch before disconnecting any components.

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

The engine is equipped with DDEC which controls the timing and amount of fuel injection by the electronic unit injectors (EUI). 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 DDEC 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

2

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 Unit Injectors (EUI) where the precise amount of fuel is injected into the engine.

3. Electronic Unit Injectors (EUI) - The EUI 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 EUI 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 unit injectors are self compensating and virtually eliminate engine tune-ups.

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

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 DDEC controlled engine will override the electronic foot pedal position until the engine is warmed up to the correct operating temperature. The engine MUST be started with foot 'OFF' the electronic foot pedal.

6. Check Engine Light - When the 'Check Engine' light comes on, the computer has detected a fault in the

SM 2121 Rev 1 11-03

Engine - Engine and Mounting Section 110-0030 SM - 1840

7 STOP

6 3 1

2

8

P

4

9 1,2

1 2 3 4 5

-

5

6 - Check Engine Light 7 - Stop Engine Light 8 - Diagnostic Request/Stop Engine Override Switch 9 - Diagnostic Test Point

Electronic Control Module (ECM) Programmable Read Only Memory (PROM) Electronic Unit Injectors (EUI) Batteries Electronic Foot Pedal

Fig. 2 - DDEC Components

engine. The fault should be diagnosed and corrected at the earliest opportunity.

7. Stop Engine Light - When the 'Stop Engine' 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.

8. Diagnostic Request/Stop Engine Override Switch - Operates as a diagnostic request switch when: a - the engine is not running and ignition is 'On'. b - the engine is idling and not in an engine protection condition.

Pressing and releasing the switch will flash out the engine codes. Pressing the switch a second time will stop the engine codes flashing.

Note: Inactive codes are displayed on Check Engine Light and active codes are displayed on Stop Engine Light. Code 25 means no codes present.

SM 2121 Rev 1 11-03

Operates as a Stop Engine Override Switch when the engine is in a rampdown protection mode for any of the following: Low Coolant Level High Coolant Temperature Low Oil Pressure High Oil Temperature 9. Diagnostic Test Point - Plug in connector for diagnostic data reader (DDR).

Operation Numbers in parentheses refer to Fig. 2.

The machine is equipped with the DDEC engine protection system, which records the stop engine malfunction in ECM (1). The stop engine and check engine lights illuminate when the engine protection system is initiated. The engine will immediately reduce to 70% of the available torque. Rampdown then commences over a 30 second period and reduces the engine to 40% of the available torque.

3

Engine - Engine and Mounting Section 110-0030 To allow for the possibility of the engine protection system being activated while the machine is operating in a critical situation, a stop engine override switch (8) is provided. If the switch is pressed and released during rampdown, the 30 second timer will reset, restoring torque to the level immediately following illumination of stop engine (7) and check engine (6) lights. The switch must be pressed and released again to obtain a subsequent override.

Note: The operator must continue to reset the automatic engine protection system by pressing and releasing stop engine override switch (8) at intervals of approximately 15 to 20 seconds.

Note: ECM (1) will record the number of times the override is activated after the fault occurs. Available Torque is the actual torque available from the engine when the fault occurred based on the actual rev/min when the fault occurred.

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 Stop Engine Light to come on are; Low Coolant Level, High Coolant Temperature, Low Oil Pressure and High Oil Temperature.

Whenever check engine light (6) or stop engine light (7) comes on, the DDEC computer will determine where the problem is and will store this information in its memory. If the malfunction is intermittent, the lights will come on and go off as the computer senses the changing engine condition.

A special diagnostic data reader (DDR) is available that can be plugged into the engine computer memory to extract information related to the cause of the problem.

Once the malfunction has been corrected, the DDEC system will return the engine to normal operation. The

4

DDR can now distinguish between active codes and those stored in the historic code memory. The malfunction code recorded in ECM (1) memory will remain until it is erased by a technician.

WARNINGS The operator of a DDEC-equipped vehicle must not attempt to use or read a DDR 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.

When engine or electronics system diagnosis is required on a DDEC-equipped vehicle, this must be done by a person other than the operator. The operator must maintain control of the moving vehicle while the assistant performs the diagnosis.

When the engine is not running and the ignition is on, or, the engine is idling and not in an engine protection condition, engine faults can be diagnosed by the operator. Pressing and releasing diagnostic request switch (8) will cause check engine light (6) or stop engine light (7) to flash a code number indicating the fault, e.g. flash twice - pause - flash five times - pause indicates a code 25. Code 25 indicates all systems are operating correctly. Pressing the switch a second time will stop the engine codes flashing. Refer to 'DDEC III & IV Diagnostic Codes' table for other code descriptions.

Note: Only one light will be flashing at any one time.

When code flashing is initiated, the active codes (or code 25) will be flashed on stop engine light (7), then the inactive codes (or code 25) will be flashed on check engine light (6). When all of the inactive codes have been flashed, the process of flashing the codes will repeat until the conditions for code flashing are no longer satisfied.

SM 2121 Rev 1 11-03

Engine - Engine and Mounting Section 110-0030

DDECIII & IV DIAGNOSTIC CODES DDEC Code # (Flashed)

PID

SID

FMI

DDEC Description

11 11 12 13 13 14 14 14 15 15 15 16 16 17 17 18 18 21 22 23 23 24 24 25 26 26 27

240 251 251 187 187 187 111 111 52 110 175 52 110 175 111 111 72 51 72 51 91 91 174 174 171

253 254 254 254 65 65 25 61 -

2 10 13 13 0 1 6 4 7 3 4 6 3 3 3 4 4 4 3 5 3 3 4 4 3 4 3 3 4 4 1 11 3

27 27 28

172 105 171

-

3 3 4

28 28 31 31 31 31 31 31 32 32 32 32

172 105 -

51 51 51 52 52 52 238 238 239 239

4 4 3 4 7 3 4 7 4 3 3 4

Fram checksum incorrect Clock module abnormal rate Clock module fault/failure Incompatible calibration version External failed RAM Internal failed RAM Entered boot via switches VSG sensor voltage low VSG switch system not responding VSG sensor high Coolant level sensor input voltage low Add coolant level sensor input voltage low Intercooler coolant temperature sensor input voltage high Coolant temperature sensor input voltage high Oil temperature sensor input voltage high Intercooler coolant temperature sensor input voltage low Coolant temperature sensor input voltage low Oil temperature sensor input voltage low Coolant level sensor input voltage high Add coolant level sensor input voltage high Throttle plate position sensor input voltage high Throttle position sensor input voltage high Bypass position sensor input voltage low Throttle plate position sensor input voltage low TPS input voltage high TPS input voltage low Fuel temperature sensor input voltage high Oxygen content circuit input voltage high Fuel temperature sensor input voltage low Oxygen content circuit input voltage low Reserved for 'No Codes' Auxiliary shutdown #1 active Auxiliary shutdown #2 active Ambient air temperature sensor input voltage high (Release 2.00 or later only) Air temperature sensor input voltage high Intake manifold temperature sensor input voltage high Ambient air temperature circuit failed low (Release 2.00 or later only) Air temperature sensor input voltage low Intake manifold temperature sensor input voltage low Aux. output #3 open circuit (high side) - S3 Aux. output #3 short to ground (high side) - S3 Aux. output #3 mechanical system fail - S3 Aux. output #4 open circuit (high side) - T3 Aux. output #4 short to ground (high side) - T3 Aux. output #4 mechanical system fail - T3 SEL open circuit SEL short to battery (+) CEL short to battery (+) CEL open circuit

SM 2121 Rev 1 11-03

5

Engine - Engine and Mounting Section 110-0030

DDEC III & IV DIAGNOSTIC CODES

6

DDEC Code # (Flashed)

PID

SID

FMI

DDEC Description

33 34 35 35 36 36 37 37 37 38 38 38 41 42 43 44 44 44 44 44 45 45 46 46 47 47 47 47 47 48 48 48 48 52 53 53 53 54 55 55 55 56 57 58 61 62 62 62 62 62 62

102 102 100 19 100 19 94 18 95 94 18 95 111 52 110 172 175 105 100 19 168 94 102 106 164 18 18 94 106 164 84 92 -

-

3 4 3 3 4 4 3 3 3 4 4 4 0 1 1 0 0 0 0 0 1 1 1 1 0 0 0 0 0 1 1 1 1 12 2 12 13 12 12 8 9 12 12 0 0 3 4 3 4 3 4

Turbo boost pressure sensor input voltage high Turbo boost pressure sensor input voltage low Oil pressure sensor input voltage high High range oil pressure sensor input voltage high Oil pressure sensor input voltage low High range oil pressure sensor input voltage low Fuel pressure sensor input voltage high High range fuel pressure sensor input voltage high Fuel restriction sensor input voltage high Fuel pressure sensor input voltage low High range fuel pressure sensor input voltage low Fuel restriction sensor input voltage low Too many SRS (missing TRS) Too few SRS (missing SRS) Coolant level low Intercooler coolant temperature high Coolant temperature high Air inlet temperature high Oil temperature high Intake manifold temperature high Oil pressure low High range oil pressure low ECM battery voltage low Sensor supply voltage low Fuel pressure high Turbo boost pressure high Air inlet pressure high Injection control pressure high High range fuel pressure high High range fuel pressure low Fuel pressure low Air inlet pressure low Injection control pressure low A/D conversion fail Non-voilatile checksum incorrect EEPROM write error Out of calibration Vehicle speed sensor fault J1939 data link fault Proprietary datad link fault (Master) Proprietary datad link fault (Receiver) J1587 data link fault J1922 data link fault Torque overload Injector xxx response time long Aux. output #1 short to battery (+) - F3 Aux. output #1 open circuit - F3 Aux. output #2 short to battery (+) - A2 Aux. output #2 open circuit - A2 Aux. output #5 short to battery (+) - W3 Aux. output #5 open circuit - W3

21 21 232 254 253 253 253 231 248 248 250 249 xxx 26 26 40 40 53 53

SM 2121 Rev 1 11-03

Engine - Engine and Mounting Section 110-0030

DDEC III & IV DIAGNOSTIC CODES DDEC Code # (Flashed)

PID

SID

FMI

62 62 62 62 62 62 62

-

54 54 55 55 56 56 26

3 4 3 4 3 4 7

62

-

40

7

62

-

53

7

62

-

54

7

62

-

55

7

62

-

56

7

63 63 63 63 63 63 63 63 63 63 63 63 63 63 63 63 64 64 65 65 65 65 65 65 66 66 66 66 66 66 67 67 67 67

103 103 51 51 51 51 107 107 109 109 106 106

57 57 58 58 59 59 60 60 57 57 58 58 59 59 60 60 76 76 76 76 99 99 -

3 4 3 4 3 4 3 4 0 1 0 1 0 1 0 1 8 0 0 1 2 7 3 4 0 3 4 7 3 4 3 4 3 4

SM 2121 Rev 1 11-03

DDEC Description

Aux. output #6 short to battery (+) - X3 Aux. output #6 open circuit - X3 Aux. output #7 short to battery (+) - Y3 Aux. output #7 open circuit - Y3 Aux. output #8 short to battery (+) - A1 Aux. output #8 open circuit - A1 Aux. output #1 mechanical system not responding properly - F3 Aux. output #2 mechanical system not responding properly - A2 Aux. output #5 mechanical system not responding properly - W3 Aux. output #6 mechanical system not responding properly - X3 Aux. output #7 mechanical system not responding properly - Y3 Aux. output #8 mechanical system not responding properly - A1 PWM #1 short to battery (+) PWM #1 open circuit PWM #2 short to battery (+) PWM #2 open circuit PWM #3 short to battery (+) PWM #3 open circuit PWM #4 short to battery (+) PWM #4 open circuit PWM #1 above normal range PWM #1 below normal range PWM #2 above normal range PWM #2 below normal range PWM #3 above normal range PWM #3 below normal range PWM #4 above normal range PWM #4 below normal range Turbo speed sensor input failure Turbo overspeed Throttle plate position above normal range Throttle plate position below normal range Throttle plate position erratic Throttle plate not responding Air filter restriction sensor voltage high Air filter restriction sensor voltage low Engine knock level above normal range Engine knock level sensor input voltage high Engine knock level sensor input voltage low Engine knock level sensor not responding Oil filter restriction sensor voltage high Oil filter restriction sensor voltage low Coolant pressure sensor input voltage high Coolant pressure sensor input voltage low Air inlet pressure sensor input voltage high Air inlet pressure sensor input voltage low 7

Engine - Engine and Mounting Section 110-0030

DDEC III & IV DIAGNOSTIC CODES DDEC Code # (Flashed)

PID

SID

FMI

DDEC Description

67 67 68 68 71 72 72 72 72 73 73 73

20 20 84 84 -

230 230 xxx 65 65 151 226 227

3 4 6 5 1 0 11 0 1 14 11 2

73 73 73 73 73 73 73 74 74 75 75 76 81 81 81 81 81 82 82 82 82 82 83 83 83 83 83 84 84 85 86 86 87 87 88 88 89 89

107 99 70 168 121 98 101 164 173 98 101 164 173 98 101 173 173 73 98 101 190 73 108 73 108 109 20 95 111

227 77 77 77 77 77 232 20 20 -

3 0 1 3 4 7 0 0 4 0 0 0 3 3 3 3 3 4 4 4 4 4 0 0 0 4 0 1 1 0 3 3 4 4 1 1 0 12

High range coolant pressure sensor input voltage high High range coolant pressure sensor input voltage low TPS idle validation circuit fault (short to ground) TPS idle validation circuit fault (open circuit) Injector xxx response time short Vehicle overspeed Vehicle overspeed (absolute) Oxygen content too high Oxygen content too low ESS transmission stuck in gear Transmission neutral switch failure (ESS Transmission) Aux. analog input data erratic, intermittent, or incorrect (ESS transmission) Aux. analog input #1 voltage high (ESS transmission) Gas valve position above normal range Gas valve position below normal range Gas valve position input voltage high Gas valve position input voltage low Gas metering valve not responding Air filter restriction high Oil filter restriction high Optimized idle safety loop short to ground ECM battery voltage high Sensor supply voltage high Engine overspeed with engine brake Timing actuator (dual fuel) input voltage high Oil level sensor input voltage high Crankcase pressure sensor input voltage high Injection control pressure circuit voltage high Exhaust temperature sensor input voltage high Timing actuator (dual fuel) input voltage low Oil level sensor input voltage low Crankcase pressure sensor input voltage low Injection control pressure circuit voltage low Exhaust temperature sensor input voltage low Oil level high Crankcase pressure high Exhaust temperature high Exhaust temperature sensor input voltage low Pump pressure high Oil level low Crankcase pressure low Engine overspeed Pump pressure sensor input voltage high Barometric pressure sensor input voltage high Pump pressure sensor input voltage low Barometric pressure sensor input voltage low Coolant pressure low High range coolant pressure low Fuel restriction high Maintenance alert coolant level fault

8

SM 2121 Rev 1 11-03

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