Alexander Dennis SUPER Dart SLF EURO 2 User manual

Publication Number: 2141 Date: JUNE 1999 (01/03)
COVERING EURO 2 CHASSIS MODELS
SFD466BR1*GW3
SFD466BR1*GW4
SFD476BR1*GW4
SFD476BR1B*GW4
SFD476BR1B*GW3
SFD477BR1*GW3
SFD477BR1B*GW3
EURO 2
SERVICE MANUAL

Dart SPD-Pub No.2141-06/99
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise
without prior written permission of Alexander Dennis.

1.1 INTRODUCTION
1.2 SERVICE CENTRES
1.3 HEALTH & SAFETY NOTES
1.4 MAINTENANCE SCHEDULE
2.1 AIR CLEANER
2.2 FRONT AXLE
3.1 REAR AXLE
3.2 REAR AXLE SERVICE
3.3 REAR AXLE OVERHAUL
3.4 REAR AXLE HUB OVERHAUL
4.1 BRAKING SYSTEM
4.2 PIPE CONNECTORS
5.1 COOLING SYSTEM
5.2 ELECTRICAL EQUIPMENT
6.1 ENGINE CONTROLS
6.2 ENGINE AND MOUNTINGS
6.3 EXHAUST SYSTEM
6.4 CRT EXHAUST SYSTEM
7.1 FUEL SYSTEM
7.2 GEARBOX - ALLISON
7.3 GEARBOX - VOITH
8.1 HYDRAULIC SYSTEM
8.2 DRIVE SHAFT
9.1 STEERING
9.2 AIR SUSPENSION SYSTEM
10.1 FRONT AIR SUSPENSION
10.2 REAR SUSPENSION
10.3 SHOCK ABSORBERS
10.4 WHEELS & TYRES
Alexander Dennis
Dennis Way
GUILDFORD
Surrey GU1 1AF
England
Tel: [phone]
Fax: [phone]
INDEX
1
2
3
4
5
6
7
8
9
10

Dart SPD-Pub No.2141-06/99

Vin Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.1.2
Using this book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.1.3
SERVICE MANUAL INTRODUCTION
SECTION 1.1

INDTRODUCTION SERVICE MANUAL
AMENDED:
1.1.2
Dart SPD-Pub No.2141-06/99
The Dart SLF can be supplied in lengths to suit 11.2 metre bodies. The exact vehicle specification is
identified by the Vehicle Identification Number stamped on the Vehicle Identification Plate, a example of
which is shown below:
W.P.O.
VEHICLE
TYPE
ENGINE
TYPE
CAB
TYPE
51486
DART SLF
CUMMINS B160 20
DENNIS
GUILDFORD, ENGLAND
TA
SFD446BR1TGW31234
V.I.N.
10500 12960
4000
8000
4480
84800
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Typical Vehicle Identification Plate
* Denotes build year in VIN number on front cover
Please quote VIN, vehicle type and WPO numbers with any enquiries concerning this vehicle.
A
B
C
D
E
F
G
DESIGN
WEIGHTS
PLATED
WEIGHTS
)This symbol, next to an item line, indicates that the item has been amended for
the current issue of the page.
TYPICAL VIN KEY TO VIN PLATE
SFD World Manufacturers Identity A Type Approval Number
4 Wheelbase B Vehicle Identification Number
6 Engine C Gross Weight
6 Transmission D Train Weight
B Air Conditioning E Axle 1 Weight
R Hand of Drive F Axle 2 Weight
1 Series / mark G Axle 3 Weight
T (*) Build / Year
G Build Plant
W Model
3 Frame Type TYPICAL VEHICLE TYPE
1234 Serial Number DART SLF

1.1.3 Dart SPD-Pub No.2141-06/99
SERVICE MANUAL MAINTENANCE
AMENDED:
USING THIS MANUAL
Structure
The manual is divided into 10 Sections. These sections are separated by blue numbered dividers.
Each of the manual's 10 Sections contains separate Sub-sections.
An index listing both the Sections and Sub-sections is at the front of the manual, following the cover
page.
At the beginning of each Section is a detailed index of its
contents.
Abbreviations
A/R = As required
c/w = complete with
Amendments
The amendment date appears at the top of the page.
This symbol, next to an item line, indicates
that the item has been amended for the current issue of the
page.
6
.
1 ENGINE
CONTROLS
6.2 ENGINE & MOUNTING
6.3 EXHAUST SYSTEM
7.1 FASTENER IDENTIFICATION
7.2 FRAME
7.3 FUEL SYSTEM
7.4 GEARBOX
8.1 HYDRAULIC SYSTEM
8.2 DRIVE SHAFT
9.1 SPEEDOMETER/TACHOGRAPH
9.2 STEERING
10.1 FRONT AIR SUSPENSION
10.2 REAR AIR SUSPENSION
10.3 AIR SUSPENSION SYSTEM
10.2 WHEELS & TYRES
6
7
8
10
9
PARTS MANUAL BRAKING SYSTEM
SECTION 3.2
Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2.2 - 3
Pipe fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2.4 - 5
Brake actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2.6 - 7
Footbrake valve assembly - ZF . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2.8 - 9
Footbrake valve assembly - Voith . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2.10 - 11
Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2.12
Handbrake interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2.13
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2.14 - 15
Sub-sections
Sections
Page numbers indicate the Section, Sub-
section, and individual page number.
Page 3.2.12
The full number appears at
the bottom of each page.
))
PARTS MANUAL ELECTR
I
AMENDED:040898
ITEM DESCRIPTION NO PART
NO USED
Alternator - Bosch T1 1 65680
4
1 Cover - air intake 1 65680
4
)2 Shield - drive end 1 65680
4
3 Bearing 1 65680
4
4 Cover plate 1 65680
4
5 Rotor 1 65680
4
6 Collector rin
g
1 65680
4

Dart SPD-Pub No.2141-06/99

Regional Service Centres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.2.2 - 4
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.2.4
SERVICE MANUAL SERVICE CENTRES
SECTION 1.2

Dart SPD-Pub No.2141-06/99
SERVICE CENTRES SERVICE MANUAL
AMENDED:050804
1.2.2
SKELMERSDALE
SKELMERSDALE PARTS CENTRE: Unit 2. Priorswood Place. East Pimbo.
Skelmersdale.WN8 9QB
TELEPHONE: [phone] FAX: [phone]
OUT OF HOURS CONTACT : [phone]
GUILDFORD
GUILDFORD PARTS CENTRE: Dennis Way. Guildford. Surrey. GU1 1AF.
TELEPHONE: [phone]/336/337 FAX: [phone]
OUT OF HOURS CONTACT : [phone]
WARE
WARE PARTS CENTRE: Widbury Hill. Ware. Hertfordshire. SG12 7AS
TELEPHONE: [phone] FAX: [phone]
OUT OF HOURS CONTACT :
FALKIRK
FALKIRK PARTS CENTRE: 91 Glasgow Road, Falkirk, FK1 4JB
TELEPHONE: [phone] / 309 / 311 FAX: -
OUT OF HOURS CONTACT :
DUBLIN
DUBLIN PARTS CENTRE Unit 3. North West Business Park. Blanchardtown.
Dublin 15. Eire
TELEPHONE: 00353 (0) 1 885 5108 FAX: - 00353 (0) 1 885 5109
OUT OF HOURS CONTACT : 00353 (0) 87 9679637

1.1.2.3 Dart SPD-Pub No.2141-06/99
SERVICE MANUAL MAINTENANCE
AMENDED:050804
SOUTH EAST
REGIONAL PARTS MANAGER MARK BOWLEY
E-MAIL : [email protected]
MOBILE : [phone]
MIDLANDS AND SOUTH WEST
REGIONAL PARTS MANAGER SIMON McFALL
E-MAIL : [email protected]
MOBILE : [phone]
NORTH
REGIONAL PARTS MANAGER MATT SHENTON
E-MAIL : [email protected]
MOBILE : [phone]
SCOTLAND AND IRELAND
REGIONAL PARTS MANAGER JOHN McPHERSON
E-MAIL : [email protected]
MOBILE : [phone]
HEAD OF UK & EIRE CUSTOMER MANAGEMENT
CUSTOMER MANAGEMENT ROB WILLIAMS
E-MAIL : [email protected]
MOBILE : [phone]

MAINTENANCE SERVICE MANUAL
AMENDED:050804
1.1.2.4
Dart SPD-Pub No.2141-06/99
BARRHEAD
BARRHEAD SERVICE CENTRE: 101 Kelburn Street. Barrhead. Glasgow. G78 1LD
TELEPHONE: [phone] FAX: [phone]
OUT OF HOURS CONTACT : [phone]
BRISTOL
BRISTOL SERVICE CENTRE: Folly Lane. St Philips. Bristol. BS2 0RH
TELEPHONE: [phone] FAX : [phone]
OUT OF HOURS CONTACT : [phone]
DURHAM
DURHAM SERVICE CENTRE: Unit 13E. Bowburn Industrial Estate. Bowburn.
Durham. DH6 5AD
TELEPHONE: [phone] FAX : [phone]
WARE
WARE SERVICE CENTRE: Widbury Hill. Ware. Hertfordshire. SG12 7AS
TELEPHONE: [phone] FAX : [phone]
OUT OF HOURS CONTACT : [phone]
WOKING
WOKING SERVICE CENTRE Unit 10. Goldsworth Park Industrial Estate.
Woking. Surrey. GU21 3BA
TELEPHONE: [phone] FAX: [phone]
OUT OF HOURS CONTACT : [phone]
UK WORKSHOP MANAGER
ERIC LINDSAY
E-MAIL : [email protected]
MOBILE : [phone]

1.2.5 Dart SPD-Pub No.2141-06/99
SERVICE MANUAL SERVICE CENTRES
AMENDED:050804
LONDON - WEST
REGIONAL SERVICE MANAGER JOHN CHAVES
E-MAIL : [email protected]
MOBILE : [phone]
LONDON - SOUTH
REGIONAL SERVICE MANAGER STEVE EDMONDS
E-MAIL : [email protected]
MOBILE : [phone]
SOUTH EAST
REGIONAL SERVICE MANAGER STEVE HARDY
E-MAIL : [email protected]
MOBILE : [phone]
SOUTH WEST
REGIONAL SERVICE MANAGER STUART BOND
E-MAIL : [email protected]
MOBILE : [phone]
NORTH
REGIONAL SERVICE MANAGER JOHN BRADLEY
E-MAIL : [email protected]
MOBILE : [phone]
SCOTLAND & IRELAND
REGIONAL SERVICE MANAGER DAVID ALLEN
E-MAIL : [email protected]
MOBILE : [phone]
UK FIELD SERVICE MANAGER
NIGEL PARKS E-MAIL : [email protected]
MOBILE : [phone]

MAINTENANCE SERVICE MANUAL
AMENDED:
1.2.6
Dart SPD-Pub No.2141-06/99
FALKIRK
PARTS TECHNICAL - BODY: 91 Glasgow Road. Falkirk. FK1 4JB.
TELEPHONE: [phone] FAX: [phone]
GUILDFORD
PARTS TECHNICAL - CHASSIS: Dennis Way. Guildford. Surrey. GU1 1AF
TEL: [phone] FAX: [phone]
FALKIRK
TECHNICAL SERVICE - BODY: 91 Glasgow Road. Falkirk. FK1 4JB
TELEPHONE: [phone] FAX: [phone]
GUILDFORD
TECHNICAL SERVICE - CHASSIS: Dennis Way. Guildford. Surrey. GU1 1AF
TEL: [phone] FAX: [phone]
WARRANTY ASSISTANCE
CALL CENTRE: Dennis Way. Guildford. Surrey. GU1 1AF
TEL: [phone]
FAX: [phone] E-MAIL : [email protected]

Moving the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.3.2
Working on the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.3.2
Hazardous materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.3.3
Points to remember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.3.4
Jacking points - wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.3.5
Supporting the vehicle for maintenance purposes . . . . . . . . . . . . . . . .Page 1.3.6
Positioning of supports stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 1.3.7
SERVICE MANUAL HEALTH & SAFETY NOTES
SECTION 1.3

1.3.2
Dart SPD-Pub No.2141-06/99
HEALTH & SAFETY NOTES SERVICE MANUAL
AMENDED:110700
MOVING THE VEHICLE
During movement of the vehicle chassis the hazards involved are those normally associated with all forms
of powered transport.
Before driving the vehicle, operators should familiarise themselves with the vehicle operator’s handbook.
With the chassis in the unbodied condition, the following areas may present hazards additional to those
normally encountered on a vehicle:
• Projections - chassis cross members, exhaust tail pipe.
• Moving parts - Cooling fan, propshaft, brake levers, steering linkage.
• Temporary components - drivers seat.
• Noise - engine and exhaust noise may exceed levels achieved on a bodied vehicle.
WORKING ON THE VEHICLE
Before commencing work on the vehicle, take note of all instructions relating to safety and hazardous
items. The following potential hazards should be considered:
Stored Energy
Certain components and systems on the vehicle contain stored energy which must not be released in a
non approved manner.
• Tyre air pressure.
• Braking system air pressure.
• Park brake spring compression.
• Cooling system pressure and temperature - the system will remain hot and under pressure after
use. Allow to cool before attempting to remove the header tank cap..
• Chassis lifting - adequate support required during jacking or lifting. Eye protection should be worn
when working under the vehicle.
• Diesel injection pumps supply fuel to the engine at very high pressure, care must be taken when
working on the injectors or injection pipes as fuel under high pressure can penetrate the skin.
• Brake drums or discs will remain at an extremely high temperature for a considerable time after
use, caution must be exercised when handling such items to avoid burns.
PLEASE READ FOR YOUR OWN SAFETY

1.3.3 Dart SPD-Pub No.2141-06/99
SERVICE MANUAL HEALTH & SAFETY
AMENDED:110700
HAZARDOUS MATERIALS
Certain components on the vehicle contain, or can produce, material which must be handled cautiously.
These materials are as follows:
Those which must not be taken internally or contact the eyes, skin, or mouth
Battery acid
Diluted sulphuric acid can cause skin burns, eye damage and internal damage if ingested. Vapour
from the solution can also irritate the respiratory system and the eyes. Take care when topping up
or carrying the battery. Also hydrogen gas is given off by the battery is highly explosive, never
allow a naked flame in close proximity.
Cooling system antifreeze
Based on ethylene glycol, and has significant toxicity if ingested, but can also be absorbed through
the skin. Causes mild eye and skin irritation. Hot fluid can also scald.
Mineral oil (Engine and Gearbox)
This type of oil contains small quantities of polycyclic aromatic hydrocarbons, which can cause
irritation, dermatitis and oil acne if allowed persistent contact with the skin. Toxicity through
ingestion is of a low order, however this should be avoided. If swallowed or gets into the eyes, seek
medical advice.
Hydraulic Fluids
These are generally made from polyalkylene glycol ethers and can cause mild irritation of the skin
and eyes. The toxicity through ingestion is generally regarded to be low order. If swallowed or gets
into the eyes, seek medical advice.
Friction Material Dust
May consist of a high percentage of white asbestos bonded in a resin. Handling and fitting lined
brake shoes or clutch plates is not regarded as a health risk. The dust produced by worn linings is
degraded by the brake or clutch is not believed to be hazardous. However it is prudent to avoid
generating airborne dust concentration, therefore dust removal should be by the use of approved
vacuum cleaner or by the use of a damp cloth (for occasional exposure).
Insulation Material
Man made fibres which include glass, rock, slag and metal oxides. These may cause skin irritation.
Inhalation of dust from the fibres should be kept below 1 fibre/ml.
Fuel
Diesel fuel is a mixture of hydrocarbons largely consisting of paraffinic hydrocarbons, with blended
constituents such as refined vacuum distillants and catalytically cracked oil. Contact with the skin
can cause irritation and dermatitis. Inhalation and ingestion are serious risks and can cause
chemical pneumonitis. If swallowed or gets into the eyes, seek medical advice.
Exhaust Emissions
Substances produced are carbon monoxide, hydrocarbons and oxides of nitrogen. Can be highly
toxic if inhaled in sufficient quantity. Emissions in enclosed spaces should be minimised unless
adequate extraction facilities are available.
PLEASE READ FOR YOUR OWN SAFETY

HEALTH & SAFETY NOTES SERVICE MANUAL
AMENDED:110700
1.3.4
Dart SPD-Pub No.2141-09/95
Those which may cause noxious fumes if allowed to burn:
Mineral oil (engine and gearbox)
These do not present a fire or explosive hazard under normal circumstances.
Hydraulic Fluids
These do not present a fire or explosive hazard under normal circumstances.
Fuel (diesel)
Not classified as flammable for most purposes.
Rubber and synthetic alternatives (tyres, hoses, bushes, seals, insulation)
Natural and synthetic rubbers are combustible and will produce unpleasant and dangerous fumes.
“Viton” seals are used in a small number of applications on the chassis and this material can leave
highly corrosive residue if burned, The rubber changes into a sticky substance which contains
Hydrofluoric acid. This is extremely corrosive, if it gets on to the skin you must seek medical advice
immediately. If dealing with a vehicle which has fire damage the use of protective gloves is
recommended, these should be discarded after use.
Coatings (Mebon chassis protection)
Generally inert in the cured state, but should be removed from areas to be welded.
Points to Remember
• Remove rings, watches before working on the vehicle, particularly necessary when working on the
electrical system.
• Wear eye protection when working underneath the vehicle.
• Use barrier cream or wear gloves as necessary to protect hands.
• Keep loose clothing and long hair away from moving parts.
• Never attempt to lift heavy components unaided.
PLEASE READ FOR YOUR OWN SAFETY

Dart SPD - Pub No. 2141 - 01/99
CHASSIS JACKING POINTS
Note: It is not permissible to jack on any part of the frame other than the proper jacking points. it is
recommended that the vehicle is supported on stands as soon as there is sufficient clearance
under the vehicle.
Front Axle
A jacking point is provided on the chassis outrigger
behind the front wheel. Whenever possible, use one
of these points to provide a secure location for a bottle
jack or floor jack. Check that the jack head is properly
located on the jacking point before starting to lift the
vehicle.
If the jacking point cannot be used (for example, if the jack is too tall to fit under the side of the vehicle), a
long reach low height floor jack should be positioned under the front of the vehicle to lift on the front axle
beam.
Rear Axle
The jack may be positioned in the following locations:
lDirectly under the base of the air spring.
Note: The jack must be directly beneath the air spring
base. Never place the jack under the unsupported
span of the member that connects the two air spring
bases.
lUnder the chassis frame, where the
crossmember in front of the rear axle crosses the
frame longitudinal.
SERVICE MANUAL HEALTH & SAFETY NOTES
AMENDED:110700
1.3.5
PLEASE READ FOR YOUR OWN SAFETY

HEALTH & SAFETY NOTES
SERVICE MANUAL
AMENDED:110700
1.3.6
Dart SPD-Pub No.2141-09/95
SUPPORTING VEHICLE FOR MAINTENANCE PURPOSES
When it is necessary to elevate the vehicle to carry out maintenance it is strongly recommended that the
wheel type lifts are used and that they remain in position to provide a stable and safe platform whilst
carrying out maintenance / inspection tasks beneath the vehicle.
Only under certain circumstances such as axle removal / replacement which require the wheel type lifts to
be removed to gain access to components, should the vehicle be supported on stands. Adaptors may be
required to support the chassis from the top of the axle stands, Please contact the axle stand
manufacturer for details of stand adaptors. When supporting the vehicle in this manner it is important that
the safety guidelines below are followed in addition to all normal workshop safety procedures:
• The recommended support stand positions should be used (refer to illustration opposite for
positions).
• On vehicles with air suspension, do not attempt the support the vehicle using suspension
components or a combination of chassis and suspension points.
• Only use stands that are in a safe condition and with a capacity that is rated to support the vehicle.
• Do not use packing between stand tops and the chassis as movement may cause the vehicle to
become unstable.
PLEASE READ FOR YOUR OWN SAFETY