TA30 A894 parte C.pdf

Section 220-0090

SM 2193 1-03 7

Steering System - Steering Valve

end of spool (16). Compress centring spring (11)radially (CCW) and engage free end of spring into slotin spool (16). See Fig. 14.

5. Install bearing race (13) onto spool (16). Usingsuitable pliers install retainer (20) onto spool (16). SeeFig. 14.

6. Apply a light coating of petroleum jelly to the insidediameter of dust seal (15) and install in valve housing (7).

7. Apply a light coating of petroleum jelly to needlethrust bearing (12), bearing race (13), 'O' ring (14),seal ring (17) and backup ring (18). Install each itemonto spool (16), as shown in Fig. 15.

Note: Needle thrust bearing is positioned between thetwo bearing races (13) and must be centered aroundretainer (20).

Note: Clamp steering valve housing (7) vertically in asoft jawed vice.

SM - 2024

SM - 2025

Fig. 13 - Installing Centring Pin and Drive Shaft

SM - 2026

11 - Centring Springs13 - Bearing Race

Fig. 14 - Installing Bearing Race and Retainer

6 - Drive Shaft8 - Sleeve

10 - Pin16 - Spool

3. Insert drive shaft (6) into spool (16) in sleeve (8)carefully so that holes line up. Install pin (10) throughsleeve (8), spool (16) and drive shaft (6) assemblyuntil pin (10) becomes flush at both sides of sleeve (8).See Figs. 12 & 13.

4. Position one end of centring spring (11) into slotted

SM - 2027

Fig. 15 - Sectional View of Seals and Bearings

16 - Spool17 - Seal18 - Backup Ring20 - Retainer

6 8

10

9

16

Fig. 12 - Installing Spool and Ball Checks

6 - Drive Shaft8 - Sleeve9 - Ball Check

10 - Pin16 - Spool

6

10

16

8

1611 2013

16 - Spool20 - Retainer

6 8 11

161099

13

17

18

1412206 - Drive Shaft8 - Sleeve

9 - Ball Check10 - Pin11 - Centring Springs12 - Needle Bearing13 - Bearing Race14 - 'O' Ring

Section 220-0090Steering System - Steering Valve

SM 2193 1-038

SM - 2028

Fig. 16 - Compressing Centering Spring

SM - 2029

Fig. 17 - Installing Spool and Sleeve Assembly

8. Using a cloth to protect the hand, place gerotor gear(19) over end of drive shaft (6). Insert special toolthrough valve housing (7) and engage with splinedend of spool (16) and sleeve (8) assembly. Twist toolto compress centering spring (11) radially CW orCCW. Refer to Fig. 16.

9. Keep centering spring (11) compressed andcarefully insert assembled parts into valve housing (7),as shown in Fig. 17.

10. Release tension on centering spring (11) andremove special tool and gerotor gear (19).

11. Lubricate and install new 'O' ring (22) in groove invalve housing (7). Refer to Fig. 18.

12. Install spacer plate (5) with the 'O' ring groove up, on

valve housing (7). Align bolt holes in spacer plate (5) withtapped holes in valve housing (7). Refer to Fig. 18.

13. Lubricate and install new 'O' ring (21) in groove inspacer plate (5). Refer to Fig. 18.

14. Install gerotor housing (4) on valve housing (7).Align bolt holes in gerotor housing (4) with tappedholes in valve housing (7). Refer to Fig. 18.

15. Align gerotor gear (19) on driveshaft (6) andgerotor housing (4), as shown in Fig. 18.

16. Lubricate and install new 'O' ring (3) in groove ingerotor housing (4).

17. Install end cap (2) on gerotor housing (4), asshown in Fig. 18.

Fig. 18 - Installing Seals and Gerotor Assembly

SM - 2030

73 4

2

121 5

22

19

1 - Capscrew2 - End Cap3 - 'O' Ring

4 - Gerotor Housing5 - Spacer Plate7 - Valve Housing

19 - Gerotor Gear21 - 'O' Ring22 - 'O' Ring

Section 220-0090

SM 2193 1-03 9

Steering System - Steering Valve

18. Align cap screw (1) holes and install seven dry capscrews (1) in end cap (2). Pre-tighten cap screws (1) to17 Nm (12.5 lbf ft) then tighten to a torque of 34 Nm(25 lbf ft), in the sequence shown in Fig. 19.

19. Using bolts (10, Fig. 4) and washers (11, Fig. 4)secure mounting plate (5, Fig. 4) to steering valve (1,Fig. 4).

INSTALLATIONNumbers in parentheses refer to Fig. 4.

Note: Tighten all fasteners to standard torques listedin Section 300-0080, STANDARD BOLT AND NUTTORQUE SPECIFICATIONS.

Note: Tighten all hydraulic lines fitted with ORFSconnections, as described in Section 220-0000,STEERING SYSTEM SCHEMATIC. Renew all'O' rings where used.

WARNINGTo prevent personal injury and propertydamage, be sure wheel blocks, blockingmaterials and lifting equipment are properlysecured and of adequate capacity to do the jobsafely.

1. Make certain area of installation is clean.

2. Install rubber mounts (4) if removed, and securesteering valve (1) and mounting plate (5) to cab floorwith bolts (7), washers (3 & 6) and locknuts (2).

3. Install nitrile seal (9) to steering shaft (14).

4. Slide bottom joint (12) of steering shaft (14) overstub shaft (8) and secure by tightening bolt. Slidebellows (13) down over bottom joint (12) and stubshaft (8).

Fig. 19 - Cap Screw Tightening Sequence

5. Remove plugs from steering valve ports and capsfrom steering lines and install steering lines to steeringvalve (1), as identified at removal.

6. Lower cab and secure with pins. Refer to Section260-0010, CAB AND MOUNTING.

7. Fill hydraulic tank with hydraulic oil, as specified inSection 300-0020, LUBRICATION SYSTEM. Refer to'Filling and Bleeding The Steering System'.

8. Remove wheel blocks from all road wheels, placethe battery master switch in the 'On' position and startthe engine. Operate the steering and check hydrauliclines for leaks. Tighten lines and fittings as required.

FILLING AND BLEEDING THE STEERINGSYSTEM1. Fill hydraulic tank to Maximum level. Be ready toadd oil when the engine is started. Do not let oil dropbelow the pump suction line to prevent air entering thesystem.

2. Start engine and let it idle. Immediately add oil to thehydraulic tank as required. When no more oil can beadded and oil is clear, proceed as follows:

a. Turn the steering wheel from lock to lock to bleedthe air in the steering cylinders and lines.

Note: Immediately upon valve spool actuation oil mustbe added to the hydraulic tank to replenish the oilmoving into the circuit.

WARNINGDo not operate the vehicle until all air is bledfrom the oil.

b. When the oil in the tank is clear (not cloudy orcreamy), the system is free of air.

Note: Slight creep or drift of the steering wheel is normal.

c. Fill hydraulic tank with hydraulic oil specified inSection 300-0020, LUBRICATION SYSTEM. Refer toSection 230-0040, HYDRAULIC TANK, for correct filllevel. Install filler cap on tank.

SM - 313

Section 220-0090Steering System - Steering Valve

SM 2193 1-0310

* * * *

SPECIAL TOOLSRefer to Section 300-0070, SERVICE TOOLS, fordetails of the centring spring installation toolreferenced in this section. This tool is available fromyour dealer.

SPECIAL TORQUE SPECIFICATIONSTORQUE

FIG. NO. ITEM NO. ITEM NAME Nm lbf ft5 1 Capscrew 34 25

STEERING CONTROL DIAGNOSISCONDITION REASON REMEDYSteering wheel does not centre Binding in steering linkage to valve Align as required

Worn gerotor Replace partsBroken centring springs Replace centring springs, drain

and flush systemBurrs on sleeve or spool Disassemble and repair or replace

partsApparent inability to steer when Dirt in system Drain and flush system. Refill withwheel is turned slowly clean oilSlow steering Excessive wear in sleeve and spool Replace sleeve and spool

Excessive wear in gerotor Replace gerotorHard steering See 'Slow Steering'Opposite steering Lines hooked up incorrectly Reconnect correctly

Wrong orientation between gerotor Realign per instructionsand gerotor drive

Steering wheel rocking back See 'Opposite Steering'and forthSteering wheel continues to turn Input linkage binding Align as required

Burr on sleeve or spool Disassemble and repair or replaceDirt in system Drain and flush system. Refill with

clean oilBroken centring springs Replace centring springs, drain and

flush systemNo steering action Sleeve and spool locked together Disassemble and repair or replace

Section 220-0120

SM 2195 Rev1 12-04 1

STEERING SYSTEM - Steering Cylinder

SM - 3372

Fig. 1 - Sectional View of Steering Cylinder and Mounting

7 - Wiper8 - Cushion Sleeve9 - Piston

10 - Grub Screw11 - Wear Ring

12 - Piston Seal13 - Spherical Bearing14 - Circlip15 - Back Up Ring16 - 'O' Ring

17 - Pin18 - Hardened Washer19 - Lockwasher20 - Bolt21 - Spacer22 - Spacer

1 - Cylinder Body2 - Piston Rod3 - End Cap4 - Lube Fitting5 - 'O' Ring6 - Rod Seal

DESCRIPTIONNumbers in parentheses refer to Fig. 1.

The steering cylinders can be identified as item 2 inSection 220-0000, STEERING SYSTEMSCHEMATIC.

There are two single stage, double acting cushionedsteering cylinders on the machine. The piston rod (2)end is connected to the articulation and oscillationpivot, and, the cylinder base end is connected to thefront frame. Single stage double acting means thatpiston rod (2) can have oil applied to either side,extending or retracting the piston rod.

Rod end cylinder mounting is by pins (17), seals (21),spacers (22) and spherical bearings (13) secured withcirclips (14). Base end cylinder mounting is by pins

(17), spacerls (21), spacers (22) and spherical bearings(13) secured with circlips (14). Spherical bearings (13)permit a limited amount of cylinder misalignment whentravelling over rough terrain.

OPERATIONWhen the operator turns the steering wheel for asteering operation, movement of the piston rodgenerates force required to pivot the tractor frame.

In the neutral position, with the steering valvecentralized, oil movement between the steeringcylinders and the steering valve is stopped. Trappedoil in the system locks both steering cylinders and theangle of steering set by the operator is maintained.Refer to Section 220-0090, STEERING VALVE, foroperation of the steering valve.

3

2

15,1676

5 129

14

10

13

11 11

48

ORIENTATION OFCUSHION SLEEVE

1413

17

2019

PART OFFRAME

18

4

17

2019

PART OFFRAME

18

1

212223

21

Section 220-0120Steering System - Steering Cylinder

SM 2195 Rev1 12-042

REMOVALNumbers in parentheses refer to Fig. 1.

WARNINGSTo prevent personal injury and propertydamage, be sure wheel blocks, blockingmaterials and lifting equipment are properlysecured and of adequate capacity to do the jobsafely.

Hydraulic fluid pressure will remainwithin the system after engine shutdown.Operate the treadle pedal continuously until thepressure has dissipated before carrying out anywork on the hydraulic system or serious injurycould result.

1. Position the vehicle in a level work area, apply theparking brake and switch off the engine. Turn steeringwheel several times to relieve any pressure in thesteering circuit. Operate brake pedal continuously torelieve pressure in the braking system.

2. Place steering lock bar in the 'Locked' position.Block all road wheels and place the battery masterswitch in the 'Off' position.

3. Identify, tag and with a suitable container in positionto catch the spillage, disconnect all hydraulic lines onone steering cylinder. Cap all lines and fittings toprevent ingress of dirt.

4. Support steering cylinder with a suitable liftingdevice.

5. Remove bolt (20), lockwasher (19) and hardenedwasher (18) securing pin (17) at base end of thecylinder. Remove pin (17) securing base end to thefront frame.

6. Remove bolt (20), lockwasher (19) and hardenedwasher (18) securing pin (17) at piston rod (2) end ofthe cylinder. Remove pin (17) securing piston rod (2)end to the articulation and oscillation pivot.

7. Remove cylinder assembly from the machine.Spacers (22 & 21) will come free at this time.

8. Remove cylinder assembly to a clean area fordisassembly. Drain oil from cylinder assembly into asuitable container.

9. Repeat steps 3 through 8 for opposite steeringcylinder assembly.

DISASSEMBLYNumbers in parentheses refer to Fig. 1.

WARNINGTo prevent personal injury and propertydamage, be sure lifting equipment is properlysecured and of adequate capacity to do the jobsafely.

1. Ensure clean working conditions, remove any portplugs thus allowing easy entry of air into the cylinder,preventing a vacuum when parts are withdrawn fromcylinder body (1).

2. Remove circlips (14) from base end of cylinder body(1) and piston rod (2) end. Press out sphericalbearings (13).

3. Using special tool which can be fabricated as shownin Fig. 2, unscrew end cap (3) until thread isdisengaged from cylinder body (1).

4. Pull end cap (3) and piston rod (2) out of cylinderbody (1) as an assembly.

5. Place piston rod (2) on supports which will notdamage the chrome piston rod diameter.

6. Remove and discard piston seal (12) and wear rings(11) from piston (9).

7. Remove grub screw (10) from wear ring groove inpiston (9).

8. Provide an anti-torsion device through piston rod (2)eye to allow unscrewing of piston (9). Using specialtool which can be fabricated as shown in Fig. 3,unscrew piston (9) from piston rod (2).

9. Remove and discard 'O' ring (5) from piston (9).Remove and retain cushion sleeve (8) from piston rod(2).

10. Pull end cap (3) assembly off piston rod (2).Remove and discard back up ring (15) and 'O' ring (16)from end cap (3) outer grooves. Remove and discardwiper (7) and rod seal (6) from end cap (3) innergrooves.

11. If damaged, remove lube fittings (4) from cylinderbody (1) and piston rod (2).

Section 220-0120

SM 2195 Rev1 12-04 3

INSPECTIONNumbers in parentheses refer to Fig. 1

1. Clean all parts of the cylinder with a suitable solventand dry with clean, lint-free cloths. Clean all groovescarefully to remove any foreign material.

2. Check cylinder body (1), end cap (3) grooves andouter diameter of piston (9) for scratches, cracks orother signs of damage. Remove ridges, nicks andscratches with a fine stone and re-clean. Replace anycomponents which cannot be repaired.

3. Inspect piston rod (2) for distortion, cracks or otherdefects. Replace piston rod (2) if defective area isirreparable.

4. Check spherical bearings (13) for wear and replace ifnecessary.

ASSEMBLYNumbers in parentheses refer to Fig. 1.


1. Press spherical bearings (13) in base end of cylinderbody (1) and piston rod (2) end. Secure sphericalbearings (13) with circlips (14).

2. Install new rod seal (6) into bore of end cap (3) withthe lip pointing towards the internal face of end cap (3).Install new wiper (7) into bore of end cap (3).

3. Install new back up ring (15) and 'O' ring (16) inexternal groove of end cap (3).

4. Guide end cap (3) assembly onto piston rod (2),taking care not to damage rod seal (6) on the thread.

5. Install cushion sleeve (8) into piston rod (2) counterbore. Note correct orientation, spigot face abutscounter bore face (see Fig. 1).

6. Install new 'O' ring (5) into internal groove of piston(9).

7. Using special tool which can be fabricated as shownin Fig. 3, screw piston (9) on piston rod (2). Tightenpiston (9) to a torque of 746 - 813 Nm (550 - 600 lbf ft).

Steering System - Steering Cylinder

8. Insert piston grub screw (10), through wear ringgroove in piston (9), into groove machined in piston rod(2). Tighten grub screw (10) to a torque of 13 - 20 Nm(10 - 15 lbf ft). Ensure the extreme of grub screw (10)is below the level of wear ring groove.

9. Insert new piston seal (12) and new wear rings (11)in piston (9) external grooves.

10. Fully grease piston (9) OD and 'O' ring (16) in endcap (3).

11. Ensure bore of cylinder is well lubricated withhydraulic oil. Carefully insert piston rod (2) and endcap (3) assembly into cylinder body (1).

12. Engage end cap (3)/cylinder body (1) thread andscrew up fully. Using special tool which can befabricated as shown in Fig. 2, tighten end cap (3) to atorque of 542 - 610 Nm (400 - 450 lbf ft).

13. Replace lube fittings (4) if required.

INSTALLATIONNumbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners to standard torques listedin Section 300-0080, STANDARD BOLT AND NUTTORQUE SPECIFICATIONS.

Note: Tighten all hydraulic lines fitted with ORFSconnections, as described in Section 220-0000,STEERING SYSTEM SCHEMATIC. Renew all'O' rings where used.


1. Install a suitable strap, or other lifting device, aroundone cylinder assembly and position cylinder assemblyon the vehicle, with piston rod (2) end of cylinder readyfor mounting.

2. Install spacers (21) and spacers (22) either side ofpiston rod (2) end of cylinder and insert pin (17).Secure pin (17) to articulation and oscillation pivot withbolt (20), lockwasher (19) and hardened washer (18).

3. Install spacers (21) and spacers (22) either side ofbase end of cylinder and insert pin (17). Secure pin (17)to front frame with bolt (20), lockwasher (19) and


SM 2195 Rev1 12-044

hardened washer (18).

4. Connect hydraulic lines to steering cylinder ports, astagged during removal.

5. Repeat steps 1 through 4 for installation of oppositesteering cylinder.

6. Lubricate pins (17) through lube fittings (4) withlubricant, as specified in Section 300-0020,LUBRICATION SYSTEM.

7. Check oil level in hydraulic tank and add oil if low.Refer to Section 230-0040, HYDRAULIC TANK, forcorrect fill level. Refer to Section 300-0020,LUBRICATION SYSTEM, for the type of oil used.

8. Place the steering lock bar in the 'Stowed' positionand remove wheel blocks.

9. Place the battery master switch in the 'On' position,start the engine and operate the steering, from lock tolock several times, to purge air out of the hydrauliclines. Check hydraulic lines and fittings for leaks.Tighten lines and fittings as required.

MAINTENANCEInspect steering cylinders regularly for leaks ordamage, repair as required. Lubricate cylinder pinsevery 250 hours, as specified in Section 300-0020,LUBRICATION SYSTEM.

SPECIAL TOOLSSpecial tools can be fabricated as shown in Figs. 2 & 3.Refer to Section 300-0070, SERVICE TOOLS, for partnumbers of general service tools required. These toolsare available from your dealer.

Fig. 2 - End Cap Torque ToolDimensions in mm (inches)

SM - 407

DRILL

DEEP

RAD TYP

SQUARE

BURN

OUT

RAD

DRILL AND REAM THROUGHAND FIT 8 (0.315) HARDENED DOWELTORQUE PINS 2 PLACES

SECURE ALUMINIUMCOLLAR WITH (3) M8CAP SCREWS

Section 220-0120

SM 2195 Rev1 12-04 5

Steering System - Steering Cylinder

* * * *

Fig. 3 - Piston Torque Tool

SM - 633

Dimensions in mm (inches)

SQUA

RE

SILVER STEEL

DOM TUBEOUTER SHIELD TO BE SECUREDTO INNER BODY WITH 2BA CAPSCREWS

SPECIAL TORQUE SPECIFICATIONSTORQUE

FIG. NO. ITEM NO. ITEM NAME Nm lbf ft1 9 Piston 746 - 813 550 - 6001 3 End Cap 542 - 610 400 - 4501 10 Grub Screw 13 - 20 10 - 15


SM 2195 Rev1 12-046

THIS PAGE IS INTENTIONALLY BLANK

3ECTION

3-2EV

BODY SYSTEM - Body System Schematic

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3ECTION

3-2EV

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7HENOILFROMTHEMAINPUMPFLOWSTHROUGHTHECONTROLSPOOLAPRESSUREISCREATEDATTHEHEADOFTHECOPYSPOOL4HECOPYSPOOLSTROKESDOWNALLOWINGAgLOADSENSEgPRESSURETOBEFEDBACKTOTHELOADSENSEPORTOFTHEMAINPUMPVIASHUTTLEVALVESAND4HEMAINPUMPTHENINCREASESITSDISPLACEMENTANDFLOWPASSESTOPORTg"gLOWERINGTHEBODY2ETURNINGFLOWFROMTHETIPPINGCYLINDERSPASSESTO0ORTg!gTHROUGHTHECONTROLSPOOLBACKTOTANK

$URINGLOWERINGTHEOPERATORCANFULLYSELECTTHEBODYCONTROLLEVERONTOANELECTRICDETENTWITHINTHELEVERBASEWHICHISCONNECTEDTOTHEHYDRAULIC%#5PIN#4HISDETENTHOLDSTHELEVERINTHEPOWERDOWNPOSITIONALLOWINGTHEOPERATORTODRIVETHEVEHICLEWHILSTTHEBODYISSTILLLOWERING

!PROXIMITYSWITCHISLOCATEDONTHECHASSISWHICHSUPPLIESA6OLTSIGNALTOTHEHYDRAULIC%#5PIN#7HENTHEBODYREACHESTHEPROXIMITYSWITCHTHE6OLTSIGNALISSWITCHEDOFFWHICHINTURNSIGNALSTHEHYDRAULIC%#5TODEENERGIZETHEELECTRICDETENTALLOWINGTHELEVERTOSPRINGBACKTOTHEMIDPOSITION!T

Body System - Body System Schematic

&IG"ODY#ONTROL,EVER/PERATORgS#AB

&IG"ODY#ONTROL,EVER0OSITIONS

3-

3-

4HELOADSENSEPRESSURECREATEDBYTHECOPYSPOOLISCONTROLLEDTOAMAXIMUMOFBARLBFINBYTHERELIEFVALVE4HISWILLRESULTINAMAXIMUMMAINPUMPDELIVERYPRESSUREFORTHEBODYRAISECIRCUITOFBARLBFIN4HISISARESULTOFTHEBARLBFINMAXIMUMLOADSENSEPRESSUREPLUSTHEBARLBFINSTANDBYPRESSUREOFTHEMAINPUMP2EFERTO3ECTION-AIN(YDRAULIC0UMP

4HEBODYRELIEFVALVEISLOCATEDONTHERAISESIDE


3-2EV

,/7%20),/402%3352%).,%44/-!).30//,

0/24g4g

0/24g"g

0/24g!g

0/24g$,g

X()$$%.

2%&,)&46!,6%3%#4)/.2!)3%0),/402%3352%).,%44/-!).30//,

3-

&IG-AIN(YDRAULIC6ALVE!SSEMBLY"ODY#ONTROL6ALVE,OCATIONS

0ROPORTIONAL#ONTROL6ALVE2AISE 0RESSURE2EDUCING6ALVE0ILOT0RESSURE &LOAT3OLENOID 0RIORITY6ALVE 3HUTTLE6ALVE 3HUTTLE6ALVE 3HUTTLE6ALVE 2ELIEF6ALVE"ODY2AISE0RESSURE,3 0ROPORTIONAL#ONTROL6ALVE,OWER #OPY3POOLS ,OAD3ENSE$UMP6ALVE /RIFICE 2ELIEF6ALVE

6ALVE#OIL2ATING

6OLTAGE6 /HMS !MPS 7ATTS

6ALVE#OIL2ATING

6OLTAGE6 /HMS !MPS 7ATTS

3ECTION

3-2EV


THESAMETIMETHEHYDRAULIC%#5RAMPSBACKTHECURRENTTOPROPORTIONALPRESSURECONTROLVALVETODESELECTTHEMAINSPOOLANDENERGIZESTHECOILONTHEFLOATSOLENOIDVALVEALLOWINGTHEBODYTOFLOATDOWNTOTHECHASSISOVERTHELASTFEWCENTIMETERSOFTRAVEL

4OPREVENTDAMAGETOTHEBODYHINGEPOINTSORTHETIPCYLINDERSTHEFLOATSOLENOIDVALVEWHICHISCONNECTEDTO0IN#ONTHEHYDRAULIC%#5ISENERGIZEDALLTHETIMETHEBODYISONTHECHASSISANDTHEENGINEISRUNNING4HISENSURESTHATTHEHEADSIDEOFTHETIPCYLINDERSISALWAYSVENTEDTOTANKANDTHEBODYISSITTINGFIRMLYONTHECHASSIS

7HENTHEBODYMEETSTHEPROXIMITYSWITCHONTHECHASSISTHECONTROLSPOOLISDESELECTEDANDREVERTSTOTHENEUTRALPOSITION4HISACTIONCLOSESTHECOPYSPOOL4HELOADSENSEDUMPVALVEALLOWSACONTROLLEDLOADSENSEPRESSUREDRAINBACKTOTHEHYDRAULICTANK

7HENTHECONTROLSPOOLMOVESTOTHENEUTRALPOSITIONOILDELIVERYFROMTHEMAINPUMPISBLOCKED4OCOMPENSATEFORTHISOVERTHELASTFEWCENTIMETRESOFTRAVELMAKEUPCHECKVALVEOPENSALLOWINGACONTROLLEDOILFLOWVIAPORTg"gTOTHELOWERSIDEOFTHETIPCYLINDERS4HEMAKEUPCHECKVALVEOPENINGSAFEGUARDSTHESYSTEMAGAINSTCAVITATIONWHENTHEMAINPUMPFLOWISBLOCKEDDURINGTHELOWERINGPROCEDUREOFTHEBODY

BODY LOWER EMERGENCY SWITCH!SWITCHISPROVIDEDONTHECONSOLEIMMEDIATELYTOTHERIGHTOFTHEOPERATORgSSEATWHICHINITIATESLOWERINGOFTHEBODYINTHEEVENTOFANENGINEHYDRAULICORHYDRAULIC%#5FAILURE4HESWITCH3ON0AGEOFTHE#IRCUIT$IAGRAMS;3ECTION=WHENOPERATEDPOWERSTHESOLENOIDOFTHEFLOATSWITCHDIRECTLYFROMTHEBATTERIES4HECAUSEOFTHEFAILUREMUSTBEINVESTIGATEDANDRECTIFIED

Note)FANELECTRICALFAULTOCCURSTHATRESULTSINTHEMAINSPOOLDEFAULTINGTOTHE.EUTRAL(OLDPOSITIONWHILETHEBODYISRAISEDLOWERINGCANBEACHIEVEDBYPRESSINGTHEBODYLOWER%MERGENCYSWITCHWHICHWILLALLOWITTODROPUNDERITSOWNWEIGHT4HEBODYMUSTREMAINLOWEREDWITHTHELEVERINTHE.EUTRALPOSITIONUNTILITISNECESSARYTOOPERATETHEBODYAGAIN&AILURETOCOMPLYWITHTHISMAYRESULTINOVERHEATINGOFTHEHYDRAULICOILANDFAILUREOFTHEHYDRAULICSYSTEMCOMPONENTS

WARNINGAlways disconnect the body control leverbefore welding on the machine.

0&"

2"

3-

&IG$IAGNOSTIC0RESSURE#HECK0OINTS"ATTERY"OX

3-

&IG"ODY,OWER%MERGENCY3WITCH

$IFFERENTIAL,OCK0RESSURE0UMP,30RESSURE &RONT"RAKE0RESSURE 2EAR"RAKE0RESSURE

0ARK"RAKE0RESSURE 3TEERING0RESSURE 4RANS2ETARDER0RESS

4RANS#ONVERTER 0RESS "ODY3YSTEM0RESS 4RANS3YSTEM0RESSURE0 0RIMARY!CCUMULATOR&" &RONT"RAKE!CCUMULATOR2" 2EAR"RAKE!CCUMULATOR


3-2EV

EMERGENCY BODY LOWERINGPROCEDURE, FOLLOWING LOSS OFHYDRAULIC AND ELECTRICAL POWER)FTHEBODYISRAISEDANDTHEVEHICLEHASLOSTELECTRICAL!.$HYDRAULICPOWERITISPOSSIBLETOMAKEADJUSTMENTSTOTHETHREADEDENDSTOPSATTHEBODYSPOOLOFTHE-AIN(YDRAULIC6ALVETHATWILLFORCEACONTROLLEDLOWERINGOFTHEBODY4HEPROCEDUREFORCARRYINGOUTTHISOPERATIONISDETAILEDBELOW

WARNINGS

To prevent personal injury and propertydamage, be sure wheel blocks, blockingmaterials and lifting equipment are properlysecured and of adequate capacity to performthe task safely.

Exercise extreme caution when accessing theMain Hydraulic Valve in order to lower thebody. Do not put yourself in any danger fromimpact with the lowering body.

0OSITIONTHEVEHICLEINALEVELWORKAREAAPPLYTHEPARKINGBRAKEANDSWITCHOFFTHEENGINE4URNTHEBATTERYMASTERSWITCHTOTHEgOFFgPOSITION

"LOCKALLROADWHEELSANDPLACETHEBATTERYMASTERSWITCHINTHEg/FFgPOSITION

4HE-AIN(YDRAULIC6ALVEASSEMBLYISACCESSEDBYRAISINGTHEOPERATORgSCAB5SINGTHEHYDRAULICHANDPUMPINSIDETHEBATTERYBOXTILTTHECABANDSECUREIT2EFERTO3ECTION#ABAND-OUNTING

WARNINGNever work under or near an unsupportedraised operator's cab assembly. Always ensurethat the cab safety prop is in the correctposition.

,OCATETHESPOOLSCREWSIDENTIFIEDAS!AND"RESPECTIVELYON&IGURE-EASUREANDRECORDTHEHEIGHTOFTHEOUTERFACEOFEACHSCREWFROMTHECASINGOFTHE"ODY3ECTIONOFTHE-AIN(YDRAULIC6ALVE

3-

&IG"ODY6ALVE3POOL3CREWS

!0/243#2%7

"0/243#2%7

9977

4 ,35

! "

3ECTION

3-2EV


,OOSENTHELOCKNUTONSPOOLSCREW"THENUNSCREWSCREW"UNTILTHETHREADEDSHOULDEROFTHESCREWISFLUSHWITHTHEFACEOFTHECASING

,OOSENTHELOCKNUTONSPOOLSCREW!THENSCREWINSCREW!UNTILTHEBODYLOWERSSLOWLYANDINACONTROLLEDFASHION

WARNINGKeep well clear of the body as it is lowering.

RESETTING MAIN HYDRAULIC VALVEAFTER HYDRAULIC AND ELECTRICALPOWER IS RESTORED

3TARTTHEENGINE

2AISETHEBODYUNTILITISRAISED

5NSCREWSPOOLSCREW!UNTILITSOUTERFACEISRETURNEDTOTHEORIGINALHEIGHTABOVETHECASINGMEASUREDIN3TEPOFTHE%MERGENCY,OWERINGPROCEDUREGIVENABOVE,OCKTHESCREWINTHISPOSITIONUSINGTHELOCKNUT

3CREWINSCREW"UNTILITSOUTERFACEISRETURNEDTOTHEORIGINALHEIGHTABOVETHECASINGMEASUREDIN3TEPOFTHE%MERGENCY,OWERINGPROCEDUREGIVENABOVE,OCKTHESCREWINTHISPOSITIONUSINGTHELOCKNUT

5SINGTHEHYDRAULICHANDPUMPINSIDEBATTERYBOXLOWERTHECABANDSECUREIT2EFERTO3ECTION#ABAND-OUNTING

CHECKING SYSTEM PRESSURES

WARNINGSTo prevent personal injury and propertydamage, be sure wheel blocks and blockingmaterials are properly secured and of adequatecapacity to do the job safely.

Hydraulic fluid pressure will remainwithin the system after engine shut down.Operate the brake treadle pedal continuouslyuntil the pressure has dissipated beforecarrying out any work on the system or seriousinjury could result.

CHECKING THE MAIN BODY SYSTEMPRESSURE0OSITIONTHEVEHICLEINALEVELWORKAREAAPPLYTHEPARKINGBRAKESWITCHOFFTHEENGINEANDTURNTHESTEERINGWHEELINBOTHDIRECTIONSSEVERALTIMESTORELIEVEANYPRESSUREINTHESTEERINGCIRCUIT

/PERATETHEBRAKETREADLEVALVECONTINUOUSLYTORELIEVEPRESSUREINTHEACCUMULATORS"LOCKALLROADWHEELSPLACETHESTEERINGLOCKBARINTHEg,OCKEDgPOSITIONANDTHEBATTERYMASTERSWITCHINTHEg/FFgPOSITION

4HISFOLLOWINGPROCEDUREWILLCHECKTHATTHEBODYRAISEPRESSUREISPROPERLYSET#ONNECTAHYDRAULICGAUGECAPABLEOFRECORDINGAPRESSUREOFBAR

LBFINTOTHEBODYSYSTEMPRESSUREDIAGNOSTICPRESSUREPOINTINSIDETHEBATTERYBOX&IGURE

0LACETHEBATTERYMASTERSWITCHINTHEg/NgPOSITIONSTARTTHEENGINEANDALLOWALLSYSTEMSTOBECHARGEDNORMALLY

0ULLBACKBODYCONTROLLEVER!LLOWBODYTORAISEOVERRELIEF4HEPRESSUREOBSERVEDONTHEPRESSUREGAUGESHOULDBEBARLBFIN

0RESSURESETTINGCANBEADJUSTEDBYADJUSTINGRELIEFVALVEONTHEMAINHYDRAULICVALVEASSEMBLY2ELIEFVALVEACTUALLYSETSTHELOADSENSEPRESSUREFORTHEBODYCIRCUITCONTROLLINGTHELOADSENSETOAMAXIMUMOFBARLBFIN4HISWILLRESULTINAMAXIMUMMAINPUMPDELIVERYPRESSUREFORTHEBODYRAISECIRCUITOFBARLBFIN4HISISDUETOTHEBARLBFINMAXIMUMLOADSENSEPRESSUREPLUSTHEBARLBFINSTANDBYPRESSUREOFTHEMAINPUMP2EFERTO3ECTION-AIN(YDRAULIC0UMP4HEOPERATORgSCABHASTOBERAISEDTOFACILITATEACCESSTOTHERELIEFVALVE2EFERTO3ECTION#ABAND-OUNTING

!DJUSTRELIEFVALVEUNTILBARLBFINISOBSERVEDONTHEPRESSUREGAUGEWHILERAISINGTHEBODYOVERRELIEF

3HUTOFFTHEENGINEANDREMOVETHEPRESSUREGAUGEFROMTHEDIAGNOSTICCHECKPOINT

2EMOVETHEWHEELBLOCKSPLACETHESTEERINGLOCKBARINTHEg3TOWEDgPOSITIONSTARTTHEENGINEANDCHECKTHEBODYSYSTEMFORPROPEROPERATION


3-2EV

CHECKING THE PILOT CONTROLPRESSURE0OSITIONTHEVEHICLEINALEVELWORKAREAAPPLYTHEPARKINGBRAKESWITCHOFFTHEENGINEANDTURNSTEERINGWHEELINBOTHDIRECTIONSSEVERALTIMESTORELIEVEANYPRESSUREINTHESTEERINGCIRCUIT

/PERATETHEBRAKETREADLEVALVECONTINUOUSLYTORELIEVEPRESSUREINTHEACCUMULATORS"LOCKALLROADWHEELSPLACETHESTEERINGLOCKBARINTHEg,OCKEDgPOSITIONANDTHEBATTERYMASTERSWITCHINTHEg/FFgPOSITION

#ONNECTAHYDRAULICGAUGECAPABLEOFRECORDINGAPRESSUREOFBARLBFININTOTHEDIFFERENTIALLOCKDIAGNOSTICPRESSUREPOINTINSIDETHEBATTERYBOX&IGURE

0LACETHEBATTERYMASTERSWITCHINTHEg/NgPOSITIONSTARTTHEENGINEANDALLOWALLSYSTEMSTOBECHARGEDNORMALLY

!HYDRAULICPRESSUREOFBARLBFINSHOULDBEOBSERVEDONTHEPRESSUREGAUGE

0RESSURESETTINGCANBEADJUSTEDBYADJUSTINGPRESSUREREDUCINGVALVEONTHEMAINHYDRAULICVALVE!DJUSTPRESSUREREDUCINGVALVEUNTILBARLBFINISOBSERVEDONTHEPRESSUREGAUGE

Note$IFFERENTIALLOCKPILOTPRESSURECANONLYBETESTEDWITHTHEDIFFERENTIALLOCK./4ACTUATED7HENTHEDIFFERENTIALLOCKISENGAGEDTHEDIAGNOSTICPRESSUREPOINTISVENTEDTOTANK

#HECKTHEBODYSYSTEMFORPROPEROPERATION

3HUTOFFTHEENGINEANDREMOVETHEPRESSUREGAUGEFROMPORTg$,g

4HEOPERATORgSCABSHOULDBELOWEREDINTOTHETRAVELPOSITION#HECKTHEHYDRAULICLINESFORANYLEAKAGE

2EMOVEWHEELBLOCKSPLACETHESTEERINGLOCKBARINTHEg3TOWEDgPOSITIONSTARTTHEENGINEANDCHECKTHEBODYSYSTEMFORPROPEROPERATION

O-RING FACE SEALS (ORFS)7HEREHYDRAULICLINESAREFITTEDWITH/2&3CONNECTIONSTHEFOLLOWINGPROCEDURESHOULDBECARRIEDOUTDURINGg)NSTALLATIONg2EFERTO&IGURE

A%NSURETHATTHE/RINGSEALISINPLACEANDTHATTHEJOININGSURFACESARECLEAN)FNECESSARYRETAINTHE/RINGSEALINPLACEWITHALIGHTCOATINGOFGREASEORVASELINE

B)NITIALLYTHENUTSSHOULDBETIGHTENEDBYHAND

C7HEREAHOSEISFITTEDENSURETHATITISNOTTWISTEDORKINKEDWHENTHENUTSARETIGHTENEDSOTHATITISALLOWEDTOADOPTANATURALPOSITION

D7HEREATUBEISFITTEDENSURETHATTHECONNECTIONISALIGNEDCORRECTLY

E4IGHTENTHENUTAFURTHERTOATURNUSINGTHECORRECTSIZESPANNERWRENCH

F#HECKTHATASATISFACTORYHOSEORTUBEROUTINGHASBEENACHIEVED

HYDRAULIC OIL4HEHYDRAULICSYSTEMSHOULDBEKEPTFILLEDWITHHYDRAULICOILASSPECIFIEDIN3ECTION,UBRICATION3YSTEM

7HENEVERTHEREISAHYDRAULICSYSTEMFAILURETHEOILSHOULDBEDRAINEDTHEENTIRESYSTEMFLUSHEDOILFILTERSREPLACEDOILSCREENSTHOROUGHLYCLEANEDANDCLEANHYDRAULICOILADDEDTOELIMINATEALLMETALPARTICLESORFOREIGNMATTER

SERVICE TOOLS)TISRECOMMENDEDTHATTHEFOLLOWINGSERVICETOOLSAREUSEDWHENCARRYINGOUTPRESSUREANDTEMPERATURECHECKSDURINGMAINTENANCEPROCEDURES4HESETOOLS

&IG!SSEMBLYOF4YPICAL/2&3#ONNECTOR

3-

/2).' /2).'3,%%6%

45"%&)44).' .54

3ECTION

3-2EV

Body System - Body System SchematicALONGWITHOTHERGENERALSERVICETOOLSAREAVAILABLEFROMYOURDEALER2EFERTO3ECTION3ERVICE4OOLSFORPARTNUMBERSOFTHESETOOLS

Multi-Gauge4HEMULTIGAUGEISBASICALLYFOURPRESSUREGAUGESINONE#ONTINUOUSSYSTEMPRESSUREREADINGSAREINDICATEDONONEOFTHREESIMULTANEOUSLYREADINGGAUGESTHROUGHAPRESSURERANGEOFINOFVACUUMTOLBFIN

4HEFOLLOWINGITEMSSHOULDBEADDEDTOTHEMULTIGAUGETOENABLETHEGAUGETOBEUSEDONTHEDIAGNOSTICPRESSURECHECKPOINTS $IAGNOSTIC#OUPLING #ONNECTORTWO (OSE!SSEMBLY(0MMLONG

Non-contact Infrared Thermometer4HEINFRAREDTHERMOMETERCANBEUSEDTOSPOTHEATPROBLEMSEARLYINELECTRICALMECHANICALANDHYDRAULICSYSTEMS(ANDHELDANDEASYTOUSEYOUSIMPLYAIMPULLTHETRIGGERANDREADTHETEMPERATURE3INCETHEREISNONEEDTOTOUCHWHATYOUAREMEASURINGTEMPERATURESOFHARDTOREACHORMOVINGCOMPONENTSCANBETAKENWITHOUTGETTINGBURNEDORSHOCKED

O-ring Face Seals (ORFS) - Seal Kit4HEBRAKINGSYSTEMUTILIZES/RING&ACE3EAL/2&3CONNECTORS!N/2&3KITISAVAILABLE4HISKITCONTAINSAMINIMUMSTOCKREQUIREMENTOFALLSIZESOF/2&3TYPESEAL


3-2EV

Body System Trouble ShootingSymptom Possible Cause Remedy

"ODYWILLNOTLIFT

,IFTFUNCTIONTOOSLOW

0RESSURE,EVELINTHESYSTEMISNOTHIGHENOUGH

.OELECTRICCURRENTATTHEPROPORTIONALCONTROLVALVE

0ROPORTIONALCONTROLVALVEFAULTY

#ONTROLLEVERINTHECABFAULTY

-AINCONTROLSPOOLINTHELIFTSECTIONOFTHEMAINHYDRAULICVALVEASSEMBLYSTICKING

#OPYSPOOLSTICKING

#ONTAMINATIONINTHELOADSENSEDRILLINGSANDTHEORIFICE

-AINPUMPFAULTY

0ROPORTIONALCONTROLVALVECURRENTNOTHIGHENOUGH

-AINCONTROLSPOOLNOTFULLYSELECTING


-AINPUMPFAULTY

#HECKTHEPRESSUREATTHEPUMPANDREADJUSTTHE2ELIEF6ALVE2EFERTO3ECTION-AIN(YDRAULIC0UMP

2ELIEFVALVESTUCKOPEN

#HECKVOLTAGEATTHEELECTRICCONNECTOROFFOR6ALVEWHENPULLINGBACKONTHELEVERINTHECAB)FNOVOLTAGEPRESENTREFERTO3ECTIONS(YDRAULIC%#5AND"ODY#ONTROL,EVER2EPLACE6ALVE

#HECKOUTPUTFROMLEVER2EFERTO3ECTIONS(YDRAULIC%#5AND"ODY#ONTROL,EVER

2EPLACELIFTSECTIONOFTHEMAINHYDRAULICVALVEASSEMBLY

#HECKCONDITIONOFCOPYSPOOLREPLACEIFNECESSARY2EPLACE-AIN(YDRAULIC6ALVE!SSEMBLY

#LEANORIFICE2EPLACE-AIN(YDRAULIC6ALVE!SSEMBLY

2EFERTO3ECTION-AIN(YDRAULIC0UMPFORCORRECTSETTINGPROCEDURES

#HECKOUTPUTFROMBODYCONTROLLEVER2EFERTO3ECTIONS(YDRAULIC%#5AND"ODY#ONTROL,EVER

2EPLACELIFTSECTIONOFMAINHYDRAULICVALVEASSEMBLY#LEANORIFICE

2EPLACE-AIN(YDRAULIC6ALVE!SSEMBLY

2EFERTO3ECTION-AIN(YDRAULIC0UMPFORCORRECTSETTINGPROCEDURES

3ECTION

3-2EV



,IFTFUNCTIONTOOSLOWCONT

"ODYWILLNOTLOWER

"ODYLOWERSTOOSLOW


%NGINE20-TOOLOW

3UPPLYFUSETOHYDRAULIC%#5BLOWN

.OELECTRICCURRENTATPROPORTIONALCONTROLVALVE

0ROPORTIONALCONTROLVALVEFAULTY


0ROXIMITYSWITCHONCHASSISREADING,/7FLOATCONDITION

,OSSOFHYDRAULICANDELECTRICALPOWER

.OTENOUGHELECTRICCURRENTATTHEPROPORTIONALCONTROLVALVE

0ILOTPRESSURENOTHIGHENOUGH

-AINCONTROLSPOOLSTICKING

&AULTYMAINPUMP

#HECKLEVEROUTPUTS2EFERTO3ECTIONS(YDRAULIC%#5AND"ODY#ONTROL,EVER

#ANAFFECTPUMPDELIVERY#HECKTHROTTLEPEDALFORCORRECTSIGNALS

#HECKTHATTHEGREEN,%$ONTHEHYDRAULIC%#5ISILLUMINATED2EPLACEFUSE&LOCATEDINSIDEFUSEBOX2EFERTO3ECTION#IRCUIT$IAGRAMS#HECKTHELINKBETWEENTHEBODYCONTROLLEVERANDTHEHYDRAULIC%#5ANDBETWEENTHEHYDRAULIC%#5ANDTHEPROPORTIONALCONTROLVALVE2EFERTO3ECTIONS(YDRAULIC%#5AND"ODY#ONTROL,EVER

#HECKCONNECTIONS2EPLACEPROPORTIONALCONTROLVALVE#HECKFOROUTPUTFROMCONTROLLEVER2EFERTO3ECTIONS(YDRAULIC%#5AND"ODY#ONTROL,EVER#HECKCONNECTIONSREPLACEPROXIMITYSWITCH

&OLLOWTHE%MERGENCY"ODY,OWER0ROCEDURE

#HECKOUTPUTFROMBODYCONTROLLEVER2EFERTO3ECTIONS(YDRAULIC%#5AND"ODY#ONTROL,EVER

2ESETTHEPILOTPRESSUREATTHEPRESSUREREDUCINGVALVE)FITCANNOTBERESETREPLACETHEPRESSUREREDUCINGVALVE

2EPLACETHELIFTSECTIONOFTHEMAINHYDRAULICVALVEASSEMBLY2EFERTO3ECTION-AIN(YDRAULIC0UMPFORCORRECTSETTINGPROCEDURES


3-2EV


"ODYWILLNOTHOLD

0OWERDOWNAVAILABLEWHENBODYISONTHECHASSIS

"ODYFAILSTOOSLOWDOWNWHENREACHINGTHEPROXIMITYSWITCHONTHECHASSIS

"ODYFAILSTOOGOINTOFLOATANDSTOPSBEFOREITREACHESTHECHASSIS

/ILBYPASSINGBETWEENCONTROLSPOOLANDVALVEBODY

/ILBYPASSINGBODYLIFTCYLINDERS

#ONTROLSPOOLNOTCENTRING

&AULTYPROXIMITYSWITCHONCHASSIS

&AULTYPROXIMITYSWITCHONCHASSIS

&AULTYHYDRAULIC%#5ORCONNECTIONS

-AINSPOOLSTICKING

&AULTYFLOATSOLENOIDVALVE

.OVOLTAGEATTHEFLOATSOLENOIDVALVE

2EPLACELIFTSECTIONOFMAINHYDRAULICVALVEASEEMBLY

2EPAIRTHELIFTCYLINDERS

#HECKTHATTHEREISZEROPILOTPRESSUREATBOTHENDSOFCONTROLSPOOL%ITHEROFPROPORTIONALCONTROLVALVESCOULDREMAINACTIVE

#HECKTHEBODYCONTROLLEVER3HOULDBEZEROOUPUTSIGNALFROMCONTROLLEVERWHENINTHENEUTRALPOSITION

#ONTROLSPOOLDAMAGED2EPLACECONTROLSPOOL#HECKCONNECTIONS2EPLACEPROXIMITYSWITCH2EFERTO3ECTION(YDRAULIC%#5FORCHECKTOOL

#HECKGAPBETWEENBODYPLATEANDPROXIMITYSWITCH-AXGAPMM2EPLACEPROXIMITYSWITCH

2EFERTO3ECTION(YDRAULIC%#5FORCHECKPROCEDURE

2EPLACEMAINHYDRAULICVALVEASSEMBLY

#HECKCONNECTIONS2EPLACEVALVE2EFERTO3ECTION(YDRAULIC%#5

#HECKCONNECTIONSATVALVEANDHYDRAULIC%#52EFERTO3ECTION(YDRAULIC%#5

* * * *


"ODYLOWERSTOOSLOWCONTINUED #LEANTHEORIFICE2EPLACETHEMAINHYDRAULICVALVEASSEMBLY

Section 230-0040

SM 2350 10-04 1

1

2,3,4

78

1816

21 20

22

23

2728

26

1819

917

13 121424256

19

1110

15

5

BODY SYSTEM - Hydraulic Tank

SM - 3316


The hydraulic tank (1) is the common reservoir for thesteering, braking, body hoist and transmission oilcooler fan drive systems. It is mounted off the frame atthe rear right hand side of the tractor.

Integral with hydraulic tank (1) assembly are filterassembly (2), oil level sight gauge (5) and access

cover (21). Located on top of the tank is filler cap (12),breather (17) and filter restriction gauge (14).

OPERATIONNumbers in parentheses refer to Fig. 2.

Oil is added to the hydraulic tank (4) through filterassembly (2). The hydraulic oil is drawn from hydraulictank (4) by main hydraulic pump (1) and pumped to themain hydraulic valve to supply the various hydraulic

Fig. 1 - Exploded View of Hydraulic Tank and Mounting

1 - Hydraulic Tank2 - Filter Assembly3 - Element4 - 'O' Ring5 - Sight Gauge6 - Bolt7 - Drain Valve8 - Seal

23 - Plug24 - 'O'-Ring25 - Guard26 - Bolt27 - Nut28 - Lockwasher

9 - 'O' Ring10 - Gasket11 - Cover Plate12 - Cap13 - 'O' Ring14 - Filter Restriction Gauge15 - Drain Adaptor Hose

16 - Lockwasher17 - Breather18 - Bolt19 - Washer20 - 'O' Ring21 - Access Cover22 - 'O' Ring

Section 230-0040Body System - Hydraulic Tank

SM 2350 10-042

SM - 2864

systems. Refer to Section 215-0050, MAINHYDRAULIC VALVE ASSEMBLY.

Emergency steering oil is drawn from hydraulic tank (4)by emergency pump (2), mounted off transmission, andis also pumped to the main hydraulic valve. Should afailure occur at the main hydraulic pump (1) theemergency pump (2) will supply the steering systemwith oil to enable the vehicle to be brought to a safehalt. Refer to Section 220-0000, STEERING SYSTEMSCHEMATIC.

Return oil from the hydraulic systems flows throughhydraulic oil cooler (3) (if fitted) and filter assembly(5) before entering the tank storage area. The filterassembly has a bypass valve which allows oil tobypass element (3, Fig. 1) when it is cold or when thefilter element is plugged. The bypass valve opens at apressure differential of 1.5 bar (22 lbf/in2). Filterrestriction gauge (14, Fig. 1) shows red when element(3, Fig. 1) requires to be changed.

MAINTENANCENumbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners without special torquesspecified to standard torques listed in Section300-0080, STANDARD BOLT AND NUT TORQUESPECIFICATIONS.


Checking Oil Level1. Operate the body hoist and steering systemsseveral times to bring the oil to correct operatingtemperature.

2. Position the vehicle in a level work area, ensure thebody is fully lowered, apply the parking brake andswitch off the engine. Turn steering wheel in bothdirections several times to relieve any pressure in the

Fig. 2 - Hydraulic Schematic of Hydraulic Tank

1 - Main Hydraulic Pump2 - Emergency Pump 3 - Hydraulic Oil Cooler 4 - Hydraulic Tank 5 - Filter Assembly

SUPPLY TOMAIN HYDRAULIC

VALVE

EMERGENCYSUPPLY TO

MAINHYDRAULIC

VALVE

RETURNTO TANK

4

321

55

Section 230-0040

SM 2350 10-04 3

Body System - Hydraulic Tank

steering circuit. Operate treadle valve continuously todischarge accumulators.

3. Block all road wheels, place the steering lock bar inthe 'Locked' position and the battery master switch inthe 'Off' position.

4. Check oil level and add if low. Oil should at leastreach the minimum level in the sight gauge (5). If oil isrequired, remove filler cap (12) from hydraulic tank (1)and fill hydraulic tank with hydraulic oil specified inSection 300-0020, LUBRICATION SYSTEM. Installfiller cap (12) on hydraulic tank (1) and tighten.

Replacing Hydraulic OilHydraulic oil should be changed every 2 000 hours.Refer to Section 300-0020, LUBRICATION SYSTEM,for hydraulic oil used in the system.

Note: When replacing the hydraulic oil due to ahydraulic failure, or at recommended change interval,element (3) must be replaced and hydraulic tank (1)cleaned thoroughly using a suitable solvent.

Replacing BreatherEvery 1 000 hours of operation, or sooner if the vehicleis being operated in extremely dusty conditions, thehydraulic tank breather should be replaced.

1. Position the vehicle in a level work area, ensure thebody is fully lowered, apply the parking brake andswitch off the engine. Turn steering wheel in bothdirections several times to relieve any pressure in thesteering circuit. Operate treadle valve continuously todischarge accumulators.


3. Unscrew breather (17) and remove from tank (1).Discard 'O' ring (9).

4. Install new 'O' ring (9) and breather (17) to tank (1).

Replacing Filter ElementEvery 2 000 hours of operation or when filter restrictiongauge (14) shows red, whichever comes first, cleanfilter assembly (2) and install new element (3).

1. Position the vehicle in a level work area, ensure thebody is fully lowered, apply the parking brake andswitch off the engine. Turn steering wheel in both

directions several times to relieve any pressure in thesteering circuit. Operate treadle valve continuously todischarge accumulators.


3. Remove blanking cap from remote drain valve (7) onthe bottom of hydraulic tank (1). Install a hose adaptor(15) on remote drain fitting, open drain cock and drainhydraulic oil into a suitable container. Close drain cock,remove hose and reinstall blanking cap on remote drainvalve (7).

4. Remove bolts (6 & 18) and washers (19) securingguard (25) and cover plate (11) to top of hydraulic tank(1). Remove guard (25), cover plates (11) and gasket(10) from hydraulic tank (1). Discard gasket (10).

5. Remove filter assembly (2) from hydraulic tank (1).

6. Remove and discard element (3) from filterassembly (2). Discard 'O' ring (4).

7. Remove bolts (18) and lockwashers (16) securingaccess cover (21) to tank (1). Remove access cover(21) and discard 'O' ring (20).

WARNINGSplashing liquid. Wear a suitable face shieldwhen using compressed air to dry hydraulictank and components.

8. Clean out the inside of hydraulic tank (1) with asuitable solvent and dry with compressed air.

9. Install new element (3) in filter assembly (2).

10. Install filter assembly (2) in tank (1), complete withnew 'O' ring (4).

11. Place new gasket (10), cover plate (11) and guard(25) on hydraulic tank (1). Secure with bolts (6 & 18)and washers (19).

12. Install new 'O' ring (20) and secure access coverplate (21) on hydraulic tank (1) with bolts (18) andlockwashers (16).

13. Remove filler cap (12) from hydraulic tank (1) andfill hydraulic tank with hydraulic oil specified in Section300-0020, LUBRICATION SYSTEM. Install filler cap(12) on hydraulic tank (1) and tighten.


SM 2350 10-044

InspectionNumbers in parentheses refer to Fig. 1.

WARNINGSplashing liquid. Wear a suitable face shieldwhen using compressed air to dry hydraulictank and components.

1. Clean hydraulic tank (1) and components with asuitable solvent and dry with compressed air.

2. Inspect hydraulic tank (1) for weld cracks andsecurity of internal pipes and weld fitments.

3. Inspect breather (17), filter restriction gauge (14) andfilter assembly (2) for damage. Replace if required.

InstallationNumbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners without special torquesspecified to standard torques listed in Section300-0080, STANDARD BOLT AND NUT TORQUESPECIFICATIONS.

Note: Tighten all hydraulic lines fitted with ORFSconnections, as described in Section 230-0000,BODY SYSTEM SCHEMATIC. Renew all 'O' ringswhere used.


1. Using a suitable lifting device, position hydraulictank (1) in position on the vehicle and secure withbolts (26), lockwashers (28) and nuts (27).

2. Remove eyebolts that were installed to lift hydraulictank (1). Reinstall two bolts (18) and washers (19) ontop of tank (1).

3. Install new 'O' rings and install all hydraulic lines andfittings to hydraulic tank (1), as tagged at removal.

4. Remove filler cap (12) and fill hydraulic tank (1) withhydraulic oil specified in Section 300-0020,LUBRICATION SYSTEM. Install filler cap (12) onhydraulic tank (1) and tighten.

14. Place the battery master switch in the 'On' positionand the steering lock bar in the 'Stowed' position,remove all wheel blocks, start the engine and operatethe steering, braking and body hoist systems tocirculate the oil.

15. Switch off the engine, check for leaks and checkoil level as described under 'Checking Oil Level'.

TANK ASSEMBLY

RemovalNumbers in parentheses refer to Fig. 1.


1. Position the vehicle in a level work area, ensurethe body is fully lowered, apply the parking brake andswitch off the engine. Turn steering wheel in bothdirections several times to relieve any pressure inthe steering circuit. Operate treadle valve continuouslyto discharge accumulators.


3. Remove blanking cap from remote drain valve (7) onthe bottom of hydraulic tank (1). Install a length of hoseon remote drain fitting, open drain cock and drainhydraulic oil into a suitable container. Close drain cock,remove hose and reinstall blanking cap on remote drainvalve (7).

4. Ensure all hydraulic lines connected to hydraulictank (1) are identified for ease of installation and, withsuitable containers available to catch leakage,disconnect hydraulic lines. Fit blanking caps andplugs to all open lines and fittings.

5. Remove two bolts (18) and washers (19) from top ofhydraulic tank (1) and install eyebolts. Attach asuitable lifting device to eyebolts and remove nuts (27),lockwashers (28) and bolts (26) securing hydraulic tank(1) to fender and support bracket.

6. Carefully remove hydraulic tank (1) assembly fromthe unit to a clean work area for inspection.

Section 230-0040

SM 2350 10-04 5

Body System - Hydraulic Tank

5. Place the battery master switch in the 'On' positionand the steering lock bar in the 'Stowed' position,remove all wheel blocks, start the engine and operatethe steering, braking and body hoist systems tocirculate the oil.

6. Switch off the engine, check for leaks and check oillevel as described under 'Checking Oil Level'.

* * * *

SPECIAL TOOLSThere are no special tools required for the proceduresoutlined in this section. Refer to Section 300-0070,SERVICE TOOLS, for part numbers of general servicetools required. These tools are available from yourdealer.


SM 2350 10-046

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3ECTION

3-2EV

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&IG3ECTIONAL6IEW/F(YDRAULIC0UMP

DESCRIPTION.UMBERSINPARENTHESESREFERTO&IGURESAND

4HE(YDRAULIC0UMPCANBEIDENTIFIEDASITEMIN3ECTION"RAKING3YSTEM3CHEMATIC

4HEHYDRAULICPUMPISMOUNTEDOFFTHEREAROFTHETRANSMISSION)TISANAXIALPISTONVARIABLEDISPLACEMENTPUMPWITHLOADSENSEANDPRESSUREREGULATORTOMATCHTHEFLOWANDPRESSURETOTHEDEMAND4HEPUMPDISPLACESCCREVANDTHEPRESSUREREGULATORISSETTOBARLBFIN

6ALVE#OVER "OLT "OLT .UT 3ET3CREW .EEDLE"EARING 6ALVE0LATE #YLINDER3PRING 3PHERICAL"USH 3ET0LATE 0ISTON3HOE

3HOE0LATE 4ILTING"USH 3WASH0LATE 3WASH0LATE3UPPORT 0UMP#ASING /RING 0LUG /RING 0LUG 3TOPPER "ACKUP2ING

3-

BODY SYSTEM - Main Hydraulic Pump

/RING 3ERVO0ISTON /RING 0IN 0IN 4ILTING0IN %YE"OLT 3PRING3EAT /UTER3PRING )NNER3PRING 0LUG

/RING 0LUG 3NAP2ING "EARING3PACER 2OLLER"EARING $RIVESHAFT /IL3EAL g/g2ING 3EAL#OVER "OLT

4HEPUMPSUPPLIESHYDRAULICOILFORTHESTEERINGBRAKINGANDBODYHOISTSYSTEMSASWELLASTHETRANSMISSIONOILCOOLERFANDRIVESYSTEM

4HECOMPONENTSOFTHEPUMPCANBEDIVIDEDINTOTHREESUBGROUPINGS

Rotating Group0ROVIDESTHEMAINROTARYPUMPINGACTION#ONSISTSOFTHEDRIVESHAFTCYLINDERBLOCKPISTONANDSHOESETPLATESPHERICALBUSHANDCYLINDERSPRINGS

Swash Plate Group6ARIESTHEPUMPgSDELIVERYFLOW

Body System - Main Hydraulic Pump3ECTION

3-2EV

3-

RATE#ONSISTSOFTHESWASHPLATESHOEPLATESWASHPLATESUPPORTTILTINGBUSHTILTINGPINSERVOPISTONANDSERVOASSISTSPRINGSAND

Valving Cover Group0ROVIDESTHESWITCHINGOFOILBETWEENSUCTIONANDDELIVERYPORTS#ONSISTSOFVALVECOVERVALVEPLATEANDVALVEPLATEPIN

OPERATION.UMBERSINPARENTHESESREFERTO&IGURESAND2EFERTO&IGURESFORHYDRAULICSCHEMATICSOFPUMP

&IG0UMP2OTATIONAND/IL&LOW

! /UTLET0ORT" /UTLET+IDNEY3LOT# )NLET0ORT$ )NLET+IDNEY3LOT

3HOE0LATE $RIVESHAFT

6ALVE0LATE #YLINDER"LOCK 0ISTONAND3HOE

3-

:%2/3(/%0,!4%!.',%-).)-5-$)30,!#%-%.4

VIEW C

$%#2%!3%$3(/%0,!4%!.',%0!24)!,$)30,!#%-%.4

VIEW B

-!8)-5-3(/%0,!4%!.',%-!8)-5-$)30,!#%-%.4

VIEW A

&IG6ARIABLE$ISPLACEMENT!CTION

7HENTHEPUMPgSDRIVESHAFTROTATESTHECYLINDERBLOCKBEINGSPLINECOUPLEDTOTHESHAFTWILLALSOROTATE)FTHESWASHPLATEHASBEENTILTEDTHEPISTONSANDSHOESARRANGEDINTHECYLINDERBLOCKDUETOTHESHOESBEINGRETAINEDONTHESHOEPLATEWILLBOTHROTATEWITHTHECYLINDERBLOCKANDRECIPROCATEONCEPERREVOLUTION

0AYINGATTENTIONTOONESUCHPISTONTHENITWILLMOVEAWAYFROMTHEVALVEPLATEFORHALFAROTATIONSUCTIONSTROKEANDMOVETOWARDSTHEVALVEPLATEFORTHESECONDHALFOFROTATIONDELIVERYSTROKE4HELARGERTHETILTANGLEOFTHESWASHPLATETHELONGERTHEPISTONSTROKEANDTHEHIGHERTHEPUMPgSDISPLACEMENT!STHESWASHPLATETILTINGANGLE

3ECTION

3-2EV

$)&&%2%.4)!,02%3352%30//,

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APPROACHESZEROTHEPISTONDOESNOTSTROKEANDTHEREFOREDELIVERSMINIMUMDISPLACEMENT2EFERTO&IGURE

Pressure Regulator.UMBERSINPARENTHESESREFERTO&IGURESAND

0RESSUREREGULATORISAPILOTOPERATEDDIFFERENTIALPRESSURETYPESPOOLREGULATORFORLOADSENSECONTROL4HELOADSENSEFEEDBACKSIGNALFROMTHEMAINHYDRAULICVALVEISFEDTOLOADSENSEPORT0,ONTOPOFTHEPRESSUREREGULATORSEE&IGURE4HISFEEDBACKSIGNALACTSONTHESPRINGCHAMBERENDOFTHESPOOL

Unregulated Condition2EFERTO&IGURE0UMPPRESSUREISLOWANDTHELOADSENSESIGNALISWIDEOPEN4HECUTOFFPRESSURESPOOLSPRINGANDPRELOADSHIFTSTHECUTOFFPRESSURESPOOLTOITSEXTREMERIGHTPOSITION3INCETHEPRESSUREDROPACROSSTHEMAINHYDRAULICVALVEISLOWBOTHSIDESOFTHEDIFFERENTIALPRESSURESPOOLSEETHESAMEPRESSUREANDTHEREFORETHESPOOLREMAINSINTHEEXTREMERIGHTPOSITION4HISCONDITIONCAUSESTHEOILATTHESERVOPISTONTOBEVENTEDCAUSINGSPRINGANDFORCETOMOVETHESERVOPISTONANDSWASHPLATETOMAXIMUMPUMPDISPLACEMENT

Regulated Condition2EFERTO&IGURE0UMPPRESSUREISSTILLRELATIVELYLOWBUTTHEPRESSUREDROPACROSSTHEMAINHYDRAULICVALVEINCREASES4HECUTOFFPRESSURESPOOLSPRINGANDPRELOADSTILLRETAINSTHESPOOLINITSEXTREMERIGHTPOSITION(OWEVERSINCETHEPRESSUREDROPISINCREASEDTHEPRESSUREONTHERIGHTHANDSIDEOFTHEDIFFERENTIALPRESSURESPOOLPUMPDELIVERYPRESSUREOVERCOMESTHECOMBINATIONOFSPRINGANDPRELOADANDPRESSUREINTHELOADSENSELINEINTHELEFTHANDSIDEOFTHEDIFFERENTIALPRESSURESPOOL4HEREFORETHESPOOLMOVESTOTHELEFTBLOCKINGTHEVENTLINEANDCAUSINGTHEPRESSURETOTHELARGESIDEOFTHESERVOPISTONTOINCREASEOVERCOMINGSPRINGANDFORCE4HISREDUCESTHESWASHPLATEANGLEANDHENCETHEPUMPDISPLACEMENT

4HISWILLCONTINUEUNTILTHEPUMPFLOWACROSSTHEMAINHYDRAULICVALVEREDUCESTHEPRESSUREDROPTOTHEVALUEDETERMINEDBYTHEDIFFERENTIALSPOOLSPRINGANDPRELOAD

Stand-by Condition2EFERTO&IGURE7HENNOHYDRAULICOPERATIONSAREREQUIREDTHEPUMPSTANDBYCONDITIONISREACHED4HELOADSENSELINEISVENTEDTOTANK4HEDIFFERENTIALPRESSURESPOOLSHIFTSTOTHEEXTREMELEFTDUETOPUMPOUTLETPRESSURE4HISALLOWS

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3-2EV

OILPRESSURETOPASSTHROUGHTHECUTOFFPRESSURESPOOLANDREACHTHELARGESIDEOFTHESERVOPISTONOVERCOMINGSPRINGANDFORCEANDREDUCINGTHESWASHPLATEANGLETOZERO

4HEPUMPALSOHASAPRESSURELIMITINGFUNCTIONUSEDFOREXAMPLEWHENSTEERINGCYLINDERREACHESTHEENDOFITgSSTROKE)NTHISCONDITIONTHEDELIVERYPRESSUREWILLRISEANDTHELOADSENSECONTROLWILLTRYTORAISEDELIVERYPRESSUREABOVETHENOWgDEADHEADgPRESSURE4HISCAUSESDIFFERENTIALPRESSURESPOOLTOSHIFTTOTHEEXTREMELEFTALLOWINGOILPRESSURETOPASSTHROUGHCUTOFFPRESSURESPOOLANDREACHTHELARGESIDEOFTHESERVOPISTONOVERCOMINGSPRINGANDFORCEANDREDUCINGTHESWASHPLATEANGLETOZERO

REMOVAL.UMBERSINPARENTHESESREFERTO&IGURESAND

WARNINGSTo prevent personal injury and propertydamage, be sure wheel blocks, blockingmaterials and lifting equipment are properlysecured and of adequate capacity to perform thetask safely.

Hydraulic fluid pressure will remainwithin the system after engine shut down.Operate the treadle pedal continuously until thepressure has dissipated before carrying out anywork on the braking system or serious injurycould result.

0OSITIONTHEVEHICLEINALEVELWORKAREAAPPLYTHEPARKINGBRAKESWITCHOFFTHEENGINEANDTURNTHESTEERINGWHEELINBOTHDIRECTIONSSEVERALTIMESTORELIEVEANYPRESSUREINTHESTEERINGCIRCUIT

/PERATETHETREADLEVALVECONTINUOUSLYTORELIEVEPRESSUREINTHEBRAKINGSYSTEM"LOCKALLROADWHEELSANDPLACEBATTERYMASTERSWITCHINTHEg/FFgPOSITION0LACESTEERINGLOCKBARINTHEg,OCKEDgPOSITION

2EMOVEBLANKINGCAPFROMREMOTEDRAINLINEATTHEBOTTOMOFTHEHYDRAULICTANK)NSTALLALENGTHOFHOSEONREMOTEDRAINFITTINGOPENTHEDRAINCOCKANDDRAINTHEHYDRAULICOILINTOASUITABLECONTAINER#LOSETHEDRAINCOCKREMOVETHEHOSEANDREINSTALLTHEBLANKINGCAP

#LEANTHEPUMPHOUSINGANDSURROUNDINGAREAWITHASUITABLESOLVENT%NSURETHATALLHYDRAULICLINESCONNECTEDTOTHEPUMPAREIDENTIFIEDFOREASEOFINSTALLATIONANDWITHSUITABLECONTAINERSAVAILABLETOCATCHLEAKAGEDISCONNECTTHEHYDRAULICLINES&IT

BLANKINGCAPSTOALLOPENLINESANDFITTINGS

3UPPORTTHEPUMPASSEMBLYWITHSUITABLELIFTINGEQUIPMENT)TISPOSSIBLETOSETUPASLINGARRANGEMENTUSINGTHEEXHAUSTCRADLE2EMOVETHEBOLTSANDLOCKWASHERSSECURINGTHEPUMPTOTHETRANSMISSION2EMOVETHEPUMPFROMTHETRANSMISSION

2EMOVETHE/RINGFROMTHEPUMP7ASHTHEOUTSIDEOFTHEPUMPTHOROUGHLYWITHASUITABLESOLVENTANDMOVEITTOACLEANWORKAREAFORDISASSEMBLY$ISCARDTHE/RING

DISASSEMBLY.UMBERSINPARENTHESESREFERTO&IGURESAND

Note:$ISCARDANDRENEWALL/RINGSANDSEALSREMOVEDDURINGDISASSEMBLY

2EMOVETHEDRAINPLUGANDDRAINTHEOILFROMTHEPUMPCASING

2EMOVETHEBOLTSANDTHENREMOVETHEREGULATORCASINGFROMTHEPUMPCASING%NSURETHATTHE/RINGDOESNOTDROPFROMTHEGASKETSURFACEOFTHEREGULATOR&ITBLANKINGCAPSTOALLOPENPORTS

2EMOVETHEBOLTSANDSECURINGTHEVALVECOVERTOTHEPUMPCASING

3EPARATETHEVALVECOVERFROMTHECASING4HEVALVEPLATEMAYDETACHFROMTHEVALVECOVER%NSURETHATTHECONTACTFACESOFTHEVALVECOVERANDCASINGARENOTDAMAGED

)FNECESSARYREMOVETHENEEDLEBEARINGANDVALVEPLATEFROMTHEVALVECOVER/NLYREMOVETHENEEDLEBEARINGIFITISNEARINGTHEENDOFITSLIFE$ONOTLOOSENTHENUTASTHISWILLINFLUENCETHEDELIVERYFLOWRATE

0ULLTHECYLINDERBLOCKOUTFROMTHEPUMPCASINGSTRAIGHTOVERTHEDRIVESHAFT0ULLOUTTHEPISTONSANDSHOESSETPLATESPHERICALBUSHANDCYLINDERSPRINGSATTHESAMETIME"ECAREFULNOTTODAMAGETHESLIDINGSURFACESOFCOMPONENTS

#OVERTHESPLINEDENDOFTHESHAFTWITHPLASTICTAPETOPREVENTTHEOILSEALBEINGDAMAGED2EMOVETHEBOLTSANDSEALCOVERENSURINGTHATTHEOILSEALISNOTDAMAGED

3ECTION

3-2EV

3-

&IG%XPLODED6IEW/F(YDRAULIC0UMP



3-2EV

)FNECESSARYREMOVETHEPLUGSANDANDORIFICEAND

ASSEMBLY.UMBERSINPARENTHESESREFERTO&IGURESAND

4HISISLARGELYTHEREVERSESEQUENCETODISASSEMBLYBUTNOTETHEFOLLOWING

A%NSURETHATALLDAMAGEDPARTSAREFIXEDORRENEWEDBEFOREASSEMBLY

B"EFOREASSEMBLYWASHEACHPARTWITHCLEANOILANDDRYTHEMWITHCOMPRESSEDAIR!SSEMBLETHEPUMPINACLEANWORKAREATOPREVENTCONTAMINATION

C7HENASSEMBLINGAPPLYCLEANOILONTHESLIDINGSURFACESANDBEARINGS

D7HENASSEMBLINGPARTSTHATEASILYDETACHFOREXAMPLE/RINGSAPPLYCLEANGREASETOPREVENTTHEMFROMBEINGMISPLACED

)NSTALLSERVOPISTONTILTINGPINOUTERSPRINGINNERSPRINGSPRINGSEATANDPLUGINPUMPCASING!PPLYADHESIVEONTHETHREADOFTHESERVOPISTON

&ITTHESWASHPLATESUPPORTINTHEPUMPCASING-AKESURETHATTHEPINENTERSINTOTHESLITOFTHESWASHPLATESUPPORT"ECAREFULNOTTOINSTALLTHESWASHPLATESUPPORTINANANGULARATTITUDE

(OLDTHEFRONTOFTHEDRIVESHAFTANDUSINGAPLASTICHAMMERTAPTHEDRIVESHAFTOUTOFTHEPUMPCASING$ONOTREMOVETHEROLLERBEARINGUNLESSITISCONSIDEREDTOBENEARTHEENDOFITSEXPECTEDLIFE

0USHDOWNTHESERVOPISTONANDREMOVETHESHOEPLATEANDSWASHPLATE

2EMOVETHESWASHPLATESUPPORTFROMTHEPUMPCASING

)FNECESSARYREMOVETHESERVOPISTONTILTINGPINOUTERSPRINGINNERSPRINGSPRINGSEATANDPLUG%NSURETHATTHESERVOPISTONANDTILTINGPINARENOTDAMAGEDWHENBEINGREMOVED

Pressure Regulator2EMOVETHEPLUGANDTHENREMOVETHESPRINGSANDANDTHESPRINGSEAT"ECAREFULNOTTODROPTHESPOOLAFTERREMOVINGTHEPLUG$ONOTREMOVETHENUTSETSCREWORSTOPPERUNLESSREQUIRED

2EMOVETHEPLUGANDTHENREMOVETHESPRINGSANDANDSPRINGSEAT"ECAREFULNOTTODROPTHESPOOLAFTERREMOVINGTHEPLUG$ONOTREMOVETHENUTSETSCREWORSTOPPERUNLESSREQUIRED

,OOSENTHEPLUGANDREMOVETHESPOOLSAND

6ALVE#OVER "OLT "OLT .UT 3ET3CREW 0RESSURE2EGULATOR 3ET3CREW .UT 0LUG 0LUG /RING /RING 3TOPPER 3TOPPER /RING /RING 3PRING 3PRING 3PRING 3PRING 3PRING3EAT

3PRING3EAT 3POOL 3POOL #ASING "OLT 0LUG /RIFICE /RING 0LUG 0LUG /RING 0LUG 0LUG /RIFICE 0LUG 0LUG /RING /RING .EEDLE"EARING 6ALVE0LATE #YLINDER"LOCK

#YLINDER3PRING 3PHERICAL"USH 3ET0LATE 0ISTON3HOE 3HOE0LATE 4ILTING"USH 3WASH0LATE 3WASH0LATE3UPPORT 0UMP#ASING /RING 0LUG /RING 0LUG "OLT ,OCKWASHER 3TOPPER "ACKUP2ING /RING 3ERVO0ISTON /RING /RING

,%'%.$&/2&)'

0IN 0IN 4ILTING0IN %YE"OLT 3PRING3EAT /UTER3PRING )NNER3PRING 0LUG 0LUG /RING /RING 0LUG 3NAP2ING "EARING3PACER 2OLLER"EARING $RIVESHAFT /IL3EAL /RING 3EAL#OVER "OLT

3ECTION

3-2EV

)FREMOVEDINSTALLTHENUTSETSCREWANDSTOPPER)NSERTTHESPRINGSANDANDSPRINGSEATINTOTHEPLUG

)NSTALLTHEPLUGINTHEREGULATORCASING

%NSURETHATTHE/RINGSAREINPLACEANDINSTALLTHEREGULATORCASINGONTHEPUMPCASINGUSINGTHEBOLTS

INSTALLATION.UMBERSINPARENTHESESREFERTO&IGURESAND

Note: 4IGHTENALLHYDRAULICLINESFITTEDWITH/2&3CONNECTIONSASDESCRIBEDIN3ECTION"RAKING3YSTEM3CHEMATIC2ENEWALL/RINGSWHEREUSED


)NSTALLANEW/RINGTOTHEPUMP

0USHTHEPUMPINWARDTOENGAGEWITHTHECOUPLINGINTHETRANSMISSION3ECURETHEPUMPASSEMBLYTOTHETRANSMISSIONWITHTHEBOLTSANDLOCKWASHERS4IGHTENTHEBOLTSTOATORQUEOF.MLBFFT

2EMOVETHECAPSANDCONNECTTHEOUTLETINLETANDLOADSENSELINESTOTHEPUMP"EFORECONNECTINGTHECASEDRAINLINEFILLTHEPUMPCASINGTHROUGHTHEDRAINPORTWITHCLEANHYDRAULICOILASUSEDINTHEHYDRAULICTANK#ONNECTTHECASEDRAINLINETOTHEPUMP&ILLTHEHYDRAULICTANKWITHOILSPECIFIEDIN3ECTION,UBRICATION3YSTEM

Note:)TISVERYIMPORTANTTHATTHEPUMPCASINGISCOMPLETELYFILLEDWITHHYDRAULICOIL4HISWILLENSUREPROPERLUBRICATIONOFTHEINTERNALPARTSOFTHEPUMPWHENITISINITIALLYOPERATED&ILLTHEPUMPCASINGTHROUGHTHEDRAINPORT&ILLINGONLYTHESUCTIONLINEISTOTALLYINSUFFICIENT

2EFERTOg0UMP3TARTING0ROCEDUREgFORPROPERSTARTUPPROCEDURE

PUMP STARTING PROCEDURE"ESURETHEPUMPCASEDRAINLINEISFREEFROMOBSTRUCTIONSTHATRESTRICTTHEPUMPCASEDRAINFLOW

0USHDOWNTHESERVOPISTONANDINSERTTHETILTINGPININTOTHETILTINGBUSHOFTHESWASHPLATE)NSTALLTHESWASHPLATEANDSHOEPLATEINTOTHEGROOVEOFTHESWASHPLATESUPPORTCORRECTLY

)NSERTTHEDRIVESHAFTINTOTHEPUMPCASINGTAPPINGTHEDRIVESHAFTLIGHTLYSOTHATTHEENDOFTHEROLLERBEARINGISSLIGHTLYABOVETHESURFACEOFTHEPUMPCASING4HISPREVENTSTHESWASHPLATESUPPORTFROMBEINGDISPLACED

#OVERTHESPLINEDENDOFTHEDRIVESHAFTWITHPLASTICTAPE!PPLYGREASETOTHELIPOFTHEOILSEALINSTALLEDINTHESEALCOVER)NSERTTHESEALCOVERSLIGHTLYINTOTHEPUMPCASING4IGHTENTHEBOLTSUNIFORMLYTOLOCATETHESEALCOVERTHENTIGHTENBOLTSTOTHESTANDARDTORQUE

3UBASSEMBLETHECYLINDERBLOCKPISTONSANDSHOESSPHERICALBUSHSETPLATEANDCYLINDERSPRINGS

0LACETHEPUMPCASINGHORIZONTALLYWITHTHESURFACEOFTHEREGULATORDOWNWARD)NSTALLTHEPISTONCYLINDERSUBASSEMBLYINTHEPUMPCASING

)NSTALLTHEVALVEPLATEONTHEVALVECOVER7HENINSTALLINGTHEVALVEPLATEENSURETHATTHEPINENTERSINTOTHESLITOFTHEVALVEPLATE)FTHESTOPPERMAXFLOWSETSCREWANDMAXFLOWSETSCREWLOCKNUTHAVEBEENREMOVEDREINSTALLTHESEPARTSONTHEVALVEPLATEBEFOREHAND

)NSTALLTHEVALVECOVERONTHEPUMPCASINGANDSECUREITUSINGTHEBOLTSAND

)NSTALLREGULATORCASINGTOPUMPCASINGANDSECUREWITHBOLTS

Pressure Regulator)FREMOVEDINSTALLTHEPLUGSANDANDORIFICEANDINTOTHEREGULATORCASING

)NSTALLTHEPLUGANDINSERTTHESPOOLSAND7HENINSERTINGTHESPOOLSCARESHOULDBETAKENNOTTODAMAGETHESLIDINGSURFACEOFTHESPOOLS

)FREMOVEDINSTALLTHENUTSETSCREWANDSTOPPER)NSERTTHESPRINGSANDANDSPRINGSEATINTOTHEPLUG

)NSTALLTHEPLUGINTHEREGULATORCASING



3-2EV

BACKTOTANKANDISACAUSEOFHIGHCASEDRAINPRESSUREWHICHCANLEADTOANEARLYPUMPFAILURE

%NSURETHATALLHYDRAULICCONTROLSARESETTOANEUTRALPOSITIONTHESTEERINGLOCKBARISINTHEg,OCKEDgPOSITIONANDTHEBATTERYMASTERSWITCHISPLACEDINTHEg/NgPOSITION3TARTTHEENGINEANDALLOWTHEPUMPTORUNUNLOADEDFORAPERIODTOENSURETHATALLRESIDUALAIRWITHINTHESYSTEMISRELEASED

#HECKFOREXTERNALLEAKAGEABNORMALNOISEANDVIBRATIONS

2EMOVETHEWHEELBLOCKSANDPLACETHESTEERINGLOCKBARINTHEg3TOWEDgPOSITION3TARTTHEENGINEANDCHECKTHEHYDRAULICSYSTEMSFORPROPEROPERATION

PRESSURE CHECKS4OCHECKPUMPDELIVERYPRESSURECUTOFFPRESSURETHESTEERINGSHOULDBEOPERATEDFULLLOCKAGAINSTTHESTOPS4HEPUMPISCHECKEDAGAINSTTHESTEERINGSYSTEMASTHISISTHEHIGHESTPRESSUREREQUIREMENTINTHEHYDRAULICCIRCUIT

WARNINGThe machine has to fully articulate to check thepump pressures, therefore the steering lock barcannot be 'Locked'. To prevent personal injuryand property damage, exercise extreme cautionwhile working around the articulation andoscillation pivot area.

Delivery Pressure (cut-off pressure))NSTALLAPRESSUREGAUGECAPABLEOFATLEASTBARLBFININTOTHE342DIAGNOSTICCHECKPOINTINTHEBATTERYBOX&IG7HENSTEERINGAGAINSTTHESTOPSTHEPRESSURESHOULDBEBARLBFIN

Differential Pressure (load sense pressure))NSTALLAPRESSUREGAUGECAPABLEOFATLEASTBARLBFININTOTHE342DIAGNOSTICCHECKPOINTINBATTERYBOX&IG)NSTALLAPRESSUREGAUGECAPABLEOFATLEASTBARLBFININTOTHE,36!,DIAGNOSTICCHECKPOINTINBATTERYBOX&IG7ITHTHESTEERINGINTHENEUTRALPOSITIONTHEPRESSUREATTHE342GAUGESHOULDBEBARLBFINGREATERTHANTHEPRESSUREATTHE,36!,GAUGE

)FTHESEPRESSURESARENOTOBSERVEDTHENPUMPMAYNEEDTOBERESETREFERTO4ROUBLESHOOTING

TROUBLESHOOTING)FTHESTEERINGCANNOTBEOPERATEDORISEXCESSIVELY

HEAVYTHEPUMPDELIVERYPRESSUREISLIKELYTOBELOWANDPUMPSETTINGSHOULDBECHECKED

)FTHEDIFFERENCE0BETWEENDELIVERYPRESSUREANDLOADSENSEPRESSUREISEQUALTOBARLBFINPROCEEDTOTHEg0UMP3ETTING0ROCEDURE0UMP$ELIVERY0RESSURE3ETTINGg

(OWEVERIFTHE0ISNOTEQUALTOBARLBFINCARRYOUTTHECOMPLETEg0UMP3ETTING0ROCEDUREg

PUMP SETTING PROCEDURENote:)TISVERYIMPORTANTTHATTHEPUMPCASINGISCOMPLETELYFILLEDWITHHYDRAULICOILBEFORETHEPUMPISOPERATED&ILLTHEPUMPCASINGTHROUGHTHEDRAINPORT&ILLINGONLYTHESUCTIONLINEISTOTALLYINSUFFICIENT

Differential Pressure Setting.UMBERSINPARENTHESESREFERTO&IGURESANDUNLESSOTHERWISESTATED

)NSTALLAPRESSUREGAUGECAPABLEOFATLEASTBARLBFININTOTHE342DIAGNOSTICCHECKPOINTINTHEBATTERYBOX&IGURETOMEASURETHEPUMPDELIVERYPRESSURECUTOFFPRESSURE'AUGE!

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4RANS#ONVERTER 0RESS "ODY3YSTEM0RESS 4RANS3YSTEM0RESSURE0 0RIMARY!CCUMULATOR&" &RONT"RAKE!CCUMULATOR2" 2EAR"RAKE!CCUMULATOR

3ECTION

3-2EV


SENSEPRESSURESETTING'AUGE"

%NSURETHATALLHYDRAULICCONTROLSARESETTOANEUTRALPOSITIONTHESTEERINGLOCKBARISINTHEg,OCKEDgPOSITIONANDPLACETHEBATTERYMASTERSWITCHINTHEg/NgPOSITION3TARTTHEENGINEANDALLOWTORUNATLOWIDLE4HISALLOWSTHEPUMPTORUNUNLOADEDFORAPERIODTOENSURETHATALLRESIDUALAIRWITHINTHESYSTEMISRELEASED#HECKFOREXTERNALLEAKS

#HECKREADINGSONBOTHPRESSUREGAUGES0UMPDELIVERYPRESSURE'AUGE!SHOULDALWAYSBEGREATERTHANLOADSENSEPRESSURE'AUGE"4HISDIFFERENTIALPRESSURE0SHOULDBEEQUALTOBARLBFIN)FTHE0PRESSUREDIFFERSFROMBARLBFINTHENCARRYOUTSTEPSTHROUGH

Note 4YPICALREADINGS342BARLBFIN,36ALBARLBFIN

Note:)FTHEPUMPDELIVERYPRESSURE'AUGE!ISLESSTHANBARLBFINDISCONNECTTRANSMISSIONOILCOOLERFANSOLENOIDCAUSINGSOLENOIDVALVETODEFAULTTOANOPENPOSITIONALLOWINGHYDRAULICOILTOTHEFANMOTOR4HISWILLPLACEADEMANDONTHEPUMPCAUSINGPUMPDELIVERYPRESSURETOINCREASE

!TTHEDIFFERENTIALPRESSURELOADSENSEPORTSEE&IGUREUNLOCKTHENUTANDTURNTHESETSCREWCLOCKWISELOOKINGSTRAIGHTATSETSCREWTOINCREASE

0PRESSUREORCOUNTERCLOCKWISETODECREASE0PRESSURE

Note:!DJUSTMENTOF0PRESSUREBARLBFININCREASEPERQUARTERTURNOFSETSCREW4HISISARESULTOFANINCREASEOFBARLBFINONTHEPUMPDELIVERYPRESSUREANDANINCREASEOFBARLBFINONTHE,3PRESSURE

Note:0RESSURESHOULDALWAYSBEADJUSTEDONTHEINCREASE(ENCEIF0PRESSUREISTOOHIGHTHESETSCREWSHOULDBETURNEDCOUNTERCLOCKWISEAPPROXIMATELYTURNSTHENTURNTHESETSCREWCLOCKWISETOATTAINBARLBFIN

2ECHECKTHEREADINGSONBOTHTHEPRESSUREGAUGES4HEPUMPDELIVERYPRESSURE'AUGE!SHOULDBEBARLBFINGREATERTHANTHELOADSENSEPRESSURE'AUGE"

/NCETHECORRECT0ISACHIEVEDTIGHTENTHENUTATTHEDIFFERENTIALPRESSURELOADSENSEPORTTO.MLBFFT

4HEDIFFERENTIALPRESSURE0ISNOWSET3WITCHOFFTHEENGINEANDRELIEVETHESYSTEMPRESSURESASDESCRIBEDINg2EMOVALg

2EMOVETHEPRESSUREGAUGESFROMTHEDIAGNOSTICPRESSUREPOINTSINTHEBATTERYBOX

Pump Delivery Pressure Setting.UMBERSINPARENTHESESREFERTO&IGURESANDUNLESSOTHERWISESTATED

WARNINGThe machine has to fully articulate to set thepump, therefore the steering lock bar cannot be'Locked'. To prevent personal injury andproperty damage, exercise extreme cautionwhile working around the articulation andoscillation pivot area.

4HERESHOULDBENOREQUIREMENTTOADJUSTTHESETSCREWATTHEDELIVERYPRESSURECUTOFFPRESSUREPORTSEE&IGUREASTHISISFACTORYSET4HECUTOFFPRESSURESETSTHEPUMPDELIVERYPRESSURE)FTHESETSCREWORNUTHASBEENMOVEDFOLLOWTHEPROCEDUREBELOWTORESETTHEPUMPDELIVERYPRESSURE

)NSTALLAPRESSUREGAUGECAPABLEOFATLEASTBARLBFININTOTHE342DIAGNOSTICCHECKPOINTINTHEBATTERYBOXTOMEASURETHEPUMPDELIVERYPRESSURECUTOFFPRESSURE

3-

&IG0UMP!DJUSTMENT!T0RESSURE2EGULATOR

$ELIVERY0RESSURE#UTOFF0RESSURE

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,OAD3ENSE0ORT0,


3-2EV

3TARTTHEENGINEANDRUNITATFULLTHROTTLE3TEERFULLLOCKAGAINSTTHESTOPS/BSERVETHEPRESSUREONTHEGAUGE4HISCUTOFFPRESSURESHOULDBEBARLBFIN)FTHEPRESSUREREADINGDIFFERSORTHESTEERINGISEXCESSIVELYHEAVYTHENCARRYOUTSTEPSTOINCLUSIVE

Note:4HESTEERINGHASTOBEOPERATEDOVERRELIEFAGAINSTTHESTOPSASTHISISTHEMAXIMUMPRESSURETHEPUMPMUSTDELIVER3ETTINGTHEPUMPAGAINSTANYOTHEROPERATIONWOULDRESULTINTHEPUMPBEINGSETATALOWERMAXIMUMDELIVERYPRESSURE

!TTHEDELIVERYPRESSURECUTOFFPRESSUREPORTSEE&IGUREUNLOCKTHENUTANDTURNTHESETSCREWCLOCKWISETOINCREASETHECUTOFFPRESSUREORCOUNTERCLOCKWISETODECREASETHECUTOFFPRESSUREADJUSTMENTBAR;LBFIN=PERTURN

Note:4HEPRESSURESHOULDALWAYSBEADJUSTEDONTHEINCREASE(ENCEIFTHECUTOFFPRESSUREISTOOHIGHTHESETSCREWSHOULDBETURNEDCOUNTERCLOCKWISETODECREASECUTOFFPRESSUREBELOWBARLBFINTHENTURNTHESETSCREWCLOCKWISETOATTAINBARLBFIN

/NCETHECORRECTCUTOFFPRESSUREHASBEENATTAINEDREVERTTHESTEERINGTOTHENEUTRALPOSITIONTHENSTEERFULLLOCKAGAINSTTHESTOPS/BSERVETHEGAUGETOCONFIRMTHATTHECUTOFFPRESSUREISSETTOBARLBFIN

Note:!CHANGEINPUMPTONESHOULDBEHEARDWHENTHECUTOFFPRESSUREISREACHEDASTHEPUMPDESTROKESTOSTANDBYCONDITION

)FNOCHANGEINPUMPTONEISHEARDTHECUTOFFPRESSUREISTOOHIGH2ETURNTOSTEPOFTHEPROCEDURE)FTHEPROBLEMPERSISTSREFERTO3ECTION3TEERING3YSTEM3CHEMATIC

4IGHTENTHENUTATTHECUTOFFPRESSUREPORTTO.MLBFFT

4HEDIFFERENTIALPRESSURELOADSENSEANDCUTOFFPRESSUREARENOWSET3WITCHOFFTHEENGINEANDRELIEVETHESYSTEMPRESSURESASDESCRIBEDINg2EMOVALg

2EMOVETHEPRESSUREGAUGEFROMTHEDIAGNOSTICPRESSUREPOINTINTHEBATTERYBOX

Note:)FTHEREARESTILLPROBLEMSWITHTHEPUMPPRESSURESAFTERCOMPLETINGTHEg0UMP3ETTING0ROCEDUREgENSURETHATTHESETSCREWHASNOTBEENADJUSTED!SADIMENSIONALCHECKTHEDISTANCEBETWEENTHEENDOFTHESETSCREWTOTHEFACEOFTHENUTSHOULDBEMM

LUBRICATION2EFERTO3ECTION,UBRICATION3YSTEMFORTHERECOMMENDEDPERIODICOILCHANGEPERIODSANDOILSPECIFICATIONS

!LLPUMPPARTSARELUBRICATEDBYHYDRAULICOILANDTHEREFORETHEOILMUSTBEKEPTCLEANTOMINIMIZEPUMPWEAR7HENEVERTHEREISAHYDRAULICSYSTEMFAILURETHEOILSHOULDBEDRAINEDTHEENTIRESYSTEMFLUSHEDOILFILTERREPLACEDANDCLEANHYDRAULICOILADDEDTOELIMINATEALLMETALPARTICLESORFOREIGNMATTER

PUMP WEAR LIMITS"EFOREREASSEMBLINGTHEPUMPAFTERDISASSEMBLYTHE0UMP7EAR,IMITSTABLESHOULDBECONSULTEDTOESTABLISHWHICHCOMPONENTSSHOULDBEREPLACED

SPECIAL TOOLS4HEREARENOSPECIALTOOLSREQUIREDFORTHEPROCEDURESOUTLINEDINTHISSECTION2EFERTO3ECTION3ERVICE4OOLSFORPARTNUMBERSOFGENERALSERVICETOOLSREQUIRED4HESETOOLSAREAVAILABLEFROMYOURDEALER

3ECTION

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* * * *

SPECIAL TORQUE SPECIFICATIONS4/215%

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PUMP WEAR LIMITS).)4)!, ,)-)4&/2

)4%- 6!,5% 2%0,!#).' !#4)/.

#LEARANCEBETWEENCYLINDER MM MM 2EPLACEPISTONCYLINDERBOREANDPISTON

%NDPLAYBETWEENPISTON MM MM 2EPLACEPISTONSHOEASSEMBLYANDSHOE

4HICKNESSOFSHOE MM MM 2EPLACEPISTONSHOEASSEMBLY

&REEHEIGHTOFCYLINDER MM MM 2EPLACECYLINDERSPRINGSPRING

#OMBINEDHEIGHTOFSET MM MM 2EPLACESETPLATEPLATEANDSPHERICALBUSH



3-2EV

4()30!'%)3).4%.4)/.!,,9",!.+

Section 230-0081

SM 2202 Rev1 02-07 1

BODY SYSTEM - Body Control Lever

Fig. 1 - Body Control Lever

SM - 3728DESCRIPTION AND OPERATIONThe body control lever is mounted on the right handside dash panel, next to the transmission shiftcontroller.

When the body control lever is operated, a voltage issent to the hydraulic ECU, which converts voltage tocurrent. This current controls the body raise and lowerproportional pressure control valves, producing a pilotpressure to shift the control spool in the main hydraulicvalve. This allows the flow of oil to reach the bodycylinders, to either raise or lower the body. Refer toSection 230-0000, BODY SYSTEM SCHEMATIC andSection 215-0050, MAIN HYDRAULIC VALVE.

The three operating positions of the joystick from frontto rear are as follows:

Power Down - Pushing the lever forward provideshydraulic force to power-down the body. Pushing thelever fully forward will engage the electric detent. Whenthe body reaches the body proximity switch, the leversprings back to 'NEUTRAL' and power down is rampedback to allow the body to float down onto the chassis.

Neutral - If the body is above the body proximityswitch, the lever in this position will stop and hold thebody at any desired height. If the body is below theproximity switch, the hydraulic ECU defaults thecontrol spool in the main hydraulic valve to the neutralposition and energises the float solenoid, allowing thebody to float down onto the chassis. The body shouldbe fully lowered and in the 'NEUTRAL' position whilethe machine is in motion. The lever will remain in the'NEUTRAL' position when released.

Raise - Pulling the lever back and holding it in thisposition directs oil to extend the body hoists and raisethe body. When released, the lever will spring back tothe 'NEUTRAL' position.

A body lower emergency switch in the cab isconnected directly to the float solenoid, within the mainhydraulic valve, to enable the lowering of the body inthe event of an engine, hydraulic or hydraulic ECUfailure. The cause of the failure must be investigatedand corrected.

Note: The body must remain lowered with lever in the'NEUTRAL' position until it is necessary to operate thebody again. Failure to comply to this could result inoverheating the hydraulic oil and failure of the hydraulicsystem components.

WARNINGAlways disconnect body control lever beforewelding on the machine.

MAINTENANCEThe body control lever is a non-serviceable item andshould be replaced completely, if damaged, as follows:

Note: Tighten all fasteners to standard torques listed inSection 300-0080, STANDARD BOLT AND NUTTORQUE SPECIFICATIONS.


Hydraulic fluid pressure will remainwithin the system after engine shut down.Operate the treadle pedal continuously until thepressure has dissipated before carrying out anywork on the hydraulic system or serious injurycould result.

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

2. Operate the treadle valve continuously to relievepressure in the hydraulic system.


Section 230-0081Body System - Body Control Lever

2 SM 2202 Rev1 02-07

4. Disconnect body control lever harness from mainharness.

5. Support body control lever and remove screwssecuring body control lever on the right hand dashpanel.

6. Remove body control lever from mounting location.

7. Secure new body control lever on the right handdash panel with screws.

Note: Ensure harness from body control lever is at thefront when lever is installed.

8. Reconnect main harness to body control leverharness.

9. Place the battery master switch in the 'On' position,start the engine and bring hydraulic oil to operatingtemperature. Operate the body control lever to ensurecorrect operation.

10. Remove wheel blocks and place the steering lockbar in the 'Stowed' position.

TROUBLESHOOTINGA faulty body control lever will cause an input error atthe hydraulic ECU. Refer to Section 190-0085,HYDRAULIC SYSTEM ECU.

SPECIAL TOOLSThere are no special tools required for proceduresoutlined in this section. Refer to Section 300-0070,SERVICE TOOLS, for part numbers of general servicetools required. These tools are available from yourdealer.

* * * *

SM 2207 9-05 1

Section 230-0130

SM - 2468

1 - Cylinder Body2 - Piston Rod3 - End Cap4 - Cushion Sleeve5 - Circlip6 - Rod Seal7 - Wiper

8 - 'O' Ring9 - 'O' Ring

10 - Lock Ring11 - Cushion Spear12 - Piston13 - Piston Seal14 - Wear Ring

15 - Grub Screw16 - 'O' Ring17 - Back Up Ring18 - Cushion Sleeve19 - Circlip20 - Spherical Bearing21 - Circlip

22 - Nylon Ring23 - Lube Fitting24 - Upper Pin25 - Spacer26 - Bolt27 - Lockwasher28 - Washer29 - Lower Pin

Fig. 1 - Sectional View Of Body Cylinder and Mounting


There are two single stage, double acting body hoistcylinders, cushioned at both ends of the stroke on thevehicle. The cylinder base end is connected to thetrailer frame and piston rod (2) end is connected at thebody. Single stage double acting means that pistonrod (2) can have oil applied to either side, extending orretracting the piston rod.

Cylinder mounting is by pins (24 & 29), spacers (25)and spherical bearings (20) secured in place withcirclips (21). Spherical bearings (20) permit a limitedamount of cylinder misalignment.

REMOVALNumbers in parentheses refer to Fig. 1.


Hydraulic fluid pressure will remainwithin the body hoist system after engineshutdown. Operate the treadle pedalcontinuously until the pressure has dissipatedbefore carrying out any work on the hydraulicsystem or serious injury could result.

BODY SYSTEM - Body Cylinder

FRAME MOUNTING

2827

2625

29

BODY MOUNTING

ORIENTATION OFCUSHION SLEEVE

GROOVETHIS SIDE

26

20

3 10 1 16 15

21

12

23 7 22,6 17,18 9 11 1314 14 23 21 2018 194 5

2824 2725

Body System - Body Cylinder

SM 2207 9-05

Section 230-0130

2

DISASSEMBLYNumbers in parentheses refer to Fig. 1.


1. Ensure clean working conditions, remove any portplugs thus allowing easy entry of air into cylinder body(1), preventing a vacuum when parts are withdrawnfrom cylinder body (1).

2. Remove circlips (21) from base end of cylinder body(1) and piston rod (2) end. Press out spherical bearings(20).

3. Remove lock ring (10) from end cap (3).

4. Using special tool which can be fabricated as shownin Fig. 2, unscrew end cap (3) until thread isdisengaged from cylinder body (1).

5. Support piston rod (2) at the rod eye and withdrawpiston rod (2) from cylinder body (1). Ensure centrelines of piston rod (2) and cylinder body (1) remaincoincidental during removal of piston rod (2).

6. Place piston rod (2) on supports which will notdamage the piston rod diameter.

7. Remove and discard piston seals (13) and wearrings (14) from piston (12).

8. Remove grub screw (15) from wear ring (14) groovein piston (12).

9. Provide an anti-torsion device through piston rod (2)eye to allow unscrewing of piston (12). Using specialtool which can be fabricated as shown in Fig. 3,unscrew piston (12) from piston rod (2).

10. Remove cushion spear (11) and 'O' rings (16) frompiston rod (2). Discard 'O' rings (16).

11. Remove cylinder end cap (3) from piston rod (2).Remove and discard cushion sleeve (4), circlip (5), rodseal (6), nylon ring (22), wiper (7), 'O' rings (8 & 9) andback up ring (17).

WARNINGExercise extreme caution when loweringthe cylinders from the body. The cylinders willswing out sharply as they leave theirmountings.

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

2. Press and hold down body hoist bleed down switchand operate the body control joystick continually torelieve pressure in the body hoist system.


4. Install a suitable strap around the cylinder andattach to a lifting device.

5. Position a suitable container at the base end of onecylinder. Identify and remove the hydraulic lines. Caphydraulic lines and cylinder ports to prevent entry ofdirt.

6. Remove bolt (26), lockwasher (27), washer (28) andupper pin (24) connecting piston rod (2) end of thecylinder to the body. If due to lack of maintenance theupper pin can not be removed from the front, there isplate on the inside of the body that can be removed toallow access to the rear of the pin to ease removal.This plate is tack welded in place so a grinder isrequired to remove it.

7. Lower cylinder slowly and remove spacers (25).

Note: Cylinder will swing out sharply as it leaves itsmounting.

8. Remove bolt (26), lockwasher (27), washer (28) andlower pin (29) connecting base end of the cylinder tothe frame.

9. Remove spacers (25) and remove cylinder assemblyto a clean area for disassembly.

10. Repeat steps 4 through 9 for opposite cylinder.

SM 2207 9-05 3

Section 230-0130Body System - Body Cylinder

6. Ensure cushion sleeve (18) and circlip (19) aresecure in piston (12).

7. Insert new piston seal (13) and new wear rings (14)in piston (12).

8. Fully grease piston (12) OD and 'O' rings (8 & 9) inend cap (3).

9. Sling assembled piston rod (2) in a manner to allowcareful leading of the assembled piston rod intocylinder body (1). Take care not to damage piston seal(13) on cylinder body (1) threads.

10. After piston (12) is inserted in cylinder body (1), pushthe piston rod assembly into cylinder body (1) maintainingcoincidental centre lines of piston rod and cylinder body.

11. Before piston rod (2) is fully home and, with slingsstill taking some of piston rod (2) weight, engage endcap (3) thread and screw home.

12. Push piston rod (2) to the fully retracted position andtighten end cap (3) to a torque of 237 Nm (175 lbf ft).

13. Re-drill

Documents

TA30 A894 parte C.pdf