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