Terex TR40 User manual
TEREX SERVICE DEPARTMENT
PURPOSE:
To advise potentially hazardous condition.
DETAIL:
It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces
a highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315° C.
The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.
We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.
b. If this is affirmed - Do Not Touch
c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.
d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by
washing thoroughly with Limewater (Calcium Hydroxide solution).
f. Any cloths, residue and gloves used MUST be safely discarded after use.
Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.
Service
Information
Alert
DATE: April 1994 B168
MODEL: General
SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS
TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046
TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752
The information contained within this
Alert must not be made available to
third parties not authorised to receive it.
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SM 222 Rev 1 9-93
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.
It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the
possible hazardous consequences of each way. Consequently, no such broad evaluation has been
undertaken. Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must
first satisfy themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the
service method he/she selects.
Two types of heading are used in this manual to attract your attention.
1. WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly
followed could result in personal injury or loss of life. Look for this symbol to point out important safety
precautions. It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.
IMPORTANT SAFETY NOTICE
WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously
jeopardize the integrity of the machine and could result in property damage or serious personal
injury.
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SM 1664 1-99 1
TABLE OF CONTENTS
Section No. Description SM No.
000 GENERAL INFORMATION
0000 TR40 Off-Highway Truck 1665
100 CHASSIS
0010 Chassis, Hood and Fenders 1666
110 ENGINE
0030 Engine and Mounting 1667
0050 Air Cleaner 1668
0130 Power Takeoff 1669
120 TRANSMISSION
0010 Transmission and Mounting 1671
0070 Commercial Electronic Control (CEC) Shift System 1680
0090 Power Takeoff 1178
0100 Transmission Oil Filter 1673
130 DRIVELINE
0010 Front Driveline - Pre June 1998 Production 1180
0010 Front Driveline - From June 1998 Production 1682
0020 Rear Driveline - Pre June 1998 Production 1311
0020 Rear Driveline - From June 1998 Production 1683
140 FRONT AXLE
0040 Wheel, Rim and Tyre 1303 Rev 1
160 REAR AXLE
0020 Differential 1298
0030 Axle Group 1299
0050 Wheel, Rim and Tyre 1300 Rev 1
165 BRAKE PARTS
0020 Brake Parts - Front Axle 1186
` 0030 Brake Parts - Rear Axle 1301
180 SUSPENSION SYSTEM
0030 Ride Cylinder - Front 1584
0050 Ride Cylinder - Rear 1302
190 CIRCUIT DIAGRAMS
0000 Circuit Diagrams 1585
0270 Switches and Sensors 1672
200 FUEL SYSTEM
0010 Fuel Tank and Mounting 1674
210 COOLING SYSTEM
0000 Cooling System 1686
0040 Radiator, Header Tank and Mounting 1677
0050 Disc Brake Oil Cooler 1679
0060 Transmission Oil Cooler 1678
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SM 1664 1-99
2
* * * *
TABLE OF CONTENTS
Section No. Description SM No.
220 STEERING SYSTEM
0000 Steering System Schematic 1591
0040 Steering and Brake Control Tank 1592
0050 Steering Pump 1204
0080 Accumulator 1205
0090 Steering Valve 1206
0110 Double Relief Valve 1208
0120 Steering Cylinder and Linkage 1304
0130 Accumulator Valve 1209
0150 Steering Filter 1593
230 BODY SYSTEM
0000 Body System Schematic 1681
0040 Body and Disc Brake Cooling Tank 1595
0050 TandemPump 1213
0060 Body Control Valve 1685
0081 Body Control Joystick 1597
0090 Kick-over Valve 1218
0120 Relief Valve 1598
0121 Pilot Supply Valve 1599
0130 Body Cylinder 1221
250 BRAKING SYSTEM
0000 Braking System Schematic 1222
0050 Brake Manifold Valve 1223
0060 Accumulator 1600
0070 Treadle Valve 1225
0090 Directional Control Valve 1226
0100 Monoblock Brake Valve 1227
0130 Retarder Control Valve 1609
0140 Shuttle Valve 1229
260 OPERATORS COMPARTMENT
0010 Cab and Mounting 1602
0110 Passenger Seat and Mounting 1603
270 BODY
0010 Body and Mounting 1675
300 MISCELLANEOUS
0020 Lubrication System 1670
0070 Service Tools 1684
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239
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Section 000-0000
1SM 1665 1-99
GENERAL INFORMATION - TR40 Off-Highway Truck
SM - 2081
ENGINE
Make/Model ......................................... Cummins N14-C475
Type ............................... 4 Cycle Turbocharged/Aftercooled
Gross Power at 2 100 rev/min ......354 kW (475 hp, 481 PS)
Net Power at 2 100 rev/min ..........331 kW (444 hp, 450 PS)
Note: Power ratings to SAE J1995 Jun 90. Engine
emission meets USA EPA/CARB MOH 40 CFR 89 and
EU NRMM (non-road mobile machinery) directive.
Maximum Torque .............................. 2 000 Nm (1 475 lbf ft)
at 1 300 rev/min
Number of Cylinders/Configuration .........................6, in line
Bore x Stroke ........................ 140 x 152 mm (6.25 x 6.25 in)
Total Displacement .................................14.0 litres (885 in³)
Starting...................................................................... Electric
Maximum Speed, Full Load ............................ 2 100 rev/min
Maximum Speed, No Load ............................. 2 400 rev/min
Idle Speed............................................... 800 (Free) rev/min
Safe Operating Angle ................................ 45°/100% Grade
TRANSMISSION
Make/Model ................................................ Allison M5600 A
Automatic electronic control with soft shift feature.
Remote mounted in the frame. Integral torque converter
and planetary gearing. Six speeds forward, two reverse.
Automatic converter lockup action in all speed ranges.
Downshift inhibitor.
Fig. 1 - Machine Dimensions
Speeds With Standard Differential
Forward
Gear 1 2 3 4 5 6
Ratio 4.00 2.68 2.01 1.35 1.00 0.67
km/h 9.7 14.5 19.3 28.7 38.7 58.0
mile/h 6.0 9.0 12.0 18.0 24.0 36.0
Reverse
Gear R1 R2
Ratio 5.12 3.46
km/h 7.6 11.2
mile/h 4.7 7.0
4 370
(14-4)
4 170
(13-8)
4 450
(14-7)
2 765 (9-1)
3 325 (10-11)
3 885 (12-9)
4 240 (13-11)
3 900 (12-10)
1 520 (5-0)
2 710 (8-11)
810
(2-8) 450
(1-6)
4 630
(15-2)
Dimensions in mm (ft-in)
4 060
(13-4)
510 (1-8)
2 350 (7-9) 3 940 (12-11) 2 410 (7-11)
8 700 (28-7)
510 (1-8)
15˚ 3 200
(10-6)
7 380
(24-2)
4 700
(15-5)
5 485
(18-0)
7 120
(23-4)
58˚
3 780
(12-5)
3 530
(11-7)
3 800
(12-6)
4 060
(13-4)
330
(1-1)
Vehicle Clearance Diameter (SAE) 20m (66ft)
Max
Body
Depth
1 120
(3-8)
Optional
Spillguard
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Section 000-0000
General Information -TR40 Off-Highway Truck
SM 1665 1-992
DRIVE AXLE
Heavy duty axle with single reduction spiral bevel gear
differential, full floating axle shafts, and planetary reduction
at each wheel.
Ratios: Standard Optional
Differential.............................................. 3.15:1 3.73:1
Planetary ............................................... 5.66:1 5.66:1
TotalReduction.................................... 17.83:1 21.11:1
SUSPENSION
Front: King pin strut type independent front wheel
suspension by self-contained, variable rate, nitrogen/oil
cylinders.
Rear: Variable rate nitrogen/oil cylinders with A-frame
linkage and lateral stabilizer bar.
Maximum Strut Stroke
Front ......................................................... 251 mm (9.9 in)
Rear .......................................................... 182 mm (7.2 in)
Maximum Rear Axle Oscillation..................... ± 6.5 Degrees
WHEELS AND TYRES
Wheel Rim Width .......................................................... 13 in
Standard Tyres (Front & Rear) ..............18.00 R 33** Radial
Note: Consult tyre manufacturers for optimum tyre selection
and correct t-km/h (ton-mile/h capacity for application.
BRAKES
Service
All hydraulic brake system. Transmission mounted pressure
compensatingpumpprovideshydraulicpressureforbrakes
and steering. Independent circuits front and rear. Each
circuit incorporates a nitrogen accumulator which stores
energy to provide consistent braking response.
Front Brake Circuit Pressure ................ 159 bar(2 300lbf/in²)
Rear Brake Circuit Pressure...................... 52bar(750lbf/in²)
Accumulators:
Nitrogen Precharge Pressure...............55 bar (800 lbf/in²)
Front:
Type............................... Dry Disc with 1 calliper per wheel
DiscDiameter .......................................... 660mm(25.5in)
PadArea,Total ..................................... 1 395 cm²(216 in²)
Rear:
Type..................Oilcooled,multiple friction discs(14total),
completelysealedfromdirtandwater.
Braking Surface, Total ....................38 310 cm² (5 938 in²)
Cooling Flow, Max. .......... 553 litres/min (146 US gal/min)
Parking
Application of rear brakes by springs in brake disc pack.
Hydraulically released.
Hold-off Pressure ..................................83 bar (1 200 lbf/in²)
Retardation
Modulated lever control of rear disc pack.
Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in²)
Emergency
Push button solenoid control applies service and parking
brakes. Automatically applies when engine is switched off.
Parking brake applies should system pressure fall below a
predetermined level.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
STEERING SYSTEM
Independent hydrostatic steering with closed-centre
steering valve, accumulator and pressure compensating
piston pump.
Accumulator provides uniform steering regardless of engine
speed. In the event of loss of engine power it provides
steering of approximately two lock-to-lock turns. A low
pressure indicator light warns of system pressure below
83 bar (1 200 lbf/in²). Steering conforms to ISO 5010,
SAE J53.
System Pressure................................ 159 bar (2 300 lbf/in²)
Relief Pressure ...................................207 bar (3 000 lbf/in²)
Steering Cylinders ................... Double Acting, Single Stage
Accumulator:
Oil Capacity ................................. 14.0 litres (3.70 US gal)
Nitrogen Precharge Pressure...............55 bar (800 lbf/in²)
Steering Angle (Left and Right) .......................................39°
Pump:
Type......................................................................... Piston
Capacity at 2 100 rev/min ..........1.4 litres/s (22US gal/min)
BODY HYDRAULICS
Two body hoist cylinders are mounted between the frame
rails. Cylinders are two-stage with power down in the second
stage.
System Relief Pressure ........................ 190bar(2 750lbf/in²)
Pump:
Type........................................................................... Gear
Capacity at 2 100 rev/min.. 210 litres/min (56 US gal/min)
Control Valve ............ Mechanically Controlled Open Centre
Body Raise Time................................................ 13 Seconds
Body Lower Time ................................................. 9 Seconds
ELECTRICAL
Type ............................................. 24 Volt, Negative Ground
Battery.........................................Two, 12 Volt, 165 Ah each
Accessories................................................................24 Volt
Alternator ..................................................................70 Amp
Starter ........................................................................ 8.9 kW
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Section 000-0000
3SM 1665 1-99
General Information -TR40 Off-HighwayTruck
BODY
Longitudinal 'V' type floor with integral transverse box-
section stiffeners. The body rests on resilient impact
absorption pads.
Body wear surfaces are high hardness (360-440 BHN)
abrasion resistant steel. Yield strength of plates 1 000 MPa
(145 000 lbf/in²).
Plate Thicknesses:
Floor ............................................................. 19 mm (0.75 in)
Side .............................................................. 10 mm (0.39 in)
Front, lower .................................................. 10 mm (0.39 in)
ROPS Cabguard SAE J1040 Feb 86. ISO 3471
Volumes:
Struck (SAE) ............................................ 17.2 m³ (22.5 yd³)
Heaped 2:1 (SAE).................................... 23.9 m³ (31.2 yd³)
SERVICE CAPACITIES
Engine Crankcase & Filters ............... 41 litres (10.8 US gal)
Transmission and Filters....................... 68 litres (18 US gal)
Cooling System................................ 120 litres (31.7 US gal)
Fuel Tank .......................................... 606 litres (160 US gal)
Steering Hydraulic Tank .................... 61 litres (16.0 US gal)
Steering System................................. 85 litres (22.5 US gal)
Body and Brake Cooling Tank ............ 235 litres (62 US gal)
Body and Brake Cooling System ........ 368 litres (97 US gal)
Planetaries (Total) ............................. 66 litres (17.4 US gal)
Differential.......................................... 60 litres (15.8 US gal)
Front Ride Strut (Each) ........................ 14 litres (3.7 US gal)
Rear Ride Strut (Each)......................... 17 litres (4.5 US gal)
Power Takeoff........................................... 4 litres (1 US gal)
TYPICAL NOISE LEVELS
OPERATOR EAR (ISO 6394) ....................................80 dbA
* * * *
*EXTERIOR SOUND RATING
(SAE J88 JUN 86)......................................................90 dbA
*The above result is for the mode giving the highest exterior
sound level when measured and operated as per the
prescribed procedures of the standard. Results shown are
for the unit in base configuration.
Note: Noise Level Exposure to the operator and bystander
personnel may be higher depending upon proximity to
buildings, rock piles, machinery etc.. The actual job site
Noise Level Exposure must be measured and applicable
regulations complied with in respect to Employee Hearing
Protection.
VEHICLE WEIGHTS (MASS)
kg lb
Chassis, with hoists 25 350 55 900
Body, standard 9 050 19 950
Net Weight 34 400 75 850
PAYLOAD, maximum 36 300 80 000
Maximum Gross Weight* 70 700 155 850
FOR UNIT EQUIPPED WITH OPTIONAL BODY LINER
PLATES:
Chassis, with hoists 25 350 55 900
Body, with wear plates 10 550 23 260
Net Weight 35 900 79 160
PAYLOAD, maximum 34 800 79 690
Maximum Gross Weight* 70 700 155 850
* Maximum permissible gross vehicle weight with options,
attachments, full fuel tank and payload.
WEIGHT DISTRIBUTION Front Axle Rear Axle
Empty % 48 52
Loaded % 34 66
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Section100-0010
1
SM 1666 1-99
CHASSIS - Chassis, Hood and Fenders
REMOVAL
WARNING
Toprevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
To remove any of the components shown in
Figs. 1, 2, 3, 4 or 5 (or similar components) the
followingproceduresshouldbecarriedout.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
2. Turn steering wheel in both directions several times
to relieve pressure in the steering circuit. Block all road
wheels.
3. Attach a suitable lifting device to the component and
removemountinghardware.Removethecomponent
from the vehicle.
INSTALLATION
Note: Tighten all fasteners to standard torques listed in
Section300-0080,STANDARDBOLTANDNUT
TORQUESPECIFICATIONS.
WARNING
Toprevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
Using a suitable lifting device, align the component to
be installed in position on the chassis. Secure the
component securely to the chassis with mounting
hardwareremovedduringremoval.
Fig. 1 - Exploded View of Chassis and Guards
1 - Frame Assembly
2 -Bushing
3 -EngineGuard
4 -Channel
5 - Bolt
6 - Nut
7 -Lockwasher
8 -Washer
9 - Bolt
10 -TransmissionGuard
11 - Bolt
SM - 2056
12 -HardenedWasher
13 - Locknut
14 - Spring Disc
15 -Washer
3
7
6
5
810
111514
12
13
2
1
4
9
7
6
8
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Chassis - Chassis, Hood and Fenders
Section100-0010
2SM 1666 1-99
SM - 2057MAINTENANCE
Inspection
Inspect the frame and attached parts at intervals not
exceeding250hours for cracked or broken weldsand
bending/twisting of the frame. Any defects found
shouldberepairedbeforetheyprogressintomajor
failures.Contactyourdealerforrecommendedweld
andrepairinstructions.
Welding
Note: It is important that the electrical connections are
disconnectedinthefollowingordertopreventdamage
to the electrical components:
a. Disconnectbatteryequalizergroundcables.
b. Disconnect battery cables from terminal posts
(groundcablefirst).
c. Disconnect battery equalizer positive cables.
d. Disconnect electrical connections at the ECU.
After welding, reconnect all of the above in the reverse
order.
WARNING
Welding and flame cutting cadmium plated
metalsproduceodourless fumeswhichare
toxic.Recommendedindustrialhygiene
practiceforprotectionofthe welding operator
from the cadmium fumes and metallic oxides
requiresenclosureventilationspecifically
designedforthe weldingprocess.A respiratory
protectivedevicesuchastheM.S.A. 'Gasfoe'
respirator with G.M.A. cartridge will provide
protectionagainstcadmium, fumesand
metallicoxides.The'Gasfoe'respiratorhas
been approved by the U.S. Bureau of Mines:
Approval number 23B-10, and is designed to
protect against gases, vapours, and/or metal
fumes.
Electric arc welding is recommended for all chassis
welding. Since the nature and extent of damage to the
framecannotbepredetermined,nodefiniterepair
procedurecanbe established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or twisted, no welding should be done
untilthepartsare straightenedor realigned.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Service Department
can be consulted regarding the feasibility of welding
repairs.
Painting
A check of the condition of the paint should be made
approximately twice a year and chassis repainted if
necessary.
WARNING
Welding,burning, heating or dressing surfaces
previouslypaintedusingpolyurethanepaint
producesfumeswhich aretoxic.Surfaces must
be prepared using paint stripper prior to area
beingreworked.RecommendedIndustrial
Hygiene and Safety Rules should be be
followedfor protection of the weldingoperator
fromfumes.
If painting of the actual frame of the unit is required,
thoroughly clean the areas to be painted. Apply a
primer coat of red oxide and then a finish coat of
polyurethaneenamel.
To keep rust and corrosion to a minimum, periodic
paintingofabrasions and other exposed metal areas on
theframeishighlyrecommended.
Fig. 2 - Exploded View of Hood and Mounting
1 - Hood Assembly
2 - Plate
3 - Bolt
4 -HardenedWasher
5 - Nut
6 - Baffle
7 - Beading
8 - Bracket
543
54
4
3
2
176
5
38
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Section100-0010
3
SM 1666 1-99
SM - 2058
Chassis - Chassis, Hood and Fenders
Fig. 3 - Exploded View of Fenders and Mounting
28 - Bolt
29 - Mudguard
30 - Mudguard
31 - RH Handrail
32 - Mirror Bracket
33 - Bolt
34 - Lockwasher
35 - Washer
36 - Mirror
1 - LH Fender Assembly
2 - LH Platform Assembly
3 - RH Fender Assembly
4 - RH Platform Assembly
5 -Crossmember
6 -Support
7 -Support
8 - Bolt
9 -Lockwire
10 - Hardened Washer
11 - Bolt
12 - Washer
13 - Nut
14 - Bolt
15 - Locknut
16 -HardenedWasher
17 - Bolt
18 - Locknut
19 - Hardened Washer
20 - Engine Access Cover
21 - LH Handrail
22 - Bolt
23 - Mirror Wide Angle
24 - Nut
25 - Washer
26 - Bolt
27 - Bolt
2210
23
181928
3
7
27
25
24 17
19
18 1
26
25
24
30
17
19
18
181928
17
19
18
11
12
13 5
14 1615 6
18 19 17
221
22
10
10 89
1922
17
19
18
29
20
4
22
10 DETAIL A
32
35
34
33
A
31
36
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Chassis - Chassis, Hood and Fenders
Section100-0010
4SM 1666 1-99
SM-1960
1 - LH Step Assembly
2 - RH Step Assembly
3 - Plate
4 - 'U' Bolt
5 - Step
6 - Bolt
7 -Washer
8 - Bolt
9 - Locknut
10 - Nut
11 - Bolt
12 -HardenedWasher
13 - Nut
14 -HardenedWasher
Fig. 4 - Exploded View of Ladders and Handrails
33
614 1413
6141413
1112
4
14
4
1210
11121210
2
5
5
11
12
12
10
11
12
12
10
8779
8779
1
4
14
4
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Section100-0010
5
SM 1666 1-99
Chassis - Chassis, Hood and Fenders
1 -RadiatorGuard
2 - Cover Plate
3 -Washer
4 - Bolt
5 - Bolt
6 - Nut
7 - Bolt
8 -Grille
9 - Bolt
Fig. 5 - Radiator Guard and Mounting
* * * *
SM-1961
10 - Bracket
11 - Bolt
12 -HardenedWasher
13 - Plate
11
12
5
12
12
6
11
10
13
712
612 12 9
18
234
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1
SM16671-99
Section 110-0030
ENGINE - Engine and Mounting
SM - 2061
Fig. 1 - Exploded View of Engine Mounting
DESCRIPTION
Numbers in parentheses refer to Fig. 1.
For engine make, model and specification, refer to
Section 000-000, GENERAL INFORMATION. For
detailed engine servicing and repair data refer to the
engine manufacturers service manual.
There are two fuel filters (2), a full flow lube oil filter
(3) and a pre-charge coolant filter (4) installed on the
right hand side of engine (1). A lube oil bypass filter
is mounted off the front left hand of the horse collar.
REMOVAL
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
damage, ensure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
1 -Engine
2 - Fuel Filter
3 - Lube Oil Filter
4 -CoolantFilter
5 - Shock Mount
6 -Washer
7 - Bracket Assembly
8 - Bolt
9 -Washer
10 -Crossmember
11 - Bolt
12 - Bolt
37 -Guard-Alternator
38 - Bolt
39 -HardenedWasher
40 - Lock
41 - Key
42 - Locknut
43 - Bolt
44 - Latch Assembly
45 - Dipstick Clamp
46 - Dipstick Clamp
47 - Cover Plate
38 -Screw
49 -Fan
25 - Locknut
26 -Damper
27 -FlangeCoupling
28 -Screw
29 - Bolt
30 -Washer
31 - Guard - Belt LH
32 -Spacer
33 - Bolt
34 -Washer
35 - Bolt
36 -Washer
13 - Nut
14 -Washer
15 - Bolt
16 -Washer
17 - Nut
18 -Clamp
19 -Filler Line
20 - Bolt
21 - Bolt
22 -Lockwasher
23 - Bracket Assembly
24 - Bolt
21.22
2
34
View on arrows A and B
B
A
C
6
6115
5
23
6
611
5
7
10
24
25
23
7
8.9
24
25
6
6
1
25
25
10
12.13.14
20
15.16
17
18 18
19
37
49
View on arrow C
33.34
SECURITY KIT
ENGINE OIL FILL
44
40
42
45
43
41
26
28
27
29.30
3132
35.36
37
38
39
44
40
42
46
43
41
SECURITY
KIT
ENGINE
DIPSTICK
47
48
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SM16671-99
Engine - Engine and Mounting
Section 110-0030
2
(1) assembly. Close all drain cocks after draining.
9. Identify cooling lines for ease of installation and
with suitable containers in position, disconnect
cooling lines from engine (1).
10. Using suitable lifting equipment, carefully remove
the radiator assembly from the vehicle. Refer to
Section 210-0040, RADIATOR AND MOUNTING.
11. Disconnect and remove air cleaner intake pipe
from the engine turbocharger and air cleaner. Refer
to Section 110-0050, AIR CLEANER.
12. Disconnect and remove exhaust tube from the
engine turbocharger.
13. Disconnect throttle control linkage from engine (1).
14. Identify heater lines for ease of installation and,
with a suitable container in position, disconnect
heater lines from engine (1).
15. Close fuel shutoff valve at filter head, identify fuel
lines for ease of installation and, with a suitable
container in position, disconnect fuel lines from
engine (1).
16. Slacken top clamp (18) securing filler hose (19)
to filler tube at the right hand frame rail. Disconnect
filler hose (19) and tie onto engine (1) to prevent
fouling.
17. Identify all electrical harnesses and cables
attached to engine (1) for ease of installation and
disconnect from engine (1).
18. Disconnect front driveline from engine coupling
and secure clear of engine (1). Refer to
Section 130-0010, FRONT DRIVELINE.
19. Remove tandem pump from the engine power
takeoff. Refer to Section 230-0050, TANDEM PUMP.
Note: The hydraulic lines can be left attached to the
tandem pump.
WARNING
Heavy assembly. To prevent personal injury
and property damage, be sure lifting device is
of adequate capacity and properly secured to
do the job safely.
20. Attach suitable lifting equipment to the lifting
WARNING
High electrical current. Disconnect battery
ground cable at battery before removing
engine attachments. High electrical current
can cause sparks and personal injury from
burns.
Note: Tag and identify all lines, hoses, cables and
linkages disconnected to remove engine.
1. Position the vehicle in a level work area, ensure
the body is fully lowered, apply the parking brake and
switch off the engine.
2. Turn steering wheel several times to relieve
pressure in the steering circuit. Block all road
wheels.
3. Disconnect battery cables from battery terminal
ports before starting removal procedures. Disconnect
ground cable first.
4. Remove mounting hardware securing the hood on
the vehicle. Remove hood assembly from the vehicle.
Refer to Section 100-0010, CHASSIS, HOOD AND
FENDERS.
5. Disconnect electrical connections from the radiator
guard and remove mounting hardware securing the
radiator guard on the vehicle. Remove radiator guard
from the vehicle. Refer to Section 100-0010,
CHASSIS, HOOD AND FENDERS.
WARNING
Harmful gas. Before disconnecting any air
conditioner lines refer to Section 260-0130,
AIR CONDITIONING. Refrigerant will rapidly
freeze all objects with which it comes into
contact, and it can cause serious damage to
the skin and eyes.
6. If the vehicle is equipped with an air conditioning
system, evacuate refrigerant from the system and
disconnect lines at the compressor. Refer to Section
260-0130, AIR CONDITIONING.
7. Place a suitable container under the engine drain
port, remove drain plug and drain the oil. After
draining, reinstall drain plug in the engine sump and
tighten securely.
8. With suitable containers in position, open drain
cocks and drain coolant from the radiator and engine
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