0349 859 0 Sys RHB en 144

REPAIR MANUAL
REPAIR
AXLES AND STEERING
ENGINE
TRANSMISSION
BOOM
CHASSIS
TECHNICAL DATA
CL
CLAA AS TTARGO
ARGO C Series
08/2003 349859.0
The machines in this handbook are designed essentially for agricultural and associated applications. This is
their intended use.
Any modifications made to the machine without prior written approval from CLAAS or if the machine is used in
any way contrary to the intended use or if the machine is not properly driven or maintained then the Company
will not accept any liability whatsoever for any damage or injury (whether direct or consequential).
The method of operation and maintenance specified in this handbook should be strictly adhered to.
For your parts requirements, it is essential that only genuine CLAAS parts are fitted. Any resultant damage
from non-genuine parts will invalidate your machine warranty.
CLAAS operates a policy of continuous improvement to its products and reserve the right to change specifica-
tions and equipment without notice. Therefore some information within this handbook may differ from your
machine.
This manual is designed to service machines:
from Serial No. 50600011

up to Serial No. 50600251.
CONTENTS
INTRODUCTION
General
Machine identification
Health and Safety
SAFETY WARNINGS
SECTION 1
AXLES AND STEERING
AXLES 1.1
Description 1.1
Front Axle 1.1
Removal 1.1
Installation 1.2
Rear Axle 1.3
Removal 1.3
Installation 1.4
Dismantling and Assembly 1.5
Dismantling 1.6
Transmission box 1.6
Trunnions (rear axle only) 1.8
Steering cylinder (front and rear axle) 1.9
Epicyclic reduction gear (front and rear axle) 1.10
Wheel hub (front and rear axle) 1.11
Axle beam trumpet (front and rear axle) 1.13
Axle beam removal 1.14
Brake group (front axle only) 1.14
Differential support group (rear axle) 1.17
Differential group (front and rear axle) 1.18
Assembly 1.20
Pinion group (front axle) 1.20
Pinion group (rear axle) 1.24
Differential group (front and rear axle) 1.26
Brake and differential housing (front axle only) 1.27
Differential carrier group assembly 1.32
Brake control group assembly (front axle) 1.36
Generic information 1.37
Brake and axle beam assembly (front axle) 1.38
Wheel hub (front and rear axles) 1.41
Epicyclic reduction gear (front and rear axles) 1.43
Steering cylinder (front and rear axles) 1.44
Toe-in adjustment 1.45
Steering angle adjustment 1.46
Transmission box assembly 1.47
Trunnion assemblies 1.49
Testing after installation 1.50
Trouble shooting 1.51
Operating problems 1.51
Axle problems 1.52
Axle noise problems and diagnosis 1.53
Special tools 1.54
Steering 1.63
Description 1.63
Operation 1.63
Checking the steering system 1.66
Steering cylinder 1.66
Steering unit (OSPF) 1.66
Servicing 1.66
Steering valve assembly 1.67
Removal 1.67
Installation 1.67
Dismantling 1.68
Assembly 1.68
CONTENTS
SECTION 1 (continued)
AXLES AND STEERING
AXLES (continued)
Brake system bleeding 1.69
Dumping (disipation) of hydraulic pressure 1.70
Hydraulic level 1.71
SECTION 2
ENGINE
Description 2.1
Engine Data 2.1
Removal and Installation 2.2
General 2.2
Removal 2.2
Installation 2.4
Testing 2.4
SECTION 3
TRANSMISSION
Description 3.1
Hydrostatic system (up to Machines S/No.50600162 only) 3.1
Hydrostatic system (from Machines S/No.50600163 only) 3.2
Operation 3.5
Hydrostatic pump 3.5
Pressure relief valve 3.7
Proportional pressure reducing valve 3.7
Multi function valves 3.7
Pressure relief valve 3.7
Over pressure valve 3.8
Bypass valve function 3.9
Setting the bypass function 3.9
Hydrostatic motor 3.10
Removal and installation 3.12
Hydrostatic pump 3.12
Removal 3.12
Installation 3.13
Hydrostatic motor 3.14
Removal 3.14
Installation 3.15
Drive shaft 3.16
Removal 3.16
Installation 3.16
Testing 3.18
Trouble shooting guide 3.22
SECTION 4
BOOM
Description and operation 4.1
Description 4.1
Operation 4.2
Maintenance 4.3
Boom 4.3
Removal 4.3
Installation 4.4
Hydraulic cylinder 4.6
Crowd cylinder 4.6
Compensator cylinder 4.6
Lift cylinder 4.6
Extension cylinder 4.6
Boom tray cassette 4.7
Removal 4.7
Installation 4.9
CONTENTS
SECTION 4
BOOM
Maintenance (continued)
Boom tray hoses 4.9
Dismantling 4.9
Assembly 4.9
Inner boom 4.10
Removal 4.10
Installation 4.11
Boom wear pads 4.12
General 4.12
Replacement of outer boom wear pads (front) 4.12
Replacement of outer boom wear pads (rear) 4.14
Quattro control handle 4.15
Removal 4.15
Installation 4.15
SECTION 5
CHASSIS
Description 5.1
Operators cab 5.2
Removal 5.2
Installation 5.3
Fuel tank 5.5
Removal 5.5
Installation 5.5
Heater and Air Conditioning 5.7
Description 5.7
Blower motor 5.7
Removal 5.7
Installation 5.8
Heater coil 5.9
Removal 5.9
Installation 5.9
Air conditioning evaporator coil 5.10
Removal 5.10
Installation 5.11
Receiver - Drier assembly 5.12
Removal 5.12
Installation 5.13
Air conditioning condensor coil 5.13
Removal 5.13
Installation 5.13
Axial fan 5.15
Removal 5.15
Installation 5.15
Compressor 5.17
Removal 5.17
Installation 5.17
CONTENTS
SECTION 6
TECHNICAL DATA
Dimensions 6.1
Weight 6.1
Machine speed 6.2
Carriage 6.2
Cycle time 6.2
Engine 6.3
Cooling 6.3
Transmission 6.3
Tyres 6.3
Hydraulics 6.4
Electrics 6.4
Capacities 6.4
Brakes 6.4
INTRODUCTION
General
The contents of this Repair Manual, although correct at the time of publication, may be subject to alteration by
the manufacturer without notice.
This manual assumes that maintenance personnel have a sound knowledge of workshop practices and
safety procedures associated with the repairs of this type of machine. This manual is designed to assist with
the more specialised information required for removal and strip-down of major components.
It is recommended that the relevant part of this Repair Manual is studied carefully before proceeding with any
maintenance.
Machine identification
To make sure that the correct parts are obtained, always quote the machine Serial Number when ordering
parts.
Health and Safety
To prevent injury to personnel and damage to equipment and machinery, care must be taken to operate in a
safe manner. Read the Safety Warnings that follow and always work in a safe manner and obey the relevant
Warnings.
Throughout this manual and on the machine there are safety notes. Each note starts with a single word. The
meaning of these single words is as follows:
Identifies a hazard exists. If proper precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously injured.
Identifies a reminder of safety practices. Failure to observe these safety practices could result
in injury to the operator (or others) or damage to the machine.
In general these notes are used to indicate that the procedures being described in the manual must be
followed to avoid serious injury or death to yourself or others. The notes are also used to protect the machine
from unsafe maintenance practices.
SAFETY WARNINGS
Always wear correct fitting protective clothing. Loose or baggy clothing can be extremely
dangerous when operating or maintaining a machine.
Where possible, only work on or close to engines or machinery when they are stopped. If this
is not practical, remember to keep tools, test equipment and all parts of your body well away
from moving parts.
Avoid contact with exhaust pipes and exhaust manifolds when the engine is running; these
can be very hot.
Many liquids used on this machine are harmful if taken internally or splashed into the eyes. In
the event of accidentally swallowing oil, diesel fuel, anti-freeze, battery acid etc., DO NOT
induce vomiting, but OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
Always obtain advice before mixing oils; some are incompatible.
Never run an engine in an enclosed space unless an exhaust extraction system is used.
Always disconnect battery cables before working on the electrical system to prevent injury
caused by electric shock.
When it is necessary to work on the electrical system with power on, for fault diagnosis,
always have a safety man in attendance
Any dust found on the machine or produced during work on the machine should be removed
by extraction, not by blowing. Dust waste should be dampened, placed in a sealed container
and marked for safe disposal.
Always dump pressure from the hydraulic system before carrying out any maintenance or
adjustment (refer to Hydraulic Repair Manual).
Never leave the machine unattended with pressure in the system.
Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to
check for hydraulic fluid leaks. Do not put your face close to suspected leaks. If hydraulic fluid
penetrates your skin OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
Never allow unqualified personnel to attempt to remove or replace any part of the machine.
Always use the correct lifting equipment to remove large or heavy components.
Never attempt to lift or hold up the machine using the lash-down points.
SECTION 1
AXLES AND STEERING

AXLES & STEERING 1.1
AXLES
DESCRIPTION
The front axle has a transmission/reduction box
fitted, with both front and rear axles having epicyclic
reduction gears contained in the wheel hubs. The
front axle is fitted with a limited slip differential whilst
the rear axle has a standard type differential. The
front axle housing incorporates the brakes.
Steering is available to both axles, depending on the

steering mode selected. The axle hubs are steered
by the operation of a double acting hydraulic cylinder
attached to the axle.
FRONT AXLE
Removal
1. Park the machine on firm level ground.
2. Raise the boom and fit the boom safety stop.
3. Set the wheels straight ahead, in line with the

chassis and fit chocks to the front and rear of the
rear wheels.
4. Stop the engine and apply the parking brake.
5. Refer to page 1.70 and dump hydraulic pressure

from the brake systems and steering system, then
disconnect the battery.
Support the drive shaft clear of the

axle to make sure it is not damaged
during axle removal.
6. Disconnect the drive shaft from the axle flange

and support clear of axle.
7. Disconnect the inductive magnetic steering sensor

electrical lead.
Support the hydrostatic motor clear

of the axle to make sure it is not
damaged during axle removal.
8. Disconnect the hydrostatic motor from the

transmission box flange and support clear of axle.
9. Slacken front axle wheel nuts.
10. Support the chassis at a sufficient height to allow

the wheels to be removed.
1.2 AXLES & STEERING
11. Support axle with a forklift or trolley jacks.
12. Remove front wheels.
13. Disconnect the parking brake linkage (1) and

position cable and attachments clear of the axle.
14. Disconnect brake pipes from left (3) and right

(not shown) brake units, fit blanks to open pipes and
brake unit connections.
15. Disconnect steering hoses (2) from steering

cylinder, fit blanks to open pipes and steering
cylinder connections.
Secure the axle to the fork lift/

trolley jacks to prevent axle tipping
1. Parking brake linkage and adjuster
on removal.
2. Steering hoses
The axle weighs 391 kg, take care
3. LH Brake pipe (RH similar)
when removing and transporting.
16. Remove the eight attachment bolts/nuts securing

axle to chassis (four each side) and remove support
plates.
17. Lower axle on fork lift/trolley jacks.
18. Move axle clear of machine and place on a

suitable support.
Installation
1. Installation is the reverse of the removal

procedure.
2. Torque load components as follows:
Axle to chassis nuts 640 Nm (472 lbf ft.)

Drive shaft bolts 61-81 Nm 45-60 lbf ft.)
Wheel nuts 300 Nm (221 lbf ft.)
Hydrostatic motor to Axle bolts 150 Nm (110 lbf ft.)
3. Check axle and wheel hub oil levels are correct.
4. When the axle has been dismantled and

reassembled, refer to the Axle Assembly section and
test the differential operation.
5. Connect the parking brake linkage (1). Refer to

testing and adjusting section to set up parking brake
control cable.
6. Refer to Page 1.69 and bleed the brakes then test

brake function and parking brake operation.
7. Start engine, make sure front wheel steering is

selected and operate steering through full range
several times to bleed air from steering system.
8. Test machine operation.

REAR AXLE
Removal

chassis and fit chocks to the front wheels.
3.Stop the engine and apply the parking brake.

from the steering system, then disconnect the
battery.
Support the drive shaft clear of the

axle to make sure it is not damaged
during axle removal.
5. Disconnect the drive shaft from the axle flange

and support clear of axle.
6. Disconnect the load sensor electrical lead.
7. Disconnect the inductive magnetic steering sensor

electrical lead.
8. Disconnect steering hoses from steering cylinder,

fit blanks to open pipes and steering cylinder
connections.
9. Slacken rear axle wheel nuts.
10. Support the chassis at a sufficient height to allow

the wheels to be removed.
11. Remove rear wheels.
12. Support axle with a forklift or trolley jacks.
13. Remove the bolts attaching the axle front

support to the chassis.
14. Remove the bolts attaching the axle rear support

to the chassis.
Secure the axle to the fork-lift/trolley

jacks to prevent axle tipping on
removal. The axle weighs 298 kg dry
weight, take care when removing and
transporting.
15. Lower axle on fork-lift/trolley jacks.
16. Move axle clear of machine and place on a

suitable support.
Installation
1. Installation it the reverse of the removal

procedure.
Axle to chassis nuts 640 Nm (472 lbf ft.)

Drive shaft bolts 70-85 Nm (52-63 lbf ft.)
Wheel nuts 300 Nm (221 lbf ft.)
Axle support bolts 370 Nm (273 lbf ft.).
3. Check axle and wheel hub oil levels are correct.
4. When the axle has been dismantled and

reassembled, refer to the Axle Assembly section and
test the differential operation.
5. Start engine, make sure rear wheel steering is

selected and operate steering through full range
several times to bleed air from steering system.
6. Test machine operation.

DISMANTLING AND ASSEMBLY
Dispose of used axle oil in

accordance with local regulations.
NOTES:
(1) Sealing Compound. Ensure both surfaces to

be sealed are clean, dry and free from grease.
(2) O-ring seals. Lubricate seals before fitting to

prevent twisting when inserting the shaft.
(3) Bearings. It is recommended that bearings

are heated to 80°C - 90°C before fitting to shaft, or
cooling with dry ice before inserting them into an
outer housing.
(4) Shims. Measure shims before use, do not

rely on measurement marked on shim.
(5) Torque loading. Torque load all components

to the recommended figure.
(6) Oil seals. To assist with the correct

installation of oil seals carry out the following:
• Ensure the shaft is clean and not damaged

• Assemble with lip side towards the oil side
• Lubricate seal with oil and fill ¾ of seal cavity
with grease
• Use special tools to install seals, where
available. Do not hammer directly on the seal
• Do not damage seals while assembling the
shaft.
(7) Special tools. Use the special tools to

dismantle and assemble the axle.
DISMANTLING
TRANSMISSION BOX
(Front Axle only)
1. Remove the drain plug (1) and drain oil into a suitable
container.
The half box is heavy and must be
supported with suitable equipment
during removal.
2. Remove the bolts (2) and the engine flange (3)

from the half box. Remove the O-ring (5) from the
engine flange.
NOTE: The mounting screws for the engine flange

are of two different lengths. The positions of which
should be noted for fitment purposes.
1. Drain Plug
2. Bolt
3. Remove the half box mounting bolts (4) and
3. Engine Flange
remove the half box using a rubber hammer.
4. Bolt
5. O-Ring
4. Remove the gear wheel (6) and separate the
6. Gear Wheel
bearings (7) using a suitable extractor.
7. Bearing
8. Circlip
5. Remove the circlip (8) and withdraw the gear
9. Gear Wheel
wheel (9) and bearing (10) from the flanged shaft
10. Bearing
(11) using a suitable extractor.
11. Flanged Shaft
12. Bearing
6. Remove the shaft (11) from the half box using a
13. Oil Seal
hammer and drift and remove the lower bearing (12).
14. Bolts
7. Remove the lower shaft oil seal (13) from the half
box with a hammer and drift.
NOTE: This will damage the oil seal, use a new oil
seal on assembly.
8. Remove the half box fixed to the axle body by

removing the mounting bolts (14).
TRUNNIONS
(Rear Axle only)
1. Remove the circlip (1) and withdraw the input

flange (2), the O-ring (3) and the washer (4).
2. Remove the front trunnion (5) and rear trunnion

(6).
3. Loosen the bolt (7) and withdraw the bush (8)

from the rear trunnion (6).
4. Inspect and replace as necessary the “A”

centering bushes (9) from the front trunnion (5) and
rear trunnion (6).
5. Loosen the grease nipple (10) and remove the

bush (11) and O-ring (12) from the front trunnion (5).
1. Circlip
2. Input flange
3. O-ring
4. Washer
5. Front trunnion
6. Rear trunnion
7. Bolt
8. Bush
9. Centering bush
10. Grease nipple
11. Bush
12. O-ring
STEERING CYLINDER
(Front and rear axle)
1. Remove the inductive magnetic steering sensor,

by loosening the locking clamp screws.
2. Loosen the track rod end nut until it covers end of

threaded pin.
3. Use a suitable tool and break the track rod joint.
NOTE: This may damage the nut, use a new nut on

assembly.
4. Remove the track rod (1) by loosening the lock

nut (2). Remove the three-cylinder attachment
bolts (3) and hydraulic adapter (4) from steering
cylinder (5). Remove cylinder from axle mounting
brackets, if necessary use a rubber hammer.
5. Cylinder overhaul
6. Refer to Hydraulic Manual for cylinder Dismantling

and Assembly.
1. Track rod
2. Nut
3. Bolt
4. Hydraulic adapter
5. Steering cylinder
EPICYCLIC REDUCTION GEAR

(Front and Rear Axle)
NOTE: This procedure is for the left or right hand

epicyclic reduction gear.
1. Position drain plug (1) at highest position and

loosen, to dissipate any pressure in axle.
2. Rotate planetary carrier (2) until drain plug is at

lowest position, remove drain plug and drain oil into
a suitable container.
3. Remove the planetary carrier retaining screws (3)

and remove carrier from wheel hub (4).
4. Position the planetary carrier on a clean

workbench and check components for wear and
condition.
5. Remove O-ring (10) and check condition.
6. If necessary, replace components in planetary

carrier as follows:
7. Remove the lock rings (5) and triangular washer

(6) from pins (7).
8. Remove planetary gears (8) from pins.
9. Remove the needle roller bearings (9) from the

gears.
NOTE: When a new planetary gear is fitted, it is

recommended that new needle roller bearings are
fitted.
1. Drain plug
2. Planetary carrier
3. Retaining screws
4. Wheel hub
5. Lock ring
6. Triangular washer
7. Pin
8. Planetary gear
9. Needle roller bearings
10. O-ring
WHEEL HUB

wheel hub.
1. Remove circlip (11) and washers (12 & 13) from

U/J shaft (14).
2. Remove hub lock ring gear attachment bolts (15).
3. Fit at least two of the hub lock ring gear

attachment bolts (15) into threaded extraction holes
(16) and tighten evenly to push the carrier off the
hub.
4. Remove hub lock ring gear (17) and epicyclic ring

gear (18) from wheel hub (19).
5. Remove the wheel hub from the axle, careful use

of hammers and levers may be necessary and retain
the outer cone bearing (21).
6. Position the wheel hub on a suitable workbench

and remove sealing ring (20) with a lever.
NOTE: This may damage the bearing seal, use a

new bearing seal on assembly.
7. Remove inner and outer bearing cups (22) from

housing using a hammer and drift.
8. Remove inner cone bearing (23) from swivel

housing (24) using a suitable extractor.
11. Circlip
12. Washer
13. Washer
14 U/J shaft
15. Bolt
16. Threaded hole
17. Hub lock ring gear
18. Epicyclic gear
19. Hub
20. Sealing ring
21. Outer cone bearing
22. Bearing cups
23. Inner cone bearing
24. Swivel housing
9. Remove lock ring (25) securing hub lock ring gear

(17) to epicyclic ring gear (18) and separate units.
10. Examine hub lock ring gear (17) and epicyclic ring
gear (18) for wear. If necessary, remove centering
bushes (26) of hub lock ring gear with a hammer and
special tool Part No CA715027.
The swivel housing is heavy and
must be supported with suitable
equipment before the king-pins are
removed.
11. Remove bolts (27) securing upper king-pin (28)

to axle beam (29), remove king pin, belleville
washers (30) and shims (33).
12. Remove bolts (27) securing the lower king-pin

(28) to axle beam (29), remove the king pin and
belleville washers (30).
13. Remove the swivel housing (24) from the axle

beam (29) and position on a suitable workbench.
14. Remove sealing ring (31) from the swivel

housing.
NOTE: This may damage the sealing ring, use a

new sealing ring on assembly.
15. Invert the housing and remove bush (32) using a

drift and hammer.
25 Lock ring
26 Bush
27 Bolt
28 King pin
29 Axle beam
30 Belleville washer
31 Sealing ring
32 Bush
33 Shim
AXLE BEAM TRUMPET

NOTE: This procedure is for the left or right

hand axle beam trumpet and brake group.
1. Remove drive shaft (1) from axle beam (2).
NOTE: The removal procedure for sealing ring

(3) will destroy the sealing ring. Use a new
sealing ring on assembly.
2. Remove sealing ring (3) with a lever and

examine bush (4) for wear.
NOTE: Only remove bush (4) if worn or

damaged, the removal procedure will destroy
the bush.
3. Remove bush (4), if worn or damaged, by

carefully cutting the bush with a chisel before
extraction.
NOTE: The Belleville washers (5) and shim (6)

may have been removed during the wheel hub
removal procedure.
4. Remove Belleville washers (5) from upper

and lower beam housing and shims (6) from
upper housing.
5. Using a suitable extractor, remove upper and

lower bushes (7 & 8) from the axle beam (2).
6. Remove bush (9) from upper and lower king

pins (10).
1. Drive shaft
2. Axle beam
3. Sealing ring
4. Bush
5. Belleville washer
6. Shim
7. Bush
8. Bush
9. Bush
10. King pin
AXLE BEAM REMOVAL
7. Put identification marks on differential (11), left/

right brake packs (12) and left/right axle beams (2)
to aid assembly.
The axle beams weighs 80 kg. Take

care when removing axle beams
from differential and use suitable
lifting gear.
8. Position the axle on a suitable workbench and attach

lifting gear to the axle beam being removed.
The brake discs and fixed discs are
loose when the axle beam is re-
moved. Take care not to damage
brake discs and fixed discs.
9. Remove axle beam retaining screws (13) and nut

from the lower stud. Remove axle beam (2) from brake
pack and differential assemblies.
10. Remove O-ring (14) from axle beam.
BRAKE GROUP
(Front Axle only)
NOTE: Record position of the splined sleeve (17) to aid

assembly.
1. Remove the brake discs (15), fixed discs (16) and

sleeve (17) from the brake pack (12).
11. Differential
12. Brake pack
13. Screw
14. O-ring
15. Brake disc
16. Fixed disc
17. Sleeve
The next step separates the brake

pack from the differential unit. Make
sure the brake pack is attached to
suitable lifting equipment before
removal.
2. Connect brake pack (12) to suitable lifting

equipment.
3. Remove upper securing screw (18) and lower

stud bolt (19). Remove brake pack from differential
unit.
4. Remove housing O-ring (20) and oil pipe O-

ring (21).
5. Loosen locknut (22) and remove adjusting

screw (23).
6. Remove lever fastening screw (24) and washer

(25).
NOTE: Mark lever (26) position on shaft (27) for use

during installation. Distinguish marks between left
and right lever and shaft assemblies.
7. Loosen lever (26) to release spring (28) tension

and remove lever (26), spring (28), washer (29) and
spacer (30).
8. Remove screws (31) and bracket (32).
NOTE: Make an alignment mark on cam (33) near

setscrew (34) for use during assembly. Distinguish
between right and left cam assemblies.
9. Remove cam setscrew (34).
10. Remove shaft setscrew (35) and steel ball (36).
11. Remove O-ring (37) and withdraw shaft (27) and

cam (33).
18. Screw 28. Spring

19. Bolt 29. Washer
20. O-ring 30. Spacer
21. O-ring 31. Screw
22. Locknut 32. Bracket
23. Screw 33. Cam
24. Screw 34. Setscrew
25. Washer 35. Setscrew
26. Lever 36. Steel ball
12. Remove upper two self-adjustment screws (38),

springs (39) and bushes (40).
13. Remove lower two self-adjustment screws (41),

bushes (42) and spacers (43).
14. Remove bleed screw (44).

Hydraulic or air pressure can be used
to remove the brake piston. Only use
the minimum pressure necessary to
move piston.
15. Attach a suitable hydraulic or air supply to brake
bleed inlet (47) on brake pack (12). Apply minimum
pressure to move the piston.
16. Remove piston (45) and O-rings (46).

38. Screws
39. Springs
17. Remove fastening screw (48) and ring nut 40. Bushes
retainer (49). 41. Screws
42. Bushes
18. Remove lock nut (50) from brake flange using 43. Spacers
special tool Part No, CA119030. 44. Bleed screw
45. Piston
46. O-ring
19. Remove bearing cup (51) with a hammer and 47. Bleed inlet
punch. 48. Screw
49. Retainer
50. Lock nut
51. Bearing cup
DIFFERENTIAL SUPPORT GROUP

(Rear Axle)
Support the differential carrier with
suitable lifting gear.
1. Remove mounting screws (1) and remove

mounting carrier (2).
2. Support the carrier and remove seal (3) from

central housing.
NOTE: The seal (3) will be damaged during removal,

use a new seal on assembly.
3. Remove screws (4) and retainers (5).
4. Remove adjuster ring nuts (6) using Special tool

Part No. CA119030 and suitable wrench.
NOTE: Before removing half-collars (8) mark their

position in relation to the carrier support housing.
5. Remove four screws (7) and two half collars (8).
6. Remove differential unit (9) and bearing cups (10).

The bearing cups are matched items.
Their positions are to be noted if they
are not being replaced.
NOTE: Ensure the bushes remain in their housing

on removal of the differential unit.
1. Screw
2. Carrier
3. Seal
4. Screw
5. Retainer
6. Ring nuts
7. Screw
8. Half-collar
9. Differential unit
10. Bearing cup
DIFFERENTIAL GROUP 1. Bolt

2. Crown wheel
3. Differential assembly
4. Bearing
When the crown wheel is removed
5. Circlip
from differential unit the two halves
6. Input flange
will separate. Make sure component
7. O-ring
parts are not dropped.
8. Shim
9. Bearing seal
NOTE: Mark the two halves of the differential before
10. Pinion ring nut
dismantling to aid assembly.
11. Washer
12. Pinion
1. Remove differential (3) from the housing and 13. Taper roller bearing
secure in a suitable clamp. 14. Washer
15. Spacer
2. Remove bolts (1) securing crown wheel (2) to 16. Taper roller bearing
differential (3) and remove the crown wheel. 17. Shim
18. Outer bearing track
3. Carefully separate the two halves of the unit. 19. Inner bearing track
4. Dismantle the components in each differential half

and examine for wear.
NOTE: The rear axle only has one thrust ring and no
discs either side of the sun gears.
5. Remove bearing (4) from each half of the unit with

a suitable extractor.
NOTE: The following two steps involving items (5) to

(9) are for the rear axle only.
6. Remove circlip (5), and slide out input flange (6).

Remove O-ring (7) and shim (8). Use an extractor
and remove bearing seal (9).
Always use the special tools to remove

the bevel pinion ring nut. Other
methods can damage the threads.
7. Remove bevel pinion ring nut (10) using special

tool Part No. CA119099 and CA715022, then
remove washer (11).
8. Remove pinion (12) from the housing by using a
soft-faced hammer to drive pinion into housing.
Remove taper roller bearing (13) from the splined
end of the housing.
9. Remove washers (14) and collapsible spacer (15)

from the pinion shaft. Remove taper roller
bearing (16) from pinion shaft (12).
10. Remove shim (17) from under the inner bearing

on the pinion shaft and check for wear.
11. Remove outer bearing track (18) using a suitable

extractor. Remove inner bearing track (19) using a
suitable drift and hammer.
ASSEMBLY
PINION GROUP
(Front Axle)
1. Position differential housing (1) on a workbench.
2. Fit outer bearing track (2) and inner bearing track

(3) for the taper roller bearings in the housing using
special tool in kit Part No. CA715401.
NOTE: To measure and set up the differential, a

false pinion Part No. CA715040 and a false
differential box Part No. CA715041 are used.
3. Fit false pinion Part No. CA715040 (4) complete

with bearings to the differential housing and tighten
ring nut (5) until backlash is eliminated (do not over-
tighten ring nut).
NOTE: Make sure the brake housings are fitted to

the correct side of the differential and the reference
marks made during disassembly are aligned.
4. Fit left and right brake housings (6) to differential.

Use at least two bolts to attach each half, space
bolts diametrically opposite to make sure housing is
seated correctly.
5. Fit false differential (7) Part No. CA715041 to the

centre body of the differential housing and make
sure it is inserted in both brake housings.
1. Differential housing
2. Outer bearing track
3. Inner bearing track
4. Special tool Part No. CA715040
5. Ring nut
6. Brake housing
7. False differential Part No. CA715041
6. Using a depth gauge through the central hole in

the false pinion, calculate dimension X by using the
following formula:
X = (conical distance to be measured)

A = (measured value)
B = (known value) = 100 mm
C = (known value) = 45 mm
(A + C) – B = X
Example: A = 164.9 mm
Therefore: X = [(164.9 + 45) – 100] = 109.9 mm
To calculate the shim (S) necessary between the

pinion and bearing, subtract the (V) value stamped
on the pinion head (8) (V = requested conical
distance) from the (X) calculated value.
S=X-V
Example: thickness S = 109.9 – 107.00 =2.9 mm
8. Pinion
7. Remove false differential (7), Part No. CA715041,

from the centre body of the differential housing.
8. Remove left and right brake housings (6) from the

differential.
9. Remove ring nut (5) and false pinion Part No.

CA715040 (4) complete with bearings from the
differential housing.
NOTE: Shims are available in the following

thickness, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3
and 3.4 mm.
10. Select a shim (9) (from the calculation for S) and

fit to pinion (8) with chamfer of shim next to pinion
gear.
11. Fit inner bearing race (10) to pinion using special

tool (11) Part No. CA715179 and a suitable press, 9. Shim
make sure bearing is fully pressed onto pinion. 10. Inner bearing race
11. Special tool Part No, CA715179
12. Washer
NOTE: Fit a new collapsible spacer on assembly
13. Collapsible spacer
14. Washer
12. Fit a washer (12), collapsible spacer (13) and 15. Outer bearing race
washer (14) to the pinion shaft. 16. Washer
17. Ring nut
NOTE: When seating the outer bearing, support the
pinion with a suitable reaction weight (e.g. a
sledgehammer).
13. Fit pinion into differential housing and fit outer

bearing race (15) onto pinion. Use special tool, Part
No. CA715179, and a hammer to fully seat the
pinion.
The torque setting is achieved by

the pre-loading measurement on the
bearings. Check the pre-loading
then gradually increase the torque
load on the pinion ring nut until the
correct pre-loading is achieved. If
the pre-loading is exceeded, the
collapsible washer must be replaced
and the process started again.
14. Fit a new ring nut washer (16) and ring nut
retainer (17).
15. Fit a new ring nut (17). Hold ring nut retainer with
special tool Part No. CA715022, tighten ring nut with
special tool Part No. CA119099.
The pinion drive seal ring must not
be fitted when the pre-loading is
checked.
18. Dynamometer
16. Tighten ring nut in small steps and measure the

pre-loading measurement (P) pinion taper roller
bearings, using a dynamometer (18) with the cord
wound on the end of the pinion.
17. When the correct pre-loading value is achieved,

peen the ring nut using a hammer and chisel.
P = 9.2 ÷ 13.8 daN

PINION GROUP
(Rear Axle)
1. Position differential support (1) on a workbench.
2. Fit bearing cups (2) in the housing using special

drift in kit Part No. CA119225 and a hammer. Fit
new bearings (3).
NOTE: To measure and set up the differential, a

false pinion Part No. CA715023 (4) with a false
differential box Part No. CA119182 (6) and Part No.
CA119228 (7) are used.
3. Fit false pinion Part No. CA715023 (4) complete

with bearings and ring nut retainer (5) to the
differential support and tighten the bearing housing
until backlash is eliminated (do not over-tighten).
4. Fit special tools Part No. CA119182 (6) and

CA119228 (7), to carrier bearings, using halfcollars
(8) and mounting bolts (9).
5. Measure distance X using a depth gauge (10)

(X = the distance between the axis of the differential
bearings and the point at which the pinion head is
supported).
6. To calculate the shim (S) necessary between the

pinion and bearing, subtract the (V) value stamped
on the pinion head (12) (V = requested conical
distance) from the (X) calculated value. 1. Differential support
2. Bearing cup
S=X-V 3. Bearing
4. False pinion
Example: thickness S = 109.9 – 107.00 =2.9 mm 5. Ring nut retainer
6. False differential box
NOTE: Shims are available in the following 7. False differential box
thickness, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3 8. Halfcollar
and 3.4 mm. 9. Bolt
10. Depth gauge
7. Remove depth gauge (10), false differential box

(6) and (7), from the centre body of the differential
housing.
8. Remove ring nut retainer (5) and false pinion (4)

complete with bearings from the differential support.
9. Select a shim (11) (from the calculation for S) and

fit to pinion (12) with chamfer of shim next to pinion
gear.
10. Fit inner bearing race (13) to pinion using special

tool Part No. CA715167 and a suitable press, make
sure bearing is fully pressed onto the pinion.
NOTE: Fit a new collapsible spacer on assembly.
11. Fit shims (14) and new collapsible spacer (15).
12. Insert pinion (12) into differential support (1).
NOTE: When seating the outer bearing, support the

pinion with a suitable reaction weight (e.g. a
sledgehammer).
13. Fit bearing (16) onto pinion. Use special tool,

Part No. CA715167 and a hammer to fully seat the
bearing.
The torque setting is achieved by the

pre-loading measurement on the
bearings. Check the pre-loading then
gradually increase the torque load on
the pinion ring nut until the correct pre-
loading is achieved. If the pre-loading
is exceeded, the collapsible spacer
must be replaced and the process
started again.
14. Insert a new ring nut washer (17) and locking 11. Shim
ring nut retainer (5). 12. Pinion
13. Bearing
15. Hold ring nut retainer with special tool Part No. 14. Shim
CA715022, tighten ring nut with special tool Part No. 15. Collapsible spacer
CA119099. 16. Bearing
17. Washer
The pinion drive seal ring must not be 18. Dynamometer
fitted when the pre-loading is checked. 19. Tool Part No. CA715116
P = 9.2 ÷ 13.8 daN
16. Tighten ring nut in small steps and measure the

pre-loading measurement (P) pinion taper roller
bearings, using a dynamometer (18) with the cord
wound on the end of the special tool (19) Part No.
CA715116 inserted on the pinion spline.
17. When the correct pre-loading value is achieved,

peen the ring nut using a hammer and chisel.
DIFFERENTIAL GROUP
1. Fit taper roller bearing (1) to each half of the

differential housing (2). Fit special tool Part No, CA
119230 to bearing and use a hammer to make sure
bearing is fully pressed onto housing.
NOTE: The rear axle has only one thrust ring and no
discs either side of the sun gears.
2. Position each half box on a bench and assemble

all inner components (sun gears, planetary gears,
thrust washers, pins, discs and fixed discs) as in
illustration.
3. Fit crown wheel (3) to differential housing (2).
4. Apply Loctite 270 to bolt thread (4) and secure

crown wheel to differential unit. Torque load bolts to
95 Nm (70 lbf/ft).
1. Taper roller bearing

2. Differential housing
3. Crown wheel
4. Bolt
BRAKE PACK AND DIFFERENTIAL HOUSING

(Front Axle Only)
NOTE: The following assembly procedure, for the

brake pack, must be carried out on both left and
right units.
1. Position flange of brake pack (1) on a flat surface

and fit bearing track (2) to brake pack using special
tool Part No. CA715299 and Handle Part No.
CA119033 and a hammer.
2. Remove brake piston (3) and fit self-adjust

housing washers (4) until they are aligned with the
inner face.
3. Apply a thin layer of grease to the piston contact 1. Brake pack

surfaces and O-rings. Fit O-rings (5). 2. Bearing track
3. Piston
4. Washers
NOTE: During fitment of the piston ensure correct 5. O ring
alignment of the brake shaft openings with the 6. O-ring
relative holes in the flange. 7. Self-adjust kit
8. Self-adjust kit
Care must be taken when fitting the
piston to avoid damage to the O-
rings.
4. Insert piston (3) into brake flange (1) using special

tool Part No. CA15056 until it is just located, then
remove the tool.
5. Fit self-adjust kits (7) and (8) and torque load to

10 Nm (7.38 lbf ft.).
6. Lubricate a new O-ring seal (6) and insert into the

oil pipe hole in the brake pack housing.
Make sure the differential is inserted

in the correct side of the casing.
7. Fit new O-ring (10) to brake pack (1).
8. Insert a suitable size bar through differential

assembly (11) and slide assembly into differential
housing (12).
During assembly, make sure the
brake packs are assembled to the
correct side of the housing and the
alignment marks made during
disassembly are aligned.
9. Fit brake pack (1) to crown wheel side of the
housing. Make sure the alignment marks made 9. Stud bolt
during removal are aligned. Secure with upper bolt 10. O ring
(13) and lower stud bolt (9). Torque upper bolt (13)
11. Differential assembly
to 80 Nm (59 lbf ft.). Torque lower stud bolt (9) to
120 Nm (88 lbf ft.). 12. Differential housing
13. Bolt
14. Ring nut
10. Remove the bar from the differential assembly.
11. Fit brake pack (1) to the other side of the

housing. Make sure the alignment marks made
during removal are aligned. Secure with upper bolt
(32) and lower stud bolt (33). Torque the upper bolt
(32) to 80 Nm (59 lbf ft.). Torque the lower stud bolt
(33) to 120 Nm (88 lbf ft.).
NOTE: The next stage involves fitting the pinion

adjusting ring nuts, tighten the ring nuts evenly from
both sides until backlash has been eliminated. Do
not over tighten the ring nuts.
12. Fit ring nuts (14) to both sides of the housing and
evenly tighten using tool Part No. CA119030 until
backlash is eliminated.
13. Assemble special tool Part No. CA715146 on

pinion end.
14. Move the pinion end alternatively and note the

pinion-ring gear backlash, measured with the
comparator, so that the feeler is in contact with, and
at 90° to, the bracket surface of the special tool in
correspondence with the reference mark.
15. Check if the measured backlash is within the

required range.
0.18 – 0.25 mm
16. Carry out adjustments, by turning the two ring

nuts (14), using special tool Part No. CA 119030.
17. Adjust the ring nuts (14), remembering that:
• If the measured backlash is less than the

given tolerance range, move the crown wheel
towards the pinion by screwing the ring nut on
the crown wheel side in and screwing the
opposite ring nut out by the same amount.
• If the measured backlash is more than the

away from the pinion by screwing the ring nut
on the crown wheel side out and screwing the
opposite ring nut in by the same amount.
18. When the pinion ring gear backlash is correct,

check that there is a minimum pre-loading on the
differential box bearings.
19. Repeat the above adjustment procedure until the

backlash is correct.

checked.
20. With the pinion-ring gear backlash set, measure

the total pre-loading (T) of the bearings (pinion-ring
gear system), using a dynamometer whose cord is
wound on the bevel pinion end. The measured value
should be within the following range:
T=(P+3.85)÷ (P+5.8) daN
Where (P) is the pre-loading effectively measured on

the pinion (see Pinion Assembly).
21. If the measurement is not within the required range,

check for correct assembly of components and adjust
the differential support ring nuts as follows:
• If the total pre-loading is less than the

required range, tighten the two ring nuts by
the same amount, keeping the pinion ring-
gear backlash unchanged.
• If the total pre-loading is higher than the

required range, unscrew the two ring nuts by
the same amount, keeping the pinion ring-gear
backlash unchanged.
NOTE: The ring nut may have to be turned slightly to

enable the retaining screw to be fitted.
22. Fit ring nut retainer (16) to secure ring nut (14) to
housing and secure with bolt (17), turn ring nut
slightly to align bolt hole, if necessary. Torque load
bolt to 13 Nm (9.6 lbf ft.).
23. Repeat previous step to other ring nut.
24. Fit bearing seal (18) to the pinion drive using

special tool Part No, CA715395 (15).
15. Tool Part No. CA715395

16. Retainer
17. Bolt
18. Bearing seal
DIFFERENTIAL CARRIER GROUP

ASSEMBLY
(Rear Axle)
Do not invert the outer races of the

tapered roller bearings and check you
are working on the correct side of the
ring bevel gear assembly.
1. Position complete differential assembly (1), with

bearing cups (2) of the taper roller bearings
assembled on differential carrier (3).
NOTE: Ensure half collars are fitted in correct

locations by referring to previously traced reference
marks.
2. Fit half collars (4) and tighten slightly in position

with mounting bolts (5).
NOTE: Ensure ring nuts are fitted in correct

marks.
3. Fit and tighten two ring nuts (6) with special tool
Part No. CA119030, to pre-load the differential
bearings slightly. Tap the bearings with a rubber 1. Differential assembly
hammer to ensure correct seating. 2. Bearing cup
3. Carrier
4. Half collar
5. Bolt
6. Ring nut
4. Assemble a magnetic-base dial test indicator (7)

on the differential carrier.
5. Move the pinion end alternatively and note the

pinion-ring gear backlash, measured with the
comparator, so that the feeler is in contact with, and
at 90° to, the bracket surface of the special tool in
correspondence with the reference mark.
6. Check if the measured backlash is within the

required range.
0.18 – 0.25 mm
7. Carry out adjustments, by turning the two ring

nuts (6), using special tool Part No. CA119030.
7. Magnetic base dial test indicator
8. Adjust the ring nuts (6), remembering that:
• If the measured backlash is less than the given

tolerance range, move the crown wheel towards
the pinion by screwing the ring nut on the crown
wheel side in and screwing the opposite ring nut
out by the same amount.
• If the measured backlash is more than the

away from the pinion by screwing the ring nut
on the crown wheel side out and screwing the
opposite ring nut in by the same amount.
9. When the pinion ring gear backlash is correct,

check that there is a minimum pre-loading on the
differential box bearings.
10. Repeat the above adjustment procedure until the

backlash is correct.

checked.
11. With the pinion-ring gear backlash set, measure

the total pre-loading (T) of the bearings (pinion-ring
gear system), using a dynamometer (8) whose cord
is wound on the end of special tool Part No,
CA715116 (9). The measured value should be within
the following range:
T=(P+3.85) ÷ (P+5.8) daN
Where (P) is the pre-loading effectively measured on

the pinion (see Pinion Assembly).
12. If the measurement is not within the required

8. Dynamometer
range, check for correct assembly of components
9. Tool Part No. CA715116
and adjust the differential support ring nuts as
follows:
• If the total pre-loading is less than the

required range, tighten the two ring nuts by
• If the total pre-loading is higher than the

required range, unscrew the two ring nuts by
NOTE: The ring nut may have to be turned slightly to

enable the retaining screw to be fitted.
13. Torque load bolts (5) of half collars (4) to 266

Nm (196 lbf ft.).
14. Fit ring nut retainers (10) to secure ring nuts (6)
to housing and secure with bolts (11), if necessary
turn ring nuts slightly to align with retainers. Torque
load bolts (11) to 13 Nm (9.6 lbf ft.).
15. Fit a new bearing seal (12) on the differential

using tool Part No. CA715043.
NOTE: Ensure mating surfaces are perfectly clean

before commencing assembly. Degrease and clean
with an appropriate cleaner.
16. Spread a film of Loctite 510 on contact surfaces

and fit the differential carrier (3) on axle beam (13).
Fit and torque load the retaining bolts (14) to 169
Nm (125 lbf ft.).
10. Retainer
11. Bolt
12. Seal
13. Axle beam
14. Bolt
BRAKE CONTROL GROUP ASSEMBLY

(Front Axle)
NOTE: Ensure cam and shafts are fitted in correct

marks.
1. Insert shaft (1) through housing (2) and cam (3).
2. Align reference marks on cam (3) with setscrew

hole. Insert cam setscrew (4) and torque load to 10
Nm (7.38 lbf ft.).
3. Insert steel ball (5) to lock shaft. Spread a film of

Loctite 270 on lock bolt (6), fit bolt and torque load to
25 Nm (18.4 lbf ft.).
4. Insert new O ring (7) onto shaft (1).
5. Position support bracket (8), fit attachment bolts

(9) and torque load to 32 Nm (24 lbf ft.).
NOTE: Ensure correct springs are fitted to left and

right brake assemblies.
6. Fit the spacer (10), washer (11) and spring (12) to

shaft (1). 1. Shaft
2. Housing
NOTE: Ensure control levers are fitted in correct 3. Cam
locations by referring to previously traced reference 4. Setscrew
marks. 5. Steel ball
6. Bolt
7. O-ring
7. Fit brake control lever (13). 8. Bracket
9. Bolt
NOTE: Assembly of the brake control can only be 10. Spacer
completed after brake and axle beam assembly. 11. Washer
12. Spring
13. Lever
GENERIC INFORMATION
To test the marks on the bevel gear teeth, paint the
ring gear with red lead paint.
The marking test should always be carried out on

both sides of the ring bevel gear teeth.
OK = Correct contact
If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
Z – Excessive contact on the tooth tip.

Move the pinion towards the ring bevel gear and
then move the ring bevel gear away from the pinion
in order to adjust the backlash.
X – Excessive contact on the tooth base.

Move the pinion away from the ring bevel gear and
then move the ring bevel gear towards the pinion in
order to adjust the backlash.
Correction movements
1 - move the pinion for type X contact adjustments.
2 – move the pinion for type Z contact adjustments.
BRAKE AND AXLE BEAM ASSEMBLY

(Front Axle)

axle beam and brake assemblies.
During assembly of the brake and

axle beams, do not move the brake
control lever. This could cause the
incorrect positioning of the discs and
self-adjustment assemblies with a
reduction in brake efficiency.
NOTE: Check friction discs and counter discs for
wear or signs of burning, replace if necessary. New
discs are to be soaked in oil before installation. Align
all holes in the friction discs to allow correct oil flow
inside the brake assembly.
1. Insert first shaped brake drive plate (1) ensuring

correct position in relation to cam (2). Fit sleeve (3)
with shortest spline against the differential. Fit Brake
discs (4) and drive plates (5) into brake pack (6).
The axle beam is heavy. Care and

suitable lifting gear should be used
when fitting the axle beam.
Care must be taken when fitting the
axle beam not to dislodge the brake
discs and drive plates.
Make sure the axle beam is fitted to
the correct side of the differential
and the alignment marks made
during dismantling are lined up.
2. Fit O-ring (7) to axle beam.
Using suitable lifting gear, position axle beam (8) on

brake pack (6) and secure with bolts (9). Torque
load bolts to 320 Nm (236 lbf ft.).
3. Fit breather (10) with notch toward the wheel hub

and torque load to 1.2 Nm (10.6 lbf in.).
1. Drive plate
2. Cam
3. Sleeve
4. Brake discs
5. Drive plates
6. Brake pack
7. O-ring
8. Axle beam
9. Bolts
10. Breather
The brakes should be applied

before moving the brake control
levers.
NOTE: The lever return spring (11) should be

disconnected from lever (12) during adjustment.
4. Apply the brake using high-pressure compressed

air through breather hole (10).
5. Operate control lever (12) to the brake on

position.
6. Measure the distance between the lever

connection holes centers and check that it is within
the range: 11. Spring
12. Lever
280 mm - 282 mm 13. Washer
14. Bolt
7. Adjust the levers on the splined shafts to obtain 15. Bolt
correct range. 16. Bracket
8. Release brake control levers, fit washers (13) and

bolts (14). Torque load bolts to 32 Nm (23.6 lbf/ft).
9. Connect return springs (11) to brake levers (12).
10. With springs connected measure distance

between the lever connection holes centres and
check that it is greater than the minimum value of
294 mm of the required range.
NOTE: If bolt (15) is not perpendicular to lever (12),

adjust position by moving support bracket (16).
11. Fit adjusting bolts (15) to brackets (16) and

screw in until they contact the levers (12).
12. Screw in both adjusting bolts equally to give a

measurement between the lever connection holes
centers of 294 mm - 296 mm.
AXLE BEAM ASSEMBLIES

NOTE: When fitting bushes to the axle beam, it is

advisable to cool bushes.
1. Fit upper and lower bushes (1) and (2) to axle

beam (3) using special tool Part No, CA715034 and
a hammer.
NOTE: Only fit bush (4) if it was removed at the

disassembly operation.
2. Fit bush (4) to axle beam (3) using special tool

Part No, CA715157 and a hammer.
3. Fit sealing ring (5) to axle beam (3) using special

tool Part No, CA715402 and a hammer.
4. Lubricate bush (4) and sealing ring (5) with 1. Bush

grease. Fit drive shaft (6) to axle to engage the 2. Bush
differential. 3. Axle beam
4. Bush
5. Sealing ring
6. Drive shaft
WHEEL HUB
(Front and Rear Axles)

wheel hub.
1. Fit bush (1) in housing (2) with a hammer or a

suitable press and special tool Part No. CA715104
(Front Axle) or special tool Part No. CA119097 (Rear
axle).
2. Apply sealing compound and fit seal (3) in housing

(2) with a hammer and special tool Part No.
CA715360.
3. Fit cone (4) of the spherical joint to lower king-

pin (5) with a hammer or a suitable press and
special tool Part No. CA715042.
4. Position a belleville washer (6) on upper and lower

king-pin housing of the axle with shim (7) under
upper belleville washer.
5. Lubricate seal lip (3) and protect the spline drive

with tape to prevent damage to the seal.
The swivel housing is heavy and must
1. Bush
be supported with suitable equipment
2. Swivel housing
until the king-pins are fitted.
3. Seal
4. Cone
6. Support swivel housing (2) with suitable lifting 5. Lower king-pin
equipment and position on axle housing. Make sure 6. Belleville washer
belleville washers are not disturbed. 7. Shim
8. Upper king-pin
9. Bolt
7. Fit upper king-pin (8) and secure with bolts (9).
Torque load bolts to 190 Nm (140 lbf ft.).
8. Fit lower king-pin (5) and secure with bolts (9).

Torque load bolts to 190 Nm (140 lbf ft.).
9. Remove protective tape from the spline drive.

10. Position wheel hub (10) on a workbench and fit
bearing tracks (11 & 12) in the hub with a hammer or
a suitable press and special tool Part No.
CA715026.
11. Fit inner taper roller bearing (13) to swivel

housing end (2). Apply sealing compound to seal
ring (14) and fit to wheel hub (10) with special tool
Part No. CA715367 and a hammer.
12. Fit wheel hub (10) to swivel housing (2) and fit
outer taper roller bearing (15) to hub.
13. Position wheel carrier (16) on a workbench and

fit bushes (17) in the hub with a hammer or a
suitable press and special tool Part No. CA715027.
Make sure bushes are level with carrier surface.
Leave two diametrically opposed bushes slightly
proud of the carrier to use as location dowels.
14. Fit wheel carrier (16) to epicyclic ring (18) and

secure with locking ring (19).
1. Wheel hub
2. Bearing rack
15. Locate the wheel carrier to the swivel housing, 3. Bearing track
make sure the two bushes, left proud, engage in the
holes on carrier. Force bushes into swivel housing 4. Inner taper roller bearing
using special tool Part No. CA715027 and a 5. Seal
hammer. 6. Outer taper roller bearing
7. Wheel carrier
16. Secure with bolts (20). Torque load all bolts to 8. Bush (Qty 6)
120 Nm (88 lbf ft.). 9. Epicyclic ring
10. Locking ring
17. Slide thrust washer (21), washer (22) onto drive 11. Bolt (Qty 6)
shaft (23) and secure with circlip (24). 12. Thrust washer
13. Washer
18. Make sure the grease nipples are fitted to the 14. Drive shaft
king-pins, then grease the king-pins. 15. Circlip
EPICYCLIC REDUCTION GEAR


epicyclic reduction gear.
1. When a new planetary gear is fitted, it is

recommended that new needle roller bearings are
fitted.
2. Position planetary carrier (1) on a clean

workbench.
3. Fit upper and lower needle roller bearings (2) to

planetary gears (3).
4. Fit planetary gears (3) to pins (4), then fit 1. Planetary carrier
triangular washer (5) and secure with circlips (6). 2. Needle roller bearings
3. Planetary gear
4. Pin
5. Fit new O-ring (7) to planetary carrier (1).
5. Triangular Washer
6. Circlip
6. Fit planetary carrier to wheel hub and secure with 7. O-ring
retaining screws (8). Torque load retaining screws to 8. Screw
25 Nm (18 lbf ft.). 9. Drain plug
7. Make sure drain plug (9) is fitted.
8. Refer to Service Manual and fill the hubs and

differential unit with oil.
9. Test differential unit operation after installation to

the machine.
STEERING CYLINDER
1. Fit swivel ends (1) to each end of the cylinder

piston (2). Torque load to 300 Nm (221 lbf ft.).
2. Fit steering cylinder (3) to mounting brackets on

the axle and secure with three cylinder attachment
bolts (4). Torque load bolts to:
Front Axle 120 Nm (88 lbf ft.)
Rear Axle 110 Nm (81 lbf ft.).
3. Fit hydraulic adapter (5) to steering cylinder (3).
4. Make sure track rod lock nuts (6) are screwed

towards swivel ends.
1. Swivel end
5. Make sure the cylinder piston is central in the 2. Piston
steering cylinder body. 3. Steering cylinder
4. Bolt (Qty 3)
5. Hydraulic adapter
6. Fit a track rod (7) to each swivel end. 6. Lock nut
7. Track rod
7. Make sure the swivel housings are parallel, then 8. Swivel housing
adjust the track rods until the ball joint can be fitted 9. Nut
to the swivel housing.
8. Fit a track rod (7) to each swivel housing (8) and

secure with a new nut (9). Torque load nuts to 220
Nm (162 lbf ft.).
NOTE: The inductive magnetic steering sensor is

adjusted after the toe in adjustments. Locking
clamps will be tightened at that stage.
9. Fit the inductive magnetic steering sensor, to the

steering cylinder and secure with the locking clamps.
10. Check and adjust axle tracking.

TOE-IN ADJUSTMENT
NOTE: The two bars must be fixed in the middle so

that they are perpendicular to the supporting surface
and parallel to the pinion shaft axis.
1. Fit a 1 meter bar on the wheel side of each hub

and secure with a wheel nut. Make sure the centre
of the bar is at the centre of the hub and the two
bars are aligned.
NOTE: The tape measure should be tensioned

evenly when taking measurements.
2. Measure the distance in mm (M) between the

bars, at both front and rear of the axle, with a
suitable tape measure.
3. Compare the difference between the two

measurements and make sure toe-in is within the
required tolerance range.
4. The normal toe-in value (A) is referred to the

external diameter of the wheel hub flange, therefore
the measured value (M) at the bar ends must be
related to the ratio between length of the bar and
flange diameter.
Nominal toe-in = A Front + 0 – 2 Rear ± 1
Measured toe-in = M Front + 0 – 5 Rear ± 3
5. If the toe-in is out of adjustment, loosen the lock

nuts (1) on the track rods (2) and, using two
wrenches, adjust the length of the track rods by
turning the adjusters (3) on the ball joints (4) equally.
Recheck the toe-in and adjust the track rods again if
necessary. When toe-in is correct tighten the track
rod lock nuts (1). Torque load nuts to 250 Nm (184
lbf ft.).
1. Lock nut
2. Track rod
3. Adjuster
4. Ball joint
STEERING ANGLE ADJUSTMENT
The steering angle on all hubs is set by adjusting the

length of the adjuster, between the hub and the head
of the adjuster, to the dimensions given in the Table.
1. Loosen lock nut (1) on all four adjusters of the

front and rear axles and screw adjusters inwards.
2. Set the adjuster bolt on all hubs of the front and

rear axles as detailed in the table, then tighten the
lock nuts.
1. Lock nut
3. Torque load all lock nuts to 100 Nm (74 lbf ft.). 2. Adjuster
AXLE POSITION 1A TYRE 1B TYRE

DIMENSION DIMENSION
FRONT A 60 mm 60 mm
FRONT B 60 mm 60 mm
FRONT C 57 mm 57 mm
FRONT D 55 mm 57 mm
REAR A 74 mm 60 mm
REAR B 74 mm 65 mm
REAR C 65 mm 65 mm
REAR D 65 mm 60 mm
1A tyres - 10.5-20 Cross Ply
1B tyres - 10.5-20 Cross Ply
TRANSMISSION BOX ASSEMBLY
NOTE: Ensure all mating surfaces are perfectly

clean before commencing assembly. Degrease and
clean with an appropriate cleaner.
1. Apply a layer of Loctite 510 on axle (1) half box

mounting. Carefully position half box (2) onto axle.
Apply Loctite 270 to bolts (3) before assembly. Fit
bolts (3) and torque load to 120 Nm (88.5 lbf ft.)
2. Position outer half box (4) on a flat surface and fit

lower sealing ring (5) with special tools Part No.
CA715038 and handle Part No. CA119033.
NOTE: Care should be taken to avoid damage to

sealing ring (5) during the following operations.
3. Fit bearing (6) and lower flanged shaft (7). Fit gear
wheel (8) and seat gear wheel and bearing using
special tool Part No. CA715145 and a hammer.
1. Axle
2. Half box
4. Fit bearing (9) with Special tool Part No. 3. Bolt
CA715145. Fit circlip (10) to lock assembly.
5. Position upper gear wheel (11) on a clean

workbench and fit bearings (12) and (13) using
special tool Part No. CA715403 and a hammer.
6. Assemble the gear wheel-bearing assembly into

the outer half box (4) and seat with special tool and
a hammer.
7. Apply an even layer of Loctite 510 to half box

mating surfaces. Carefully position outer half box (4)
onto half box (2) and seat with a rubber hammer.
8. Fit mounting bolts (14) and torque load to 60 Nm

(44.3 lbf ft.).
9. Lubricate and fit O-ring (15) to transmission box.

Fit engine flange (16) with bolts (17) and torque load
to 60 Nm (44.3 lbf ft.).
4. Outer half box

5. Sealing ring
6. Bearing
7. Shaft
8. Gear wheel
9. Bearing
10. Circlip
11. Gear wheel
12. Bearing
13. Bearing
14. Bolt
15. O-ring
16. Flange
17. Bolt
TRUNNIONS ASSEMBLY
(Rear Axle)
1. Place front trunnion (1) and rear trunnion (2) on a

clean bench and fit bushes (3) and (4). Fit bush
retaining bolts (5) and (6) and torque load to 84 Nm
(62 lbf ft.). Fit new O-ring (7) to rear trunnion.
2. Spread an even layer of Loctite 638 to centralizing

bushes (8) and fit to trunnions.
3. Fit trunnions to axle taking care not to damage the

rear trunnion O-ring.
4. Fit seal ring (9) to housing with special tool Part 1. Trunnion
No. CA715043 and a hammer. 2. Trunnion
3. Bush
5. Fit shim (10), O-ring (11) and pinion shaft flange 4. Bush
(12) and secure with circlip (13). 5. Bolt
6. Volt
7. O-ring
6. Lubricate trunnions after assembly to axle
8. Bush
housing.
9. Seal ring
10. Shim
11. O-ring
12. Flange
13. Circlip
TESTING AFTER INSTALLATION
After the axle has been installed to the machine, test

the operation of the differential as follows:
1. Make sure the engine is switched off.
2. Lift the machine so that all the wheels on the

vehicle being tested are clear of the ground.
3. Engage a gear so that the pinion is locked.
4. With the assistance of a second person, rotate

both wheels in a forward direction as far as possible
(both the wheels should stop after a while).
5. Keep the machine in gear to lock the pinion, rotate

the left wheel in the forward direction of travel and
the right wheel in the rearward direction of travel.
The wheels should both move freely without difficulty
when the axle has been assembled correctly.
6. Repeat the above test while turning the wheels in

the opposite direction.
If the wheels do not rotate freely in

both directions, the axle assembly is
not correct and must be re-checked.
TROUBLESHOOTING
Operating problems
The following information is given as a guide to Operating problems and possible causes.
Possible Causes
Problems
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; halfshaft

breakage * * * * *
Steering is difficult; vehicle goes straight while

it is turning * * * * *
No differential action; jamming while steering * * * *
Excessive transmission noise * * * * * * * *
Uneven tyre wear * * * * * * * *
Friction noise * * * * * * *
Vibration during forward drive, intermittent

noise * * * * *
Key to Operating problems table Machines with wide steering angles may proceed
with kicks, have steering difficulty or cause tyre
1. Incorrect installation/defective axle wearing on sharp turns. Reduce the steering angle
Correct installation or repair or replace the differential to minimum and decelerate the machine when the
in case it does not survive any one of the test steering begins to kick.
phases.
7. Incorrect wheel adjustment
2. Overloading/incorrect weight distribution Check group integrity and wheel side bearings.
Remove excessive weight and redistribute load, Adjust accordingly.
following instructions related to the machine.
8. Spoiled or worn out axle parts
3. Different rotation radius of the tyres Check the condition of the ring gear, pinion gear,
If one tyre has a smaller radius, it will cause partial bearings etc. Replace components as necessary.
wheel slipping when force is applied. The other tyre
with larger radius will have to support all the work. 9. Contamination in the axle box or incorrect
Replace the tyre or adjust pressure to have same assembly of parts
radius on both tyres. Look for foreign particles. Check the assembly of the
axle components.
4. Broken halfshaft
It is not advisable to operate the machine with a 10. Incorrect adjustment of bevel gear set: Parts
broken halfshaft. It is acceptable to move the of the transmission worn out
machine (engine off loaded) a few metres only. Replace or adjust as required (transmission gears, U
joints etc.).
5. Bent halfshaft
Replace halfshaft. 11. Incorrect use of the product
Refer to the machine manufactures instructions.
6. Blocked differential
Abnormal functioning of the differential or breakage/
blockage of command device. Verify assembly and
all components.
Axle problems
The following table gives a description of common axle problems, the cause and repair action to correct the
problem.
Problem C au se Action
Ring gear tooth broken at the outer side 1. Excessive gear load compared to the Replace bevel gear set. Follow carefully the
one forseen. recommended operations for the adjustment
2. Incorrect gear adjustment (excessive of bevel gear and backlash.
backlash).
3. Pinion nut loose.
Ring gear tooth broken side 1. Load bump. Replace bevel gear set. Follow carefully the
2. Incorrect gear adjustment (insufficient recommended operations for the adjustment
backlash). of bevel gear and backlash.
3. Pinion nut loose. Use correct lubricants, fill to the correct level
and replace at correct intervals.
Overheated ring and pinion teeth. See if 1. Prolonged functioning at high Replace bevel gear set. Use correct
gear teeth have faded. temperatures. lubricants, fill to the correct level and replace
2. Incorrect lubrication. at correct intervals.
3. Low oil level.
4. Contaminated oil.
Pinion teeth pitting 1. Excessive use. Replace bevel gear set. Use correct
2. Insufficient lubrication. lubricants, fill to the correct level and replace
at correct intervals.
Axle beam body bent 1. Machine overloaded. Replace axle beam body.
2. Machine accident.
3. Load bump.
Worn out or pitted bearings 1. Insufficient lubrication. Replace bearings. Use correct lubricants, fill
2. Contaminated oil. to the correct level and replace at correct
3. Excessive use. intervals.
4. Normal wear.
5. Pinion nut loose.
Oil leakage from gaskets and seals 1. Prolonged functioning at high oil Replace the gasket or seal and mating
temperatures. surface, if damaged.
2. Oil gasket assembled incorectly. Use correct lubricants, fill to the correct level
3. Seal lip damaged. and replace at correct intervals.
4. Contaminated oil.
Excessive wearing out of input flange spline 1. Exhaustive use. Replace the flange. Check that the pinion
2. Pinion nut loose. spline is not excessively worn. Replace
3. Pinion axle backlash. bevel gear set if necessary.
Fatigue failure of pinion teeth. See if 1. Exhaustive use. Replace bevel gear set.
fracture line is well defined (wave lines, 2. Continuous overload.
beach lines)
Pinion and ring gear breakage 1. Crash load of differential components. Check and replace other differential
components.
Side gear spline worn out. Replace all 1. Excessive use. Replace differential gear group. Replace
scratched washers (excessive backlash) halfshaft if necessary.
Thrust washer surface worn out or 1. Insufficient lubrication. Use correct lubricants, fill to the correct level
scratched 2. Incorrect lubrication. and replace at correct intervals.
3. Contaminated oil. Replace all scratched washers and those
with 0.1 mm thickness less than the new
washers.
Inner diameter of tapered roller bearing 1. Excessive use. Replace bearing. Check pinion axial
worn out 2. Excessive pinion axial backlash. backlash.
3. Insufficient lubrication. Use correct lubricants, fill to the correct level
4. Contaminated oil. and replace at correct intervals.
Bent or broken halfshaft 1. Machine intensively operated or Replace.

overloaded.
Halfshaft broken at wheel side 1. Wheel support loose. Replace. Check that wheel support is not
2. Beam body bent. worn out or incorrectly adjusted.
Axle noise problems and diagnosis
The following table gives a description of axle noises problems, the cause and repair action to correct the
problem.
Noise while driving 1. Excessive backlash between pinion and ring gear. 1. Adjust.
2. Worn out pinion and gear ring. 2. Replace.
3. Worn out pinion bearings. 3. Replace.
4. Pinion bearings loose . 4. Adjust.
5. Excessive axial pinion backlash. 5. Adjust.
6. Worn out differential bearings. 6. Replace.
7. Differential bearings loose. 7. Adjust.
8. Ring gear not conecentric. 8. Replace.
9. Low lubricant level. 9. Replenish.
10.Bent halfshaft. 10. Replace.
Noise while driving in 1. Noises coming from axle are usually heard when 1. Replace or adjust (see above).
neutral machine moves in neutral gear but are not loud.
2. Incorrect backlash between pinion and ring (sound 2. Replace.
heard while decelerating, disappears while
accelerating).
3. Pinion or input flange worn out. 3. Replace.
Intermittent noise 1. Ring gear damaged . 1. Replace bevel gear set.

2. Differential box bolts loose. 2. Tighten to correct torque load.
Constant noise 1. Ring gear teeth or pinion damaged. 1. Replace bevel gear set.
2. Worn out bearings. 2. Replace.
3. Pinion spline worn out. 3. Replace.
4. Bent halfshaft. 4. Replace.
Noise while steering 1. Worn out differential gears. 1. Replace.

2. Worn out differential box or spider. 2. Replace.
3. Differential thrust washer worn out. 3. Replace.
4. Halfshaft spline worn out. 4. Replace.
Special Tools
It is recommended that the correct special tools are
used when dismantling and assembling the axle.
The interchangeable handle should always be used
when removing and fitting bearings and bushes,
together with a suitable safety handle.
Ring nut wrench

CA119030
Interchangeable handle
CA119033
Driver for swivel bush

CA119097
Pinion lock nut wrench

CA119099
Spacing bush for false differential box

CA119182
Differential bearing cup driver

CA119225
Spacing tool for false differential box

CA119228
Driver for bearing

CA119230
Pinion shaft lock wrench

CA715022
False pinion
CA715023
Bearing cone driver

CA715026
Bush driver
CA715027
Ball-joint joint pin driver

CA715034
Oil seal driver

CA715038
Dummy pinion
CA715040
False differential box

CA715041
Driver for king pin bush

CA715042
Pinion oil seal driver

CA715043
Oil seal driver

CA715056
Bush driver
CA715104
Pre-load measurement extension

CA715116
Bearing driver
CA715145
Backlash measurement kit

CA715146
Bush driver
CA715157
Pinion bearing cone driver

CA715167
Bearing cone driver

CA715179
Bearing cup driver

CA715299
Swivel housing oil seal driver

CA715360
Oil seal driver

CA715367
Central body oil seal driver

CA715395
Bearing race insertion kit

CA715401
Driver for oil seal

CA715402
Bearing driver
CA715403
Oil seal driver

CA715404
STEERING
Description
The steering system is fully hydrostatic. This means

that the steering motion is transmitted hydraulically
with no mechanical linkage between the steering
wheel and the steered wheels. The hydraulic supply
is by a dynamic system working with a load-sensing
(LS) pump. Pump supply passes through a priority
valve and generates a load-sensing signal.
Operation
The steering unit (OSPF) interfaces the steering

control valve with an adapter. Depending on the
steering mode selected in the cab, (two-wheel steer/
four-wheel steer/crab steer), the steering control
valve directs oil to the selected steering cylinder
when input is made from the steering wheel. C1 To rear cylinder
C2 To rear cylinder
In the neutral position, oil is allowed to flow freely
C4 To front cylinder
from the priority valve through the steering control
valve to return (LS to T). As the steering wheel is P STAC valve from LS pump
turned the spools of the valve rotate against each T Hydraulic tank
other and proportionally direct oil to the selected
steering cylinder. Not until the rotary valve is fully
open is the LS connection to the hydraulic tank fully
closed.
A pressure relief valve is fitted in the control valve. If

the pressure rises above 175 bar (2537 psi), the
PRV will open and return excess pressure to the
hydraulic tank.
Two shock valves are fitted in the control valve, to

protect the cylinders and hoses and are set at a
higher pressure than the PRV.
When hydraulic pressure fails, the vehicle can be

steered manually. The steering wheel, when turned,
drives the outer spool with the cross pin and the
rotor is turned by the cardan shaft which acts as a
manual pump to supply oil to the steering cylinder. In
this case the steering effort required will be
increased significantly.
Control Valve specification

C3 To front cylinder
Type OSPF250LS
PRV 170-175 bar (2465-2537 psi) O OSPF250 valve (21)
Shock valve 225-245 bar (3262-3552 psi) A Adapter
Displacement 250 cu.cm/rev E Selector valve (24)
LS LS – line
1. Tank, hydraulic 23. Shock valve, 225 - 245 bar

2. Hydraulic pump, main 24. Steering selector valve - attached to OSPF
4. Header tank valve
5. Filter 25. Pressure relief valve 175 bar
10. Steering & Accumulator charge valve (STAC) 26. Non-return valve
11. Regulator 27. Steering cylinder (rear axle)
12. Accumulator charge valve 28. Steering cylinder (front axle)
13. Filter 73. Test point 1 (STAC Ls pressure)
14. Filter 74. Test point 2 (STAC Brake pressure)
15. Priority valve A. To front brakes
21. Control valve, steering - Danfoss OSPF B. To trailer brake
22. Steering control valve spool C. To control valve
Checking the steering system
Steering cylinder (27 & 28)
1. Raise and securely support the front axle.
2. Turn steering fully to left.
3. Disconnnect hose from adapter on right hand end

of cylinder
4. Start the engine and operate steering wheel fully

left to apply maximum hydraulic pressure to cylinder.
Make sure no oil flows from open right hand
connection.
5. Stop engine, connect hose to right hand hose to

adapter and repeat above check on left hand side of
cylinder.
6. Repeat all above checks on rear axle steering

cylinder.
7. Start engine and bleed the hydraulic lines free of

air.
Steering unit (OSPF) (21)
1. Start the engine and run until oil is at normal

operating temperature and any air is purged from
system.
2. Set engine at maximum rev/min, turn the steering

wheel until the steering stops make contact.
3. If the steering wheel can be turned, the rotor,

spool or shock valves are faulty and the steering unit
must be replaced.
Servicing
Servicing is normally limited to the replacement of

the three main components (steering unit, adapter
and steering valve) and the seals between these
components.
Steering valve assembly
Removal

chassis and fit chocks to the front and rear of the
rear wheels.

from the brake system, then disconnect the battery.
5. Remove the front cover from outside of the cab.
6. Make sure the steering valve assembly is free

from dirt to avoid contamination of the hydraulic
system.
7. Identify and label the electrical connectors on the

steering valve. Disconnect the electrical connectors
and fit blanks to the connectors and valve.
8. Position a suitable container under the steering

valve assembly to collect any oil spillage during
removal.
9. Identify and label the hydraulic hoses. Disconnect

all hoses from the steering valve assembly and
blank open connections on valve and hoses. Tie
hoses clear of valve.
10. From inside the cab, remove the nut, washer,

three bolts and washers securing the valve to the
steering column. Remove the valve from the
machine by disconnecting the splined drive
Installation
1. Installation is the reverse of the above procedure.
2. Make sure all hoses and electrical connectors are

connected to the correct service.
3. Refer to Page 1.72 and replenish the hydraulic

tank before the engine is started.
4. Purge the hydraulic system by starting the engine

and operating the steering to fully extend and retract
front and rear steering cylinders several times.
5. Refer to Page 1.72 and check the hydraulic level

and replenish if necessary.
6. Check the steering operates correctly in all

modes, (two-wheel steer, four-wheel steer and crab
steer).
Dismantling
1. Remove the four cap head screws (1) attaching

the steering valve (2) to the adapter (6). Remove
and discard the O-ring seals (3).
2. Remove the two cap head screws (7) attaching

the adapter (6) to the steering unit (4). Remove and
discard the O-ring seals (5).
3. Examine the steering valve for damage to the

block or solenoids and electrical connectors. If any
damage is found, the valve must be replaced as a
unit.
4. Examine the adapter for damage to the block. If

any damage is found, the adapter must be replaced.
5. Examine the steering unit for damage to the

block. If any damage is found, the unit must be
replaced.
Assembly
1. Assemble the steering valve assembly in the

reverse order to dismantling.
1. Cap head screw – M5 x 45
2. Steering valve
2. Use new O-rings during assembly.
3. O-ring
4. Steering unit
3. Tighten the screws progressively in rotation.
5. O-ring
6. Adapter
7. Cap head screw – M10 x 46
BRAKE SYSTEM BLEEDING
General
Bleed the brake system after a brake system

component change and when air in the system is
suspected. Air in the system will not allow the brakes
to release properly and may cause damage.
1. Start the engine and allow the accumulator to fully

charge.
2. Stop the engine.
3. Slowly apply and release brakes until they will not

apply, waiting for one minute between applications.
Repeat this operation three times.
4. Start the engine and allow the accumulator to fully

charge then stop the engine. Operate the engine as
necessary to maintain accumulator at working
pressure throughout the bleeding procedure.
5. Attach a bleed tube to the bleed screw on the

brake unit nearest to the brake valve (front right) and
put the bleed tube into a suitable container. Carefully
open bleed screw, apply brakes until all air is bled
out of line then close bleed screw and remove bleed
tube. Bleed the other brake units and the trailer
brake valve in the order that follows:
1. Front left
2. Trailer brake valve (if fitted)
6. Release brake pressure for at least one minute.
7. Apply brakes, hold pedal down for ten seconds

then release pressure for one minute. Repeat this
operation two more times.
8. Bleed the brakes one more time.
9. Check the system components and brake lines for

leaks.
10. Test the operation of the brakes.

Dumping (dissipation) of hydraulic

pressure
Always dump all hydraulic

pressure from the system before
servicing any hydraulic
component.
Ensure there is sufficient space

and headroom around machine
before operating any hydraulic
control.
To dump brake system pressure

1. Stop the engine.
2. Make sure the machine is parked on firm and

level ground and chock the wheels.
3. Turn the ignition switch to position (1).
4. Set the parking brake switch, if necessary, to the

parking brake applied position.
5. Press the brake pedal repeatedly until the brake

charge warning lamp illuminates.
6. Press the brake pedal a further twenty times to

ensure that residual pressure in the brake system is
fully dissipated.
7. Turn the ignition switch to off.
To dump a system pressure

NOTE: This procedure applies to all machine hydraulic
systems, except brakes.
1. Stop the engine.
2. Make sure the machine is parked on firm and

level ground and chock the wheels.
3. Turn the ignition switch to position ‘I’.
4. Operate the applicable system until all hydraulic

pressure has been dissipated.
5. Turn the ignition switch to off.

HYDRAULIC OIL LEVEL

Fine jets of hydraulic fluid at high
pressure can penetrate the skin.
Do not use your fingers to check for
hydraulic fluid leaks. Do not put our
face close to suspected leaks. If
hydaulic fluid penetrates your skin
seek mecical help immediately.
Check
1. Place the machine on level ground.
2. Make sure all hydraulic cylinders are fully closed.
4. Open the engine pod cover.
NOTE Wait for two minutes before checking

hydraulic fluid level.
5. Clean filler cap and remove.
6. Make sure fluid level is between the high and low

marks on the dipstick.
7. Top up as necessary using clean hydraulic fluid of

the correct specification.
1. Header tank
8. Refit the filler cap. 2. Filler cap
3. Dipstick
9. Close engine pod cover.
SECTION 2
ENGINE
ENGINE 2.1
DESCRIPTION
The machine is fitted with a side mounted Perkins

1004.42 4.2 litre direct injection diesel engine.
The engine cooling system is by a gear driven water

pump on the engine and a rear mounted radiator. The
radiator is cooled by a fan, which is driven by a V-belt
by a hydraulic motor. A thermostat controls the
temperature of the coolant in the engine.
Fuel is supplied from an 85 litre tank, located below

the cab, to a pre-filter (water separator) then a
cartridge filter. The pre-filter has a drain tap fitted. The
cartridge filter is a replaceable item, only use genuine
Perkins filters.
Induction air passes through a pre-cleaner (externally

mounted) and then two filter elements. A filter
blockage sensor is fitted to the air cleaner body and
lights a warning indicator in the cab when the filter
requires cleaning. The engine must not be operated
when the warning indicator is illuminated.
The engine and transmission hydrostatic pump

should always be removed as an assembly
For specific engine tests, refer to the Perkins Engine

Manual.
Engine Data
Engine C40 C50
Perkins 1004.42 64kW (86 PS) 64kW (86 PS)
Net output 300 Nm @ 1.400 rpm 300 Nm @ 1.400 rpm
Max RPM 2200 2200

2.2 ENGINE
REMOVAL AND INSTALLATION

General
The engine is usually removed complete with the

transmission hydrostatic pump.
Removal

chassis and fit chocks to the front and rear of the rear
wheels.
3. Refer to page 1.71 and dump hydraulic pressure,

then disconnect the battery.
4. Open the upper engine cover and remove the bolts

securing the hinges to the engine cover. Remove the
engine cover from the machine.
5. Open the latch on the lower engine cover and open

the engine cover. Remove the engine cover from the
machine if necessary.
NOTE: Identify and label all hoses and electrical

connectors before removal. Tie back all hoses and
electrical cables to make sure they are not damaged
during engine removal.
Do not drain the coolant until the engine
is cold.
6. Drain the engine cooling system.
7. Drain the transmission system oil.
8. Disconnect the inlet and outlet coolant hoses from

the radiator. Disconnect the expansion tank hose
from the radiator.
9. Disconnect the oil coolant hoses from the oil

cooler.
10. Disconnect the hydraulic hoses to the fan

hydraulic pump. Fit blanks to the adapters and
hoses.
11. Disconnect the starter motor and starter solenoid

electrical cables.
12. Disconnect the alternator electrical cables and

main earth cable.
13. Disconnect the speed sensor from the engine.

ENGINE 2.3
14. Disconnect the fuel supply and fit blanks to the

engine and fuel pipes.
15. Disconnect the air conditioning system

compressor hoses and fit blanks to the compressor
and hoses (if fitted).
16. Disconnect the main hydraulic pump hoses from

the pump and support clear of engine. Fit suitable
blanks to the pump and hoses.
17. Disconnect the auxiliary hydraulic pump hoses

from the pump and support clear of engine. Fit
suitable blanks to the pump and hoses.
NOTE: Before disconnecting the solenoids, mark the

wiring/plugs to prevent cross connections.
18. Disconnect the solenoid plugs from the

hydrostatic transmission pump connectors.
NOTE: Before disconnecting the hydrostatic

transmission pump hoses, mark the hoses to aid
installation.
19. Disconnect the six hydraulic hoses from the

hydrostatic transmission pump and fit suitable blanks
to the pump and hoses.
20. Disconnect the elbow adapter under the

hydrostatic transmission pump and fit suitable blanks
to the pump and adapter.
21. Disconnect the following:
- Air cleaner blocked cables

- Oil pressure sender cable
- Transmission dump
- Thermostat cable.
22. Unclip the wiring loom from the engine and tie
clear of engine.
23. Disconnect the accelerator cable from the engine.
24. Disconnect the air cleaner to engine hose.

Remove the air cleaner assembly from the machine.
25. Disconnect and remove the flexible exhaust pipe

between the engine and silencer. Remove the
silencer.
26. Fit a suitable lifting sling to the engine and attach

to a suitable overhead lifting device.
2.4 ENGINE
The engine and transmission assem-

bly is heavy. The combined assem-
bly is in excess of 320 Kg in weight.
Take care during removal.
During removal make sure the engine

and chassis components are not
damaged. Make sure all hoses,
electrical cables and controls are
disconnected.
27. Remove the four mounting bolts securing engine

and transmission to chassis.
28. Lift the engine and transmission from the

chassis. Place the unit on a suitable work stand.
Installation
1. Installation is the reverse of the above procedure,

however pay particular attention to the following:
2. Make sure engine and chassis mounted

components are not damaged during installation.
3. Make sure all electrical leads are connected to the

correct components.
4. Secure wiring loom to engine.
5. Torque load the attachment bolts as follows:
Engine/transmission to chassis - 150 Nm (110 lbf ft.)
6. Replenish the cooling system, hydraulic system,

transmission and engine lubricating oil.
7. Charge the air conditioning system (if fitted) using

suitable equipment.
8. Start engine and make sure all warning lights

operate correctly.
9. Make sure all disturbed hoses and pipes do not

leak.
10. Stop the engine and check the fluid levels of the
cooling system, hydraulic system, transmission and
engine lubricating oil. Replenish as necessary.
11. Test the machine.
Testing
For specific engine tests, refer to the Perkins Engine

Manual.
SECTION 3
TRANSMISSION
TRANSMISSION 3.1
DESCRIPTION
Hydrostatic system - (up to Machines

S/No.50600162 only)
NOTE: The numbers in brackets refer to the equivalent

item on the hydraulic circuit diagrams in the Hydraulic
and Electrical Servicing manual.
The hydrostatic transmission system consists of an

engine mounted variable displacement pump (55) and
an axle mounted displacement motor (66) controlled
by the hydrostatic electronic control unit (SUSMIC).
The hydrostatic drive enables smooth and accurate
handling of loads.
The hydrostatic circuit is independent of the hydraulic

system, using the same oil supplly from the hydraulic
tank (1).
Oil from the hydraulic tank (1) is pumped by the

auxilliary hydraulic pump (3), through the fan motor
(7), pressure relief valve (8) and filter (9) to the
hydrostatic pump (55), which controls the flow of oil
to the hydrostatic motor (66). Oil is returned from the
hydrostatic pump (55) to the hydraulic tank (1)
through a non-return valve (6). Oil is also returned
from the hydrostatic motor (66) to the hydraulic oil
tank (1) through an oil cooler (72).
The hydrostatic pump (55) is a non-feedback

electrical proportional, engine driven pump with no
mechanical feedback.
The pump (55) houses a charge circuit pressure relief

valve (56) and two proportional pressure reducing
valves (57), which control forwards and reverse motion
through a servo ram that directs the pump
swashplate.
Two multifunction valves (58) and (62) are housed in

the pump. One functions as a pressure limiter valve,
which prevents hydrostatic pump output overpressure
by regulating back the steering pump swashplate
servo ram, if the pressure reaches the maximum set
value.
The second multi function valve operates as a loop

flushing valve, which prevents low oil level in the
hydrostatic circuit. If the pressure in the low-pressure
side of the circuit falls below a set value of the charge
pressure, charge oil is passed into the circuit
compensating for leakage. Losses occur through
normal leaks in the pump components and through
the purge valve in the motor.
An overpressure relief valve relieves overpressure on

the high pressure side of the system caused by
pressure peaks due to external forces acting on the
drive.
3.2 TRANSMISSION
Manually operated bypass valves (59) enable the

vehicle to be moved without the pump running. Both
by-pass valves must be fully opened to maintain the
by-pass function.
The direction of rotation of the hydrostatic motor (66)

is controlled by supply pressure from the hydrostatic
pump (55).
The motor (66) houses an servo control cylinder (67)

that controls the motor swash plate angle.
The loop flushing valve (68) allows circuit cooling of

the high-pressure circuit and removal of
contamination. It is also equipped with a purge
pressure relief valve (69).
The brake pressure defeat valve (70) is a change over

valve that is actuated by respective position pressure
and provides high pressure to the pressure
compensator override.
This controller regulates the constant pressure for the

motor capacity depending on high pressure. When
high pressure remains below control pressure the
adjusting unit maintains the position for minimum
motor capacity. If high pressure exceeds the
pressure setting its affect on the adjusting unit
causes motor capacity to increase, which increases
torque with a corresponding reduction in the speed of
the motor shaft.
Mounted on the pressure compensator override is a

solenoid valve (71). A 12 Volt power supply is applied
through the SUSMIC module to the solenoid operated
valve, when the speed limiter in the twist grip is
selected. The motor remains at max. capacity and
maintains the lower speed range of 8 Km/h.
Hydrostatic system - (from Machines

S/No.50600163 only)
The hydrostatic transmission system is similar in

design and operation, except that oil from the
hydraulic tank (1) is pumped by the auxilliary
hydraulic pump (3) through the fan reverse valve (79)
and oil filter (9) to the hydrostatic pump (55).
TRANSMISSION 3.3
Transmission hydraulic circuit (up to Machines S/No.50600162 only)
Transmission hydraulic circuit (from Machines S/No.50600163 only)

3.4 TRANSMISSION
Key to Transmission hydraulic circuits (Page 3.3)
Item Description Note
1 Hydraulic tank
3 Charge pump (Auxiliary pump) max. 19 l/min
6 One way valve (bypass) Located in the leakage oil circuit (3 bar)
7 Fan motor 13 cm3
8 Pressure relief valve 160 bar (up to Machine S/No.50600162)

120 bar (from Machine S/No.50600163)
9 Filter with bypass Pressure filter with 3.5 bar bypass
55 Hydrostatic drive pump Series 90R75 NFPE
56 Charge pressure, pressure relief valve 30 bar
57 Solenoid operated servo valve Proportional pressure reducing valves
58 Multi-function valve
59 Bypass valve Used for example when towing the vehicle
60 Pressure relief valve/Pressure limiter 480 ± 10 bar
61 Over pressure, pressure relief valve 530 bar ± 10 bar (shock function)
62 Multi-function valve
63 Purging (check valve) Allows Charge Pressure to Top Up System
64 One way valve (relief valve) Separation of charge pressure and position pressure
65 Servo ram (load sensing pump) Operates swashplate in pump
66 Hydrostatic motor Series 51D110
67 Adjusting unit from motor Servo control cylinder (servo ram)
68 Purge valve/ loop flushing
69 Purge pressure relief valve Opens at about 16 bar
70 Travel directional valve Brake pressure defeat V
71 Constant pressure regulator Pressure compensator override
72 Oil cooler In return line
75 Test port High pressure 480 ± 10 bar reverse
76 Test port High pressure 480 ± 10 bar forwards
77 Test port Charge pressure
79 Fan reverse motor (from Machine S/No.50600163 only)
L1 Return port Via one way valve (cooler bypass)
L2 Return port Via motor and oil cooler
M3 Test port Position pressure, ram rod side.
M4 Test port Position pressure, ram rod side.
A-B Pressure output forward Pump to motor
B-A Pressure output reverse Pump to motor
M4-XB Charge pressure Forward Input Pump to motor
M5-XA Charge pressure Reverse Input Pump to motor

TRANSMISSION 3.5
OPERATION
Hydrostatic Pump (55)
When the engine is running it rotates the drive shaft (3)

which operates the radially arranged cylinder rotors (1)
and piston rods (2). The piston rods (2) and slides (4)
are forced onto the swashplate (5) by oil pressure from
the engine mounted charge pump.
The servo valve (6) controls the servo ram (7) to deflect
the swashplate (5) to control direction of travel and
speed. During this procedure the piston rods (2) rotate
around the drive shaft (3). Oil is forced out of the filled
cylinder space at pressure by the angled swashplate
(5) depressing the piston rods (2).
The piston rods (2) continue around the drive shaft on

the inclined swashplate (5) where they are filled on the
low-pressure side by charge pressure oil from the
charge pump.
The servo valve (6) controls the servo ram (7) to act on
the swashplate (5) which is then moved to exchange
the high and low pressure sides
The ground speed is dependent on the volume of oil and

on the swashplate (5) angle. The SUSMIC senses the
engine speed and then controls the solenoid valve
mounted on the servo valve (6) to control the servo ram
(7) and also controls the constant pressure regulator to
regulate the swashplate angle in the hydrostatic motor.
The base (8) separates the high and low-pressure sides

in the pump unit. For sealing purposes the cylindrical
rotor (1) is pressed against the base (8) by spring
pressure.
The accurate return of the swashplate (5) to the neutral

position is achieved by springs (9). The alignment of the
mechanical neutral position is carried out by means of
the eccentric screws (10).
3.6 TRANSMISSION
1. Cylindrical rotor
2. Piston rod
3. Drive shaft
4. Slide
5. Swashplate
6. Servo valve
7. Servo ram
8. Base
9. Return spring
10. Eccentric screws
TRANSMISSION 3.7
Pressure relief valve (56)
The charge pressure relief valve housed in the

hydrostatic pump maintains a pressure of 30 bar. This
pressure is measured against the housing pressure
and set whilst at a speed of 1500 rpm and at a neutral
setting.
The type plate on the pump specifies the pressure

relief valve setting. The charge pressure is adjusted by
means of a setscrew. One turn of the setscrew
corresponds to approx. 3.5 bar.
Proportional pressure reducing valve (57)
The proportional pressure reducing valve mounted on

the servo valve controls position pressure. This position
pressure is internally transferred to the pump servo ram
to operate the swashplate and the constant pressure 1. Pressure relief valve
regulator in the hydrostatic motor. 2. Servo valves with solenoid valves
3. Multi-function valves
Multi function valves (58)
The pump contains a multi-function valve for each side

of the drive circuit that acts as a purge valve, pressure
relief valve and over pressure valve according to which
side of the circuit it is operating on.
Pressure relief valve (60)
On the high pressure side the pressure relief valve

regulates the steering pump if the pressure reaches the
maximum value set.
If the max. pressure (approx. 480 ± 10 bar) is reached

the pressure relief valve (1) lifts off its seat against the
compressive force of the spring. This allows oil to be
fed via the outlet (3) to the servo ram to regulate the
pump.
The pressure relief valve (1) can be adjusted with

setscrew (4). To adjust the pressure relief valve loosen
the locknut on the multi-function valve and turn the
setscrew (4). One turn of the setscrew corresponds to 1. Pressure relief valve
approx. 93 bar. 2. Charge pressure
3. Outlet to servo ram
4. Setscrew for pressure relief valve
3.8 TRANSMISSION
In the low-pressure circuit if the pressure falls below the

set value of the charge pressure (6), the charge
pressure displaces the purge valve (5) to the left against
the spring force. This causes charge oil to flow into the
circuit to compensate for fluid losses.
Normal internal leaks in the pump components and the

purging valve in the hydrostatic steering motor cause oil
loss.
5. Purge valve
6. Charge pressure
Over pressure valve
On the high-pressure side of the system an over

pressure valve acts to protect the system from high-
pressure peaks. These can occur when external forces
affect the drive.
The high pressure (7) displaces the pressure relief valve

(1) against the spring force, which results in a pressure
drop in the spring chamber. The high pressure
overcomes the spring force and displaces the over
pressure valve (8) to the left. The high-pressure oil can
flow through the charge circuit into the low-pressure side
of the circuit (return).
The over pressure valve (8) opens if the high pressure

7. High pressure
side of the closed circuit rises above the set value of
8. Over pressure valve
approx. 530 bar.
TRANSMISSION 3.9
Bypass valve function (59)
The by-pass function is included in the multi function

valve and allows the vehicle to be moved without the
pump operating. For example, an unserviceable
vehicle may be moved to a service location or
winched onto a trailer without operating the
transmission system.
When working on the by-pass valves

ensure the drive is off and there is no
pressure in the high-pressure
system. Both by-pass valves must
be open to maintain the by-pass
function.
Bypass valves are intended for moving 9. Main body
a vehicle for very short distances at 10. By-pass adjuster
very low speeds. They are not intended
for use as towing valves.
Setting the by-pass function
Do not open the by-pass valve more

than 3½ turns otherwise pressure
system fluid will escape.
1. Hold the main body (9) (large hexagon) of the valve

with an open-ended spanner and turn the by-pass
adjuster (10) (middle sized hexagon) counter
clockwise three turns to open the by-pass valve fully.
2. Resetting is the reverse of the setting procedure.
3. Torque load the by-pass adjuster nut to 41 Nm (30

lbf/ft.).
4. Carry out a test of the Transmission system using

the procedure laid down at the end of this section.
3.10 TRANSMISSION
Hydrostatic motor (66)
The hydraulic motor uses spherical pistons (1) and

piston rings. The angle between the cylinder block (2)
and the output shaft (3) can be adjusted between 32°
and 6°, providing a 5 to 1 maximum to minimum
displacement ratio.
At maximum displacement the motor achieves its

maximum output torque with minimum speed,
dependant on pressure and flow from the pump.
At minimum displacement and the same input

conditions the shaft speed increases 5-fold, whilst
the output torque reduces to one fifth of the maximum
capacity.
The displacement is changed by servo piston (4)

connected to the valve segment (5).
Charge pressure is directed from the pump solenoid

operated servo valve to the combined travel direction
and constant pressure regulator valve (6) in the motor
head.
Servo pressure directs pump output pressure through

the travel directional valve and through the constant
pressure regulator (6) to the piston (4) to control the
motor displacement.
Solenoid valve (7) controls speed range selection

from 0-8 km/h or 0-20 km/h (or higher in country
speed).
A synchronising shaft (8) with spherical rollers

synchronises the rotation of the output shaft (3) and
the cylinder block (2). The ball end of each piston
runs in a socket bush, pressed into the output shaft.
No other parts are used to connect the output shaft
to the pistons. The output shaft is supported by two
taper roller bearings (9).
TRANSMISSION 3.11
1. Piston
2. Cylinder block
3. Output shaft
4. Servo piston
5. Valve segment
6. Constant pressure regulator
7. Solenoid valve
8. Shaft
9. Bearing
3.12 TRANSMISSION
REMOVAL AND INSTALLATION
Hydrostatic Pump (55)
Removal
NOTE: The Hydrostatic pump is located in the engine

compartment. Remove components as necessary to
get access to the pump.

wheels.

6. Make sure the pump and hoses are free from dirt
to avoid contamination of the hydraulic system.
NOTE: The position of the hoses and electrical

connections should be noted for fitment purposes.
Blanks must be fitted to all open pipes and
connections to prevent the ingress of foreign bodies
into the hydraulic system.
7. Disconnect electrical connectors (1) to solenoids.
8. Remove eight mounting bolts (2) and washers (3)

from half clamps (4) and disconnect hoses (5).
Remove O-rings (6).
9. Disconnect elbow (7) from underside of pump (8).
10. Disconnect hoses (9, 10 11 & 12) from pump.
The hydrostatic pump weighs 49 Kg.

Make sure appropriate lifting
equipment is used when removing
pump.
11. Remove four bolts (13) and washers (14) securing

pump to adapter plate (15).
12. Remove pump and place on a clean work surface.
13. Remove cap screw (16) and circlip (17) from gear
hub (18). Slide gear hub from pump shaft.
TRANSMISSION 3.13
Installation
Installation is the reverse of removal.
Fit new O-rings (6) between pump (8) and hoses (5).
Torque load components as follows:
Adapter plate to engine bell housing bolts -

55 Nm +/- 10 Nm (40 lbf/ft. +/- 7.4 lbf ft.)
Drive coupler to pump
82 Nm + 8/- 0 Nm (60.4 lbf ft. + 5.9/- 0 lbf ft.)
Carry out a test of the Transmission system using

1. Electrical connector 10. Hose

2. Bolt 11. Hose
3. Washer 12. Hose
4. Half clamp 13. Bolt
5. Hose 14. Washer
6. O-ring 15. Adapter plate
7. Elbow 16. Cap screw
8. Pump 17. Circlip
9. Hose 18. Gear hub
3.14 TRANSMISSION
Hydrostatic Motor (66)
Removal
NOTE: The Hydrostatic motor is mounted on the

transmission box on the front axle above the drive
shaft.

wheels.

The following procedure will require

the vehicle to be raised with wheels
clear of the ground. All necessary
precautions are to be taken to avoid
injury to personnel.
6. Jack up the vehicle and release the parking brake.
The drive shaft is very heavy and

must be supported with the
appropriate lifting equipment during
removal and installation.
7. Remove the drive shaft in accordance with the

instructions in this chapter.
8. Make sure the pump and hoses are free from dirt
to avoid contamination of the hydraulic system.
NOTE: The position of the hoses and electrical

connections should be noted for fitment purposes.
Blanks must be fitted to all open pipes and
connections to prevent the ingress of foreign bodies
into the hydraulic system.
9. Disconnect electrical connection (1) to solenoid.
10. Remove eight mounting bolts (2) and washers (3)

from half clamps (4) and disconnect hoses (5).
Remove O-rings (6) and discard.
11. Disconnect elbow (7) from side of motor (8).
12. Disconnect hoses (9,10 & 11) from motor.

TRANSMISSION 3.15
The hydrostatic motor weighs 44 Kg.

Make sure appropriate lifting equip-
ment is used when removing motor. 1. Electrical connector
2. Bolt
13. Remove four cap screws (12) and washers (13) 3. Washer
securing motor to front axle transmission box. 4. Half clamp
5. Hose
14. Remove motor from transmission box and place 6. O-ring
on a clean work surface. 7. Elbow
8. Motor
Installation 9. Hose
10. Hose
1. Installation is the reverse of removal. 11. Hose
12. Cap screw
2. Fit new O-rings (6) between motor (8) and 13. Washer
hoses (5).
Motor mounting cap screws 150Nm (110 lbf/ft.)

Drive shaft bolts 50 Nm (37 lbf/ft.).
4. Carry a out test of the transmission system using

3.16 TRANSMISSION
Drive shaft
Removal

chassis.
4. Stop the engine and disconnect the battery.
The drive shaft is very heavy and

must be supported with appropriate
lifting equipment during removal and
installation.
NOTE: Mark the drive shaft flanges (front and rear) for
installation purposes.
5. Support drive shaft (1) with appropriate stands or

trolley jacks.
6. Remove bolts (2) and washers (3).
7. Remove shaft and position on suitable stand.
Installation
1. Installation is the reverse of removal.
2. Torque load the mounting bolts as follows:
Front drive shaft bolts 61-81 Nm (45-60 lbf ft.)

Rear drive shaft bolts 70-85 Nm (51-62 lbf ft.).
3. Carry out a test of the Transmission system using

TRANSMISSION 3.17
1. Drive shaft
2. Bolt
3. Washer
3.18 TRANSMISSION
TESTING
Start-up procedure post hydrostatic pump or motor

installation.
The following start up procedure must be followed

after either the pump or motor has been removed.
1. Park the machine on firm level ground and apply

the parking brake.

chassis.
The following procedure will require
the machine to be raised with wheels
clear of the ground. All necessary
precautions are to be taken to
prevent injury to personnel.
4. Raise the machine clear of the ground, position on
suitable stands and release the parking brake.
5. Fill the reservoir with recommended hydraulic fluid,

which must be filtered through a 10-micron filter
(nominal, no bypass).
6. Prime the inlet line from the reservoir to the pump

with recommended hydraulic fluid prior to start up.
7. Fill the pump or motor housing by pouring

recommended and filtered hydraulic fluid into the
upper drain port (1).
8. Install a 50 bar (1000 psi) pressure gauge in the

charge pressure gauge port M3a (2) to monitor the
pressure during start up.
9. Connect manometers to both high pressure sides

M1 (3) and M2 (4).
Do not start the engine unless the

pump is in neutral. Take precautions
to prevent machine movement in
case pump is actuated during start
up.
NOTE: It is recommended that the external electrical

connectors to the solenoid controlled servo valves are
disconnected at the pump until after initial start up to
ensure the pump remains in neutral.
10. Disconnect the pump solenoid controlled servo

valves electrical connectors (5).
TRANSMISSION 3.19
1. Upper drain port

2. M3a charge pressure port
3. M1 high pressure port
4. M2 high pressure port
5. Electrical connectors
3.20 TRANSMISSION
11. Start/stop the engine until charge pressure starts

to rise. Start the engine and run at the lowest
possible RPM until charge pressure has been
established.
12. Air can be bled from the manometer connections

(3 & 4).
Low charge pressure will affect the

operators ability to control the
vehicle.
13. Once charge pressure has been established,

increase speed to normal operating RPM. Ensure
nominal charge pressure is achieved.
14. Shut down the engine and reconnect the servo

valves electrical connectors (5) at the pump. 6. Connector
Withdraw connector (6) from potentiometer (7) on the 7. Potentiometer
brake pedal (8). 8. Brake pedal
15. Start the engine and check the pump remains in

neutral. Slowly check forward and reverse operations.
Continue to cycle between forwards and reverse for at
least five minutes.
16. Run until an operating temperature of approx.

60°C is reached, then set diesel engine to upper
idling speed.
17. Ensure indicated charge pressure at port M3a (2)

is 30 ± 3 bar (435 ± 43.5 psi). A maximum difference
between indicated pressures at ports M1 (3) and M2
(4) of 7 bar (100 psi) is allowed.
The following procedure is to be carried

out for a maximum of 15 seconds in
forwards and 15 seconds in reverse.
18. Set the FNR control lever (9) to the forwards

position (10).
19. Press the brake pedal (8) until its maximum

operating position has been reached. 9. FNR Control lever
10. Forwards position
20. Monitor the manometers. The high pressure M2 11. Reverse position
(4) should increase to approx. 480 bar (6960 psi).
21. The low pressure M1 (3) should indicate a

minimum 14 bar (200 psi).
22. Release the brake pedal (8).
23. Set the FNR control lever (9) to the reverse

position (11).
TRANSMISSION 3.21
24. Press the brake pedal (8) until its maximum

operating position has been reached.
25. Monitor the manometers. The high pressure M1

(3) should increase to approx. 480 bar (6960 psi).
26. The low pressure M2 (4) should indicate a

minimum 14 bar (200 psi).
27. Set the FNR control lever (9) to neutral.
28. Release the brake pedal (8).
29. Shut down the engine and release hydraulic

pressure (refer to Page1.71).
30. Reconnect connector (6) to potentiometer (7) on

the brake pedal (8).
31. Remove gauges from pump ports M3a, M1 and

M2 and fit plugs.
32. Check reservoir level and replenish if necessary.
33. Lower vehicle to the ground and apply the parking

brake.
34. Carry out a check of the transmission system by

referring to the operators manual.
3.22 TRANSMISSION
Troubleshooting guide
Refer to the following troubleshooting guide for the
diagnosis of typical transmission problems.
Neutral difficult or impossible to find 1. Input to pump control is operating Check control input and repair or replace as
incorrectly. necessary.
2. Pump displacement control linkages Adjust, repair or replace control module as
are not secure, control orifices blocked necessary.
etc.
System operating hot 1. Insufficient hydraulic fluid will not meet Fill reservoir to correct level.
cooling demands of system.
2. Heat exchanger not cooling system Check airflow and input air temperature for
sufficiently. heat exchanger. Clean, repair or replace
heat exchanger.
3. Low charge pressure overworking Measure charge pressure. Inspect and
system. adjust or replace charge relief valve. Repair
leaking charge pump.
4. Charge pump inlet vacuum Inspect inlet filter and replace as necessary.
overworking system. Dirty filter or Check for correct line diameter, length or
inadequate line size will restrict flow. other restrictions.
5. System relief valve settings are too Verify settings of pressure limiters and high
low. Relief valves are overworked. pressure relief valves and adjust or replace
multi-function valves as necessary.
6. Internal leakage in motor reducing low Monitor motor case flow without loop
side system pressure and overworking flushing in the circuit (use defeat spool) . If
system. flow is excessive, replace motor.
7. High system pressure overheating Measure system pressure. If pressure is
system. high reduce loads.
Transmission operates normally in one 1. Input to control module is operating Check control input and repair or replace as
direction only. incorrectly. necessary.
2. Pump control linkages are not secure, Repair or replace control module as
control orifices are blocked etc. necessary.
3. Incorrect operation of interchange Interchange the multi-function valves to show
system pressure limiters, high pressure if the problem is related to the functions
relief valves and system check valves in contained in the multi-functionf valves. If the
multi-function valves. problem changes direction, repair or
replace the valve on the side that does not
operate.
4. Charge pressure decaying in one Measure charge pressure in forward and
direction caused by the loop flushing reverse. If pressure decays in one direction,
valve sticking in one direction. inspect and repair the motor loop flushing
valve.
System will not operate in either direction. 1. Insufficient hydraulic fluid to supply Fill reservoir to correct level.
system loop.
2. Input to control is operating incorrectly. Check control input and repair or replace as
necessary.
3. Pump displacement control linkages Repair or replace control module as
not secure, control orifices blocked. necessary.
4. Bypass valves are open, system loop Close bypass valves. Replace multi-function
depressurised. valves if defective.
5. Low charge with pump in neutral, Measure charge pressure with pump in
pressure insufficient to charge system neutral. If pressure is low, go to step 6;
loop. otherwise continue with step 5.
6. Low charge pressure with pump in Measure charge pressure with pump in
stroke indicates a motor charge relief stroke. If pressure is low. adjust or replace
valve or system pressure relief valve may motor charge relief valve, otherwise go to
be improperly set. step 9.
7. Pump charge relief valve is leaking or Adjust or replace the pump charge relief
set too low depressurising the system. valve as necessary.
8. Clogged filter reducing supply to Inspect filter and replace if necessary.
system loop.
9. Charge pump malfunction providing Repair or replace the charge pump. If OK
insufficient charge flow. go to last step.
10. Pump displacement control linkages Repair or replace control module as
are not secure, control orifices blocked, necessary.
etc.
11.Low system pressure not providing Measure system pressure. Continue with
power necessary to move load. next step.
12. Defective multi-function valves Repair or replace multi-function valves.
causing system pressure to be low.
TRANSMISSION 3.23
Low motor output torque 1. Pressure limiter causing low pressure Measure system pressure at motor. If
at the motor reducing torque. pressure limiter setting is low, increase
setting.
2. Variable motor stuck at minimum Check control supply pressure or repair
displacement, yielding low output torque. displacement control. Check motor control
orifices.
3. Internal leakage reducing system Check for leakage in O-rings, gaskets and
pressure. other fittings. Repair unit as required, or
replace leaking unit.
Improper motor output speed 1. Insufficient hydraulic fluid reducing Fill reservoir to correct level.
motor speed.
2. Incorrect pump outflow affecting output Measure pump output and check for correct
speed. Incorrect output flow indicates the pump speed. Check that the pump is in full
swashplate is out of position. stroke.
3. Variable motor displacement control See if variable motor displacement control
not functioning correctly. Variable motor is responding. If not, replace control.
swashplate may be in wrong position.
pressure. other fittings. Repair or replace unit as
required.
Excessive noise and/or vibration 1. Insufficient hydraulic fluid leading to Fill reservoir to correct level.
cavitation.
2. Air in sytem leading to cavitation. Look for foam in reservoir. Check for leaks
on inlet side of system loop. Afterwards let
reservoir settle until bubbles are gone. Run
system at low speed to move system fluid
reservoir. Repeat operation until clear of air.
3. High pump inlet vacuum creating Inspect and relace filter as necessary.
excessive noise. Check suction line for correct size or
restrictions.
4. Loose shaft coupling causing Replace loose shaft coupling in charge
excessive noise. pump or replace pump or motor.
5. Misaligned shaft causing frictional Align shafts.
noise.
System response is sluggish 1. Insufficient hydraulic fluid reducing Fill reservoir to correct level.
system output pressure.
2. Multi-function valves pressure setting Adjust or replace multi-function valves.
incorrect, affecting system reaction time.
3. High pump inlet vacuum reducing Measure charge inlet vacuum. If high
system pressure. replace inlet filter.
4. Low engine speed reducing system Adjust engine speed.
performance.
5. Incorrect charge or control pressures Measure charge and control pressures and
affecting system performance. correct if necessary.
pressure. other fitings.
SECTION 4
BOOM
BOOM 4.1
DESCRIPTION AND OPERATION

DESCRIPTION
The machine has a two section telescopic boom.

Each section consists of a box section with the inner
section moving inside the outer section.
The boom is controlled using the ‘Quattro’ control

handle located in the cab.
The inner section can be extended to any position

from fully retracted to fully extended. The boom
position is limited, depending on the weight being
carried, boom angle and boom extension.
To prevent an overload, the machine is fitted with an

overload indicator, located in the cab. The overload
indicator gives a progressive indication of load on the
rear axle to warn the operator when the machine is
nearing its safe working load.
To ensure the inner section operates smoothly, non-

metallic wear pads are fitted between the inner and
outer sections, at the front of the outer boom and the
rear of the inner boom.
The boom operations consist of:

• lift/lower
• extend/retract
• carriage crowd back/tip forward.
The carriage is fitted to the front of the inner boom

section and carries the attachments. The
attachments are secured to the carriage by a locking
mechanism, which is either manually or hydraulically
operated.
A cassette tray is fitted inside the inner boom to

house the hydraulic pipes for the crowd cylinder and
the forward services.
4.2 BOOM
OPERATION
The ‘Quattro’ handle in the cab operates all boom

services.
The carriage crowd cylinder is hydraulically

connected to the compensator cylinder. Oil is
transferred between the crowd and compensator
cylinders during the lifting/lowering of the boom to
make sure the carriage stays at the same angle to
the ground throughout the arc of the lift. This works
independently of the crowd function, which allows the
carriage to be rolled forwards or backwards.
The extension cylinder is fitted inside the inner boom.

The forward end is secured to the inner boom and the
rear end is secured to the outer boom.
When the boom is operated, the hydraulic hoses for

the front auxiliary services and the crowd cylinder are
withdrawn from the cassette to allow the boom to
extend.
The front auxiliary services are connected to a

manifold on the left side of the inner boom drop-down
link and are connected, by flexible pipes to the
carriage.
A joystick lockout lever is provided to give the

following facilities:
• Lockout the carriage tilt function,

preventing accidental operation and
allowing safe maintenance platform
operation. To lock out, push in the lever
whilst slightly moving the joystick until it
locks side to side
• To disable all boom functions pull out

the lever until it locks completely and
select the rotary isolator switch to boom
extend/retract and auxiliary functions
lockout position.
• A Joystick/Boom control isolator rotary

switch, in the cab, gives the following
facilities:
• To prevent operation of the carriage

locking pins when attachments are fitted
to the carriage
• To prevent all boom and auxiliary

hydraulic functions.
BOOM 4.3
MAINTENANCE
BOOM
Removal
NOTE: This procedure details the removal of the

boom as a complete assembly.
1. Make sure the boom is fully retracted and

horizontal.

wheels.

The boom is very heavy and must be

supported with appropriate lifting
equipment during removal and
installation.
5. Remove the boom rear cover.
6. Disconnect boom light fitting electrical connectors.
7. Disconnect multi way connector at boom base and

disconnect loom conduit at three mounting brackets.
8. Remove loom and conduit and stow clear of lifting

operations.
9. Connect suitable overhead lifting equipment, to the

boom front and rear lifting eyes on the outer boom.
10. Take the weight of the boom with the lifting 1. Hoses
equipment. 2. Boom connector bracket
3. Auxiliary hydraulic hoses
NOTE: Identify all hydraulic hoses to make sure they 4. Plate
are reconnected correctly and blank all open
hydraulic hoses and connections.
11. Disconnect the hydraulic hoses (1) to the boom

connector bracket (2) and the auxiliary services
hoses (3) (if fitted) to boom cassette back plate (4).
12. Support the upper end of the lift cylinder (5).
13. Remove the bolt (6), and washer (7) securing the
upper attachment pin (8).
14. Drive out the upper attachment pin (8) and lower
the cylinder onto a suitable support placed between
the chassis and side members.
4.4 BOOM
15. Support the upper end of the compensator

cylinder (9).
16. Remove the bolt (10) and washer (11) retaining

the upper attachment pin (12).
17. Drive out the upper attachment pin (12) and lower
the cylinder onto the lift cylinder or a suitable
support.
18. Remove the bolts (13), washers (14) and keep

plates (15) securing the boom (18) pivot pins (16 &
17) to the trunnion on each side of the chassis (19).
NOTE: Shims (20) are fitted between the left side of

the boom (18) and the chassis (19), make sure the
shims are not trapped during removal of pin (16) and
boom.
NOTE: Identify pivot pins to aid installation.
19. Drive out the boom pivot pins (16 & 17), using a
slide hammer and suitable punch, maintaining
alignment of the boom and chassis trunnions.
5. Lift cylinder
Make sure that the boom does 6. Bolt
not swing as it is lifted from the 7. Washer
machine. 8. Attachment pin
9. Compensator cylinder
20. Operate the overhead lifting equipment and 10. Bolt
remove boom from machine. 11. Washer
12. Attachment pin
Installation
NOTE: Shims (20) are fitted between the left side of

the boom (18) and the chassis (19). Make sure the
shims take up the play between the chassis and
boom. Various thickness shims are available. When
fitting the boom pivot pin (16), make sure the shims
are not damaged or trapped as the pin is fitted.

tank before engine is started.

and operating the boom services to fully extend and
retract cylinders several times.

BOOM 4.5
13. Bolt
14. Washer
15. Keep plate
16. Pivot pin
17. Pivot pin
18. Boom
19. Chassis
20. Shim
4.6 BOOM
HYDRAULIC CYLINDER
Crowd cylinder
For the removal, installation and maintenance of the

crowd cylinder refer to the Hydraulic Manual.
Compensator cylinder

compensator cylinder refer to the Hydraulic Manual.
Lift cylinder

lift cylinder refer to the Hydraulic Manual.
Extension cylinder

extension cylinder refer to the Hydraulic Manual.
BOOM 4.7
BOOM TRAY CASSETTE

Removal
1. Make sure the boom is in the horizontal position

and extended until the forward extension cylinder pin
is accessible.
2. In 4-wheel steer turn the steering fully left, stop the

engine, apply the parking brake and chock the
wheels.
3. Refer to Page 1.70 and dump hydraulic pressure.
4. Disconnect the battery.
NOTE: Removal of the crowd cylinder is not required

for this task but will make it easier. If the crowd
cylinder is to be removed it should be carried out at
this stage by referring to the hydraulic section.
5. Remove boom rear cover (1) and radiator grille (2).
6. Undo oil cooler quick release catches (3).

Disconnect wiring connectors to rear lights and
reverse alarm.
7. Remove screws securing radiator/oil cooler

surround (4) and remove surround.
8. Slide oil cooler (5) out to the limits of its travel.
The coolant system capacity is 26

litres, make sure the drain tank has
sufficient capacity to hold the
contents of the coolant system. Do
not drain the coolant until the system
is cold. Identify cooling system pipes
and hoses during removal
procedures to make sure they are
reconnected correctly.
9. Refer to operators manual and drain coolant

system.
10. Remove screws mounting radiator (6) to chassis.
11. Disconnect upper hose (7) and expansion tube (8)

from radiator (6). Partially remove radiator (6) and
disconnect bottom hose (9).
12. Remove screws (10) and top cover plate (11).
1. Cover 7. Hose
2. Grille 8. Expansion tube
3. Catch 9. Hose
4. Surround 10. Screw
5. Oil cooler 11. Plate
6. Radiator
4.8 BOOM
Take care when disconnecting motor

hoses to avoid damaging green sealing
O-rings.
13. Disconnect hoses (12, 13 & 14) from hydraulic

fan motor (15). Remove hydraulic fan, motor (15) and
radiator (6) as a complete assembly.
Identify all hydraulic hoses, pipes and

connectors during removal procedures
to make sure they are reconnected
correctly. Blank all hoses, pipes and
connectors to prevent ingress of for-
eign matter.
14. If not previously removed, refer to hydraulic 11. Hose

section and disconnect hoses to crowd cylinder and 12. Hose
remove elbow connectors. 13. Hose
14. Motor
15. Disconnect hoses at the forward end of the boom
from the auxiliary service/crowd cylinder and remove
connectors from bulkhead.
16. Refer to hydraulic section and disconnect hoses

to extension cylinder and boom tray. Remove hoses
from boom tray.
17. Refer to hydraulic section and remove pin from

inner boom and extension cylinder and bolts holding
extension cylinder spigot blocks to outer boom.
The extension cylinder is very heavy

and must be supported with appropriate
lifting equipment during removal and
installation.
Care must be taken when withdrawing the

cylinder. It is supported in a guide block
for the first half of travel during removal.
It is necessary to lift the cylinder after
clearing the block to avoid damage to the
ram.
If the crowd cylinder is still fitted ensure

hoses are able to pass around cylinder
before fully withdrawing the extension cyl-
inder.
NOTE: Make a note of the position of the spigot

blocks located on each side of the rear cylinder.
18. Withdraw extension cylinder, boom tray and

spigot blocks from the boom.
19. Place the assembly on a stand.

BOOM 4.9
Installation
Installation is the reverse of the above procedure.
NOTE: When installing the extension cylinder, use

draw lines in the boom to pull through hoses. The
crowd cylinder hoses pass left and the auxiliary
hoses pass to the right of the cylinder.

tank. Also, replenish the cooling system before
engine is started.

3. Refer to the operators manual and check the

hydraulic and cooling system levels and replenish if
necessary.
BOOM TRAY HOSES
Dismantling
Identify hydraulic pipes and hoses

during removal procedures to make
sure they are reconnected correctly. Fit
blanks to all open pipes, hoses and
connections.
NOTE: The boom tray hoses can only be removed

when the boom tray cassette has been removed.
1. Remove bolt holding clamp assembly to boom

tray.
2. Withdraw the steel tubes from boom tray cassette.
3. Disconnect hoses from steel pipes from boom tray.
4. Remove sliding pipes and hoses the cassette.
Assembly
1. Assemble the boom tray hoses in the reverse of

the above procedure.
2. Install the boom tray in the boom.

4.10 BOOM
INNER BOOM
Removal
1. Make sure the boom is in the horizontal position

and fully extended.
3. Disconnect the battery.
4. Support the inner boom.
5. Remove the outer boom wear pads.
6. Remove the boom rear cover.
Identify all hydraulic hoses, pipes

and connectors during removal
procedures to make sure they are
reconnected correctly. Blank all
hoses, pipes and connectors to
prevent ingress of foreign matter.
7. Disconnect the four hydraulic pipes (1) on the

bulkhead connector bracket (2) to the crowd cylinder
and auxiliary services.
8. Remove the two bolts and washers (3) securing

the bulkhead connector bracket to the extension
cylinder (4). Pull the bracket and hoses rearwards by
0.5 m (1.6 ft) to clear the boom.
9. Disconnect the four hydraulic pipes (5) from the

adapters on the bulkhead connector bracket (2) to
the crowd cylinder and auxiliary services.
The inner boom is very heavy and must
be supported with appropriate lifting
equipment during removal and
installation.
10. Remove the circlip (6) securing the extension

cylinder forward attachment pin (7) to the inner boom
and drive out the pin.
11. Lift the inner boom out of the outer boom using
either a forklift or overhead lifting equipment.
NOTE: An alternative method of removing the inner

boom is to reverse the machine away from the inner
boom.
1. Pipe 5. Pipe
2. Bracket 6. Circlip
3. Bolt and washer 7. Attachment pin
4. Extension cylinder
BOOM 4.11
Installation

tank before engine is started.


4.12 BOOM
BOOM WEAR PADS

General
The front boom wear pads can be removed and

installed with the boom assembled. The rear boom
wear pads can only be removed and installed with the
inner boom removed.
The wear pads are self-lubricating.
The pads should be fitted in pairs to the front lower

positions of the outer boom and the rear upper
section of the inner boom. At all other positions they
may be fitted singly, as required.
Replacement of outer boom wear pads (front) 1. Bolt

2. Washer
1. Park machine on firm level ground. 3. Retainer
4. Wear pad
2. Extend the boom and roll the carriage face down 5. Shim
onto the ground until the weight of the inner boom is 6. Outer boom
supported and the weight is off the front lower wear
pads.
3. Stop the engine, apply the parking brake and

chock the wheels.
5. Remove the bolt (1), washer (2), and retainer (3)

and withdraw the wear pads and shims (4 & 5) at
positions E and F from the bottom of the outer
boom (6).
6. Clean and inspect the pads for wear and damage.
7. Fit wear pads E and F to the lower side of the

boom with a 2.5 mm (0.10 in.) shim under each pad.
8. Start the engine and raise the boom until the

weight rests on the bottom wear pads.
9. Stop the engine.
11. Remove bolt (1), washer (2), and retainer (3) and
withdraw the wear pad and shims (4 & 5) at positions
A and D from the left and right side of the outer boom
(6).
12. Clean and inspect the wear pads for wear and
damage. Fit wear pad D to the side of the boom with
a 2.5 mm (0.10 in.) shim the pad.
BOOM 4.13
Lever the boom against the inner boom in direction è.

Fit wear pad A to the side of the boom and shim to
give a clearance of less than 1.0 mm (0.040 in.).
Remove bolt (1), washer (2), and retainer (3).

Withdraw the wear pad and shims (4 & 5) at
positions B and C from the upper side of the outer
boom (6).
Clean and inspect the wear pads for wear and

damage.
Fit wear pad B and C to the upper side of the boom

then shim to give a clearance of less than 1.0 mm
(0.040 in.).
4.14 BOOM
Replacement of outer boom wear pads

(rear)
1. Remove the inner boom.
2. Remove Locknut (1), stud (2), and shim (3) and

wear pads (4) from all positions of the inner boom (5).
3. Clean and inspect the wear pads for wear and

damage.
4. Fit wear pad A to the lower boom with a 2.5 mm

(0.10 in.) shim under the pad.
5. Fit wear pad D to the left side of the boom with a

2.5 mm (0.10 in.) shim under the pad.
1. Locknut
6. Fit wear pads B and C to the upper side of the 2. Stud
boom with a 2.5 mm (0.10 in.) shim under the pad. 3. Shim
4. Wear pad
7. Fit wear pads F and E to the lower side of the 5. Inner boom
boom with a 2.5 mm (0.10 in.) shim under the pad.
8. Refit the inner boom.
9. Lever the boom against the outer boom in direction

ç. Measure the clearance between the wear pad D
and the outer boom then shim to give a clearance of
less than 1.0 mm (0.040 in.).
10. Measure the clearance between the wear pads B

and C and the outer boom then shim to give a
clearance of less than 1.0 mm (0.040 in.).
BOOM 4.15
QUATTRO CONTROL HANDLE
Removal
1. Park the machine on firm level ground and apply

the parking brake.
2. Set the wheels straight-ahead, in line with the

chassis.
5. Disconnect the vehicle battery.
NOTE: The Quattro control handle (1) is located in

the cab to the right of the seat.
6. Remove screws (2) and gain access beneath

cover (3).
7. Remove mounting screws (4), washers (5) and

nuts (6).
8. Remove gaiter (7), gaiter retainer (8) and cover (3).
9. Disconnect the loom (9) at connector (10).
10. Disconnect cable locator (11) from base (12). 1. Quattro control handle
2. Screw
11. Loosen locknut (13) and unscrew the handle (1) 3. Cover
from the base (12), retaining the washer (14) in the 4. Screw
process. 5. Washer
6. Nut
Installation 7. Gaiter
8. Retainer
Before reconnecting cables ensure
the control handle is locked in the
neutral position.
1. Lock the control handle in the neutral position

using the lockout lever (15).
2. Installation is the reverse of the removal procedure.
3. Carry out a full check of the boom controls in

accordance with the operators manual.
4.16 BOOM
9. Loom
10. Connector
11. Locator
12. Base
13. Locknut
14. Washer
15. Lever
SECTION 5
CHASSIS
CHASSIS 5.1
CHASSIS
Description
The chassis is constructed using a primary plate

manufactured from high-grade steel that runs the
length of the machine.
Attached to the chassis are the engine pod on the

right side and the cab pod on the left side. The
cooling pack is mounted at the rear.
The side mounted engine pod can be removed as a

unit from the chassis to provide quick and easy
engine/transmission removal. For engine removal
refer to the engine manual.
The rear mounted cooling pack allows easy access

for maintenance and cleaning.
The cab pod is attached to the left side of the

chassis and houses the fuel tank. The operators cab
is secured to the cab pod.
The operators cab is easily removed for access to the

fuel tank.
The front and rear axles are attached to mounting

points on the chassis.
The chassis is reinforced at the boom mounting

points, which is situated at the rear for good stability.
5.2 CHASSIS
Operators Cab
Removal
1. Park the machine on firm level ground, apply the

parking brake and chock the wheels.
2. Raise the boom and fit the safety stop.

from the brake systems and steering system, then
disconnect the battery.
NOTE: Apply identification marks to all cables,

electrical cables and hoses as an aid to assembly.
5. Remove the front cover from cab pod below the

front windscreen.
6. Disconnect the cable to the parking brake and tie

clear of the cab.
7. Disconnect the hoses to the brake valve and tie

clear of the cab.
8. Disconnect the front and rear windscreen washer

pipe at the washer bottle.
9. Disconnect the four electrical connector plugs from

the cab front bulkhead.
10. Disconnect hoses from the steering valve and tie

back clear of the cab. Fit blanks to open pipes and
steering valve connections.
11. Remove the left headlight and sidelight from the

cab. Remove the left side worklight (If fitted).
Do not drain the coolant until the engine
is cold.
12. Clamp the heater hoses at the rear of the cab to

prevent leakage, then drain the engine coolant
system.
13. Remove the external heater pipes from the rear of

the cab.
14. If air conditioning is fitted, recover the gas from

the system and disconnect the two pipes from the
plate at the rear of the cab.
15. Disconnect the throttle cable at the throttle pedal.

CHASSIS 5.3
The fuel tank capacity is 85 litres,

make sure the drain tank has sufficient
capacity to hold the contents of the
fuel tank.
16. Remove the drain plug and drain the contents of

fuel tank into a suitable container.
17. Remove the two fuel hoses from the back of the
tank and fit suitable blanks to the hoses and
connectors.
18. Support the cab using suitable lifting equipment.
19. Remove the front and rear bolts attaching the cab
to the pod.
20. Lift the cab from the machine using suitable lifting
equipment and position on a stand.
Installation
1. Before installation of the cab, inspect the rubber

mounts on the pod and make sure they are
serviceable. Replace if necessary.
2. Before installation of the cab, inspect the fuel tank

for security. Make sure it is not damaged or leaking.
3. Fit new sealing washer to fuel tank drain plug.
4. Make sure the fuel supply and return hoses are

correctly routed, to avoid trapping and chaffing.
5. Installation is the reverse of the above procedure,

note the following points.
6. Torque load the cab attachment bolts to 250 Nm

(184 lbf ft).
7. Refit cooling hoses and top up system as required.
8. Refit fuel hoses, refuel the tank and check for

leaks. To bleed the fuel system refer to the operators
manual.

and replenish as required.
10. Refer to Page 1.69 and bleed the brakes. Also

check parking brake set-up.
5.4 CHASSIS
11. Check the following machine functions and

indications.
• Start engine, make sure oil pressure warning

light goes out and the tacho and hour meter
operates. Make sure battery charge indicator
light goes out
• Make sure fuel and temperature gauges
indicate.
• Select all forward and reverse gears and check
indication
• Operate all boom functions
• Operate all lights, including rear foglight
• Operate horn
• Operate the direction indicators and hazard
warning lights
• Operate parking brake. Make sure warning
light is on
• Operate foot brakes
• Operate steering in all modes to bleed air from
the system and check indicator lights
• Operate front and rear wipers and washers
• Operate the rear, side and boom worklights (if
fitted)
• Test overload indicator
• Test heater/air conditioning
• Operate rotating beacon
• Check hydraulic and cooling system fluid
levels and fill to correct level as necessary
• Road test machine.
CHASSIS 5.5
Fuel Tank
Removal
2. Stop the engine, chock the wheels and disconnect

the battery.
3. Refer to the operators cab removal procedure and

remove the cab from the pod.
4. Gain access under the seat floor mat and

disconnect cable (1) from fuel sender unit (4).
The fuel tank capacity is 85 litres,

make sure the drain tank has sufficient
capacity to hold the contents of the
fuel tank.
5. Remove the drain plug (1) and sealing washer (2)

and drain the contents of fuel tank into a suitable
container.
6. Remove bolts (7) washers (6) and nuts (5) from the
rear bulkhead. Remove bolts (10) and washers (9)
from the front bulkhead.
7. Remove tank (8) from under the cab.
Installation
1. Inspect the pod for damage.
2. Inspect the interior of the tank, make sure clean

and clear of debris.
3. Fit drain plug (1) and a new sealing washer (2) to

fuel tank (8).
4. Installation is the reverse of the removal procedure.
5. Refer to the operators cab installation and fit cab

to pod and carry out tests.
6. Refuel the tank and check for leaks. Start engine,

refer to the operators manual and bleed the fuel
system if necessary.
5.6 CHASSIS
1. Drain Plug 6. Washer

2. Sealing washer 7. Bolt
3. Cable 8. Fuel tank
4. Sender unit 9. Washer
5. Nut 10. Bolt
CHASSIS 5.7
Heater and Air Conditioning

Description
The heater assembly is fitted in a compartment

behind the cab seat and includes the heater coil and
blower motor.
When the air conditioning option is fitted, the heater

compartment also contains the evaporator coil,
receiver, trinary switch and expansion valve. The
condenser coil and axial fans are fitted in a housing
outside the cab, above the rear screen. The
compressor is fitted in the engine compartment and
driven by a V-belt from the engine crankshaft.
Blower Motor
Removal

the battery.
The seat weighs 50 kg (approx), take
care when lifting.
3. Remove the seat as follows:
• Remove plastic rivets from skirt

• Disconnect joystick wiring harness
• Remove four bolts securing seat to cab base
• Remove the seat from the cab.
4. Remove the rear cab trim panel.
5. Remove the self-tapping screws (3) securing the

housing lid (2), lift the housing lid to get access to
the blower motor electrical connections.
6. Disconnect the blower motor electrical connectors

(5) and remove housing lid complete with blower
motor (4).
7. Remove the self-tapping screws (1) securing

blower motor (4) to the housing lid (2) and remove
blower motor (4).
5.8 CHASSIS
Installation
2. Test the blower motor before fitting the seat.
3. After fitting the seat, test the joystick controls.
1. Self-tapping screw
2. Housing lid
3. Self-tapping screw
4. Blower motor
5. Electrical connectors
CHASSIS 5.9
Heater Coil
Removal

the battery.
3. Refer to the Blower Motor removal procedure and

get access to the heater housing.
4. Clamp the two hoses (1) and (3) to the heater coil
(4).
5. Remove the hose clips (2) from the hoses and

disconnect the two hoses from the heater coil.
6. Slide the heater coil out of the housing (5).
Installation
2. Remove the clamps from the heater hoses (1) and

(3).
3. Start the engine, check the hoses for leaks.
4. Stop the engine and check the coolant level, fill to

correct level as necessary.

5.10 CHASSIS
1. Hose
2. Hose clip
3. Hose
4. Heater coil
5. Housing
Air Conditioning Evaporator Coil

Removal

the battery.

4. Recover the gas from the system using suitable

equipment.
5. Disconnect the two adapters (2) and (3) connecting

the evaporator coil (4) to the expansion valve (1).
6. Slide the evaporator coil (4) out of the housing (5).

CHASSIS 5.11
Installation
4. Charge the system using suitable refrigerant

charging equipment.
5. Test the air conditioning system.
1. Expansion valve
2. Adapter
3. Adapter
4. Evaporator coil
5. Housing
5.12 CHASSIS
Receiver-Drier Assembly
Removal

the battery.


equipment.
5. Disconnect the adapter (4) connecting the receiver-

drier (2) to the expansion valve (1).
6. Disconnect the adapter (5) connecting the receiver-

drier (2) to the external pipe (7).
7. Remove the two self-tapping screws (6) securing

the receiver-drier (2) to the housing (3) and remove
the receiver-drier (2).
1. Expansion valve 5. Adapter

2. Receiver-drier 6. Self-tapping screws
3. Housing 7. Pipe
4. Adapter
CHASSIS 5.13
Installation

charging equipment.
Air Conditioning Condenser Coil

Removal

the battery.
3. Remove the two wingnuts (12) and washers (11)

and (10) securing the grille (15) below the condenser
coil (16). Remove the grille (15).

equipment.
5. Disconnect the two pipes (14) and (13) to the

condenser coil (16). Remove the pipe support blocks
(6) from the coil housing (5).
6. Remove the cab roof lining and disconnect the

multiplug from the condenser. Identify the wiring
connectors then disconnect the wiring loom (1) to the
axial fans (17).
7. Support the unit then remove the four bolts (3) and
washers (4) securing the condenser coil housing (5)
to the machine support (2) and remove the unit.
Pulling the cable through from the cab.
8. Remove the bolts (7) and washers (8) and (9)

securing the condenser coil (16) to the housing (12)
and remove the condenser coil (16).
Installation

charging equipment.

5.14 CHASSIS
1. Wiring loom 10. Washer

2. Machine support 11. Washer
3. Bolt 12. Wingnut
4. Washer 13. Pipe
5. Condenser coil housing 14. Pipe
6. Support block 15. Grille
7. Bolt 16. Condenser coil
8. Washer 17. Axial fan
9. Washer
CHASSIS 5.15
Axial fan and Relay

Removal
NOTE: Two axial fans are fitted, the removal

procedure is the same for both fans.

the battery.
3. Remove the two wingnuts (15) and washers (14)

and (13) securing the grill (18) below condenser coil
(19). Remove the grille (18).
4. Disconnect the pipes (17) and (16) to the

condenser coil (19). Remove the pipe support blocks
(9) from the condenser coil housing (8).
5. Remove the cab roof lining and disconnect the

multiplug from the condenser. Identify the wiring
connectors then disconnect the wiring loom (2) to
axial fans (22).
6. Support the unit then remove four bolts (4) and

washers (5) securing the condenser coil housing (8)
to machine support (3) and remove the unit. Pulling
the cable through from the cab.
7. Remove the bolts (10) and washers (11) and (12)

securing the condenser coil (19) to the housing (8)
and remove the condenser coil (19).
8. Electrically disconnect the axial fan(s) (22) from

the wiring loom and relay (1). Remove the relay, if
necessary, by removing the attachment bolt, washers
and nut.
9. Remove the bolts, (6) washers (7 & 21) and nuts

(20) securing the axial fan(s) (22) to housing (8) and
remove fan(s) (22) .
Installation

charging equipment.

5.16 CHASSIS
1. Relay 12. Washer

2. Wiring loom 13. Washer
3. Machine support 14. Washer
4. Bolt 15. Wingnut
5. Washer 16. Pipe
6. Bolt 17. Pipe
7. Washer 18. Grill
8. Condenser coil housing 19. Condenser coil
9. Support block 20. Nut
10. Bolt 21. Washer
11. Washer 22. Axial fan
CHASSIS 5.17
Compressor
Removal

the battery.
3. Open the engine pod cover.

equipment.
5. Disconnect the hoses (2) and (4) to the

compressor (9).
6. Disconnect the electrical lead (3) from the

compressor (9).
7. Loosen the nut (10) on attachment bolt (1).
8. Remove the adjuster bolt (5), washers (6) and nut

(8).
9. Rotate the compressor (9) and remove pulley belt

(7) from the pulley.
10. Support the compressor (9) then remove the bolt

(1) and nut (10) securing the compressor (9) to the
mounting bracket (11) and remove the compressor
(9).
Installation

charging equipment.
3. Tension the pulley belt to 22 N. This will give a

belt deflection of no more than 16 mm at the mid-
point of the longest span.

5.18 CHASSIS
1. Bolt 7. V-belt
2. Hose 8. Nut
3. Electrical lead 9. Compressor
4. Hose 10. Nut
5. Bolt 11. Mounting bracket
6. Washer
SECTION 6
TECHNICAL DATA
TECHNICAL DATA 6.1
C 40 C 50
Dimensions
A Length to front of carriage mm 3650 3850
B Length front to rear wheels mm 3342 3368
C Overall width over tyres mm 1800 1900
D Track width mm 1464 1564
E Height over cab on std tyres mm 1960 2130
F Interior cab width mm 845 845
G Wheelbase mm 2300 2300
H Ground clearance mm 320 400
I Turning radius on std tyres mm 2999 3100
J Overall bobywork width mm 1800 1800
Weight (unladen) kg 5000 5500

6.2 TECHNICAL DATA
C 40 C 50
Machine speed (km/hr)
Forward Low 8 8
Forward High 30 30
Carriage
Max crowd forward fully lowered - 50 50

degrees below horizontal
Max crowd back fully lowered - 14 14

degrees behind vertical
Max crowd forward fully raised - 15 15

degrees above horizontal
Max crowd backward fully raised - 79 79

degrees beyond vertical
Total carriage rotation - degrees 154 154
Max distance between forks - mm 1200 1200
Cycle time
Lift se c 6.0 6.0
Lower se c 4.5 4.5

Extend se c 4.9 5.7
Retract se c 3.4 4.3

Crowd forward (dump) se c 2.2 2.2
Crowd backward se c 2.7 2.7

TECHNICAL DATA 6.3
C 40 C 50
Engine
Perkins 1004.42 (diesel) kW (PS) 64 (86) 64 (86)
Max speed rpm 2200 2200
Net output Nm (rpm) 300 (1400) 300 (1400)
Cooling
Thermostat - opens °C 70 - 80 70 - 80
Thermostat - fully open °C 90 - 95 90 - 95
Transmission
Drive type 4WD 4WD
Transmission type Hydrostatic Hydrostatis
Gear Selector Non APC Non APC
Max road speed km/hr 32, 25 or 20 32, 25 or 20
Tyres
Cross Ply, Agri 10.5 - 20 N/A
Cross Ply, Agri 12.5 - 20 12.5 - 20
Radial Ply, Ind 275 R 20 N/A
Radial Ply, Ind 335 R 20 335 R 20
Radial Ply, Agri N/A 375 R 20

6.4 TECHNICAL DATA
C 40 C 50
Hydraulics
Pump type Gear Gear
Primary system max. pressure bar 240 240

Primary system max flow l/min 80 @ 2200 rpm 80 @ 2200 rpm
Secondary system max. pressure bar 150 150
Secondary system max flow l/min 35 35
Electrics
Battery capacity Amp/hr 110 110
Alternator output Amp 65 65
Capacities
Hydraulic system litre 25 25
Hydraulic tank litre 70 70

Fuel tank litre 85 85
Engine oil litre 8.5 8.5
Engine coolant litre 28.5 28.5
Transmission transfer box litre 0.7 0.7
Axle - front litre 7.0 7.0

Axle - rear litre 7.0 7.0
Axle - final drive (each) litre 0.8 0.8
Screen wash litre 2.0 2.0
Brakes
Foot brake Servo (front axle) Servo (front axle)
Parking brake Front axle Front axle

Paul Dodd
Field Service Manager
Following the policy of Caterpillar to improve their products as technical developments continue, Caterpillar
reserve the right to make alterations which may not necessarily correspond to text and illustrations contained
in this publication, and without incurring obligation to alter any machines previously delivered.
Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of
Caterpillar.
All rights under the provision of the Copyright Act are reserved.
349859.0
08/2003

0349 859 0 Sys RHB en 144

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REPAIR MANUAL

This manual is designed to service machines:

from Serial No. 50600011

Health and Safety

Always obtain advice before mixing oils; some are incompatible.

Never leave the machine unattended with pressure in the system.

AXLES AND STEERING

Steering is available to both axles, depending on the

1. Park the machine on firm level ground.

2. Raise the boom and fit the boom safety stop.

3. Set the wheels straight ahead, in line with the

4. Stop the engine and apply the parking brake.

5. Refer to page 1.70 and dump hydraulic pressure

Support the drive shaft clear of the

6. Disconnect the drive shaft from the axle flange

7. Disconnect the inductive magnetic steering sensor

Support the hydrostatic motor clear

8. Disconnect the hydrostatic motor from the

9. Slacken front axle wheel nuts.

10. Support the chassis at a sufficient height to allow

11. Support axle with a forklift or trolley jacks.

12. Remove front wheels.

13. Disconnect the parking brake linkage (1) and

14. Disconnect brake pipes from left (3) and right

15. Disconnect steering hoses (2) from steering

Secure the axle to the fork lift/

16. Remove the eight attachment bolts/nuts securing

17. Lower axle on fork lift/trolley jacks.

18. Move axle clear of machine and place on a

1. Installation is the reverse of the removal

2. Torque load components as follows:

Axle to chassis nuts 640 Nm (472 lbf ft.)

3. Check axle and wheel hub oil levels are correct.

4. When the axle has been dismantled and

5. Connect the parking brake linkage (1). Refer to

6. Refer to Page 1.69 and bleed the brakes then test

7. Start engine, make sure front wheel steering is

8. Test machine operation.

1. Park the machine on firm level ground.

2. Set the wheels straight ahead, in line with the

3.Stop the engine and apply the parking brake.

4. Refer to page 1.70 and dump hydraulic pressure

Support the drive shaft clear of the

5. Disconnect the drive shaft from the axle flange

6. Disconnect the load sensor electrical lead.

7. Disconnect the inductive magnetic steering sensor

8. Disconnect steering hoses from steering cylinder,

9. Slacken rear axle wheel nuts.

10. Support the chassis at a sufficient height to allow

11. Remove rear wheels.

12. Support axle with a forklift or trolley jacks.

13. Remove the bolts attaching the axle front

14. Remove the bolts attaching the axle rear support

Secure the axle to the fork-lift/trolley

15. Lower axle on fork-lift/trolley jacks.

16. Move axle clear of machine and place on a

1. Installation it the reverse of the removal

2. Torque load components as follows:

Axle to chassis nuts 640 Nm (472 lbf ft.)

3. Check axle and wheel hub oil levels are correct.

4. When the axle has been dismantled and

5. Start engine, make sure rear wheel steering is