Ultraflex EMEI User manual
TRUCK, CARGO, LIGHT, CREW CAB, WINCH, MC2 -
LAND ROVER 110 6 x 6
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS Issue 1, May 92
FIELD AND BASE REPAIR
This EMEI is authorised for issue by the CGS. It provides direction, mandatory con-
trols and procedures for the operation, maintenance and support of equipment. Per-
sonnel are to obey the instructions and follow the procedures contained in this
publication.
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL VEHICLE G 2641
ENGINEERING INSTRUCTIONS Issue 1, May 92
AMENDMENT CERTIFICATE
It is certified that the amendments promulgated in the undermentioned Amendment Lists have been
incorporated in this COPY
of
the Publication: -
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page number OR brief
details of page(s) amended, inserted or
cancelled.
UNCONTROLLED WHEN PRINTED
VEHICLE G 264-l
Issue 1, May 92 ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS
AMENDMENT CERTIFICATE (Continued)
Amendment List Topic/Section ‘Amendment Effect Amended By Date
10.
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Insert EMEI
cancelled.
amendment number and page number OR brief details
Paw(s)
amended, inserted or
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL VEHICLE G 264-l
ENGINEERING INSTRUCTIONS Issue 1, May 92
LIST OF CONTENTS
Para No. Page No.
AMENDMENT CERTIFICATE ........................................................................................
LIST OF CONTENTS ......................................................................................................
LIST OF ILLUSTRATIONS .............................................................................................
LIST OF TABLES ...........................................................................................................
ASSOCIATED PUBLICATIONS .....................................................................................
MAINTENANCE SUPPLY ITEM (MSI) IDENTIFICATION .............................................
LIST OF LUBRICANTS ..................................................................................................
INTRODUCTION .............................................................................................................
ENGINE -GROUP 1
Air Compressor
Disassembly (field and Base Repair) ...................................................................
Cleaning and Inspection (Field and Base Repair) .................................................
Reassembly (Field and Base Repair). ...................................................................
ELECTRICAL - GROUP 15
Wiring Harness
General Precautions ..............................................................................................
Replacement (Field and Base Repair). ..................................................................
FRAME -GROUP 16
Frame
Inspection (Base Repair) .......................................................................................
Alignment (Base Repair). .......................................................................................
BODY -GROUP 17
Cab Removal (Field and Base Repair). ........................................................................
Inspection (Field and Base Repair) .......................................................................
installation (Field and Base Repair) .......................................................................
Cargo Body
Removal (Field and Base Repair). .........................................................................
Inspection (Field and Base Repair) .......................................................................
Installation (Field and Base Repair) .......................................................................
i
...
III
iv
V
vi
vii
VIII
ix
1 1
2 2
3 2
4 5
5 5
6 9
7 9
8 13
9 14
10 14
11 15
12 15
13 15
UNCONTROLLED WHEN PRINTED
VEHICLE G 264-l ELECTRICAL AND MECHANICAL
Issue 1, May 92 ENGINEERING INSTRUCTIONS
LIST OF ILLUSTRATIONS
Fig. No. Title
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Truck, Cargo, Light, Crew Cab, Winch, MC2 .......................................................................
Air Compressor - Exploded View.. .....................................................................................
Crank-pin - Removal.. ........................................................................................................
Crankshaft - Removal ........................................................................................................
Connecting Rod Bush - Removal.. .....................................................................................
Crankshaft Inner Bearing - Installation.. .............................................................................
Crankshaft - Installation .....................................................................................................
Connecting Rod - Installation.. ...........................................................................................
Manifold Bridge - Installation ..............................................................................................
Front Wiring Harness ...........................................................................................................
Cab Wiring ............................................................................................................................
Rear Wiring Harnesses ........................................................................................................
Frame Alignment.. ................................................................................................................
Cab - Removal ...................................................................................................................
Page No.
ix
1
2
2
2
2
3
3
3
5
6
6
11
13
iv
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS
Table No.
VEHICLE G 264-l
Issue 1, May 92
LIST OF TABLES
Title Page No.
1 Location of Identification Numbers on Maintenance Supply Items.. ..................................... vii
2 List of Lubricants ....
.................................................................................................................
VIII
3 Compressor Wear Limits ...................................................................................................... 2
4 Frame Dimensions.. ............................................................................................................. 9
UNCONTROLLED WHEN PRINTED
VEHICLE G 264-l
Issue 1, May 92
1.
2.
3.
Standing Orders for Vehicle Operation and Servicing (Vol. 2 - B Vehicles)
MEMA Vol. 3
Australian Army Books:
4.
5.
6.
7.
TGM 120 Record Book for Service Equipment - Army
Complete Equipment Schedules (CES):
(a) SCES 12046 Truck, Cargo, Light, Crew Cab,
(b) Equipment Kit SCES 12045 I Winch, MC2
Block Scale 2406/31 Issue 1 - Special Tools for RAEME - B Vehicles - Truck,
Cargo, Light, MC2 (Land Rover Model 110)
EMEI VEH A 029 - Servicing of B Vehicles
EMEI VEH A 119-22 - Repair of Vehicles Under Warranty Agreement - Policy
Instruction
8.
9.
10
11
12
13
14
EMEI VEH G 202 - Technical Description (Truck, Cargo, Light, MC2)
EMEI VEH G 203 - Unit Repair (Truck, Cargo, Light, MC2)
EMEI VEH G 204 - Field Repair (Truck, Cargo, Light, MC2)
EMEI VEH G 204-l - Base Repair (Truck, Cargo, Light, MC2)
EMEI VEH G 209 - Servicing instruction
EMEI VEH G 260 - Data Summary (Truck, Cargo, Light, Crew Cab, Winch, MC2)
EMEI VEH G 262 -Technical Description (Truck, Cargo, Light, Crew Cab, Winch,
MC2)
15 EMEI VEH G 263 - Unit Repair (Truck, Cargo, Light, Crew Cab, Winch, MC2)
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS
ASSOCIATED PUBLICATIONS
16. EMEI WKSP E 652 - Occupational Health and Safety (Polyurethane Paint)
17. Repair Parts Scale 02219
vi
UNCONTROLLED WHEN PRINTED
-
0
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS
MAINTENANCE SUPPLY ITEM (MSI)
IDENTIFICATION
Table 1 - Location of Identification Numbers on
Maintenance Supply Items
Chassis No. - Right hand side of the chassis, forward of the
spring mounting turret
Chassis nameplate - Left hand seat box, in the cab
Engine No. - Left hand side of the engine block
Injection pump identification - Side of the pump
Transmission and transfer case - Rear of the transfer case
Torque limiter - On rear end of the drive plate
Front axle No. - Adjacent to the axle breather
Intermediate axle No. - Adjacent to the axle breather
VEHICLE G 264-l
Issue 1, May 92
Rear axle No. - Adjacent to the axle breather
Air compressor - Front outer mounting point
vii
UNCONTROLLED WHEN PRINTED
VEHICLE G 2&l ELECTRICAL AND MECHANICAL
Issue 1, May 92 ENGINEERING INSTRUCTIONS
LIST OF LUBRICANTS
Equipment
Table 2 - List of Lubricants
Lubricant Capacity (Litres)
Engine (including filter)
Transmission
Transfer Case (with PTO)
Front Axle
Intermediate Axle
Rear Axle
Swivel Pin Housings
Brake Master Cylinder
Clutch Master Cylinder
Power Steering System Reservoir
Fanbelt Jockey Pulley
Wheel Bearings
Winch Cable
Radiator Inhibitor
Clutch Pedal Trunnion
Speedometer Cable
Propeller Shaft
Winch Drive Line
Parking Brake Adjuster
Windscreen Wiper Drive Cable
Winch
Air Compressor
OMD-115
OMD-115
OMD-115
OEP-220
OEP-220
OEP-220
OEP-220
OX (Aust) 8
OX (Aust) 8
OX46
XG-274
XG-274
ZX8
ALFLOC 2001
XG-274
XG-274
XG-274
XG-274
XG-274
XG-274
OEP-220
XG-274
8.5
2.7
5.8
1.7
2.6
2.3
0.35 (each)
Fill to level
Fill to level
1.25
As required
As required
As required
0.65
As required
As required
As required
As required
As required
As required
2.1
As required
VIII
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS VEHICLE G 264-l
Issue 1, May 92
TRUCK, CARGO, LIGHT, CREW CAB, WINCH, MC2 -
LAND ROVER 110 6 x 6
FIELD A BASE REPAIR
INTRODUCTION
1. This EMEI contains procedures for removing,
dismantling, repairing, assembling and installing
various components of the Truck, Cargo, Light,
Crew Cab, Winch shown in Fig. 1. Where applicable,
instructions for the adjustment, lubrication and minor
servicing of these items are included. This EMEI
should be read in conjunction with EMEI VEH G 204
and VEH G 204-l.
2. Prevent dirt and foreign objects from entering
any component by placing clean temporary cover-
ings over all exposed openings, including hoses,
tubes and lines.
/
/
/ CAUTION
Do not use adhesive tapes to seal fuel or oil
I openings. The adhesive tape is soluble in fuel
or oil and can cause contamination. Remove
temporary covers before assembling.
3. When disconnecting electrical connectors, hos-
es and fittings, remove clamps as required to gain
slack and avoid damage to connectors and fittings,
components, disconnect the battery leads.
4. Discard all used gaskets, seals, cotter pins, tab
washers, lock pins, key washers and lock washers.
Discard all contaminated fuel and lubricants drained
from the vehicle.
5. Use only those fuels and lubricants specified in
the Servicing Instruction, EMEI VEH G 209 and the
User Handbook when replenishing fuel or lubricants.
6. Any fastenings orfittings being tightened to pre-
scribed torques are to have dry, clean threads un-
less otherwise specified. When specified, thread
sealants are to be applied to dry, clean, oil-free
threads.
7. The engine cooling system contains Alfloc 2001
corrosion inhibitor at a concentration of 5% total vol-
ume.
8. This vehicle is painted in polyurethane paint.
WARNING
Precautions should be taken prior to cartying
out repairs which include painting, sanding,
scraping or welding. For safety precautions
refer to Introduction Into Service Instruction,
Materiel Management Policy Statement,
Painting Policy for Vehicles and Equipment or
relevant EMEI.
Figure 1 - Truck, Cargo, Light, Crew Cab, Winch, MC2
ix/x
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS VEHICLE G 264-l
Issue 1, May 92
ENGINE - GROUP 1
Air Compressor
1.
Disassembly (Field and Base Repair)
a. Remove the air compressor (refer to EMEI
VEH G 263 - GROUP 1).
b. Remove the remote breather pipe and the
sealing blocks from the cylinder heads.
c. Remove the Allen screws securing the cyl-
inder heads (see Fig. 2), then remove the
cylinder heads, valve plates and gaskets.
Separate the cylinder heads from the outlet
manifold, and discard the O-rings.
i6 IE
1. /
20 19 18 17 1
‘..
‘./ /”
‘,\,
I )I
:i ’
L
,
1 Cylinder head 9 Air line connector
2 Gasket 10 Outlet valve 17 Crank-pin rod bush
3 Valve plate 11
4 Sealing block Teflon plug 18 Connecting
19 Connecting rod
12 20 Crankshaft
5 Remote breather Gudgeon pin
pipe 13 Piston
6 Inlet valve nng
14 Ptston 21 Key
7 Relief valve 15 22 Crankshaft beanng
8 Outlet manifold End plate
16 End plate gasket 23 Spacer
24 Cylinder block
Figure 2 - Air Compressor - Exploded View
UNCONTROLLED WHEN PRINTED
VEHICLE G 264-l
Issue 1, May 92 ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS
d. Remove the four Allen screws securing the
end cap to the crankcase, remove the cap
and all excess lubricant.
e. Suitably clamp the crankshaft in a vice fitted
with soft jaw clamps, and remove the Allen
screw securing the crank-pin (see Fig. 3).
Using suitable pliers, remove the crank-pin.
ALLEN
SCREW
--. ..
Y
CONNECTING ; i,‘“y
i /:
RODS
Figure 3 - Crank-pin - Removal
f. Remove each piston and connecting rod
out through the cylinder bores. Remove the
teflon pads from the gudgeon pin bore of
the piston and press the gudgeon pin out,
using a suitable arbor and press.
g. Using a suitable press, remove the crank-
shaft out of the crankcase (see Fig. 4).
CRANKSHAFT
,.-1=s-::
-==-I/ ’
BEARING ,’ :
)I I
‘I
Figure 4 - Crankshaft - Removal
NOTE
The crankshaft, inner bearing and
spacer will be removed as one
assembly.
h. Using a suitable press, remove the bearing
from the crankshaft,
i. Using a suitable arbor, press the outer
bearing from the crankcase.
j. Using a suitable arbor, press out the bush
from the connecting rod (see Fig. 5).
BUSH \ / PRESS / ARBOR
CONNECTING
f-
Figure 5 - Connecting Rod Bush - Removal
2. Cleaning and Inspection (Field and Base
Repair)
a. Clean all parts in a suitable cleaning agent
and inspect for excessive wear (refer to Ta-
ble 3). Replace worn or defective parts as
necessary.
Table 3 - Compressor Wear Limits
Crankcase bore maximum diameter......40.060m m
Piston minimum diameter.. .................... .39.875mm
Connecting rod bush maximum
internal diameter .................................... 12.731 mm
Crank-pin minimum diameter.. .............. .12.598mm
3. Reassembly (Field and Base Repair)
a. Using a suitable press, install the inner
bearing on the crankshaft (see Fig. 6), en-
suring that the bearing is hard against the
crankshaft web.
ARBOR PRESS
BEARING
CRANKSHAFT w
Figure 6 - Crankshaft Inner Bearing - Installation
b. Suitably support the compressor, and press
the crankshaft and bearing into the crank-
case, ensuring that the bearing is installed
correctly (see Fig. 7). Install the spacer and
press in the outer bearing.
2
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL VEHICLE G 264-l
ENGINEERING INSTRUCTIONS Issue 1, May 92
PRESS ---I
CRANKSHAFT
Figure 7 - Crankshaft - Installation
c. Press in the connecting rod bushes, then
using the oil supply hole in the connecting
rods as a guide,
drill a
3
mm hole
through
the wall of the bushes. Clean the connect-
ing rods, then install the connecting rods,
gudgeon pins and Teflon pads in the pis-
tons (see Fig. 8).
O-RING
PISTON
PISTON
TEFLON PAD
GUDGEON PIN
w CONNECTING ROD
Figure 8 - Connecting Rod - Installation
d. Lightly smear the cylinder bores and gud-
geon pins with a suitable grease, then
insert the pistons in the bores.
e. Align both connecting rod pin holes with the
crankshaft pin hole. Apply Loctite 222 to the
threads of the Allen screw then insert the
CYLINDER HEAD
INLET VALVE
BRIDGE
VALVE PLATE
Figure 9 - Manifold Bridge - Installation
GASKETS
3
UNCONTROLLED WHEN PRINTED
VEHICLE G 264-l
Issue 1, May 92
crank-pin and Allen screw into the crank-
shaft. Tighten the Allen screw securely.
f. Install two new O-rings onto the manifold
bridge and fit the cylinder heads to the ends
(see Fig. 9). Fit the inlet and exhaust valves
in the head and retain in position by the new
gaskets and valve plate. Install the cylinder
heads complete with the manifold bridge.
g. Install the eight cylinder head screws and
tighten them securely.
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS
h. Fill the crankcase to approximately two
thirds full with a suitable grease, install a
new gasket on the crankcase then fit the
end cover. Install the four Allen screws and
tighten securely.
i. Install the sealing blocks in the cylinder
heads, then install the remote breather
pipe.
j. Install the compressor (refer to EMEI VEH
G 263 - GROUP 1).
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS VEHICLE G 264-l
Issue 1, May 92
ELECTRICAL - GROUP 15
Wiring Harness
4. General Precautions
a. Use suitable testing meters or circuit tester
to trace or locate faults or check circuits.
The practice of arcing wires to earth to de-
termine if the wire is live, will destroy solid
state components, and must not be used.
b. After tracing electrical faults, and before
carrying out any electrical repairs, discon-
nect the battery, negative terminal first,
then disconnect the positive terminal.
c. Before carrying out any electrical arc weld-
ing on the vehicle, disconnect the battery
and the alternator. Failure to disconnect the
alternator will cause the transistors and di-
odes to fail as a result of current flow
throughout the chassis when arc welding.
d. When installing the battery, ensure that the
terminals are connected to the correct
posts. Reversing battery polarity will cause
serious damage.
5. Replacement (Field and Base Repair)
a. Disconnect the battery, negative terminal
first, then disconnect the positive terminal.
NOTE
All electrical wiring in the vehicle is co-
lour coded for identification and refer-
ence. If necessary, refer to the wiring
diagram (EMEI VEH G 263), in con-
junction with the relevant illustration,
when replacing a wiring harness.
b. After determining which harness is to be re-
placed (see Figs. 10, 11 and 12), discon-
nect the harness. As an added precaution
and to assist in the installation of the re-
placement harness, tag each wire and ter-
minal in turn as the wire is disconnected.
16 1 2
-----
h,--------+- 53
r-ill -lJ I
wr-----'~~c~ I
Illll l4
1H-u 13
ii
IFI L--t‘ +
fil 1 1 Ill $t
k -uAA
‘ml1 -----(y&t
--it1 lr f ---
-~-----ml-, --q
----- -l-\=,ll
r-----11 II JlJ IA, \\lt
I
I y//l *
\,’ I
\ ‘A[
-6
- 7
-8
q Qj ,‘, i I(! /( i
,ftt-,, 7 T ,fl !I1I II
;Lji 1 j l--L1 I
L-----1 --.-\k I
-----7 i,---\~---AfZ.?f/I:
---_ --
12 1 2
1 Repeater light 6 Horn
2 Indicator/park light 7 Earth strap
3 Reduced head lights 8 Water temperature sender unit
4 Blackout lights 9 Alternator
5 Headlights 10 Starter motor
11
011
switchespressure
12 Brake master cylinder
13 Fuse and relay panel
14 Multi-pin connector
15 Glow plugs
16 Pad wear lndxator
Figure 10 - Front Wiring Harness
UNCONTROLLED WHEN PRINTED
VEHICLE G 264-l ELECTRICAL AND MECHANICAL
Issue 1, May 92 ENGINEERING INSTRUCTIONS
Figure 11 - Cab Wiring
1 Warmng light panel
2 Swatch panel
3. Voltmeter
4 Water temperature
gauge
5 Fuel gauge
6 Speedometer
7 Heater (blower) motor
switch
8 lgnitron switch
9 Lrght swrtch
10. Combmatron switch
11 Interior (dome) light
12 Washer/wiper switch
13 Drmmer switch
14 Map reading light
15 Blackout switch
16 Fuse and relay panel
17 Heater (blower) motor
18 Windscreen wrper
motor
8
1 PTO warnmg light switch
2 Fuel tank
3 Reverse light switch
4 Fuse and relay panel
5
Duff
lock warnrng lrght switch
6 Fuel tank
7 6WD warnrng lrght swatch
8 Convoy light
9 Tall light assembly right hand side
10 Blackout light right hand srde
11 Power outlet socket
12 NATO secret
13 Blackout light left hand side
14 Tail light assembly left hand side
Figure 12 - Rear Wiring Harnesses
6
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS
Disconnect the zip clamps and brackets,
then remove the harness from the vehicle.
c. Ensure that the replacement harness is of
the correct capacity and that the wires are
correctly colour coded. Using the old har-
ness and tags as a guide, connect the wires
to the appropriate terminals.
VEHICLE G 264-l
Issue 1, May 92
d. Install and tighten the zip clamps and
brackets, then connect the battery. Connect
the positive terminal first, then connect the
negative terminal
e. Test the function of the components associ-
ated with the wiring harness that has been
replaced to ensure correct function.
718
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS VEHICLE G 264-l
Issue 1, May 92
FRAME -GROUP 16
Frame
6. Inspection (Base Repair)
a. Inspect the frame assembly for cracks and
corrosion, and replace the frame if the re-
pairs are beyond standard workshop proce-
dures
7. Alignment (Base Repair)
a. Place the assembled vehicle on a level floor
and hold a plumb line against one of the
points shown in Fig. 13. Mark the point with
chalk directly below the plumb bob. Repeat
the procedure for the remaining points to
determine the frame squareness.
I
NOTE
When measuring the diagonals, en-
sure that the exact opposite plumb line
positions are used on both frame side
rails.
b. Move the vehicle forward away from the
chalk marks, then take the dimensions
between the related diagonal. Each
dimension must be within 9.5 mm.
c. Using a suitable measuring device, mea-
sure the distance between the front axle
centre line and the spring equalizer centre
line (dimension Y).
NOTE
When checking the frame for misalign-
ment using the datum line, not all di-
mensions can be determined with the
body and engine in position.
d. Side rail checks can be made while refer-
ring to Fig. 13.
e. If the frame dimensions are not within the
specification listed in Table 4, and cannot
be aligned using standard workshop proce-
dures, the frame assembly must be re-
placed.
Table 4 - Frame Dimensions
Check Point and Dimension Check Point and Dimension
A - 1701.8 mm Q - 5028 mm
B -197mm R - 424 mm
C - 878 mm S - 424 mm
D - 835 mm T - 5734 mm
E - 417.5 mm U -134mm
F - 458.5 mm v -16mm
G - 458.5 mm W - 372 mm
H - 555 mm X -32mm
I - 2547 mm Y - 3490 mm
J - 3099 mm Z - 2175 mm
K - 3344.5 mm AA -1052mm
L -108mm AB -878 mm
M -89mm AC -173 mm
N - 453 mm AD -98mm
0 - 1538 mm AE - 791 mm
P - 2623 mm AF -268mm
9/10
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL VEHICLE G 264-l
ENGINEERING INSTRUCTIONS Issue 1, May 92
PLUMB
LINE POSITION
PLUMB LINE POSITION
PLUMB LINE POSITION
I
--AB-
1
4 Z
. JjJ
REAR
1CROSSMEMBER
FRONT AXLE CENTPE LINE
-.\._ -K _] CE;TRE LINE
1FRAME
DATUM
LINE
PLUMB LINE
POSITION
-_
l_“L - -Y
SPRING EQUALIZER
PLUMB LINE POSITION PLUMB LINE POSITION -,
/ CENTRE LINE
PLUMB LINE POSITION
Figure 13 - Frame Alignment
11112
UNCONTROLLED WHEN PRINTED
ELECTRICAL AND MECHANICAL
ENGINEERING INSTRUCTIONS VEHICLE G 264-l
Issue 1,
May 92
0
a
Cab
8.
Removal (Field and Base Repair)
BODY - GROUP 17
a.
b.
C.
d.
8.
f.
h.
i.
Chock the vehicle’s wheels to prevent
movement in either direction.
Remove the clip and pin securing the bon-
net stay-bar to the bonnet, then remove the
bonnet from the vehicle.
Remove the mudguards (refer to EMEI
VEH G 204 - GROUP 17).
Disconnect the earth lead from the battery.
Disconnect the bottom radiator hose and
drain the engine coolant/inhibitor into a suit-
able clean receptacle. Retain the coolant/
inhibitor for reuse if not contaminated.
Loosen the heater hose clamps and discon-
nect the hoses from the engine.
Disconnect the accelerator linkage and the
throttle cable from the injector jump.
Disconnect the brake pipes, which run from
the proportroning valve to the wheels, at the
proportioning valve.
Remove the air cleaner assembly from the
engine, then disconnect the chassis wiring
harness at the connectors on the firewall.
j. Disconnect the wiring from the alternator,
the starter motor, the temperature sensor,
the oil pressure sensor and the glow plugs
and secure the ends to the cab.
k. Tag and disconnect the differential and the
output shaft lock vacuum hoses at the vac-
uum chambers and disconnect the vacuum
supply hose from the engine.
I. Disconnect the windscreen washer hose
from the washer reservoir.
m. Disconnect the speedometer cable from the
transmission, together with the wiring from
the reverse light switch, the differential lock
and the output shaft lock indicator switches.
n. Remove the bolts securing the clutch slave
cylinder to the transmission bell housing,
then remove the slave cylinder from the bell
housing and secure the cylinder to the fire-
wall.
o. Ensure that the fuel level in the tanks is be-
low the filler neck opening in the tanks, then
slacken the clamps and remove the filler
necks and the fuel tank breathers from the
tanks. Plug all the openings in the fuel
tanks.
p. Turn the steering wheel to the straight
ahead position, match mark the upper
Figure 14 - Cab Removal
13
UNCONTROLLED WHEN PRINTED
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