property of american airlines maintenance...any fluid shows on the dipstick, do not add transmission...

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Chapter 2660 Mobile Belt Loader Table of Contents

CHAPTER 2: MAINTENANCE

TABLE OF CONTENTS

SECTION 1: SERVICING .......................................................................................................... 2-1-1A. Preparation for Use............................................................................................... 2-1-1

1. Fuel System.............................................................................................. 2-1-12. Battery ...................................................................................................... 2-1-13. Brake System ........................................................................................... 2-1-14. Engine and Transmission ......................................................................... 2-1-15. Rear (Drive) Axle ....................................................................................... 2-1-26. Tire Inflation ............................................................................................... 2-1-27. Units Equipped with Cummins B3.3 Engine ............................................. 2-1-2

B. Periodic Maintenance Schedule ........................................................................... 2-1-21. Daily .......................................................................................................... 2-1-22. Weekly or at 50 Hours .............................................................................. 2-1-33. Bi-Weekly or 100 Hours ............................................................................ 2-1-44. Monthly or 200 Hours ................................................................................ 2-1-45. Every Two (2) Months or 400 Hours ......................................................... 2-1-66. Every Five (5) Months or 1000 Hours ....................................................... 2-1-67. Every Six (6) Months or 1200 Hours ......................................................... 2-1-68. Yearly or 2400 Hours................................................................................. 2-1-7

C. Lubrication ............................................................................................................ 2-1-7D. Instructions for Jacking and Positioning Vehicle ................................................. 2-1-10E. Accelerator Cable and Mechanical Modulator Adjustment .................................. 2-1-11

1. Accelerator .............................................................................................. 2-1-112. Modulator (Diesel Units) .......................................................................... 2-1-11

F. Park Brake Adjustment ....................................................................................... 2-1-111. Discussion .............................................................................................. 2-1-112. Procedure ............................................................................................... 2-1-11

G. Transmission Linkage Adjustment ...................................................................... 2-1-12H. Hoof Governor Adjustment (Ford 300 Gasoline Engine) ..................................... 2-1-12

1. Adjusting Screw Adjustment ................................................................... 2-1-122. Secondary Screw Adjustment ................................................................. 2-1-13

SECTION 2: TROUBLESHOOTING ........................................................................................ 2-2-1A. Engine / Transmission .......................................................................................... 2-2-1B. Brakes .................................................................................................................. 2-2-3

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Chapter 2Table of Contents 660 Mobile Belt Loader

C. Park Brake ............................................................................................................ 2-2-5D. Steering................................................................................................................. 2-2-6E. Conveyor Hydraulics ............................................................................................. 2-2-7F. Conveyor Belt ....................................................................................................... 2-2-8G. Electrical ............................................................................................................. 2-2-10H. Electrical Schematics and Wiring Diagrams ...................................................... 2-2-13

Figure 2-1. Electrical Schematic, Gasoline Engine - Ford 300 .......................... 2-2-13Figure 2-2. Electrical Schematic, Gasoline Engine (Manual Belt Control) ......... 2-2-14Figure 2-3. Electrical Schematic, Gasoline Engine (Electric Belt Control) ........ 2-2-16Figure 2-4. Wiring Diagram, Ford 300 Gasoline Engine (with 3 Belt Controls) .. 2-2-18Figure 2-5. Wiring Diagram, Ford 300 Gasoline Engine

(with 3 Belt Controls and Shift Inhibitor) .................................................. 2-2-19Figure 2-6. Electrical Schematic, Ford 4.2L ...................................................... 2-2-20Figure 2-7. Electrical Schematic, Ford 4.2L with EPM ...................................... 2-2-21Figure 2-8. Wiring Diagram, Ford 4.2L with EPM (with 3 Belt Controls) ............ 2-2-22Figure 2-9. Wiring Diagram, Ford 4.2L with EPM - CAL (w/ 4 E-Stops) ............. 2-2-23Figure 2-10. Electrical Schematic, Diesel Engine ............................................. 2-2-25Figure 2-11. Electrical Schematic, Perkins 4.135/4.236 Diesel Engine

(Manual Belt Control) .............................................................................. 2-2-26Figure 2-12. Electrical Schematic, Perkins 4.135/4.236 Diesel Engine

(Electric Belt Control) .............................................................................. 2-2-28Figure 2-13. Wiring Diagram, Perkins 1000-4 Diesel ........................................ 2-2-30Figure 2-14. Wiring Diagram, Perkins 1000-4 Diesel (with 3 Belt Controls) ...... 2-2-31Figure 2-15. Electrical Schematic, Perkins 1104C-44 Tier II Diesel ................... 2-2-32Figure 2-16. Electrical Schematic, Deutz F4L1011F Diesel Engine

(Manual Belt Control) ............................................................................. 2-2-33Figure 2-17. Electrical Schematic, Deutz F4L1011F Diesel Engine

(Electric Belt Control) .............................................................................. 2-2-34Figure 2-18. Wiring Diagram, Deutz F4L1011F Diesel Engine

(3 Belt Controls) (FedEx) ........................................................................ 2-2-35Figure 2-19. Electrical Schematic, Deutz F4M2011 Tier II Diesel Engine .......... 2-2-36Figure 2-20. Wiring Diagram, Deutz F4M2011 Tier II Diesel Engine

(3 Belt Controls) (FedEx) ........................................................................ 2-2-37Figure 2-21. Wiring Diagram, Deutz F4M2011 Tier II Diesel Engine

w/Durst Velvet Drive Transmission (FedEx) ........................................... 2-2-38Figure 2-22. Wiring Diagram, Deutz F4M2011 Tier II Diesel Engine

w/Durst Velvet Drive Transmission - CE Option (FedEx) ...................... 2-2-39Figure 2-23. Electrical Schematic, Cummins B3.3

(FedEx Master Schematic) (Sheet 1 of 4) .............................................. 2-2-40

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Figure 2-23. Electrical Schematic, Cummins B3.3(FedEx Master Schematic) (Sheet 2 of 4) .............................................. 2-2-41



Figure 2-24. Wiring Diagram, Durst Velvet Drive Transmission -Sheet 1 of 3 (FedEx) ............................................................................... 2-2-44



Figure 2-25. Wiring Diagram, Electronic Control Module (ECM) -Durst Velvet Drive Transmission (FedEx) ............................................... 2-2-47

Figure 2-26. Electrical Schematic, Protecto-Start System ................................ 2-2-48Figure 2-27. Electrical Diagram, Protecto-Start (Delco Alternator) .................... 2-2-49Figure 2-28. Power Distribution Diagram, Delco Alternator Ammeter ................ 2-2-50Figure 2-29. Electrical Schematic, Low Oil Pressure and

High Water Temperature Shutdown ........................................................ 2-2-51Figure 2-30. Electrical Schematic, Neutral/Park Brake -

Conveyor Interlock and Belt Emergency Stop ......................................... 2-2-52Figure 2-31. Electrical Diagram, 2-Place Conveyor Belt Controls ..................... 2-2-53Figure 2-32. Electrical Schematic, Emergency Engine

Shutdown System (Gasoline) ................................................................. 2-2-54Figure 2-33. Electrical Schematic, Emergency Engine

Shutdown System (Diesel) ..................................................................... 2-2-54Figure 2-34. Electrical Schematic, Glow Plug System ...................................... 2-2-55Figure 2-35. Electrical Schematic, Fuel Heater System .................................... 2-2-55Figure 2-36. Wiring Harness - Engine Foot Throttle (Ford 4.2L) ....................... 2-2-56Figure 2-37. Wiring Harness - Park Brake Limit Switch .................................... 2-2-57Figure 2-38. Wiring Harness - Headlight / Turn Signal ....................................... 2-2-58Figure 2-39. Wiring Harness - Watermann Hydraulic Valve ............................... 2-2-59

I. Hydraulic Schematics ......................................................................................... 2-2-60Figure 2-40. Hydraulic System Schematic (Up to S/N 2738) ............................. 2-2-60Figure 2-41. Hydraulic System Schematic - Manual (S/N 2738-6199) .............. 2-2-61Figure 2-42. Hydraulic System Schematic - Electric (S/N 2738-6199) .............. 2-2-62Figure 2-43. Hydraulic System Schematic - Manual (S/N 6200 & Up) ............... 2-2-63Figure 2-44. Hydraulic System Schematic - Electric (S/N 6200 & Up) .............. 2-2-64

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SECTION 3: REMOVAL / INSTALLATION ................................................................................ 2-3-1A. Engine / Transmission .......................................................................................... 2-3-1

1. Removal ................................................................................................... 2-3-12. Installation ................................................................................................. 2-3-2

B. Rear Axle .............................................................................................................. 2-3-31. Removal ................................................................................................... 2-3-32. Installation ................................................................................................. 2-3-3

C. Front Axle .............................................................................................................. 2-3-41. Removal ................................................................................................... 2-3-42. Installation ................................................................................................. 2-3-4

D. Conveyor .............................................................................................................. 2-3-51. Removal ................................................................................................... 2-3-52. Installation ................................................................................................. 2-3-5

E. Belt Drive Motor .................................................................................................... 2-3-61. Removal ................................................................................................... 2-3-62. Installation ................................................................................................. 2-3-7

F. Conveyor Belt Control Valve ................................................................................. 2-3-71. Removal ................................................................................................... 2-3-72. Installation ................................................................................................. 2-3-8

G. Holding Valve ........................................................................................................ 2-3-81. Removal ................................................................................................... 2-3-82. Installation ................................................................................................. 2-3-9

H. Lift Cylinder Control Valve ..................................................................................... 2-3-91. Removal ................................................................................................... 2-3-92. Installation ............................................................................................... 2-3-10

I. Front Lift Cylinder ................................................................................................ 2-3-101. Removal ................................................................................................. 2-3-102. Installation ............................................................................................... 2-3-11

J. Rear Lift Cylinder ................................................................................................ 2-3-111. Removal ................................................................................................. 2-3-112. Installation ............................................................................................... 2-3-12

K. Hydraulic Pump .................................................................................................. 2-3-121. Removal ................................................................................................. 2-3-122. Installation ............................................................................................... 2-3-13

L. Alternator ............................................................................................................ 2-3-141. Removal ................................................................................................. 2-3-142. Installation ............................................................................................... 2-3-15

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SECTION 4: BELT TRACKING INSTRUCTIONS ................................................................... 2-4-1A. Discussion ............................................................................................................ 2-4-1B. Procedure ............................................................................................................. 2-4-2

SECTION 5: SYSTEM PRESSURE SETTINGS AND METHODS ......................................... 2-5-1A. General ................................................................................................................. 2-5-1B. Valve Settings ....................................................................................................... 2-5-1

1. Main Two-Lever Control Valve ................................................................... 2-5-12. Pilot Operated Check Valve, Reverse Direction Only ............................... 2-5-13. Pressure Relief Valve, Front Cylinder Down ............................................. 2-5-24. Pressure Relief Valve, Steering................................................................. 2-5-2

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Chapter 2660 Mobile Belt Loader Section 1

SECTION 1: SERVICING

A. PREPARATION FOR USE

1. Fuel System

(a) Check all fuel line connections to make sure they are properly connected.

(b) Check fuel level, and add fuel if needed.

2. Battery

(a) Check the battery fluid level. Top off with distilled or approved drinking water, asneeded.

(b) Connect the battery cables, if disconnected.

3. Brake System

(a) Check master cylinder fluid level.

(b) If low, check for leaks in brake lines.

4. Engine and Transmission

(a) Check engine oil level, add oil if needed.

(b) Check radiator coolant/water mixture level. If coolant is needed, make sure radiatordrain valve is closed, then add required coolant/water mixture. (Deutz diesel unitsexcluded.)

(c) Check transmission fluid level.

NOTE: This check is to determine if there is fluid in the transmission. Ifany fluid shows on the dipstick, do not add transmission fluid until it ischecked with the engine running, after the engine has reached normaloperating temperature.

(d) Check transmission cooling lines for proper connections.

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Chapter 2Section 1 660 Mobile Belt Loader

5. Rear (Drive) AxleCheck oil level in the rear axle and add oil, if needed.

6. Tire InflationCheck air pressure in tires (45 psi) and add air, if needed.

7. Units Equipped with Cummins B3.3 EngineIn cold weather, ensure that the engine preheat toggle switch, located on the engine side of thefirewall, is in the ON position. The switch may be turned off in warm weather climates.

B. PERIODIC MAINTENANCE SCHEDULE

The tractor should be maintained in accordance with the following schedules:

1. Daily

(a) Check that all controls, including belt controls, are in good working order. Report afaulty unit and do not use until repaired.

(b) Check fuel level.

(c) Check engine oil level.

(d) Check hydraulic oil level. If low, check for leaks.

(e) Check radiator coolant/water level. (Deutz diesel units excluded.)

CAUTION: THE RECOMMENDED TIRE PRESSURE LISTED IS FORTHE TIRES THAT ARE STANDARD ON THE 660 UNIT. OTHEROPTIONAL TIRES SHOULD BE INFLATED ACCORDING TO THETIRE MANUFACTURER SPECIFICATIONS.

(f) Check that the pressure of the standard pneumatic tires is 45 psi.

WARNING: DO NOT CHANGE A PNEUMATIC TIRE FOR A CUSHIONTIRE OR VICE VERSA WITHOUT FIRST CONSULTING TUG.

(g) Check tire treads for damage. Remove any stones, etc.

(h) Check voltmeter (gasoline units) or ammeter (diesel units) for charging.(Ford ESG-642 4.2L units excluded.)

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(i) Check governor operation (Ford 300 units only).

(j) Check operation of the headlights and if aimed correctly.

(k) Check operation of backup, tail, stop and turn signal lights.

(l) Check operation of the cab marker lights, the heater, the wiper and the cab light, ifequipped.

(m) Sound horn.

(n) Durst Transmissions: Visually inspect transmission to determine if the oil cooler fins(if liquid to air) are clear of dirt, and to ensure that hoses and fittings are not damagedor leaking.

(o) Durst Transmissions: Check transmission oil for signs of water or othercontaminants. Check (smell) oil for signs of burnt oil (overheating). The fluid must bechanged, the transmission flushed and the torque converter changed if the oil iscontaminated with water (fluid is pink), has gone rancid with a foreign substance(smell), has clutch debris (the fluid has a dark color) or burned (fluid smells burned).If these conditions exist, it may be necessary to remove and dismantle thetransmission to flush and replace the torque converter. See the Durst TransmissionService Manual in Chapter 5 for more information.

2. Weekly or at 50 Hours

(a) Check conveyor belt for proper tension and alignment.

(b) Check belt drive chain adjustment.

(c) Lubricate belt drive chain.

(d) Check rear finger guard adjustment.

(e) Check that the wheel lug nuts are tightened to 125 ft-lb (135.6 Nm).

WARNING: LUG NUTS MUST BE RETIGHTENED TO 125 FT-LB(135.6 N-M) AFTER ANY TIME THE LUG NUTS HAVE BEENLOOSENED FOR ANY REASON, AND AT THE INTERVALSSPECIFIED IN THIS PERIODIC MAINTENANCE SECTION.

(f) Check the level of the brake fluid in the master cylinder. If low, top off as necessary.

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(g) Check battery charge and fluid level.

(h) Check drive axle mounting bolts and tighten if required.

(i) Check transmission fluid level (with engine running and at normal operatingtemperature).

(j) Check cylinder head bolt torque and all nuts and bolts for tightness. If required,torque cylinder head bolts. See engine manufacturer specifications for torque ratings.

(k) Check drive axle oil level.

(l) Check underneath for oil leaks and damage.

(m) Check ball joints for looseness.

(n) Check exhaust system for leaks and holes.

(o) Check crankcase ventilation (PCV) system (gasoline only).

(p) Check/drain water separator (diesel only).

(q) Check neutral safety switch adjustment.

(r) Change engine oil and filter.

NOTE: Only the intial change is required at the 50-hour maintenance level,change monthly or every 200 hours thereafter.

3. Bi-Weekly or 100 Hours

(a) Durst Transmission: Inspect control lever operation for looseness or binding.

(b) Durst Transmission: Inspect cooler for signs of leakage, damage or loose mountingbolts.

(c) Durst Transmission: Inspect for damage or signs of leakage around bell housingand bolts.

4. Monthly or 200 Hours

(a) Check the service brake pedal for proper operation. Adjust if required.

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(b) Check the parking brake. With the parking brake handle in ‘lock’ position, the unitshould not move on a 8% or less grade. If the tractor does not move, no adjustmentis necessary, but if the tractor rolls, then adjustment is advised. Follow therecommended adjustment instructions in this section.

(c) Check the fan and alternator belts; tighten if necessary.

(d) Check air cleaner temperature control (Ford 300 units only).

(e) Check EGR system (gasoline only).

(f) Check hoses and clean radiator exterior.

(g) Check brake pads and shoes; replace if pads are less than 1/8".

(h) Change engine oil and filter.

NOTE: The intial oil change is required at the 50-hour maintenance level,change monthly or every 200 hours thereafter.

(i) Check air filter. Clean or replace.

(j) Lubricate service brake pedal linkage pivots.

(k) Lubricate parking brake lever pivots.

(l) Lubricate throttle linkage.

(m) Lubricate conveyor side and handrail pivots.

(n) Lubricate motor access cover hinges.

(o) Lubricate belt reduction gear box using appropriate high quality gear oil.

(p) Lubricate seat slide.

(q) Lubricate drive shaft joints.

(r) Lubricate steering axle links and king pins.

(s) Lubricate exhaust control valve and free-up. Use penetrating oil and rust inhibitor(Ford 300 units only).

(t) Lubricate all grease fittings. (See paragraph C.2. for list of zerk fitting locations.)

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5. Every Two (2) Months or 400 Hours

(a) Change hydraulic oil filter.

(b) Check cooling system for dirt or rust in coolant.

(c) Check ignition timing, adjust if necessary (Ford 300 units only).

(d) Check injector pump timing, adjust if necessary (diesel only).

(e) Check idle rpm and mixture, adjust if necessary.

(f) Check thermostat in cooling system.

(g) Check spark plugs; clean, adjust and test (gasoline only).

(h) Inspect front wheel bearings; clean and repack.

(i) Check tie rod ends looseness.

(j) Clean distributor cap (Ford 300 units only).

(k) Adjust governor (Ford 300 units only).

(l) Adjust carburetor (Ford 300 units only).

6. Every Five (5) Months or 1000 Hours

(a) Durst Transmission: Change transmission fluid and clean filter and screen withinpan.

(b) Durst Transmission: Check transmission mounting bolts for tightness. Refer to theDurst Transmission Service Manual in Chapter 5 for torque specifications.

7. Every Six (6) Months or 1200 Hours

(a) Check cylinder compression.

(b) Check spark plug wire resistance (gasoline only).

(c) Check intake manifold bolts and tighten, if necessary.

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(d) Change fuel filter.

(e) Change spark plugs (gasoline only).

(f) Change PCV valve (gasoline only).

8. Yearly or 2400 Hours

(a) Adjust automatic transmission bands.

(b) Change transmission fluid and filter.

(c) Change drive axle oil, use appropriate high quality gear oil.

(d) Drain, flush and refill and bleed the hydraulic brake system.

C. LUBRICATION

1. Periodic lubrication should be performed according to the Periodic Maintenance Schedule inparagraph B of this section. (See also Table 1-1)

2. Use grease at pressure zerks in the following locations as equipped:

(a) Ball Joints, Upper and Lower (4)

(b) Tie Rod Ends (2)

(c) Hydraulic Lift Cylinders (4)

(d) Steering Cylinder Tie Rod Ends (2)

(e) Conveyor Roller Bearings (8)

3. See Figure 1-1, Figure 1-2 and Table 1-1 for more lubircation information.

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Figure 1-1. Chassis Lubrication Diagram

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Figure 1-2. Body Lubrication Diagrams

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Ambient Temperature

- 60 °F to + 50 °F

- 15 °F to + 140 °F

Ambient Temperature

- 10 °F to + 90 °F and Above Gasoline Engine: 10W-40 Diesel Engine: 15W-40

Component Interval Lubricant

Transmission Check Level Weekly Dexron II ATF

Brake Cylinder Check Level Weekly DOT 3 Heavy Duty Brake Fluid

Conveyor Drive Chain Lube Weekly Same as Engine Oil

Rear Axle Check at 6 Months 85W-90 Limited Slip

Zerk Fittings Lube at 6 Months Chassis Grease

Wheel Bearings Repack at 24 Months Wheel Bearing Grease

Hydraulic Oil (Check Level Daily)

Engine Oil (Check Level Daily)

Oil (Must meet API Service SE/CC)

Chassis Components

Hydraulic Fluid

Mobil DTE II

Mobil DTE 13

Table 1-1. Lubrication Instructions

D. INSTRUCTIONS FOR JACKING AND POSITIONING VEHICLE

WARNING: IMPROPER JACKING CAN RESULT IN PERSONALINJURY, DEATH, AND/OR POSSIBLE DAMAGE TO THE LOADER.

1. Engage the parking brake and chock the wheels.

2. Position jack under front or rear bumper and raise the loader.

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E. ACCELERATOR CABLE AND MECHANICAL MODULATOR ADJUSTMENT

1. Accelerator

(a) Ensure that the throttle pull springs and throttle pull rod are properly installed and theaccelerator cable is attached to the accelerator pedal and the throttle.

(b) Loosen the fastener(s) on the accelerator linkage clamp.

(c) Position the accelerator cable such that the accelerator pedal is all the way up and thethrottle pull springs are relaxed. Tighten the fastener(s) on the accelerator linkageclamp.

2. Modulator (Diesel Units)

(a) With the accelerator cable properly adjusted, fully depress the accelerator pedal.

(b) Measure the cable travel. Travel should be 1.5".

(c) Adjust as necessary by loosening the fasteners on the cable clamp, positioning thecable and tightening the fasteners.

F. PARK BRAKE ADJUSTMENT

1. DiscussionWhen properly adjusted, the parking brake will prevent the loader from rolling when parked ona 8% grade. Since the parking brake is on the drive shaft and brakes through the reduction inthe differential, engaging a properly adjusted parking brake should not require an excessiveamount of force; however, some slight resistance will be present when engaging.

2. Procedure

(a) If parking brake hand lever is equipped with a locking set screw, loosen the set screw.

(b) To tighten parking brake, turn knurled knob at the end of the hand lever clockwise.

(c) To loosen parking brake, turn knurled knob at the end of the hand lever counter-clockwise.

(d) If parking brake hand lever is equipped with a locking set screw, tighten the setscrew.

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G. TRANSMISSION LINKAGE ADJUSTMENT

NOTE: The transmission linkage must be properly adjusted to preventdamage and maintain safe operation.

1. Place shifter in neutral position.

2. Remove swivel from transmission shift lever and back off lockout from swivel.

3. Place transmission in neutral.

(a) Rotate shift lever fully counter clockwise.

(b) Rotate shift lever clockwise to second position from full counter clockwise for 2-speed transmission (gasoline engine) or third position from full counter clockwise forthree 3-speed transmission (diesel engine).

4. Tighten or loosen swivel one turn at a time until it is perfectly aligned with the hole in the shiftlever, then reinstall swivel in shift lever.

5. Tighten lockout until it is firmly engaged with swivel.

H. HOOF GOVERNOR ADJUSTMENT (FORD 300 GASOLINE ENGINE)

1. Adjusting Screw Adjustment

(a) Remove welch plug covering the adjusting screw by drilling the plug with a 1/16"drill. Insert a 1/16" rod in drilled hole and pry off welch plug.

(b) Remove brass lock washer.

(c) Use an engine tachometer to read engine speed at full throttle. Adjust speed to 2400to 2600 rpm.

NOTE: Use a screwdriver to turn the adjusting screw as needed on thehousing to increase or decrease engine speed.

(d) Seal adjusting screw by replacing the brass lock washer in the screw slot and reinstallthe welch plug. Tap lightly using a flat punch.

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2. Secondary Screw AdjustmentThe secondary adjusting screw in this governor has been factory set to cover a wide range ofengine speeds. In setting governor to desired road or engine speed, use the main adjustingscrew only. If governor control is too sharp or not sharp enough, adjust using instructionsbelow.

NOTE: Only in rare instances will the secondary adjustment need to bechanged.

(a) Remove welch plug covering the secondary adjusting screw by drilling the plug with a1/16" drill. Insert a 1/16" rod in drilled hole and pry off welch plug.

(b) If governor control is too sharp, causing surging or hunting, turn the secondaryadjusting screw clockwise 1/4 turn at a time.

NOTE: It will be necessary to turn the main adjusting screw counter-clockwise approximately one turn to compensate for every 1/4 turn ofclockwise secondary screw adjustment.

(c) If governor control is not sharp enough, causing too great a variation in speedbetween load and no-load conditions, turn the secondary adjusting screw counter-clockwise 1/4 turn at a time.

NOTE: It will be necessary to turn the main adjusting screw clockwiseapproximately one turn to compensate for every 1/4 turn of counter-clockwise secondary screw adjustment.

(d) Seal secondary adjusting screw by replacing the brass lock washer in the screw slotand reinstall the welch plug. Tap lightly using a flat punch.

CAUTION: TOO SHARP A BLOW TO THE WELCH PLUG MAYUPSET THE SECONDARY ADJUSTMENT SCREW ADJUSTMENT.

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SECTION 2: TROUBLESHOOTING

A. ENGINE / TRANSMISSION

PROBLEM CAUSE CORRECTION

(a) Loose or corroded battery cables.

(a) Clean and tighten cable connections.

(b) Undercharged battery. (b) Charge or replace battery.

(c) Defective starter relay. (c) Replace starter relay.

(d) Loose or broken cable to starter.

(d) Tighten or replace cables.

(e) Loose or open wiring through neutral switch.

(e) Repair, adjust or replace.

1. Engine will not crank.

(f) Defective starter motor. (f) Repair or replace.

(a) Defective starter motor. (a) Remove starter, inspect for broken or worn drive.

2. Engine will not crank - starter spins.

(b) Defective flywheel ring gear. (b) Inspect ring gear teeth. Replace fly wheel and ring gear if necessary.

3. No start in Neutral. (a) Defective neutral safety switch.

(a) Adjust or replace.

(a) Loose or disconnected cable end.

(a) Tighten cable ends.

(b) Improper cable or lever adjustment.

(b) Adjust cable or lever.

4. Transmission cannot be shifted into or out of forward, neutral, or reverse gear range.

(c) Snow or ice obstructing movement.

(c) Remove obstacle.

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(a) Lack of lubrication. (a) Clean and lubricate.

(b) Foreign object or excessive dirt or corrosion in lever housing.

(b) Clean and lubricate.

(c) Kinked or mashed cable housing.

(c) Repair or replace.

5. Excess binding transmission selector or hand throttle.

(d) Carburetor or transmission linkage binding.

(d) Inspect and repair.

(a) Hand throttle linkage out of adjustment.

(a) Adjust or repair linkage. 6. Engine speed too high with hand throttle in idle position.

(b) Choke or idle speed is out of adjustment.

(b) Inspect and adjust.

7. Engine speed too low at maximum speed position of hand throttle.

(a) Linkage or cable loose or disconnected.

(a) Adjust or repair linkage.

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2-2-3Rev 26

CD314


B. BRAKES


(a) Low fluid level. (a) Add fluid, bleed system, and check for leaks.

(b) Hydraulic system. (b) Refer to master cylinder.

(c) Drum brakes out of adjustment, worn.

(c) Repair or replace as required.

(d) Loose or improper attachment of pedal, pedal support booster and master cylinder.

(d) Repair or replace as required.

1. Excessive pedal travel or pedal goes to floor consistently.

(e) Misaligned anchor plate. (e) Refer misaligned disc brake anchor plate diagnosis.

(a) Low fluid level. (a) Add fluid, bleed system, check for leaks.

(b) Brakes out of adjustment. (b) Adjust brakes.

(c) Front wheel bearing out of adjustment.

(c) Adjust front wheel bearings.

(d) Disc brake caliper attachment loose.

(d) Replace or tighten as required.

2. Brake pedal feels spongy when fully applied.

(e) Worn or damaged self-adjusters.

(e) Remove drum and check lining for proper adjustment.

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2-2-4Rev 26

CD314



(a) Worn or scored brake drums and lining or rotors and pads.

(a) Inspect, repair or replace as required.

(b) On disc brakes - missing or damaged brake pad insulators.

(b) Replace disc brake pads.

(c) Burrs or rust on caliper that would obstruct seating of shoe to caliper.

(c) Clean or deburr caliper.

3. Noise at wheels when brakes are applied - squeaks or chatter.

(d) Dirty, greased or glazed linings.

(d) Clean or replace.

(a) Unequal air pressure in tires. (a) Inflate tires to correct pressure.

(b) Grease or fluid on lining. (b) Clean, sand and/ or replace linings.

(c) Loose or missing disc brake caliper attaching bolts.

(c) Replace missing bolts. Tighten to proper torque.

4. Brakes pull to one side.

(d) Restricted brake lines or hoses.

(d) Repair or replace as required.

(a) Low fluid level. (a) Add fluid, bleed system and check for leaks.

(b) Worn or damaged brake warning switch.

(b) Replace switch.

5. Brake warning light on.

(c) Worn or damaged master cylinder.

(c) Perform master cylinder diagnosis test. Repair or replace as required.

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2-2-5Rev 26

CD314


C. PARK BRAKE


(a) Parking brake cable out of adjustment.

(a) Adjust parking brake cable.

(b) Rear brakes out of adjustment.

(b) Adjust rear brakes.

1. Parking brake will not hold.

(c) Parking brake linkage, release lever, clevis and ratchet binding.

(c) Repair or replace linkage as required.

(a) Manual release brake control components binding or damaged.

(a) Repair or replace manual parking brake control.

(b) Parking brake linkage and cable binding.

(b) Repair or replace as required.

2. Parking brake will not release or fully return.

(c) Worn or damaged rear brake components.

(c) Check rear brake shoe retracting springs and parking brake levers. Repair as required.

(a) Brake handle out of adjustment.

(a) Adjust or repair. 3. Parking brake lever hard to pull up.

(b) Frozen or damaged brake cable.

(b) Light taps with a mallet may free cable and brakes. Other- wise, apply warm air from a ground equipment heater.

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2-2-6Rev 26

CD314


D. STEERING


(a) Lack of lubrication on axle. (a) Lubricate.

(b) Low fluid in hydraulic reservoir.

(b) Fill as needed.

(c) Steering column bent or bearings are damaged.

(c) Check steer column. Replace if necessary.

(d) Low hydraulic pressure. (d) Check pressure. Gasoline units: Replace power steering pump. Diesel units: Check pressure regulator. If no problems found, replace power steering pump.

1. Steering is difficult.

(e) Damaged CharLynn valve. (e) Replace.

(a) Loose/worn studs or king pins.

(a) Tighten or replace. 2. Front wheel appears to wobble.

(b) Worn or damaged bearings and/or hubs.

(b) Repair or replace.

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2-2-7Rev 26

CD314


E. CONVEYOR HYDRAULICS


(a) Low oil level due to leak in system.

(a) Service hydraulic tank, locate and repair leak. Recheck system.

(b) Hydraulic pump drive belt slipping or broken.

(b) Replace and/or adjust.

(c) Defective hydraulic pump. (c) Repair or replace.

(d) Relief valve set too low. (d) Adjust or repair.

1. The front and rear lift arms will not raise conveyor.

(e) Lift control valve defective. (e) Replace or repair.

(a) Pump belt slipping. (a) Adjust.

(b) Internal valve leak. (b) Repair or replace.

(c) Internal cylinder leak. (c) Repair or replace.

(d) Low oil level in tank. (d) Add oil.

(e) Worn hydraulic pump. (e) Repair or replace.

(f) System relief valve too low. (f) Adjust.

2. Conveyor rises too slowly.

(g) Relief valve leaking internally. (g) Repair or replace.

3. Conveyor creeps down with control valve in the “OFF” position.

(a) Internal leak in cylinder or valve.

(a) Repair or replace.

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2-2-8Rev 26

CD314


F. CONVEYOR BELT


(a) Defective control valve. (a) Repair or replace.

(b) Belt drive chain broken or too loose.

(b) Adjust or replace.

(c) Belt drive shaft key missing. (c) Replace.

(d) Defective hydraulic motor. (d) Repair or replace.

(e) Optional shifter-brake interlock out of adjustment with parking brake.

(e) Adjust or replace.

(f) Defective control box, circuit or solenoid control valve.

(f) Repair or replace.

(g) Defective neutral start switch or circuit breaker. Check by stopping and restarting engine.

(g) Adjust or replace.

1. Conveyor belt will not run in either direction when controls are actuated.

(h) Open wiring or stop button stuck in open circuit.

(h) Inspect circuit and repair.

(a) Low oil level in tank. (a) Add oil.

(b) Pump drive belt slipping. (b) Adjust.

(c) Loose conveyor belt. (c) Adjust rear take-up.

(d) Too much load on conveyor and/or conveyor angle too steep.

(d) Basic capacity is 2000 lb. At conveyor angles exceeding 15°, the capacity must be reduced below 2000 lb.

2. Forward belt speed too low.

(e) Binding in belt drive or rollers. (e) Adjust, lubricate, repair or replace. Pro

perty

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2-2-9Rev 26

CD314



3. Reverse belt speed too fast. (a) Belt drive motor holding valve out of adjustment.


(a) Belt drive motor holding valve out of adjustment.

(a) Adjust or replace.

(b) Relief valve set too low or defective.

(b) Adjust, repair or replace.

4. Belt will only run forward.

(c) Open electrical circuit or defective solenoid.

(d) Repair or replace.

5. Drive chain is noisy. (a) Chain is out of adjustment. (a) Adjust and lubricate.

6. Belt does not track properly. (a) Rollers are out of adjustment. (a) Adjust.

7. Belt will not continue to run after push button is released.

(a) Defective R1 or R2 belt control relay or open wiring.


(a) Short to ground by-passing "STOP" button.

(a) Repair. 8. Belt will not stop when "stop" button is pushed.

(b) Short circuit across ineffective "STOP" button.

(b) Repair or replace.

9. Belt stops running although engine continues to run and “stop” button has not been pressed.

(a) Defective control relay, solenoid or 15 ampere circuit breaker.

(a) Replace.

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2-2-10Rev 26

CD314


G. ELECTRICAL


(a) Worn or damaged battery. (a) Test battery, replace if necessary.

(b) Loose or worn alternator belt. (b) Adjust or replace belt.

(c) Worn or damaged wiring or cables.

(c) Clean, repair as required.

(d) Defective alternator or regulator.

(d) Perform general charging systems test. Repair or replace as required.

1. Battery does not stay charged - engine starts O.K.

(e) Other vehicle electrical system malfunction.

(e) Check other systems for current draw. Repair as required.

(a) Loose or worn alternator belt. (a) Adjust or replace belt.

(b) Bent pulley flanges. (b) Replace pulley.

2. Alternator noisy.

(c) Defective alternator. (c) Perform alternator tests, replace as required.

(a) Worn or damaged battery. (a) Check battery, replace if necessary.

(b) Poor regulator ground. (b) Ensure good ground.

(c) Loose wiring connection. (c) Tighten all wiring connections.

3. Charge indicator gauge shows steady charge.

(d) Defective alternator or regulator.

(d) Perform general charging systems test. Repair or replace as required.

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2-2-11Rev 26

CD314



(a) Loose or worn alternator belt. (a) Adjust or replace belt.

(b) Worn or damaged wiring. (b) Check battery-to-alternator wiring for ground or open. Repair if necessary.

(c) Defective alternator or regulator.

(c) Perform general charging system test. Repair or replace as required.

(d) Defective charge indicator gauge wiring and connections.

(d) Repair as required.

(e) Worn or damaged gauge. (e) Replace gauge.

4. Charge indicator gauge shows discharge.

(f) Other vehicle electrical system malfunction.

(f) Check and repair as required.

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2-2-12Rev 26

CD314



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2-2-13Rev 26

CD314


Figure 2-1. Electrical Schematic, Gasoline Engine - Ford 300

H. ELECTRICAL SCHEMATICS AND WIRING DIAGRAMS

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2-2-14Rev 26

CD314


Figure 2-2. Electrical Schematic, Gasoline Engine (Manual Belt Control)

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2-2-15Rev 26

CD314


2- Wiring Harness, Gas 6602-1 Battery, 12V2-2 Alternator, 60 AMP2-3 Voltage Regulator2-4 Starter2-5 Ignition Switch2-6 Ignition Module2-7 Ignition Coil2-8 Distributor Assembly2-9 Circuit Breaker, 20 AMP2-10 Headlight Switch2-11 Headlight Assembly2-12 Tail/Stop Light Assembly2-13 Turn Signal Control2-14 Flasher Base2-15 Flasher2-16 Turn Signal Assembly2-17 Neutral Start Switch2-18 Back-Up Light Assembly2-19 Stop Light Switch

2-20 Brake Warning Light2-21 Brake Proportioning Valve2-22 Spotlight Switch2-23 Spotlight Assembly2-24 Ammeter2-25 Oil Pressure Gauge2-26 Oil Pressure Sensing Unit2-27 Water Temperature Gauge2-28 Water Temperature Sensing Unit2-29 Hour Meter2-30 Oil Timer Switch2-31 Horn Button Kit2-32 Horn Relay2-33 Horn Assembly2-34 Microswitch2-35 Hydraulic Solenoid2-36 Emergency Hydraulic Pump, 12V2-37 Momentary Push Button Switch2-38 Back-Up Alarm

Fig/Ind Description Fig/Ind Description

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2-2-16Rev 26

CD314


Figure 2-3. Electrical Schematic, Gasoline Engine (Electric Belt Control)

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2-2-17Rev 26

CD314


Fig/Ind Description Fig/Ind Description3-1 Battery, 12V3-2 Alternator, 60 AMP3-3 Voltage Regulator3-4 Starter3-5 Ignition Switch3-6 Ignition Module3-7 Ignition Coil3-8 Distributor Assembly3-9 Circuit Breaker, 20 AMP3-10 Headlight Switch3-11 Headlight Assembly3-12 Tail/Stop Light Assembly3-13 Turn Signal Control3-14 Flasher Base3-15 Flasher3-16 Turn Signal Assembly3-17 Neutral Start Switch3-18 Back-Up Light Assembly3-19 Stop Light Switch3-20 Brake Warning Light3-21 Brake Proportioning Valve3-22 Spotlight Switch

3-23 Spotlight Assembly3-24 Ammeter3-25 Oil Pressure Gauge3-26 Oil Pressure Sensing Unit3-27 Water Temperature Gauge3-28 Water Temperature Sensing Unit3-29 Hour Meter3-30 Oil Timer Switch3-31 Horn Button Kit3-32 Horn Relay3-33 Horn Assembly3-34 Emergency Hydraulic Pump, 12V3-35 Momentary Push Button Switch3-36 Watertight Enclosure (Left Rear Control)3-37 Watertight Enclosure (Right Rear Control)3-38 Watertight Enclosure (Left Front Control)3-39 Relay3-40 Electric Valve Body3-41 Solenoid3-42 Terminal Block3-43 Back-Up Alarm

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2-2-18Rev 26

CD314


IS

COIL CAP

WIRERESISTOR

TACH LEAD

WHTBRN

GRN

YEL

WHTBRN

GRN

GR

N

WH

TR

ED

COIL LEAD

DISTRIBUTOR

PLUG 4

PLUG 1

PLUG 5

PLUG 3 PLUG 6

PLUG 2

ORG

GRN

PURBLK

9

8 99

21

R1

98

7

TO STARTMUST LIGHT

(GREEN)

R2

R1

25A

7AG

7AG

R2

RELAYREVERSE FORWARD

RELAY

NOTES:

THIS REVISION MODIFIES THE STARTER INTERLOCK CONTROLCIRCUIT OPERATED BY THE E-STOP SWITCHES.

WIRES "6E" AND "6F" ARE 10 GAUGE WIRES.

THIS REVISION "A" EFFECTIVE AS OF 12/8/99. Figure 2-4. Wiring Diagram, Ford 300 Gasoline Engine (with 3 Belt Controls)

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2-2-19Rev 26

CD314


COIL CAP

WIRERESISTOR

TACH LEAD

WHTBRN

GRN

YEL

WHTBRN

GRN

GR

N

WH

TR

ED

COIL LEAD

DISTRIBUTOR

PLUG 4

PLUG 1

PLUG 5

PLUG 3 PLUG 6

PLUG 2

ORG

GRN

PURBLK

98

99

NC

NC

C

NO

NO

C

25A

22

24A

21

8

19 P

UR

6

7

2

PILOTSWITCH

KILL

4

35

1

SOCKETRELAY

OCTAGON

CONFIGURATION

19 PURLIGHT

98

20A

CONFIGURATION

CONVEYR BELTINFERRED

RELAY

CONVEYR BELT

CONFIGURATIONRELAY

FWD/REV

BLK

RED53 GRN

SOLENOID12 V INHIBITORTRANSMISSION

54 GRY53 GRN

GRYGRN

LIGHT

SHIFTINHIBITOR

INHIBITORCONTROL

RELAY

RED

PRESSURE SWHYDRALIC BRAKE

20A

20A

20A

20A

2020

OIL/WATERWARNING

LIGHT

WATERTEMPSTAT

SWITCH

PRESSURESTAT

SWITCH

OIL

21

20A

SHIFT

IS

Figure 2-5. Wiring Diagram, Ford 300 Gasoline Engine(with 3 Belt Controls and Shift Inhibitor)

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2-2-20Rev 26

CD314


Figure 2-6. Electrical Schematic, Ford 4.2L

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2-2-21Rev 26

CD314


Figure 2-7. Electrical Schematic, Ford 4.2L with EPM

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2-2-22Rev 26

CD314


RED

RED

CONVEYER

RELAYREVERSE

LT BLU/BLK

SWITCHSELF TEST

OFF

ON

BASE

10A

30A

20A

20A

20A

11 11

RELAY

IGNITIONPOWER INTERLOCK

STARTER

RELAYPOWER

CONVEYOR

RELAY

6 ORG

RELAYMOTOR

STARTER

POSITIVE

TRACTOR BATTERY12 VOLT DC

NEGATIVE

YEL/WHT

MOTORCRAFTALTERNATOR

GR

OU

ND

HE

RE

MO

TOR

CR

AFT

F77 U

- 103

16-A

A

TO

TE

S TW

HT/

BLK

WH

T/B

LK

SI A

BLK

/OR

G

LT G

RN

/RE

D

6A R

ED

YE

L/W

HT

2 P

UR

MOTOR

ENGINESTARTER

6B B

LU

6B BLU

6B BLU

BAT

TB

ATT

BA

TT

RED

7 RED

3D

B PNK

YEL 12GA

1

BLK

BLK

1

RED

ELECTRIC RADIATOR FAN

25 T

AN

6 ORG

4 TAN

25 TAN

YEL 12GA

B

3D

6 O

RG

24A BRN PNK/LT GRN

RED/LT GRN

PNK/LT BLU

PNK/BLK

LT BLU/BLK

RED/LT BLU

DRK/BLU

YEL 12 GA

7AG BRN

25 TANRED

WHT

25 T

AN

5 P

UR

21 O

RG

21 ORG

ENGINECODELIGHT

BLK

/OR

G

YE

L 12

GA

YE

L 12

GA

6 ORG

GR

Y/R

ED

BR

N/W

HT

20 P

UR

RED

RE

D

4 TAN

7R ORG

11 ORG

2

365 4

78 1

BAT ACC ST

GRDIGN

6 ORG

IGNITIONSWITCH

WIRE HARNESSMALE PLUG

FORD P/NF2VB-14A459-B

COMPANY MAINFORD MOTOR

24 B

RN

HOURMETER

5 PUR

PNK/BLK

ELECTRICFUEL

12 VDC

PUMP

34 P

UR

BLK

2 P

UR

2 P

UR

3 Y

EL

5 P

UR

5 P

UR

5 P

UR

BRAKE SYSTEMWARNING LIGHT

(RED)

33 WHTBRAKE

PRESSUREWARNINGSWITCH

BLK

BLK

1 34

613

5

31

915

814

4233

25

5 P

UR

NEUTRAL/SAFETYSWITCH

SHIFTER

BA

TT

34 P

UR

2 P

UR

EMERGENCY

8 YEL

MOTORHYD PUMP

HYD PUMPEMERGENCY

RELAY

2 P

UR

2 P

UR

2 P

UR

8 YE

L

5 PUR

5 PUR

HEADLIGHTSWITCH

OFF

10 B

LU

ON

5 P

UR

30 B

LU10

BLU

SWITCH

OFF

WORKLIGHT

ON

5 PUR

6 O

RG

6 O

RG

6 O

RG

RED

WHT GRN

BLK

5 P

UR

3 Y

EL

6 ORG

3 YEL

BLK

/YEL

HYDRAULIC

1617

1617

1212

16 16

1612

2

1716 7 3

1

2

203 7

1

16 8

64

17 5

17

8

46

2122 20

5

17

1616

12

VALVE

16

11

222120 2019 21

2120

17 2019

22

18 1817

22

2122 1920

1717

CONVEYER SWITCHES

BELTFWD/REV

CONVEYER

REV 17

20

211122

3 NO

REV

4 11

1818

1920

11

21201918

22

1820

211922

NO318 4

REV

20

19 4NO3

REV

43 NO

STOP

NC1 2 11

21

CONVEYER SWITCHES

FWD

LEFT FRONT

4NO343 NO21

19

STOP

NC

21

1 2

STOP

2120

NC1 2

20

CONVEYER SWITCHES

FWD

LEFT REAR

FWD

RIGHT REAR

211922

1921

19

21

2020

718

456 3

2

BASE

FORWARDCONVEYER

RELAY

COIL

FWDCOIL

11A

BLK/WHT

BLK/WHT

6 O

RG

3 YEL

BRN

BR

N

21 ORG

3C 3C

5 P

UR

5 P

UR

5 P

UR

5 P

UR

5 P

UR

LIMIT SWITCHPARKING BRAKE

3C

11A

A

4 TA

N

5 PUR

B

CH24059 CH24059 CH24059

FUS

EA

BLE

LIN

K

(NORMAL)

TIME DELAYMAXIMUM

.3 SECONDS

FORD

C

C

SWITCH IS OFF

ENGINE OPERATIONDURING NORMAL

7A7A

D

D

SHIFTERLIGHT

30 BLU

19 P

UR

3C

2018

20

18

11 O

RG

R2

OR

G

CONTROLSPEED

CONVEYER

A

BRN/WHT

GRY/RED

BLK/YEL

RED

BLK/YEL

7R O

RG

GRY/RED

BRN/WHT

WHT/GRY

BLU/BLK

11 O

RG GR

Y/R

ED

BR

N/W

HT

WH

T/G

RY

RED

BLK/YEL

BLU/BLK

WHT/GRY

B PNK

RELAY

7 28 1

56

43

BASE

TIMER

ACCELERATORCONTROL

BLU/BLK

10

91

7

8

6

234

5

ACCELERATORCONNECTOR

NOTUSED

3

Figure 2-8. Wiring Diagram, Ford 4.2L with EPM (with3 Belt Controls)

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2-2-23Rev 26

CD314


PROPRIETARY AND CONFIDENTIALSTEWART & STEVENSON

Figure 2-9. Wiring Diagram, Ford 4.2L withEPM - CAL (w/ 4 E-Stops)

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2-2-24Rev 26

CD314



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2-2-25Rev 26

CD314


Figure 2-10. Electrical Schematic, Diesel Engine

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2-2-26Rev 26

CD314


Figure 2-11. Electrical Schematic, Perkins 4.135/4.236 Diesel Engine (Manual Belt Control)

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2-2-27Rev 26

CD314


Fig/Ind Description Fig/Ind Description11-1 Battery, 12V11-2 Alternator11-3 Starter11-4 Ignition Switch11-5 Momentary Push Button Switch11-6 Circuit Breaker, 20 AMP11-7 Headlight Switch11-8 Headlight Assembly11-9 Tail/Stop Light Assembly11-10 Turn Signal Control11-11 Flasher Base11-12 Flasher11-13 Turn Signal Light Assembly11-14 Neutral Start Switch11-15 Back-Up Light Assembly11-16 Stop Light Switch11-17 Brake Warning Light

11-18 Brake Proportioning Valve11-19 Spotlight Switch11-20 Spotlight Assembly11-21 Ammeter11-22 Oil Pressure Gauge11-23 Oil Pressure Sensing Unit11-24 Water Temperature Gauge11-25 Water Temperature Sensing Unit11-26 Hour Meter11-27 Oil Timer Switch11-28 Horn Button Kit11-29 Horn Relay11-30 Horn Assembly11-31 Emergency Hydraulic Pump, 12V11-32 Momentary Push Button Switch11-33 Back-Up Alarm

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2-2-28Rev 26

CD314


Figure 2-12. Electrical Schematic, Perkins 4.135/4.236 Diesel Engine (Electric Belt Control)

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2-2-29Rev 26

CD314


Fig/Ind Description Fig/Ind Description

12-1 Battery, 12V12-2 Alternator12-3 Starter12-4 Ignition Switch12-5 Momentary Push Button Switch12-6 Circuit Breaker, 20 AMP12-7 Headlight Switch12-8 Headlight Assembly12-9 Tail/Stop Light Assembly12-10 Turn Signal Control12-11 Flasher Base12-12 Flasher12-13 Turn Signal Light Assembly12-14 Neutral Start Switch12-15 Back-Up Light Assembly12-16 Stop Light Switch12-17 Brake Warning Light12-18 Brake Proportioning Valve12-19 Spotlight Switch12-20 Spotlight Assembly

12-21 Ammeter12-22 Oil Pressure Gauge12-23 Oil Pressure Sensing Unit12-24 Water Temperature Gauge12-25 Water Temperature Sensing Unit12-26 Hour Meter12-27 Oil Timer Switch12-28 Horn Button Kit12-29 Horn Relay12-30 Horn Assembly12-31 Emergency Hydraulic Pump, 12V12-32 Momentary Push Button Switch12-33 Watertight Enclosure (Left Rear Control)12-34 Watertight Enclosure (Right Rear Control)12-35 Watertight Enclosure (Left Front Control)12-36 Relay12-37 Electric Valve Body12-38 Solenoid12-39 Terminal Block12-40 Back-Up Alarm

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2-2-30Rev 26

CD314


Figure 2-13. Wiring Diagram, Perkins 1000-4 Diesel

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2-2-31Rev 26

CD314


S I

G G

TEMPWATER OIL

PRESS

5

278 1

3

45

66

87

5

12

4

3

RELAY

REV

FORWARDREVERSERELAY

30

EMERGPUMP

SWITCH

EMITTERQ196E

FWD

DRIVEFWD/REV

BELT

HYDVALVE

FLASHUNIT

SIGNALTURN550

SWITCHBRAKE

STBAT ACC

GRDIGN

RELAYHYD PUMP

EMERGENCY

SWITCH

OFF

WORK

ON

SENDERPRESSURE

OIL

TEMPSENDER

WATER

305

LIGHT

VEHICLEHORN

S

I

HYD PUMP

EMERGENCYMOTOR

BUTTONHORN

HORNRELAY

31

25

HOURMETER

2

11

19

FWD/REV RELAYCONFIGURATION

BELT LOADER

86

85

30

87

16

18

18 3

20

NO

20

REV

1921

2119

22

4

CONTROL SWITCHESLEFT REAR

20

1

NEUT

NC

3FWD

NO

192

214

1921

20

3

20

NO

22

4REV

1921

19

20

1

3

NEUT

NC 2

FWDNO

214

RIGHT REARCONTROL SWITCHES

1820

3 NO

20

REV

1121

11

22

4

21

CONTROL SWITCHESREMOTE

20

1

NEUT

NC

3FWD

NO

112

214

18

22 21 20 19

2222

1920

2220 21

1918

1819

20

1811

20 212120

20

17161211

B

Q19SN6RRECEIVER

8 6

4 2

75

3 1

171612

12 1211B

BLU

BRN

BLK

20

22

20

1716 18 18

17

BAT

ALTERNATORDELCO AC

Battery12 Volt DC

NEG

VehiclePOS

GRN

BLU

WHTYEL

NOTUSED

1R

B ALT

RELAY IGNITION

StarterRelay

EngineStarterMotor

6A

1

DIODE

8

66B

LM

C

H

MOTORBLOWERHEATER

BLOWERSWITCH

STARTERRELAY

WH

T

GRN BLK

NS/REV SWITCHSHIFTER

NE

UT

REV

LIG

HT

RELAYBELT LOADER

1R 2

BACKUPALARM

LIGHTRT REV LF REV

LIGHT

20ACB1

1R2

3 BLK 3 BLK

RE

D

BLU

BLK

BLK

WH

T

WH

T

37 37A

16

OFF

SWITCH

ON

WORK LTHEAD LIGHT

LIGHTWORK

1655 10

HEADLEFT

HEADRIGHT

10 1010

LIGHT LIGHT

WARNINGLIGHT

BRAKE

PRESSURESWITCH

LOWBRAKE

343434

34

34

G

S I

VOLTMETER

30

30

30

30 30

4

4101010

5

30 5

5 5 5

LIGHTBRK/TRNBRK/TRN

LIGHT

BLK

BLK30 30 30

5

303030

305 5

555

2425

2425

5 5

24

5

5

WH

T

WH

T

RT REARLF REAR

WH

T

WH

T

TURN LIGHTRT FRONT

25

24

24

LF FRONTTURN LIGHT

BLU

BR

N

11

83 82

33

1

1

B ALT

5

81828380

BLU

BLUYELBRN

8485

868486

85

GRY/BLKYEL

REDGRYBLKGRN

SWITCHWIPER

50

1

2

7

3

846

5

8

7

6 4

1

5 32

BELT LOADERINFRARED RELAYCONFIGURATION

B2

B2

B2

B2B

2

B3

B17

7

3D

B AL

T

6

6

6

11A

11A

6

6

6

11A 11A 11A

11

1111

81828380

2

852

812

828380

2502

5

SHUTOFFSOLENOID

66

FUEL

19

11B

63

1R

2 2

10 10

7

7

6B

6

6

RE

DR

ED

RED

RED

WIPERMOTOR

SINGLE SPEED

SWITCHSINGLETURN

BR

N

BLU

B IGN

7B

HANDBRAKELIMIT

11

12

BLU

12

12A

12A

12A

BRN

51

SWITCHHEATER

MANIFOLDHEATER

MANIFOLD

SWITCH

11

12

12

80A80A80A

80A

80A

NO

NC

341 2

20ACB2

555

2

20ACB3

2

1R

SWITCHIGNITION

5

5

5

50

50 55 5

50 5

BRN

19

34

5

50 80A

80A

FUELHEATER

27

27

22

5502219

2

MUSTLIGHT

TO RUN

SWITCHSHUTDOWN

EMERGNECY

BRN

27

1

1

80A 80A

80A

80A

BRN

20ACB4

2125

A

66

63HEATER

CAB

2 50

4

3 BLK2

1R

1R

11

11

4

23 BLK

2

2

34

50

32

C7-A20C7-A20

LOCATEDIN CAB

BREAKER

21

12

171717

17

1616

161616

63

1R

INFRAREDRELAY

SOCKET(GREEN)

(RED)

Figure 2-14. Wiring Diagram, Perkins 1000-4 Diesel(with 3 Belt Controls)

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Figure 2-15. Electrical Schematic, Perkins 1104C-44 Tier II Diesel

MATERIAL:

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CD314


Figure 2-16. Electrical Schematic, Deutz F4L1011F Diesel Engine(Manual Belt Control)

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2-2-34Rev 28A

CD314


Figure 2-17. Electrical Schematic, Deutz F4L1011F Diesel Engine(Electric Belt Control)

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2-2-35Rev 28A

CD314


Figure 2-18. Wiring Diagram, Deutz Diesel Engine (3 Belt Controls) (FedEx)

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CD314


Figure 2-19. Electrical Schematic,Deutz F4M2011 Tier II Diesel Engine

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Figure 2-20. Wiring Diagram, Deutz F4M2011 Tier II Diesel Engine (3 Belt Controls) (FedEx)

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2-2-38Rev 28A

CD314


Figure 2-21. Wiring Diagram, Deutz F4M2011 Tier II Diesel Engine w/Durst Velvet Drive Transmission (FedEx)

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CD314


Figure 2-22. Wiring Diagram, Deutz F4M2011 Tier II Diesel Engine w/Durst Velvet Drive Transmission - CE Option (FedEx)

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Figure 2-23. Electrical Schematic, Cummins B3.3 (FedEx Master Schematic) (Sheet 1 of 4)

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2-2-42Rev 29

CD314



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2-2-43Rev 29

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CD314


Figure 2-24. Wiring Diagram, Durst Velvet Drive Transmission - Sheet 1 of 3 (FedEx)

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2-2-46Rev 28A

CD314



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2-2-47Rev 28A

CD314


Figure 2-25. Wiring Diagram, Electronic Control Module (ECM) - Durst Velvet Drive Transmission (FedEx)

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CD314


Figure 2-26. Electrical Schematic, Protecto-Start System

26-1 Battery, 12V26-2 Starter, 300 CID, Delco26-3 Starter, Ford26-4 Starter, Cummins/Onan26-5 Solenoid26-6 Ignition Switch26-7 Neutral Start Switch26-8 Ammeter26-9 Alternator26-10 Protector Start Relay

Fig/Ind Description

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2-2-49Rev 28A

CD314


Figure 2-27. Electrical Diagram, Protecto-Start (Delco Alternator)

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2-2-50Rev 28A

CD314


Figure 2-28. Power Distribution Diagram,Delco Alternator Ammeter

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2-2-51Rev 28A

CD314


Figure 2-29. Electrical Schematic, Low Oil Pressure and High Water Temperature Shutdown

Fig/Ind Description

29-1 Circuit Breaker, 20 AMP29-2 Momentary Push Button Switch29-3 Low Oil Pressure Sending Unit29-4 High Water Temperature Sending Unit29-5 Ignition Coil29-6 Fuel Shut-Off Solenoid

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CD314


Figure 2-30. Electrical Schematic, Neutral/Park Brake - Conveyor Interlock and Belt Emergency Stop

Fig/Ind Description

30-1 Circuit Breaker, 20 AMP30-2 Neutral Start Switch30-3 Ignition Switch30-4 Hydraulic Solenoid30-5 Microswitch30-6 Starter30-7 Battery, 12V30-8 Conveyor Switch30-9 Solenoid30-10 Microswitch

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2-2-53Rev 28A

CD314


Figure 2-31. Electrical Diagram, 2-Place Conveyor Belt Controls

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2-2-54Rev 28A

CD314


Figure 2-32. Electrical Schematic, Emergency Engine Shutdown System (Gasoline)

32-1 Battery, 12V32-2 Starter32-3 Ignition Switch32-4 Ignition Module32-5 Ignition Coil32-6 Distributor Assembly32-7 Contact Block

Fig/Ind Description

Fig/Ind Description

Figure 2-33. Electrical Schematic, Emergency Engine Shutdown System (Diesel)

33-1 Circuit Breaker, 20 AMP33-2 Fuel Shut-Off Solenoid33-3 Contact Block

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2-2-55Rev 28A

CD314


Figure 2-34. Electrical Schematic, Glow Plug System

Figure 2-35. Electrical Schematic, Fuel Heater System

Fig/Ind Description

34-1 Battery, 12V34-2 Starter34-3 Relay, Electric Solenoid34-4 Ignition Switch34-5 Circuit Breaker, 20 AMP34-6 Momentary Push Button Switch34-7 Glow Plug34-8 Glow Plug Controller34-9 Fuse, 80 AMP

Fig/Ind Description

35- Fuel Heater Kit35-1 Circuit Breaker, 60 AMP35-2 Relay, 80 AMP35-3 Lighted Toggle Switch35-4 Fuel Line Heater35-5 Ignition Switch35-6 Alternator

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CD314


Figure 2-36. Wiring Harness - Engine Foot Throttle (Ford 4.2L)

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CD314


Figure 2-37. Wiring Harness - Park Brake Limit Switch

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2-2-58Rev 28A

CD314


Figure 2-38. Wiring Harness - Headlight / Turn Signal

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2-2-59Rev 28A

CD314


Figure 2-39. Wiring Harness - Watermann Hydraulic Valve

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2-2-60Rev 28A

CD314


Figure 2-40. Hydraulic System Schematic (Up to S/N 2738)

40-1 Hydraulic Pump40-2 Emergency Hydraulic Pump, 12V40-3 Ball Valve, ¼-Turn40-4 Hydraulic Tank Assembly40-5 Filter Block with Element40-6 Check Valve40-7 Check Valve40-8 Relief Valve40-9 Hydraulic Manifold, Large40-10 Hydraulic Pressure Gauge40-11 Hydraulic Brake Booster40-12 Steer Valve40-13 Power Steering Cylinder40-14 Control Valve with Manual Relief40-15 Relief Valve40-16 Holding Valve40-17 Hydraulic Front Lift Cylinder40-18 Hydraulic Rear Lift Cylinder40-19 Control Valve40-20 Counter Balance Valve40-21 Cushion Valve40-22 Hydraulic Manifold, Small40-23 Hydraulic Motor

Fig/Ind DescriptionI. HYDRAULIC SCHEMATICS

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Figure 2-41. Hydraulic System Schematic - Manual (S/N 2738-6199)PROPRIETARY AND CONFIDENTIALSTEWART & STEVENSON

Fig & Ind

Tug Part Number

Description

41-1 660-4-0010-1 Pump, Hydraulic - Ford 300, Perkins660-1-2912 Pump, Hydraulic - Ford 4.2L660-1-2287 Pump, Hydraulic - Deutz

41-2 660-1-3028 Pump, Hydraulic Emergency41-3 660-4-0010-12 Valve, Ball ¼ Turn41-4 660-4-1045 Tank, Hydraulic Assembly41-5 660-4-0010-10 Filter, Hydraulic with Indicator41-6 660-4-0010-31 Valve, Cartridge Check41-8 660-4-0010-32 Valve, Cartridge Relief41-9 660-4-0010-30 Manifold, Hydraulic, Large41-10 660-ND-1371 Gauge, Hydraulic Pressure41-11 660-1-1342-1 Booster, Hydraulic Brake41-12 660-1-3028 Valve, Steer41-13 660-2-1031 Cylinder, Power Steer, COM41-14 660-4-0010-2 Valve, Control - Conveyor Lift41-15 660-4-0010-20 Valve, Relief41-16 660-4-0010-3 Valve, Holding41-17 660-2-0062 Cylinder, Hydraulic Lift - Front41-18 660-2-0063 Cylinder, Hydraulic Lift - Rear41-19 660-4-0010-6 Valve, Control (Manual Belt Control)41-20 660-4-0010-8 Valve, Counter Balance41-21 660-4-0010-7 Valve, Cushion41-22 660-4-0010-33 Manifold, Hydraulic, Small41-23 660-4-0010-9 Motor, Hydraulic

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CD314



Figure 2-42. Hydraulic System Schematic - Electric (S/N 2738-6199)

Fig & Ind

Tug Part Number

Description


42-2 660-1-1148 Pump, Hydraulic Emergency42-3 660-4-0010-12 Valve, Ball ¼ Turn42-4 660-4-1045 Tank, Hydraulic Assembly42-5 660-4-0010-10 Filter, Hydraulic with Indicator42-6 660-4-0010-31 Valve, Cartridge Check42-8 660-4-0010-32 Valve, Cartridge Relief42-9 660-4-0010-30 Manifold, Hydraulic, Large42-10 660-ND-1371 Gauge, Hydraulic Pressure42-11 660-1-1342-1 Booster, Hydraulic Brake42-12 660-1-3028 Valve, Steer42-13 660-2-1031 Cylinder, Power Steer, COM42-14 660-4-0010-2 Valve, Control - Conveyor Lift42-15 660-4-0010-20 Valve, Relief42-16 660-4-0010-3 Valve, Holding42-17 660-2-0062 Cylinder, Hydraulic Lift - Front42-18 660-2-0063 Cylinder, Hydraulic Lift - Rear42-19 660-ND-1396 Body, Valve - Electric42-20 660-4-0010-9 Motor, Hydraulic

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CD314



Figure 2-43. Hydraulic System Schematic - Manual (S/N 6200 & Up)

Fig & Ind

Tug Part Number

Description


43-2 660-1-1148 Pump, Hydraulic Emergency43-3 660-4-0010-12 Valve, Ball ¼ Turn43-4 660-4-1045 Tank, Hydraulic Assembly43-5 660-4-0010-10 Filter, Hydraulic with Indicator43-6 660-4-0010-31 Valve, Cartridge Check43-8 660-4-0010-32 Valve, Cartridge Relief43-9 660-4-0010-30 Manifold, Hydraulic, Large43-10 660-ND-1371 Gauge, Hydraulic Pressure43-11 660-1-1342-1 Booster, Hydraulic Brake43-12 660-1-3028 Valve, Steer43-13 660-2-1031 Cylinder, Power Steer, COM43-14 660-4-0010-2 Valve, Control - Conveyor Lift43-15 660-4-0010-20 Valve, Relief43-16 660-4-0010-3 Valve, Holding43-17 660-2-0062 Cylinder, Hydraulic Lift - Front43-18 660-2-0063 Cylinder, Hydraulic Lift - Rear43-19 660-4-0010-6 Valve, Control (Manual Belt Control)43-20 660-4-0010-8 Valve, Counter Balance43-21 660-4-0010-7 Valve, Cushion43-22 660-4-0010-33 Manifold, Hydraulic, Small43-23 660-4-0010-9 Motor, Hydraulic43-24 MT-2-1144-1 Flow Divider, Gresen CFD50-2NR

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Figure 2-44. Hydraulic System Schematic - Electric (S/N 6200 & Up)

Fig & Ind

Tug Part Number

Description


44-2 660-1-1148 Pump, Hydraulic Emergency44-3 660-4-0010-12 Valve, Ball ¼ Turn44-4 660-4-1045 Tank, Hydraulic Assembly44-5 660-4-0010-10 Filter, Hydraulic with Indicator44-6 660-4-0010-31 Valve, Cartridge Check44-8 660-4-0010-32 Valve, Cartridge Relief44-9 660-4-0010-30 Manifold, Hydraulic, Large44-10 660-ND-1371 Gauge, Hydraulic Pressure44-11 660-1-1342-1 Booster, Hydraulic Brake44-12 660-1-3028 Valve, Steer44-13 660-2-1031 Cylinder, Power Steer, COM44-14 660-4-0010-2 Valve, Control - Conveyor Lift44-15 660-4-0010-20 Valve, Relief44-16 660-4-0010-3 Valve, Holding44-17 660-2-0062 Cylinder, Hydraulic Lift - Front44-18 660-2-0063 Cylinder, Hydraulic Lift - Rear44-19 660-ND-1396 Body, Valve - Electric44-20 660-4-0010-9 Motor, Hydraulic44-21 MT-2-1144-1 Flow Divider, Gresen CFD50-2NR

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SECTION 3: REMOVAL / INSTALLATION

The following procedures for removal and installation of vehicle components outline the steps andprecautions to take when removing items for replacement or repair.

WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TOPERFORMING WORK ON THIS EQUIPMENT.

A. ENGINE / TRANSMISSION

1. Removal

(a) Disconnect battery. Remove conveyor assembly (see specific section).

(b) Remove exhaust system.

(c) Disconnect flange at exhaust manifold.

(d) Disconnect drive shaft at transmission universal.

(e) Disconnect park brake cable.

(f) Disconnect water temperature connections at sender.

(g) Disconnect transmission selector cable at transmission selector lever.

(h) Disconnect battery and alternator wiring.

(i) Disconnect wiring at ignition coil and oil pressure sender.

(j) Disconnect fuel line at fuel pump.

(k) Drain radiator and engine block coolant system.

(l) Disconnect coolant hoses to engine at radiator.

(m) Disconnect transmission oil cooler lines at radiator.

(n) Disconnect speedometer cable at transmission.

(o) Disconnect air intake hose.

(p) Remove the ground strap.

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(q) Attach lifting sling to engine.

(r) Remove transmission mounting bolts.

(s) Remove engine frame mounting bolts.

(t) Remove hydraulic pump and bracket (and alternator) and swing aside (do notdisconnect oil lines).

(u) Hoist engine slowly, ensuring all lines, cables, wires, etc. are disconnected, and clearas engine is raised.

2. InstallationInstallation of engine/transmission is performed by reversing the order of steps A.1.(a)through (q), preceding.

WARNING: DO NOT CONNECT BATTERY UNTIL ALL ALTERNATORWIRING IS CONNECTED. LEAD-ACID BATTERIES GENERATEEXPLOSIVE GASES. KEEP SPARKS, FLAME, AND SMOKINGMATERIALS AWAY FROM BATTERIES. DO NOT SMOKE IN THEVICINITY OF THE BATTERY. DO NOT SHORT BATTERYTERMINALS. BEFORE REMOVING OR INSTALLING BATTERYREMOVE METAL BRACKETS, WRISTWATCH BANDS, RINGS, ETC.POSITIVE MUST BE DISCONNECTED FIRST TO PREVENT SPARKSFROM ACCIDENTAL GROUNDING. ALWAYS WEAR EYEPROTECTION AROUND BATTERIES. WASH HANDS OR CLOTHINGIMMEDIATELY IF ACCIDENTALLY IN CONTACT WITHELECTROLYTE.

CAUTION: ENSURE OIL, TRANSMISSION OIL AND COOLANTSYSTEM HAVE BEEN SERVICED BEFORE STARTING ENGINE.ADJUST TRANSMISSION SELECTOR CONTROLS FOR PROPERDETENT OPERATION. ENSURE THAT FAN IS FREE TO ROTATE.

NOTE: Adjust alternator belt for proper tension.

NOTE: Check for proper engine oil pressure during initial engine run.

Note

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B. REAR AXLE

1. Removal

(a) Jack up the rear frame of the mobile conveyor and place jack stands under the frameforward of the rear axle.

(b) Disconnect drive shaft at rear axle universal.

(c) Disconnect hydraulic brake line mounted on rear axle.

CAUTION: WIPE CONNECTIONS CLEAN BEFORE OPENING BRAKESYSTEM.

CAUTION: CAP OR PLUG ALL OPEN PORTS OR LINES.

NOTE: Use back up wrenches on all mating parts.

(d) Use a transmission jack to support the axle.

WARNING: DO NOT LIFT VEHICLE OFF JACK STANDS.

(e) Remove U-bolts attaching axle to frame.

(f) Lower transmission jack and roll axle out to the rear.

2. Installation

WARNING: BLEED AIR FROM BRAKE SYSTEM UPONCOMPLETION OF INSTALLATION.

Installation of the rear axle is performed by reversing the order of steps B.1.(a) through (f),preceding.

Note

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C. FRONT AXLE

1. Removal

(a) Jack up the front frame of the mobile conveyor and place jack stands under the framerearward of the front axle.

(b) Disconnect hydraulic brake lines from front disc brake assemblies.

(c) Disconnect hoses at steer cylinder.




(c) Use a transmission jack to support the axle.

WARNING: DO NOT LIFT VEHICLE FRAME OFF JACK STANDS.

(d) Remove U-bolts attaching axle to frame.

(e) Lower transmission jack and roll axle out to the rear.

2. Installation

WARNING: BLEED AIR FROM BRAKE SYSTEM UPONCOMPLETION OF INSTALLATION.

Installation of the front axle is performed by reversing the order steps C.1. (a) through (e),preceding.

Note

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D. CONVEYOR

1. Removal

(a) Raise conveyor hydraulically, both front and rear, high enough to remove hardwarefrom pivot points.

WARNING: ALWAYS USE SAFETY PROP WHEN WORKING UNDERCONVEYOR.

(b) Block up rear end of conveyor between vehicle frame and conveyor cross member, orsupport with sling and hoist.

(c) Disconnect electrical control cable (between frame and conveyor when equipped) atterminal block in enclosure mounted on cross member at rear of conveyor.

(d) Disconnect hydraulic lines (between rear lift frame and conveyor) at hose to tubeconnection at rear lift frame.




(e) Loosen nut on cam follower pivot bolt, and allow the follower plate to swingdownward.

(f) Remove pivot bolt, nut and washer from rear lift frame and conveyor pivot.

WARNING: HOIST AND SLING CAPACITY SHALL BE 2000 LBMINIMUM.

(g) Using proper lifting gear of 2000 lb minimum capacity, lift conveyor from pivotattaching points.

2. InstallationInstallation of conveyor is performed by reversing the order of steps D.1. (a) through (g),preceding.

Note

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E. BELT DRIVE MOTOR

1. Removal


WARNING: KEEP HANDS AND CLOTHING AWAY FROM CONVEYORBELT AND BELT DRIVE WHILE BELT IS IN MOTION.

(a) Drive belt slowly, until drive chain master link is visible in the area just behind thedrive pulley.


(b) Stop belt and engine and disconnect battery.

(c) Slacken chain.

(1) Loosen four (4) bolts on face of motor mounting plate.

(2) Turn adjusting screw (located on rear face of take-up) clockwise to slackenchain.

(d) Remove drive chain.

(1) Remove chain master link.

(2) Disengage chain from drive sprocket.

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(e) Disconnect hydraulic lines from motor.

CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENINGSYSTEM

CAUTION: CAP OR PLUG ALL OPEN PORTS AND LINES.

NOTE: Use back up wrenches on all mating fittings.

(f) Remove hydraulic motor.

(1) Remove motor mounting bolts.

(2) Pull motor straight out. Sprocket will pass through motor mounting hole.

2. InstallationInstallation of the drive motor is performed by reversing the order of steps E.l. (a) through (f),preceding.

F. CONVEYOR BELT CONTROL VALVE

1. Removal


(a) Raise conveyor.

(b) Position conveyor support prop.

Note

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(c) Tag and disconnect hydraulic lines.

CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENINGSYSTEM.

CAUTION: CAP OR PLUG ALL OPEN PORTS.


(d) Tag and disconnect solenoid wires (electric belt control only).

(e) Remove hardware and valve.

2. InstallationInstallation of the control valve is performed by reversing the order of steps F.1. (a) through(e), preceding.

G. HOLDING VALVE

1. Removal

WARNING: DISCONNECTING HYDRAULIC LINES FROM ACONVEYOR CYLINDER HOLDING VALVE WILL RESULT INLOWERING OF THE CONVEYOR NOT OTHERWISE SUPPORTED.

(a) Tag and disconnect hydraulic hoses and tube fittings at the valve.




Note

Note

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WARNING: USE SAFETY PROP WHENEVER WORKING UNDERCONVEYOR.

(b) If removing the front lift cylinder holding valve, raise the front of the conveyor andsupport with the safety prop.

(c) If removing the rear lift cylinder holding valve, raise and block up the rear of theconveyor.

(d) Remove attaching hardware and valve.

2. InstallationInstallation of the holding valve is performed by reversing the order of steps G.1. (a) and (b),preceding.

H. LIFT CYLINDER CONTROL VALVE

1. Removal

(a) Remove seat and seat plate.

(b) Remove cotter pins from hand lever to valve linkage and remove hand levers.

(c) Tag and disconnect hydraulic tube fittings.




(d) Remove attaching hardware and valve.

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2. InstallationInstallation of the control valve is performed by reversing the order of steps H.1. (a) through(d), preceding.

WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR IS BLEDFROM SYSTEM.

CAUTION: DO NOT OVER TORQUE ATTACHMENT HARDWARE.OVER TORQUING MAY DISTORT VALVE BODY AND CAUSEBINDING OF VALVE SPOOLS. PERFORM OPERATIONAL CHECK OFHYDRAULIC SYSTEM.

I. FRONT LIFT CYLINDER

1. Removal

(a) Elevate front of belt conveyor either hydraulically or with a hoist and sling (whileholding lift cylinder control valve open).

(b) Position conveyor support prop under conveyor lift arms (cylinder attaching point).

(c) Disconnect hydraulic hoses from holding valve (mounted on cylinder).




WARNING: DISCONNECTING HYDRAULIC LINES FROM ACONVEYOR LIFT CYLINDER HOLDING VALVE WILL RESULT INLOWERING OF THE CONVEYOR IF NOT OTHERWISE SUPPORTED

(d) Disconnect hydraulic tube fittings at each end of cylinder and remove holding valve.

(e) Remove nut and pivot bolt from cylinder rod end.

(f) Remove nut and pivot bolt from cylinder base end.

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(g) Remove cylinder with portable hoist or equal.

WARNING: DO NOT BUMP CONVEYOR OR SUPPORT FRAME WITHHOIST OR CYLINDER AXLE REMOVING FRONT LIFT CYLINDER.

2. Installation

(a) Using a portable hoist or equal, position cylinder with cylinder base mount alignedwith frame mounting bracket.

WARNING: DO NOT BUMP CONVEYOR OR SUPPORT FRAME WITHHOIST OR CYLINDER WHILE INSTALLING FRONT LIFTCYLINDER.

(b) Install bolt and nut in cylinder base mounting hole.

(c) Replace holding valve and connect hydraulic line to base of cylinder.

(d) Start engine and hydraulically extend cylinder rod to lift frame attaching point.

(e) Install bolt and nut.

(f) Connect hydraulic line to rod end of cylinder.

WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR HAS BEENBLED FROM SYSTEM.

(g) Start engine, raise conveyor and stow conveyor support prop.

J. REAR LIFT CYLINDER

1. Removal

(a) Raise rear of conveyor and block up lift frame to prevent it from lowering.

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(b) Tag and disconnect hydraulic hoses to holding valve.




(c) Disconnect hydraulic lines at each end of cylinder and remove holding valve.

(d) Remove nut and bolt from rod end of cylinder.

(e) Remove nut and bolt from base of cylinder.

(f) Remove cylinder.

2. InstallationInstallation of the rear lift cylinder is performed by reversing the order of steps J.1. (a)through (f), preceding.

WARNING: STAND CLEAR OF CONVEYOR UNTIL AIR HAS BEENBLED FROM SYSTEM.

K. HYDRAULIC PUMP

1. Removal

(a) Raise front of conveyor and position conveyor support prop under lift frame crossmember.


(b) Raise engine cover.

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(c) Disconnect hydraulic lines from pump.




NOTE: For block-mounted pumps, remove mounting hardware and pump.Omit steps (d) through (f).

(d) Loosen pump mounting hardware and remove belt from pulley.

(e) Remove pulley mounted on pump shaft with set screw.

(f) Remove mounting hardware (2 bolts), spacer and pump.

2. Installation

(a) Installation of the hydraulic pump is performed by reversing the order of steps K.1.(a) through (f), preceding.

(b) Adjust hydraulic pump drive belt tension.

Note

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L. ALTERNATOR

1. Removal


(a) Remove battery ground cable.

(b) Disconnect wiring from:

(1) Alternator Input.

(2) Auxiliary

(3) Field Terminal

(4) Ground Terminal

CAUTION: IF FIELD TERMINAL (WIRE) IS GROUNDED WITH THEBATTERY STILL CONNECTED. THE VOLTAGE REGULATOR WILLBE BURNED OUT.

(c) Remove adjusting bolt at top flange of alternator housing.

(d) Loosen pivot bolt at bottom flange of alternator housing.

(e) Rotate alternator towards engine and remove drive belt.

(f) Remove pivot bolt and alternator.

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2. Installation

(a) Ensure battery ground cable is disconnected.

(b) Position alternator at mount and install pivot bolt, washer and nut hand tight.

(c) Install alternator drive belt. If worn or cracked, install a new belt.

(d) Install adjusting bolt finger tight through slotted adjusting brace and through hole inalternator flange.

(e) Adjust alternator drive belt tension.

(f) Connect all disconnected alternator wires at their correct positions.


(g) Connect battery.

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SECTION 4: BELT TRACKING INSTRUCTIONS

The following procedure is offered as a guide for aligning the cargo belt to the center of the rollers in aminimum length of time.

WARNING: KEEP HANDS AND CLOTHING AWAY FROM ROLLERSWHILE CONVEYOR IS RUNNING.

Figure 4-1. Conveyor Components

A. DISCUSSION

Basic fundamentals of belt alignment are as follows:

1. Moving the rear idler roller to the rear on one side with the jack screw tightens that side ofthe belt, causing the belt to move to the other side.

Moving the rear idler roller to the front on one side with the jack screw loosens that side ofthe belt, causing the belt to move to that side.

2. Moving a crowder roller end toward the large end roller will tighten that side of the belt andforce the belt to the other side of the end roller.

Moving a crowder roller end toward the center of the conveyor will loosen that side of thebelt and allow the belt to move to that side of the end roller.

These fundamentals hold true on both ends of the conveyor.

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Adjust the front crowder roller only when the belt is running in the reverse direction. Adjustthe rear crowder roller only when the belt is running forward.

3. It is necessary to work from end to end when tracking a belt as adjustment at one end willaffect the other end. When tracking, make small adjustments and allow the belt to run andsettle in between adjustments. Normal time for an experienced mechanic to track a belt is 45minutes to one hour.

B. PROCEDURE

NOTE: Refer to safety chapter prior to performing any maintenance taskon this equipment and observe all applicable precautions.

1. Check the roller end bearings for failure.

2. Check the front driver and rear idler roller bearings and collar set screws. There are two setscrews in a collar that positions each roller in the frame. Insure that the rollers are centeredand that the set screws are tight. If either roller is not centered, loosen the set screws, pry theroller into position and secure the set screws. See Figure 4-2 for locations.

Figure 4-2. Set Screw Locations

3. Raise the front of the conveyor and insure that the front crowder roller is centered and thatthe bearing collar set screws are tight. Make any necessary adjustments as in step 2 above.

4. Raise the rear of the conveyor and insure that the rear crowder roller is centered and that thebearing collar set screws are tight. Make any necessary adjustments as in step 2 above.

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5. Raise the front of the conveyor to approximately 4' high and the rear to about 3'6" incheshigh.

6. Position the front crowder in its adjusting slots as shown in Figure 4- 3.

7. Position the rear crowder roller in its adjusting slots as shown in Figure 4- 4.

Figure 4-3. Front Crowder Roller Figure 4-4. Rear Crowder Roller

8. Adjust the rear idler roller at the jack screw nuts to tension the belt. Adjust the rear idlerroller so that it is equidistant from the rear end of the conveyor on both sides. Correct tensionis achieved when 4 to 6" of the belt can be rolled up at the center of the conveyor. (See Figure4- 5)

Figure 4-5. Idler Adjustment

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WARNING: KEEP HANDS AND CLOTHING AWAY FROM ROLLERSWHILE CONVEYOR IS RUNNING.

9. With the belt running in the reverse direction, observe the position of the belt at the front ofthe conveyor and correct as follows:

(a) To adjust belt in direction shown in Figure 4- 6, move left side (as viewed from rear)of the front crowder roller toward the front driver roller, both bolts, until the belttracks on center. Move 1/8" at a time.

WARNING: STOP CONVEYOR ANY TIME THE LEFT SIDE FRONTCROWDER ROLLER IS ADJUSTED!

(b) To adjust belt in opposite direction, move right side (as viewed from rear) of the frontcrowder roller forward the front driver roller, both bolts, until the belt tracks oncenter. Move 1/8" at a time.

(c) To adjust belt in direction shown in Figure 4- 7, move right side (as viewed fromrear) of the front crowder roller toward the front driver roller, until the belt tracks oncenter. Move 1/8" at a time.

(d) To adjust belt in opposite direction, move left side (as viewed from rear) of the frontcrowder roller toward the front driver roller, until the belt tracks on center. Move 1/8"at a time.

Figure 4-6. Belt Centering (Conveyor Front End View)

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10. Continue to make adjustments until the belt runs at the center of the front roller.

11. Continue to run the conveyor in reverse while adjusting the rear jack screw nuts to center thebelt on the rear idler roller.

12. Repeat steps 9 through 11 until both ends of the belt are centered and running true, then shiftbelt into forward direction.

13. Adjust the rear crowder roller to center the belt on the rear idler roller.

14. When belt is running on center, reverse belt direction and observe alignment. If beltalignment is still satisfactory in reverse, Shift belt direction back to forward. The belt shouldstay within 1/2" in both directions at both ends. If it does not, go back to step 9 and repeatsteps as often as necessary to track belt.

15. Once belt is tracked, shut off motor and securely tighten all adjusting bolts.

Figure 4-7. Belt Centering (Conveyor Rear End View)

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SECTION 5: SYSTEM PRESSURE SETTINGS AND METHODS

A. GENERAL

Adjust the following valves in the order in which they are listed. All pressure checks and settings areto be made when the engine is at normal operating temperature, choke open and at normal idle speed.

WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TOPERFORMING WORK ON THIS EQUIPMENT.

B. VALVE SETTINGS

If not already installed, install a 0-3000 psi hydraulic gauge in the tee fitting which is located behindthe left front wheel and approximately 6" in front of the axle.

1. Main Two-Lever Control Valve

(a) Pressure relief valve setting is 1500 psi.

(b) The main system pressure valve is located in the left side of the two-lever valveunder the seat.

While observing the pressure gauge, move the rear cylinder lever down and hold inthe down position, dead-heading the pump. Pressure should read 1500 +50 psi. Toadjust, turn the valve screw clockwise to raise pressure or counter-clockwise toreduce pressure. Access is provided by the hole in the plate beside the valve levers.Loosening or tightening the lockout may require removing the seat and plate.

2. Pilot Operated Check Valve, Reverse Direction Only

(a) Pressure relief valve setting is 850-900 psi.

(b) The blue Racine holding valve is approximately 4" x 5" x 1.5" in size and is locatedunder the front of the conveyor.

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While observing the pressure gauge, run the conveyor in the reverse direction.Pressure should read 850-900 psi.


To adjust, turn off the engine and remove the Allen socket plug from the rear of thevalve. Insert the Allen wrench into the valve and turn clockwise to raise pressure orcounter-clockwise to reduce pressure. One full turn will change the pressure settingby approximately 75 psi. Replace the plug and recheck the pressure setting.

3. Pressure Relief Valve, Front Cylinder Down

(a) Pressure relief valve setting is 900 +50 psi.

(b) The blue Racine relief valve is approximately 3" x 3" x 1.5" in size and is locatedunder the seat. Access can be gained through the opening in the left frame rail besidethe seat.

(c) While observing the pressure gauge, lower the front of the conveyor from the fullyraised position. Pressure should read 900 +50 psi.

(d) To adjust, turn the knob on the valve clockwise to raise pressure or counter-clockwiseto reduce pressure.

4. Pressure Relief Valve, Steering

(a) Pressure relief valve setting is 1000 +50 psi.

(b) The blue Racine relief valve is approximately 3" x 3" x l.5" in size and is locatedbehind the left front wheel against the left frame rail.

While observing the pressure gauge, turn the steering wheel to full left and hold.Pressure should read 1000 +50 psi.

To adjust, turn the knob on the valve clockwise to raise pressure or counter-clockwiseto reduce pressure.Prope

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CHAPTER 3: OVERHAUL

TABLE OF CONTENTS

SECTION 1: RECOMMENDED OVERHAUL PERIODS ......................................................... 3-1-1A. General ................................................................................................................. 3-1-1B. Engine .................................................................................................................. 3-1-1C. Transmission ........................................................................................................ 3-1-1D. Front (Steer) Axle .................................................................................................. 3-1-1E. Rear (Drive) Axle................................................................................................... 3-1-1F. Rear Wheel Drum Brakes .................................................................................... 3-1-1G. Front Wheel Disc Brakes ..................................................................................... 3-1-2H. Hydraulic Cylinders ............................................................................................... 3-1-2I. Hydraulic Pump .................................................................................................... 3-1-2

SECTION 2: FRONT (STEER) AXLE ....................................................................................... 3-2-1A. Description ........................................................................................................... 3-2-1B. Inspection and Overhaul ...................................................................................... 3-2-1

1. Bearings and Seals................................................................................... 3-2-12. Ball Joints .................................................................................................. 3-2-23. Connecting Rod Ends............................................................................... 3-2-2

SECTION 3: REAR (DRIVE) AXLE ............................................................................................ 3-3-1A. Description ........................................................................................................... 3-3-1B. Removal and Installation ....................................................................................... 3-3-1

1. Rear Axle Shaft Removal and Disassembly ............................................. 3-3-12. Rear Axle Shaft Assembly and Installation ................................................ 3-3-3

C. Disassembly and Assembly ................................................................................. 3-3-31. Disassembly ............................................................................................. 3-3-32. Differential Case ....................................................................................... 3-3-83. Pinion Bearing Cups ............................................................................... 3-3-114. Depth Gauge Check ............................................................................... 3-3-125. Pinion Bearing Preload ........................................................................... 3-3-136. Assembly of Differential into Housing ..................................................... 3-3-14

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D. Specifications ..................................................................................................... 3-3-181. Dana Axle Adjustments ........................................................................... 3-3-182. Dana Axle Torque Limits ......................................................................... 3-3-183. Dana Axle Approximate Oil Capacity ....................................................... 3-3-18

SECTION 4: REAR WHEEL DRUM BRAKES .......................................................................... 3-4-1A. Adjustments .......................................................................................................... 3-4-1

1. Brake Shoe Adjustment ............................................................................ 3-4-12. Manual Adjustment .................................................................................... 3-4-2

B. Removal and Installation ....................................................................................... 3-4-41. Rear Brake Drum ..................................................................................... 3-4-42. Brake Shoe and Adjusting Screw.............................................................. 3-4-53. Brake Wheel Cylinder ............................................................................... 3-4-64. Rear Brake Backing Plate ......................................................................... 3-4-7

C. Disassembly and Assembly ................................................................................. 3-4-81. Brake Wheel Cylinder ............................................................................... 3-4-82. Master Cylinder ......................................................................................... 3-4-9

D. Specifications ..................................................................................................... 3-4-121. Wheel Torque Limits ............................................................................... 3-4-122. Special Tools ........................................................................................... 3-4-12

SECTION 5: FRONT WHEEL DISC BRAKES ......................................................................... 3-5-1A. Brake Pad Replacement ...................................................................................... 3-5-1

1. Preparation ............................................................................................... 3-5-12. Caliper Removal ....................................................................................... 3-5-13. Brake Pad Removal .................................................................................. 3-5-24. Cleaning and Inspection ............................................................................ 3-5-25. Brake Pad Installation ............................................................................... 3-5-36. Caliper Installation ..................................................................................... 3-5-47. Check-Out ................................................................................................ 3-5-5

B. Caliper Overhaul ................................................................................................... 3-5-61. General Layout .......................................................................................... 3-5-62. Removal ................................................................................................... 3-5-63. Disassembly ............................................................................................. 3-5-64. Cleaning and Inspection ............................................................................ 3-5-85. Reassembly .............................................................................................. 3-5-86. Installation ................................................................................................. 3-5-97. Check-Out ................................................................................................ 3-5-9

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C. Rotor ..................................................................................................................... 3-5-91. Rotor Removal .......................................................................................... 3-5-92. Cleaning .................................................................................................. 3-5-103. Inspection................................................................................................ 3-5-104. Installation ............................................................................................... 3-5-105. Check Out ............................................................................................... 3-5-10

D. Bleeding the Disc Brake System ........................................................................ 3-5-111. General ................................................................................................... 3-5-112. Manual Bleeding ...................................................................................... 3-5-113. Pressure Bleeding .................................................................................. 3-5-124. Check-Out .............................................................................................. 3-5-12

SECTION 6: HYDRAULIC CYLINDER ..................................................................................... 3-6-1A. Disassembly ......................................................................................................... 3-6-1B. Inspection and Assembly ...................................................................................... 3-6-1

SECTION 7: HYDRAULIC PUMP ............................................................................................. 3-7-1A. General ................................................................................................................. 3-7-1B. Disassembly ......................................................................................................... 3-7-2

1. Disassembly of Basic Pump .................................................................... 3-7-22. Disassembly of Flow Control and Relief Valve Covers ............................. 3-7-23. Disassembly of the Priority Valve Cover ................................................... 3-7-2

C. Inspection and Repair ........................................................................................... 3-7-41. Cleaning .................................................................................................... 3-7-42. Inspection and Repair ............................................................................... 3-7-4

D. Assembly .............................................................................................................. 3-7-51. Assembly of Flow Control Cover .............................................................. 3-7-52. Assembly of Priority Valve Cover .............................................................. 3-7-63. Assembly of Pump.................................................................................... 3-7-6

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SECTION 1: RECOMMENDED OVERHAUL PERIODS

A. GENERAL

The following overhaul periods are approximate and can vary greatly due to different operatingconditions. Units operating in extreme conditions such as high or low temperatures, long periods ofsustained operation, continued operation in sand or dust or continued exposure to sea air or moisturerequire careful, regular inspections. Overhaul periods may be adjusted with time and experience inoperating this belt loader. If an overhaul of a component or system is anticipated or required, theprocedures that cover that component or system should be read and fully understood prior toattempting any part of the overhaul.

B. ENGINE

Overhaul when oil consumption exceeds 1 qt per 50 hours of operation or 5000 hours on the enginehour meter. Engine workshop manuals are available by request.

C. TRANSMISSION

Overhaul when the engine hour meter exceeds 5000 hours. Transmission workshop manuals areavailable by request.

D. FRONT (STEER) AXLE

If vehicle has been properly lubricated and maintained and has not experienced damage to thesteering system, the steering components will provide many hours of service without an overhaul.Overhaul the steer axle when excessive play in axle components cannot be corrected by replacing theindividual components.

E. REAR (DRIVE) AXLE

If vehicle has been properly lubricated and maintained and has not experienced damage, the driveaxle will provide many hours of service without an overhaul. Overhaul when individual gears orcomponents cannot be replaced in order for the axle to perform adequately.

F. REAR WHEEL DRUM BRAKES

Service when brake shoes are worn or damaged.

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G. FRONT WHEEL DISC BRAKES

Replace all brake pads on the axle whenever the thickness of any lining is worn to the approximatethickness of the metal backing. Overhaul the calipers whenever they fail to perform. Inspect rubbingsurfaces on rotor for evidence of corrosion, pitted or scratches. Replace if scratched, corroded, pittedor whenever the thickness has reached its minimum limit.

H. HYDRAULIC CYLINDERS

Overhaul when external or internal leakage is evident, after 5000 hours of operation under extremeconditions or 10,000 hours of operation under normal conditions.

I. HYDRAULIC PUMP

Overhaul when internal or external leakage is evident or after 5000 hours.

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SECTION 2: FRONT (STEER) AXLE

A. DESCRIPTION

The front (steer) axle is a Dana Model 44 with disc brakes.

WARNING: OBSERVE ALL SAFETY PRECAUTIONS DISCUSSED INTHE SAFETY SECTION OF THIS MANUAL!

B. INSPECTION AND OVERHAUL

If vehicle has been properly lubricated and maintained and has not experienced damage to the steeringsystem, the steering components will provide many hours of service without an overhaul. Shouldoverhaul be required, follow the procedure below:

Jack up the front end of the vehicle using normal jacking procedures (i.e., chock rear tires, apply handbrake, and place blocks under vehicle front bumper).

Inspect the steering linkage rod for damage. Also check for wear of the linkage rod ball joints bygrasping the rod and shaking it. If the linkage rod ball joints are loose, replace the rod.

1. Bearings and SealsGrasp the top and bottom of each tire and shake it in and out while observing the hub andspindle area to detect any wobble or looseness. If any wobble or looseness is noted in the huband the spindle is rigid, the wheel bearings and seals should be adjusted by tightening the hubretainer nut. If excessive noise is experienced after adjustment, the bearings and seals shouldbe replaced as follows:

(a) Remove the front wheels by removing the lug nuts on each wheel.

(b) Remove the hub dust cap, outer hub retainer nut, nut lock and inner hub retainer nut.

(c) Grasp the hub and slide it off the axle shaft.

(d) Remove the inner and outer seals and bearings from the hub and wipe the hubinterior clean.

(e) Inspect hub interior surfaces (bearing races) for scoring. If the races are scored orworn, replace with new races.

(f) Install new bearings and seals into the hub, packing the bearings with lithium-basedgrease, and replace the hub onto the axle shaft.

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(g) Secure the hub with the retainer nuts and nut lock and replace the hub dust cap.

(h) Install the wheel.

2. Ball JointsGrasp the top and bottom of the wheel and check for ball joint wear by observing the hub andspindle area while shaking the wheel in and out. If the hub is rigid, but the spindle has play init at the axle connection, the ball joints should be replaced for each wheel as follows:

(a) Remove the front wheels.

(b) Remove the cotter pin from the castellated nut on the end of the ball joint.

(c) Remove snap ring on the opposite end of the ball joint.

(d) Press out ball joint by pressing away from the spindle.

(e) Reinstall ball joint by reversing steps 1 through 4 above, taking care not to warp theball joint housing during reinstallation.

3. Connecting Rod EndsGrasp the sides of the wheel and shake it from side to side while observing the rod ends. Ifexcessive movement is observed in the rod connection ends, replace the connecting rod endsas follows:

(a) Disconnect the rod ends from the spindle arms, removing the cotter pins and retainernuts.

(b) Remove the connecting rod and remove the rod end retainer clamps.

(c) Screw the new rod ends approximately 1/4" into each end of the rod.

(d) Install the connecting rod to the spindle arms, securing the connecting rod ends to thespindle arms with the two (2) retainer nuts and cotter pins.

(e) With the wheels pointing straight forward, adjust the “toe-in” by turning theconnecting rod until the centerline-to-centerline distance across the back of the tiresis 0 to 1/8" longer than the centerline-to-centerline distance across the front of thetires.

(f) After the toe-in adjustment has been accomplished, install the rod end clamps,securing the connecting rod adjustment.

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SECTION 3: REAR (DRIVE) AXLE

A. DESCRIPTION

The pinion gear and shaft is supported by two opposed roller bearings which are assembled in theforward side of the carrier housing. Pinion locating shims, installed between the rear bearing cup andthe cup seat, control the drive pinion depth adjustment. The pinion bearing preload is controlled byshims located between the pinion front bearing and the shoulder on the drive pinion shaft.

The differential case assembly is supported by two opposed tapered roller (side) bearings and cups,which are retained in the housing by removable caps. Shims, installed between each differential sidebearing and the shoulder on the case, perform three functions: they take up the differential case sideclearance; they adjust the backlash between ring gear and pinion; and they establish differential sidebearing preload.

A cover on the rear of the carrier housing provides access for inspection, removal and installation ofthe differential assembly and drive pinion. A metal tag, stamped with the gear ratio, part numbers andlimited slip (if applicable), is secured to the housing by two of the cover bolts.

Model 60, (Figure 3-1) has full-floating axle shafts. This means that loads are borne by the axlehousing and the shafts can be removed without disturbing the wheel bearings, which are taperedroller bearings.

B. REMOVAL AND INSTALLATION

1. Rear Axle Shaft Removal and Disassembly

(a) Lift vehicle and install safety stands.

(b) Remove wheel from brake drum.

(c) Remove axle shaft bolts and pull out axle shafts. If gasket is present between the axleshaft flange and hub, discard and replace it at time of reassembly.

(d) Remove wheel bearing outer locknut, lock washer and inner wheel bearing adjusting nut.

(e) Remove the hub and drum assembly. The outer wheel bearing cone will slide out asthe hub is removed.

(f) Place the hub on a bench and remove the grease seal. Discard the grease seal andreplace it at time of assembly.

(g) Remove the inner and outer bearing cups from the hub.

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Figure 3-1. Rear Axle Assembly

1. Stud Nut2. Adaptor - Stud Nut3. Stud - Hub4. Axle Shaft5. Spindle Nut6. Lock Washer - Spindle Nut7. Outer Wheel Bearing and Race8. Hub - Wheel9. Inner Wheel Bearing and Race10. Seal - Hub11. Nut - Brake Mounting12. Bolt - Brake Mounting13. Thrust Washer - Differential Pinion14. Differential Pinion15. Differential Shaft

16. Differential Bearing and Cup17. Cap - Differential Bearing18. Differential Gear19. Spacer - Differential Gear20. Differential Disc21. Bolt - Differential Bearing22. Shim - Differential Bearing23. Bolt - Drive Gear24. Differential Case25. Differential Plate26. Clip - Differential Clutch Retainer27. Lock - Differential Shaft28. Carrier Cover Gasket and

RTV Sealant29. Bolt - Carrier Cover

30. Carrier Cover31. Plug - Cover32. Drive Gear and Pinion33. Differential Plate (Selective Thickness)34. Inner Pinion Bearing35. Shim - Drive Pinion Adjusting36. Baffle - Pinion Bearing37. Shim - Pinion Bearing Adjusting38. Outer Pinion Bearing39. Slinger - Pinion Bearing Outer40. Seal - Pinion41. End Yoke Assembly42. Washer - Pinion Bearing43. Pinion Nut44. Axle Housing

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2. Rear Axle Shaft Assembly and Installation

(a) Assemble the new outer bearing cup.

(b) Assemble the new inner bearing cup.

(c) Pack with grease and assemble the new bearing cone.

(d) Assembly the new grease seal. Apply a small amount of the specified grease aroundthe lip of the seal.

(e) Install the hub assembly onto the spindle. Pack with grease and assemble the newouter bearing cone.

(f) Install the inner wheel bearing adjusting nut, lockwasher and outer wheel bearinglocknut.

(g) Place new gasket on axle tube.

(h) Install axle shaft in tube.

(i) Install new bolts and lockwashers and tighten to 40-50 ft-lb (54.2-63.7 Nm).

(j) Install wheel on drum

(k) Lower vehicle.

C. DISASSEMBLY AND ASSEMBLY

1. Disassembly

(a) Remove the rear axle from the vehicle as outlined in Removal and Installation.

(b) Remove cover plate and drain lubricant from axle. The lubricant will drain out as thecover plate is removed.

(c) Remove cover plate screws, cover plate and cover plate gasket. Discard old gasket.Tip carrier to allow lubricant to drain completely. Also during this time clean thecover face of the carrier, being sure it is free from any nicks and any particles left bythe old gasket.

(d) Remove bearing caps.

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NOTE: Mating letters are stamped on caps and carrier (Figure 3-2). It isimportant that they are assembled exactly as removed. Letters or numbersare in vertical and horizontal position.

Figure 3-2. Removing Bearing Caps

Bearing Caps: Note Mating Numbers

CAUTION: BEFORE REMOVING DIFFERENTIAL CASE AND RINGGEAR. BE SURE THE AXLE SHAFTS ARE PULLED OUT FARENOUGH TO PROVIDE ADEQUATE CLEARANCE FORDIFFERENTIAL REMOVAL.

(e) Place differential housing spreader tool 4000-E on the case. Install dial indicator, tool4201-C on the case. Do not spread case more than 0.015" (0.38 mm).

NOTE: Whenever removing the ring gear bolts, always replace with newbolts upon assembly.

(f) Pry differential case from carrier with two pry bars. After differential case has beenremoved, remove spreader. Use caution to avoid damage to ring and pinion. Mark ortag bearing cups, indicating from which side they were removed.

(g) Remove differential bearings with special tool P79L-4621-A, pinion bearing coneremover. Wire shims, bearing cup and bearing cone together. Identify from whichside they were removed (ring gear side or opposite side). If shims are damaged,replace with new ones at time of assembly. Shims are available in thicknesses of0.003" (0.08 mm), 0.005" (0.13 mm), 0.010" (0.25 mm), and 0.030" (0.76 mm).Reposition case in puller and remove other bearing cone as described above. Replacebearings whenever they are removed from the carrier.

Note

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(h) Place a few shop towels over the vise to prevent the ring gear teeth from being nickedafter it is free from the case. Place case in vise. Remove ring gear bolts. Tap ring gearwith a rawhide hammer to free it from the case. Remove case and ring gear from vise.

(i) Replace case in vise and drive out the lock pin which secures the pinion mate shaft.Use a small drift as shown in Figure 3-3.

Figure 3-3. Removing Lock Pin

(j) Remove pinion mate shaft with drift as shown in Figure 3-4.

Figure 3-4. Removing Pinion Mate Shaft

Pinion MateGear

Pinion Mate ShaftSide Gear

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(k) To remove side gears and pinion mate gears, rotate the side gears. This will allow thepinion mate gears to turn to the opening of the case. Remove pinion mate gears andthe spherical washers behind the gears. Lift out side gears and thrust washers. Inspectall parts, including the machined surfaces of the case itself. If excessive wear isvisible on all parts, it is suggested that the complete differential assembly bereplaced. If any one of the gears are to be replaced, THEY MUST BE REPLACEDAS A SET.

NOTE: Axle shafts which require end play adjustment have a spacer blockin the differential case. The spacer block controls the end thrust of the axleshaft. If the ends of the spacer block are worn, it is to be replaced duringassembly. Spacer block must not be used with ball or unitized wheelbearings.

(l) Turn nose of carrier to a horizontal position and remove pinion nut. Hold end yoke orflange with tool T57T-485LB companion flange holding tool, and remove pinion nutand washer.

(m) Remove end yoke of flange. If end yoke or flange shows wear in the area of the sealcontact, it should be replaced.

CAUTION: DO NOT DROP PINION AS THIS IS LIKELY TO RESULTIN DAMAGE.

(n) Remove pinion by tapping with a rawhide hammer.

NOTE: There are bearing preload shims on the spline end of the pinion.These shims may stick to the pinion or bearing or fall out. These shims areto be collected and kept together since they will be used later in assembly.Avoid damaging shims. If shims are damaged, replace with new ones. Shimsare available in thicknesses of 0.003" (0.08 mm), 0.005" (0.13 mm), 0.010"(0.25 mm), and 0.030" (0.76 mm).

(o) Pull out pinion seal with puller D78P-1225-B, bearing cup puller. Discard seal.REPLACE WITH NEW ONE AT TIME OF ASSEMBLY. Remove bearing cone andouter oil slinger.

Note

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(p) Turn nose of carrier down. Remove outer pinion bearing cup with tool D78P-1225-B,bearing cup puller. Locate driver on back edge of cup and drive cup out of carrier.

CAUTION: DO NOT NICK CARRIER BORE.

NOTE: The front and rear carrier section may vary in pinion bore depth dueto the possibility of the need for either a baffle or slinger or both. The baffleserves as a dam to assure that the pinion bearings are kept lubricated. Theslinger serves the purpose of assisting the lubricant to flow up through the oilchannels to lubricate the pinion bearings. If used, they are part of the pinionsetting adjustment. The four different options are shown in Figure 3-5.

Figure 3-5. Pinion Attachments

Oil Slinger Oil Baffles

(q) Remove the inner bearing cup with tool D78P-1225-B, bearing cup puller.

NOTE: Shims are located between the bearing cup and carrier bore andmay also include an oil baffle. If shims and baffles are bent or nicked, theyshould be replaced at time of assembly. Wire, stack together and measureeach. If stack has to be replaced, replace with same thickness.

(r) Remove bearing from pinion with an appropriate puller.

NOTE: Both baffle and slinger are part of the pinion adjustment shims andare to be kept intact for assembly.

Note

Note

Note

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2. Differential Case

(a) Assembly

(1) Place differential case in vise. Apply grease to new side gear thrust washersand to hubs and thrust face of the new side gears. Assemble both side gears.Apply grease to the new spherical washers, and the new pinion mate gears.Assemble new pinion mate gears and washers.

NOTE: For ease of assembly, all parts of side gears and pinion mate gearsshould be lubricated before assembly.

(2) Assemble both side gears and thrust washers, hold them in place with hand,then assemble the pinion mate gears and washers to hold the side gears inplace.

(3) Rotate the side gears until the holes of the washers and pinion gears line upwith the holes of the case. If the gears cannot be rotated by hand, install oneof the axle shafts into the side gear spline and use a pipe wrench to turn theshaft.

(4) Use a drift to line up the holes with those of the differential case.

(5) Assemble pinion mate shaft and drive on shaft to remove drift. Be sure lockpin hole of the shaft is lined up with the lock pin hole in case.

(6) Assemble lock pin. Peen metal of case over pin to lock in place.

(7) Be sure flange face of the case is free of nicks and burrs. Assemble ring gearto case. Line up holes of the ring gear with those of the case. Use new ringgear screws. Draw up screws alternately and evenly. Torque ring gear screwsto 100–120 ft-lb (136–163 Nm).

(8) Install differential bearings onto case. Remove all nicks, burrs, dirt, etc.,from hubs to allow bearings to rotate freely.

(9) Assemble differential case into carrier (less pinion). Mount dial indicatorwith a magnetic base as shown in Figure 3-6. Locate tip of indicator on flatsurface of one of the ring gear screw spot faces. Mark location with chalk.Force differential assembly as far as possible in the direction toward theindicator. With force still applied, set indicator at zero (0).

NOTE: Dial indicator should have a minimum travel of .200" (5.08mm).

Note

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(10) Force the differential assembly as far as it will go in the opposite direction.Repeat these steps until they produce the same reading. Record the readingof the indicator. This will be the total amount of shim required (less preload)and will be calculated later during assembly. After being sure the readingsare correct, remove indicator and differential assembly from housing. DONOT REMOVE MASTER BEARINGS FROM DIFFERENTIAL CASE ATTHIS TIME.

(11) Ring gears and pinions are supplied in matched sets only. Matching numberson both the pinion and ring gear are etched for verification. If a new gear setis being used, verify the number of each pinion and ring gear beforeproceeding with assembly (Figure 3-7).

The distance from the center line of the ring gear to the bottom end of thepinion for the model 60 (front and rear axle is 3.125" (79.37mm).

On the button end of each pinion, there is etched a plus number, a minusnumber, or a zero which indicates the best running position for eachparticular gear set. This dimension is controlled by the shimming behind theinner pinion bearing cup.

For example, if a pinion is etched with a plus +3 (m+8), this pinion wouldrequire 0.003" (0.08 mm) less shim than a pinion etched “0”. By removingshims, the mounting distance of the pinion is increased to 3.128" (98.45 mm).

Figure 3-6. Assembling the Differential Case

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Figure 3-7. Pinion & Ring

If the old ring and pinion set is to be reused, measure the old shim pack andbuild a new shim pack to this same dimension. If a baffle is used in the axleassembly, it is considered as part of the shim pack. To change the pinionadjustment, shims are available in thicknesses of 0.003" (0.08 mm), 0.005"(0.13 mm), 0.010" (0.25 mm), and 0.030" (0.76 mm)..

NOTE: If baffle or slinger is bent or damaged, it should be replaced.

Measure each shim separately with a micrometer and add together to get thetotal shim pack thickness from the original build up.

If a new gear set is being used, note the (+) or (-) etching on both the old andnew pinion and adjust the thickness of the new shim pack to compensate forthe difference of these two figures. Refer to shim tables (Tables 3-1 and 3-2)for correct shim selection.

Note

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3. Pinion Bearing Cups

(a) Drive the inner pinion bearing cup into the inside of the carrier housing with theappropriate driver tool.

(b) Turn the housing over and install the outer pinion bearing cups into the carrier withthe appropriate tool.

Table 3-1. Shim Selection Chart - Inches

-4 -3 -2 -1 0 1 2 3 4

4 0.008 0.007 0.006 0.005 0.004 0.003 0.002 0.001 0.000

3 0.007 0.006 0.005 0.004 0.003 0.002 0.001 0.000 -0.001

2 0.006 0.005 0.004 0.003 0.002 0.001 0.000 -0.001 -0.002

1 0.005 0.004 0.003 0.002 0.001 0.000 -0.001 -0.002 -0.003

0 0.004 0.003 0.002 0.001 0.000 -0.001 -0.002 -0.003 -0.004

-1 0.003 0.002 0.001 0.000 -0.001 -0.002 -0.003 -0.004 -0.005

-2 0.002 0.001 0.000 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006

-3 0.001 0.000 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

4 0.000 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

New Pinion MarkingOld Pinion

Marking

Table 3-2. Shim Selection Chart - Metric

-10 -8 -5 -3 0 3 5 8 10

10 0.200 0.180 0.150 0.130 0.100 0.080 0.050 0.030 0.000

8 0.180 0.150 0.130 0.100 0.080 0.050 0.030 0.000 -0.030

5 0.150 0.130 0.100 0.080 0.050 0.030 0.000 -0.030 -0.050

3 0.130 0.100 0.080 0.050 0.030 0.000 -0.030 -0.050 -0.080

0 0.100 0.080 0.050 0.030 0.000 -0.030 -0.050 -0.080 -0.100

-3 0.080 0.050 0.030 0.000 -0.030 -0.050 -0.080 -0.100 -0.130

-5 0.050 0.030 0.000 -0.030 -0.050 -0.080 -0.100 -0.130 -0.150

-8 0.030 0.000 -0.030 -0.050 -0.080 -0.100 -0.130 -0.150 -0.180

-10 0.000 -0.030 -0.050 -0.080 -0.100 -0.130 -0.150 -0.180 -0.200

New Pinion MarkingOld Pinion

Marking

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4. Depth Gauge Check

(a) Refer to Table 3-3 for the correct tools for the particular axles.

NOTE: If any of the gauge surfaces become nicked, the high spots must beremoved with a medium India oilstone to ensure no erroneous readings areobtained.

Tool Tool NumberAxle Model

60 & 61-1

Aligning T76P-4020-A3 X

Adaptor D8OT-4020-F48

Gauge Disc T78P-4020 X

D8OT-4020-F44

D8OT-4020-F45

Gauge Block T8OT-4020-F42 X

Screw T80T-4020-F42 X

Handle T76P-4020-A11 X

Gauge Tube D8OT-4020-F47

DSOT-4020-F48 X

Table 3-3. Pinion Depth Tool Selection

(b) Place a new rear pinion bearing over the proper aligning adaptor and insert into thepinion bearing retainer assembly. Place the front pinion bearing (new or used if ingood condition) into the bearing cup, assemble the handle onto the screw and handtighten. Note the 3/8" square drive in the handle to be used for obtaining the properpinion bearing preload.

(c) Center the proper gauge tube into the differential bearing bore. Install the bearingcaps and torque to proper specifications.

(d) Using a feeler gauge tool, select the thickest feeler shim that will fit between thegauge tube and the gauge block. Insert the feeler gauge directly along the gaugeblock to ensure a correct reading. The feeler gauge fit between the gauge tube and thegauge block should be a slight drag-type feeling.

(e) After the correct feeler gauge feel is obtained, check the reading. This is thethickness oil shim(s) required, providing that there are no markings on the servicepinion gear.

Note

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NOTE: If the service pinion gear is marked with a plus (+) reading, thisamount must be subtracted form the thickness dimension obtained in step(d). If the service pinion gear is marked with a minus (-) reading, thisamount nust be added to the thickness dimension obtained in step d. In theaddition, the same new rear pinion bearing that was used in the previoussteps must be used.

(f) Place the selected shim(s) and oil slinger (if used) on the pinion and press on thebearing.

NOTE: If a baffle or slinger is used, replace with a new one upon assembly(see Figure 3-5) and measure as part of the shim stack.

(g) After following these procedures, continue to build the remaining components withproper pinion and differential bearing preload torques and ring gear backlash.

5. Pinion Bearing Preload

(a) Assemble preload shims and slinger (if used) onto pinion. Assemble bearing cone.

(b) Pack ESA-M1C75-B lubricant or equivalent on the lips of the pinion seal andassemble into carrier.

(c) Assemble end yoke, washer and new pinion nut. Torque nut to 240–300 ft-lb(325–406 Nm).

(d) Using a torque wrench, rotate pinion (Figure 3-9). Torque to rotate pinion shouldread between 1.67-3.34 ft-lb (2.26-4.53 Nm). To increase preload, remove shimsfrom pinion. To decrease preload, add shims to pinion.

The illustration in Figure 3-8 shows the arrow in the pinion pointing in twodirections. The arrow pointing toward the end yoke indicates that by removingpinion position shims, the distance from the center line of the axle to pinion button isincreased, giving a plus reading. The pinion bearing preload shim pack does noteffect the pinion depth setting. Arrows on the ring gear illustrate the method toincrease or decrease backlash and differential bearing preload.

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Figure 3-9. Measuring Pinion Preload

Figure 3-8. Differential Assembly

6. Assembly of Differential into Housing

(a) Ring Gear and Pinion Backlash

(1) Place differential assembly (with pinion installed) into housing. Differentialmaster bearings should still be assembled to case.

(2) Set up dial indicator as shown in Figure 3-6. Be sure to locate dial indicatoron same location as marked in step 9. Force ring gear into mesh with thepinion. Rock ring to allow the teeth of the gears to mesh. With force stillapplied to the differential case, set indicator at zero “0”.

(3) Force the differential case (ring gear) away from the pinion gear to obtain anindicator reading. Repeat until the same reading is obtained each time. Thisreading will be the necessary to determine the amount of shim requiredbetween the differential case and differential bearings on the ring gear side.Remove indicator and differential case from the carrier. Remove bearingsfrom differential case.

(4) Assemble the required amount of shim onto hub (ring gear side) asdetermined in the above step. Place bearing cone on hub of case. Use anappropriate installer to seat bearing cone.

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(5) Assemble the remaining of the total shim pack which was determined in Step9 of Assembly-Differential Case on the opposite side of the differential case.Add an additional 0.015" (0.38mm) of shim on this side to compensate fordifferential bearing preload.

For example, assume that in Step 9 of Assembly-Differential Case (lesspinion), a total of 0.107" indicator reading was recorded.

In Step 3 above (with pinion) a total of 0.055" indicator reading was recorded.

This leaves a balance 0.052" of shims for the opposite side and adds up to the0.107" which was first recorded. Add an additional 0.015" shims on theopposite side for bearing preload and backlash.

(Ring Gear Side 0.055" (1.40 mm); Opposite Side 0.052" (1.32 mm);Opposite Side Preload 0.015" (0.38 mm))

(6) Install spreader and indicator to carrier. Do not spread carrier over 0.020"(0.51 mm). Remove indicator.

(7) Assemble differential bearing cups to differential bearing cones.

(8) Install bearing caps. Make sure the letters stamped on the caps correspondwith those on the carriers. Torque bearing cap screws to 80-90 ft-lb(108-122 Nm).

(9) Check ring gear and pinion backlash in three equally spaced points with dialindicator. Backlash tolerance is 0.004–0.009" (0.10–0.23 mm) and cannotvary more than 0.002" (0.05 mm) between points checked.

High backlash is corrected by moving the ring gear closer to the pinion.

These corrections are made by switching shims from one side of thedifferential case to the other.

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(10) Install new cover gasket and install cover plate. Torque screws to 30–40 ft-lb(41–54 Nm).

NOTE: There are two different design cover plates. One cover has a flatmounting surface, and the other design has ribs between the screw holes.

Figure 3-10. Differential Cover Plates

Rib

Figure 3-10 shows the flat mounting surface cover plate side-by-side with theribbbed surface cover plate used on Dana design axles. The flat cover platerequires the use of a silicone rubber sealer material rather than a gasket.

The cover face of the carrier and the flat surface of the cover plate must befree of any oil film or foreign material.

Sealant material must meet specifications of ASTN3, GE303, A19, B37, E16,E36, 21, 22, and 23 sealant or equivalent.

Apply ESB-M4C92A-RTV Gasket sealer or equivalent to cover platesurface. Ensure that the sealer bead is laid on the inside of the cover screwholes. The bead is not to pass through the holes or outside of the holes.

The bead is to be 1/8", to 1/4" (3.18- 6.35 mm) high and 1/8" to 1/4" (3.18-6.35 mm) wide.

Note

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Assemble two cover screws into cover at the 8 o’clock and 2 o’clockpositions. Use these two screws to guide cover plate into position on thecarrier.

Install remaining screws. Tighten alternately and evenly. Torque screws to30–40 ft-lb (41–54 Nm). Allow one hour cure time before filling carrier withthe proper amount of specified lubricant and vehicle operation.

On the cover plate with rib design (see previous page), a gasket .must beused. Do not use silicone sealer. Torque screws to 30–40 ft-lb (41–54 Nm).

Figure 3-11. Application of Sealant on Non-Ribbed Cover Plate

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D. SPECIFICATIONS

1. Dana Axle Adjustments

2. Dana Axle Torque Limits

Description Specification

Backlash between Ring Gear on Pinion 0.004-0.009" (0.10-0.23 mm)

Backlash Maximum Variation between Teeth 1.27" (0.05 mm)

Pinion Bearing Preload 20-40 ft-lb (2.26-4.53 Nm)

3. Dana Axle Approximate Oil Capacity

Description ft-lb Nm

Pinion Shaft Nut 250-270 339-366

Differential Bearing Cap Bolts 80-90 109-147

Rear Gear Attaching Bolts 110-125 150-169

Oil Filter Plug 20-30 28-40

U-Joint Bolts 15-20 21-27

Cover to Housing Bolts 30-40 41-54

Axle Model Ford Specification U.S. Pints Imp. Pints Liters

60-30 ESW-M2C105-A 5 4.16 2.37

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SECTION 4: REAR WHEEL DRUM BRAKES

A. ADJUSTMENTS

1. Brake Shoe AdjustmentThe brake shoes are automatically adjusted when the vehicle is driven in reverse and thebrakes applied several times sharply. Manual brake adjustment is required only after thebrake shoes have been relined or replaced. Perform the manual adjustment with the drumsremoved, using the tool and the procedure described below.

(a) Clean away all rust and dirt from the points where the shoes touch the backing plate.

(b) Apply a small amount of Multi-Purpose Lubricant, Ford Specification ESA-M1C75-B or equivalent to the points where the shoes touch the backing plate. Take care notto get the lubricant on the linings.

(c) Use Rotunda Tool (Figure 4-1), and adjust to the inside diameter of the drum brakingsurface.

(d) Reverse the tool as shown in (Figure 4-2) and adjust the brake shoes until they touchthe gauge. The gauge contact points on the shoes (Figure 4-2) must be parallel to thevehicle with the center line through the center of the axle. Hold the automaticadjusting lever out of engagement while rotating the adjusting screw, to preventburring the screw slots. Be sure the adjusting screw rotates freely. If necessary,lubricate the adjusting screw threads with a thin, uniform coating of Multi-PurposeLubricant, Ford Specification ESA-NlC75-B or equivalent.

Figure 4-1. Diameter of Brake Drum Figure 4-2. Diameter of Brake Shoes

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(e) Install the drums. Install the retaining nuts and tighten securely.

(f) Install the wheels on the drums and tighten the mounting nuts to specification, aslisted at the end of this section.

(g) Complete the adjustment by applying the brakes several times while driving thevehicle in reverse.

(h) After adjusting the brake shoes, check brake operation by making several stops whiledriving forward.

2. Manual AdjustmentAdjust the single anchor brake by turning an adjusting screw located between the lower endsof the shoes (Figures 4-3 and 4-4).

(a) Raise the vehicle until the tires clear the floor.

(b) Remove the cover from the adjusting hole at the bottom of the brake backing plate,and turn the adjusting screw inside the hole to expand the brakes shoes until theydrag against the brake drum and lock the drum (Figure 4-3).

Figure 4-3. Adjustment Expanding

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(c) When the shoes are against the drum, loosen the adjusting screw an additional 10 to12 notches so that the drum rotates freely without drag (Figure 4-4). If the drum doesnot rotate freely, remove the wheel and drum, and blow out any dust and dirt from thelinings. Using sand paper, remove any rust from the points where the shoes touch thebacking plate. Apply a light coating of Multi-Purpose Lubricant, Ford SpecificationESA-M1C75-B or equivalent. Do not get the lubricant on the linings. Install thewheel and drum and adjust the shoes.

Figure 4-4. Adjustment Retracting

(d) Install the adjusting hole cover on the brake backing plate.

(e) Check and adjust the other three brake assemblies.

(f) Apply the brakes. If the pedal travels more than halfway to the floor, there is toomuch clearance between the brake shoes and the drums. Repeat Steps (a) and (b)above.

(g) When all brake shoes have been properly adjusted, lower the vehicle and road test tocheck brake operation. Perform the road test only when the brakes will apply and thevehicle can be safely stopped.

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B. REMOVAL AND INSTALLATION

1. Rear Brake Drum

WARNING: UNDER NO CIRCUMSTANCES SHOULD COMPRESSEDAIR BLOW OFF BE USED TO CLEAN BRAKES, BRAKE DRUMS,CLUTCHES, AND ASSOCIATED COMPONENTS.

(a) Removal

(1) Raise the vehicle and install safety stands under the rear axle.

(2) Remove the wheel and tire as an assembly. Loosen the rear brake shoeadjustment screw.

(3) Remove the rear axle retaining bolts and lockwashers, axle shaft and gasket.

(4) Remove the wheel bearing locknut, lockwasher, and adjusting nut.

(5) Remove the hub and drum from the axle.

(6) Check the drum for damage or wear, repair or replace as necessary. If a newdrum will be installed, remove the wheel studs and the brake drum from thehub.

(b) Installation

(1) If new drum is installed, remove the protective coating with carburetordegreaser. Install new grease retainer seals whenever a wheel and hub isremoved.

(2) Check the brake surface drum run-out. If the run-out exceeds 0.007"(0.178mm) the hub and drum assembly should be turned.

(3) Place the hub and drum assembly on the axle and start the adjusting nut.

(4) Adjust the wheel bearing nut and install the wheel bearing lock washer andlocknut.

(5) Install a new gasket and install new bolts and lockwashers.

(6) Install the wheel and tire as an assembly. Tighten wheel nuts tospecification.

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(7) Adjust the brake shoes. Remove the safety stands and lower the vehicle.

2. Brake Shoe and Adjusting Screw

(a) Removal

(1) Raise the vehicle so the wheels clear the floor and install safety stands underthe axle.

(2) Remove the wheel and drum. If the drum does not clear the brake shoes,retract the brake shoes. Remove the parking brake lever assembly retainingnut from behind the backing plate and remove the parking brake. (Figure 4-5)

(3) Remove the adjusting cable assembly from the anchor pin, cable guide andadjusting lever.

(4) Remove the brake shoe retracting springs.

(5) Remove the brake shoe hold-down spring from each shoe.

(6) Remove the brake shoes and adjusting screw assembly.

(7) Disassemble the adjusting screw assembly.

(b) Installation

(1) Clean the ledge pads on the backing plate. Sand lightly to bare metal.

(2) Apply Multi-Purpose Lubricant, Ford Specification ESA-M1C75-B orequivalent, to the retracting and hold-down spring contacts on the brakeshoes and backing plate.

(3) Apply Multi-Purpose Lubricant, Ford Specification ESA-M1C75-B orequivalent, to the threads and socket end of the adjusting screw.

(4) Install the upper retracting spring on the primary and secondary shoes asshown in Figure 4-6 and position the shoe assembly on the backing platewith the wheel cylinder push rods in the shoe slots.

(5) Install the brake shoe hold-down springs.

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(6) Install the brake shoe adjustment screw assembly (with the slot in the head ofthe adjusting screw toward the primary shoe), lower retracting spring,adjusting lever spring and adjusting lever assembly. Connect the adjustingcable to the adjusting lever. Position the cable in the cable guide and installthe cable anchor fitting on the anchor pin. Install the adjusting screwassemblies in the same locations from which they were removed.Interchanging the brake shoe adjusting screw assemblies from one side of thevehicle to the other will cause the brake shoes to retract rather than expandeach time the automatic adjusting mechanism is operated. To preventincorrect installation, the socket end of each adjusting screw is stamped withan R or L to indicate proper installation on the right or left side of thevehicle. The adjusting pivot nuts can be distinguished by the number of linesmachined around the body of the nut. Two lines indicate a right hand nut;one line indicates a left hand nut.

(7) Install the parking brake assembly in the anchor pin and secure with theretaining nut behind the backing plate.

(8) Adjust the brakes before installing the drums, using Rotunda Brake ShoeGauge (model 11001 or 110002) or equivalent, as described in this section.

3. Brake Wheel Cylinder

(a) Removal

(1) Remove the wheel, drum and brake shoes. Remove the cylinder-to-shoeconnecting links.

(2) Disconnect the brake line from the brake cylinder.

(3) Remove the brake cylinder retaining bolts and lockwashers, then remove thecylinder from the backing plate.

(b) Installation

(1) Place the brake cylinder on the backing plate and install the retaining boltsand lockwashers.

(2) Install a new gasket on the brake line fitting (if equipped) and connect thebrake line to the brake cylinder.

(3) Install the brake shoes and the connecting links between the shoes andcylinder. Install the drum and the wheel.

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(4) Adjust the brakes and bleed the system. Check pedal operation beforemoving the vehicle.

Figure 4-5. Drum Brake Assembly

4. Rear Brake Backing Plate

(a) Removal

(1) Remove the wheel, hub and drum assembly. Disconnect the brake line fromthe brake cylinder and submerge the end of the brake line in a can containinga small amount of brake fluid to prevent air from entering the system.Remove the brake shoes and brake cylinder.

(2) Remove the nuts. Pull the axle shaft assembly out of the housing using tool4235-C, and a slide hammer tool T50T-100-A. Lift off the backing plate.

(3) On units equipped with Dana integral carrier rear axles, refer to Axle Shaft-Removal. Remove the backing plate after the axle shafts have been removed.

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(b) Installation

(1) Position the rear backing plate on the retaining bolts in the axle housingflange. Insert the axle shaft assembly into the housing so the splines engagethe differential side gear, with the bearing retainer sliding onto the retainingbolts and against the backing plate. Install the retaining nuts through theaccess hole in the axle shaft flange. Install axle shafts after referring to AxleShaft installation in the Rear Axle Section.

(2) Install the brake cylinder and brake shoes.

(3) Connect the brake line to the brake cylinder and install the brake drum andwheel. Adjust the brake shoes and bleed air from the system.

C. DISASSEMBLY AND ASSEMBLY

1. Brake Wheel Cylinder

(a) Disassembly

(1) With the wheel cylinder removed, remove the rubber boots from the ends ofthe brake cylinder. Remove the pistons, cups, piston return spring and pistonexpander assembly from the cylinder.

(2) Remove the bleeder screw from the cylinder.

(b) Assembly

(1) Coat all brake cylinder parts with clean extra heavy duty brake fluid ESA-M6C25-B or equivalent.

(2) Install the bleeder screw (Figure 4-6) in the brake cylinder.

(3) Place the piston return spring and piston expander assembly, cups andpistons in the cylinder bore, and install a boot and link over each end of thecylinder. Clamp the brake cylinder pistons against the ends of the cylinder.When using a brake cylinder repair kit, follow the instructions in the kit anduse all of the parts provided.

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2. Master CylinderRemove the master cylinder from the vehicle. (Refer to Figure 4-7). When it is necessary torepair the master cylinder during the warranty period, replace the cylinder as a unit instead ofoverhauling the cylinder with a service repair kit.

(a) Disassembly

(1) Clean the outside of the master cylinder and remove the reservoir cover andreservoir diaphragm. Drain any fluid left in the cylinder. Be careful withbrake fluid as it damages painted surfaces.

(2) Remove the push rod boot (if equipped), from the groove at the rear of themaster cylinder, and slide the boot away from the rear of the master cylinder.

(3) Remove the snap ring holding the pistons in the cylinder body.

(4) Remove the push rod (if equipped), and primary piston assembly from themaster cylinder. Discard the piston assembly, including the boot (ifequipped).

WARNING: USE LOW AIR PRESSURE TO REMOVE THE PISTON.HIGH PRESSURE COULD RESULT IN DAMAGE OR PERSONALINJURY.

(5) Using an air hose in the rear brake outlet port of the cylinder body, carefullyblow the secondary piston out of the cylinder body. Remove the returnspring, spring retainer, cup protector and cups from the secondary piston.Discard the cup protector and cups.

Figure 4-6. Brake Wheel Cylinder Assembly

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(b) Inspection and Repair

(1) Clean all parts in clean isopropyl alcohol or Rotunda Brake Parts Washer(Model 650016) or equivalent, and inspect the parts for chipping, excessivewear or damage. Replace them, if necessary. When using a master cylinderrepair kit, use all the parts provided.

(2) Check all recesses, openings and internal passages to be sure they are openand free of foreign matter.

(3) Inspect the hydraulic master cylinder bore for etching, pitting or rust.Replace the master cylinder if any of these conditions exist.

(c) Assembly

(1) Remove the master cylinder from the vise. Check the outlet ports for brassburrs and remove, if present.

Figure 4-7. Master Cylinder Assembly

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(2) Dip all the parts except for the cylinder body in clean ESA-M6C25-B extraheavy duty brake fluid or equivalent and lubricate the bore walls with brakefluid.

(3) Assemble the secondary cup and 0-ring back-to-back in the grooves near theend of the secondary piston. Assemble the cup protector, primary cup, springretainer and secondary piston return spring on the other end of the secondarypiston.

(4) Install the secondary piston assembly in the master cylinder. Wet the sealswith the brake fluid and use caution when inserting the piston assembliesinto the bore to prevent damage to the seals.

(5) Install the primary piston assembly in the master cylinder. Push the primarypiston inward and tighten the secondary piston stop bolt to hold thesecondary piston in the bore.

(6) Position the stop plate and snap ring on the primary piston. Depress theprimary piston and install the snap ring in the cylinder body.

(7) Bleed the master cylinder.

(d) Before installing the master cylinder on the vehicle, bleed the unit as follows:

(1) Support the master cylinder body in a soft-jawed vise and fill both fluidreservoirs with ESA-M6C25-A extra heavy duty brake fluid or equivalent.

(2) Install plugs in the front and rear brake outlet ports. Bleed the rear brakesystem first.

(3) Loosen the plug in the rear brake outlet port. Depress the primary pistonslowly to force the air out of the master cylinder. Tighten plug while piston isdepressed to prevent air from entering the master cylinder.

(4) Repeat this procedure until air ceases to exit at the outlet port.

(5) Repeat steps (3) and (4) for the front brake outlet port with the rear brakeoutlet plugged.

(6) Tighten the plugs and attempt to depress the piston. The piston will resistdepression after all air is expelled.

(7) Install the cover and diaphragm assembly, being sure the cover retainer istightened securely. Remove the plugs.

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D. SPECIFICATIONS

1. Wheel Torque LimitsNut Size (ft-lb) Nm1/2-20 100 136

2. Special ToolsNumber Description110002 Safe-Set Gauge2035 N or W Brake Spring Installation/Removal Tool4235-C Axle shaft adaptor for removal of axle shaft. To be used with T50T-100-C.T50T-100-A Slide HammerJ-22742 Metering Valve Bleeder65001-G Brake Parts Washer

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SECTION 5: FRONT WHEEL DISC BRAKES

A. BRAKE PAD REPLACEMENT

Inspect the brake linings any time that the wheels are removed. Check both ends of the outboard padby looking in each end of the caliper. These are the points at which the highest rate of wear normallyoccurs. However, at the same time, check the lining thickness of the inboard pad to make sure that ithas not worn prematurely. Look down through the inspection hole in the caliper to view the inboardpad. Whenever the thickness of any lining is worn to the approximate thickness of the metal backing,all pads on the axle should be replaced.

1. PreparationFor front service, chock rear wheels and raise front of vehicle. For rear service, chock fronttires and raise rear.

2. Caliper Removal

(a) Remove 2/3 of brake fluid from master cylinder reservoir.

(b) Push the piston back into its bore. This can be accomplished by using a C-clamp.

(d) Using 3/8" Allen wrench, loosen and remove (2) mounting (retainer) bolts (seeFigure 5-1). Lift the caliper off the rotor and position on drive axle so that the brakehose will not support the weight of the caliper.

Figure 5-1. Brake Pad Mounting Bolts

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NOTE: If only brake pads and linings are being replaced, omit step (e).

(e) Disconnect brake line from caliper and plug openings in caliper and line to preventfluid loss and to keep out contamination. (See Figure 5-2.)

(f) Inspect mounting bolts for corrosion. If corrosion is found, use new bolts wheninstalling caliper.

Figure 5-2. Brake Line Disconnection

3. Brake Pad Removal

(a) Remove the inboard pad and spring from piston. Dislodge the outboard pad andremove from caliper.

(b) Remove sleeves from mounting bolt holes and discard. Remove the four rubberbushings from the grooves in each of the caliper ears and discard. (See Figure 5-3.)

4. Cleaning and Inspection

(a) Examine the piston area for fluid leaks by looking for excessive moisture aroundboot area. Check dust boot for cracks, cuts or other damage that would affect itsability to seal piston bore. If leaks are present or boot shows damage, the calipershould be overhauled. See specific section.

(b) If no defects are found, wipe clean the inside of the caliper including the four earswhere bushings are to be installed. Wipe the outside surface of the dust boot so thatwhen piston is pressed to bottom of bore, boot will fold back without coming out ofgroove.

Note

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5. Brake Pad Installation

(a) Using Delco Silicone Lube No. 179-651, lubricate new sleeves, new rubber bushings,and bushing grooves. Install rubber bushings in all four caliper ears.

NOTE: It is essential that the new sleeves and rubber bushings which areincluded in each Delco pad kit be used, and that lubrication instructions befollowed to ensure proper functioning of the sliding caliper design.

(b) Use Delco Tool, J-22835, to install the sleeve. Position the sleeves so that the endtoward the pad is flush with the machined surface of the ear.

(c) Attach pad retainer clip to inboard pad lining so that spring vee is on inner arc of pad.

Figure 5-3. Brake Pad Assembly

Note

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(d) Install inboard pad and lining as shown. (See Figure 5-4.) Position outer arc of padagainst inner arc of caliper. Depress spring vee to collapse it and enable it to slipinside of piston cup. Snap pad into place.

(e) Clip outer pad into place opposite inner pad. Make sure that the tab at the bottom ofthe pad is engaged in the caliper cut-out.

Figure 5-4. Brake Pad Installation

6. Caliper Installation

(a) Position caliper over rotor and line up holes in caliper ears with holes in themounting bracket. Make sure the brake hose is not twisted or kinked.

(b) Lubricate both ends of the mounting bolts with Delco Silicone Lube No. 179-651.Start the bolts through the sleeves in the inboard caliper ears and mounting bracket,making sure that the ends of the bolts pass under the retaining ears of the inboardpad. Push the bolts through to engage the bushings in the outboard caliper ears,while threading the bolts into the mounting bracket. Tighten bolts. (See Figure 5-5.)

(c) Torque bolts to 30-45 ft-lb (40.7-61.0 N-m).

(d) Remove temporary plugs from brake pipe and fittings, connect brake pipe to caliper.Torque to 15 ft-lb (20 N-m).

(e) If brass bolt and block were removed with brake pipe, unplug fittings and install boltand block using (2) new copper washers. Torque to 30 ft-lb (40 N-m).

(f) Fill master cylinder and bleed hydraulic system.

(g) After installing caliper, set caliper by applying heavy force to brake pedal.

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7. Check-Out

(a) Check brake pedal for sponginess or hard pedal.

(b) Drive vehicle slowly and make several slow speed stops.

(c) Check all brake fluid line fittings and caliper areas for fluid leakage.

(d) Correct any discrepancies before returning vehicle to service.

Figure 5-5. Brake Caliper Installation

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B. CALIPER OVERHAUL

1. General Layout

Figure 5-6. Brake Caliper Assembly

2. RemovalSee Pad Replacement Section. Removal of the caliper for overhaul is the same as for Padreplacement except that it will be necessary to disconnect the brake hose.

3. Disassembly

(a) Move the caliper to a work bench for overhaul.

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(b) Drain fluid from caliper.

(c) Remove pad and spring clip from end of piston.

(d) Before beginning caliper disassembly, thoroughly clean exterior using denaturedalcohol.

(e) Support caliper in a vise and pad caliper interior with shop cloths. Use a piece of 1x6 soft pine to prevent piston from coming out completely (See Figure 5-7).

Figure 5-7. Brake Piston Removal

(f) Use just enough compressed air in caliper brake line port to force piston out.Excessive air may cause piston to be blown out of bore and become damaged.

WARNING: USE OF COMPRESSED AIR WITHOUT WOOD BLOCKMAY RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THEPISTON.

(g) Remove wood block. Gently work piston the rest of the way out of bore.

(h) Use a screwdriver to pry boot out of caliper as shown. Use care to avoid scratchingthe caliper bore (See Figure 5-8).

(i) Remove piston seal from caliper bore. Use a piece of wood or plastic (a woodentoothpick is ideal) so as not to damage caliper bore.

(j) Remove bleed valve.

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4. Cleaning and Inspection

(a) Thoroughly clean all parts not in repair kit with denatured alcohol. Inspect caliperbore for scoring, nicks, corrosion or wear. Use crocus cloth to polish out any lightcorrosion. Replace caliper housing if bore will not clean up using crocus cloth.

(b) Carefully examine the piston exterior for scoring, nicks, corrosion and worn ordamaged surfaces. If any surface defects are detected, replace the piston.

CAUTION: THE PISTON OUTER SURFACE IS THE PRIMARYSEALING SURFACE IN THE CALIPER ASSEMBLY. IT ISMANUFACTURED AND PLATED TO CLOSE TOLERANCE.REFINISHING BY ANY MEANS, OR THE USE OF ANY ABRASIVE INTHE FIELD IS NOT ACCEPTABLE.

5. Reassembly

(a) Lubricate piston assembly with clean brake fluid.

(b) Position the seal in the caliper bore groove.

(c) Assemble a new boot into the piston groove so that the fold faces the open end of thepiston.

(d) Press piston assembly into caliper bore using C-clamp (See Figure 5-9). Be carefulnot to unseat the seal.

Figure 5-8. Brake Piston Boot Removal

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(e) Position outside diameter of boot in caliper counterbore and seat with Delco tool no.J-22904.

6. InstallationInstall caliper following instructions given in Pad and Lining Replacement Section. Bleedsystem.

7. Check-Out




(d) Correct any discrepancies before returning vehicle to service.

C. ROTOR

1. Rotor Removal

(a) Chock the rear tires. Jack the front wheels off the ground.

(b) Inspect the lug nuts which secure the wheel to the drive axle hub and remove.

(c) Remove the hub cap, remove the nut and washer.

(d) Remove caliper assemblies. See specific section.

Figure 5-9. Brake Piston Reassembly

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(e) Slide the wheel hub and rotor off the axle.

2. Cleaning

WARNING: NO SMOKING, FIRE OR OPEN FLAME IS PERMITTEDIN AREAS WHERE ALCOHOL IS BEING USED. AVOID INHALATIONOF FUMES.

(a) Clean rotor with alcohol.

(b) Use lint-free cloth to dry.

3. Inspection

(a) Inspect rubbing surfaces for evidence of corrosion, pitting or scratches. Replace ifscratched, corroded or pitted.

(b) Check the thickness and out of plane limits of the rotor. The minimum limit shouldbe 0.885".

4. Installation

(a) Slide the wheel hub and rotor onto the axle.

(b) Replace axle nuts, washer and hub cap. Seal with silicone sealer.

(c) Attach caliper assemblies. See specific Section.

(d) Replace wheel and secure with lug nuts.

(e) Lower front wheels to the ground and un-chock rear wheels.

5. Check Out


(b) Drive belt loader slowly and make several slow speed stops.


(d) Correct any discrepancies before returning vehicle to normal service.

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D. BLEEDING THE DISC BRAKE SYSTEM

1. General

(a) If the caliper was removed for overhaul, or if the brake hose or steel line wasdisconnected for any other reason, it will be necessary to bleed all air from thecalipers and connecting lines.

(b) Prior to bleeding the system, it is important to check the master cylinder reservoir.Use hydraulic fluid, DOT 3, Extra Heavy Duty Brake Fluid to bring the level up towithin 1/8" of the top.

(c) Brakes can be bled either manually or with pressure bleeding equipment.

CAUTION: FLUID WHICH IS DRAINED, FLUSHED OR BLED OUT OFA VEHICLE’S BRAKE SYSTEM SHOULD BE DISCARDED. IT IS NOTSAFE FOR REUSE FOR ANY PURPOSE.

2. Manual Bleeding

(a) Manual bleeding requires two people; one to pump the brake pedal and another tooperate the bleeder valves. Make sure that the master cylinder is full. After thebleeder valve is opened, depress the brake pedal one full stroke, close bleeder valve,then allow the pedal to return slowly to the released position. Allowing the pedal toreturn too quickly may draw air into the system. Continue operating the pedal in thismanner until caliper is bled. Refill the master cylinder and go on to next caliper.

CAUTION: IN ORDER TO ENSURE THAT NO AIR CAN BE SUCKEDBACK INTO THE SYSTEM, THE BLEEDER VALVE MUST BE CLOSEDA THE END OF EACH STROKE, BEFORE THE BRAKE PEDAL ISRELEASED.

(b) Check the fluid level in the reservoir frequently during the bleeding procedure.

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3. Pressure Bleeding

(a) If the equipment is available, the pressure bleeding is faster, since the master cylinderdoes not have to be refilled several times. Pressure bleeding equipment must be ofthe diaphragm type. That is, it must have a rubber diaphragm between the air supplyand the brake fluid to prevent air, moisture, oil and other contaminants from enteringthe hydraulic system. Install the special bleeding adapter to the master cylinder.Make sure that the pressure tank is at least 1/3 full of fluid.

Position the tank so that its hose will easily reach the adapter on master cylinder ofthe vehicle being serviced, then make the air pressure connection to the tank (20 to25 psi). Open the tank valve to bleed all air out of the hose before connecting it tothe adapter. After making this connection, open the valve when ready to beginbleeding.

CAUTION: DO NOT LIFT, MOVE OR SHAKE THE TANK AFTER AIRPRESSURE IS APPLIED. THIS MAY CAUSE AIR TO BECOMETRAPPED IN THE FLUID.

(b) Bleed front calipers.

NOTE: Pressure bleeding process may be completed more quickly bylightly tapping the brake pedal when the bleeder valve is opened. Thiscreates pulsations that tend to purge air from the system.

4. Check-Out




(d) Correct any discrepancies before returning vehicle to normal service.

Note

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SECTION 6: HYDRAULIC CYLINDER

A. DISASSEMBLY

1. Mount cylinder (cap end) in vise, while supporting "rod-end" of cylinder with saw horse.

2. Pull rod out until it contacts "head" of cylinder (rod will be fully extended).

3. Push rod back in approximately 12".

4. Using a large pair of snap ring pliers, collapse snap ring in head assembly.

5. Pull rod out briskly and let piston snap against head of cylinder. This will "knock" the headout of tube and allow entire rod/head/piston assembly to be pulled out of tube assembly.

6. Rod/head/piston assembly may now be disassembled.

(a) Remove nut that holds piston on rod end.

(b) Remove piston.

(c) Remove head (over piston end of rod).

B. INSPECTION AND ASSEMBLY

1. Inspect for damage to cylinder, i.e. scored tube ID, rod damage, etc.

2. If components of cylinder are in good condition:

(a) Install new seals in head and piston. Use grease or hydraulic oil to lubricate seals.

(b) Install back-up ring and O-ring on head with O-ring toward press.

(c) Install rod U-cup with lips of rod U-cup toward press.

(d) Install rod wiper with "wiping lip" toward outside of cylinder.

(e) Install TP style (single) piston Buna seal with back-up ring on either side.

(f) Install head backward over piston end of rod.

(g) Install piston.

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(h) Install nut that holds piston on rod end.

(i) Install snap ring into head assembly.

(j) Collapse snap ring and slide entire rod/piston/head assembly into tube assembly.

(k) Release snap ring to hold rod/piston/head assembly in place. The cylinder shouldnow be ready to install and operate.

1. Tube Assembly2. Rod Assembly3. Head4. Piston5. Nut6. Piston Seal

7. O-Ring8. O-Ring9. Back-up Ring10. Rod Seal11. Rod Wiper12. Snap Ring

Figure 6-1 Hydraulic Cylinder Assembly

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SECTION 7: HYDRAULIC PUMP

WARNING: BEFORE BREAKING THE CIRCUIT CONNECTION,MAKE SURE POWER IS OFF AND SYSTEM PRESSURE IS RELEASED.LOWER ALL VERTICAL CYLINDERS, DISCHARGEACCUMULATORS, AND BLOCK ANY LOAD THAT COULDGENERATE PRESSURE.

A. GENERAL

Plug all removed units and cap all lines to prevent the entry of dirt into the system. Duringdisassembly, pay particular attention to identification of the parts, especially the cartridges, for correctassembly. Pump bearings, pressed in the bodies or on the shafts, should not be removed unlessdefective. Figure 7-2 is an exploded view that shows the proper relationship of the parts fordisassembly and assembly. Refer to Figure 7-1 and Figure 7-2 for the correct assembled relationshipof the parts.

Outlet port

Pressureplate

Spring

Body

Bearing

Driveshaft

Seal

Inlet port

Pumpingcartridge

Rotor

Ring

Vane

Figure 7-1 Pump Assembly

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B. DISASSEMBLY

1. Disassembly of Basic Pump

(a) See Figure 7-2. If a foot bracket is used, remove before dismantling the pump. Clampthe pump body in a vise (not too tightly), cover end up, and remove the four coverscrews. Note the position of the cover port with respect to the body port before liftingoff the cover and O-ring.

(b) Remove the pressure plate and spring. Note the position of the ring for correctreassembly. Lift off the ring and remove the locating pins. Separate the vanes fromthe rotor and remove the rotor from the shaft.

(c) Turn the pump body over, and then remove the shaft key and the snap ring thatretains the bearing. Tap with a soft hammer on the splined end of the shaft to force theshaft out of the body. Remove the small snap ring located on the shaft behind thebearing. Support the bearing inner race and press the shaft out of the bearing. Pull theshaft seal out of the body with a suitable hooked tool.

CAUTION: DO NOT DISASSEMBLE THE RELIEF VALVE S/A THAT ISREMOVED IN THE FOLLOWING STEP. THE UNIT IS FACTORY SETAND COULD MALFUNCTION IF DISASSEMBLED.

2. Disassembly of Flow Control and Relief Valve Covers

See Figure 7-2. Remove the plug and O-ring from the snap ring side of the cover. Thenremove the plug and O-ring that releases the spring and relief valve S/A. Insert a suitable toolfrom the snap ring end of the bore. Slide the relief valve S/A from the cover. Remove thesnap ring with care. DO NOT scratch the bore.

3. Disassembly of the Priority Valve Cover

See Figure 7-2. Remove the plug, O-ring and spring from one end of the priority valve bore,and the plug and O-ring from the other end of the bore. Insert a suitable tool into the snap ringend of the bore (snap ring used with pipe thread plugs only) and slide the priority valve spoolfrom the cover. If the snap ring exists, remove it from the cover. Disassemble the relief valveby removing the plug, spring, poppet and shims. On later designs a spring guide is used. SeeFigure 7-2. DO NOT remove the seat unless inspection of the poppet contact area reveals aproblem in the seat area. If removal of the seat is required, thread the seat with a suitable tapapproximately 3/8" into the seat. Thread a long bolt into the seat and pull the bolt and seatfrom the bore with a small gear puller.

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Priority Valve CoverV10-10 / V20-11/-12

Plug

Spring

Piston

Cover

Snap Ring (V20 only)

“O” RingPlug

Plug

Primary Port(Used to determinecover position) Seat

PistonSpring

Spring Guide Shim“O” Ring

Plug

Plug“O” Ring

Plug

Spring

Plug“O” Ring

Relief Valve S/A

Cover

Tank Port

Snap Ring

Plug

Flow Control Valve Cover“O” Ring

Plug

Cover

ScrewTorque to35-45 lb.ft. (V10)75-85 lb.ft. (V20)

“O” Ring

Spring

Pressure Plate

Rotor

Vane

Ring

Pin

“O” Ring

Screw

BodySeal

Snap Ring

Shaft

Key

Foot Bracket

NOTEPriority Cover Information

V10-10 early models and V20-11 designmodels use pipe threaded plugs.V10-10 current design and V20-12 modelsuse straight threaded plugs and “O” rings.

Flow Control Cover InformationV10-20 early models and V20-11 designmodels use pipe threaded plugs.V10-20 current design models use straightthreaded plugs and “O” rings. The V20-11 is thecurrent design and uses pipe threaded plugs.

Bearing

Snap Ring

Figure 7-2 Pump Assembly (Exploded View)

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C. INSPECTION AND REPAIR

1. Cleaning

(a) All parts must be thoroughly cleaned and kept clean during inspection and assembly.The close tolerance of the parts makes this requirement more stringent than usual.Clean all removed parts using a commercial solvent that is compatible with thesystem fluid. Compressed air may be used in cleaning, but it must be filtered toremove water and contamination. Clean compressed air is particularly useful incleaning spools, orifices and cover passages.

(b) Discard the used shaft seal and all O-rings. Wash the metal parts in a solvent, blowthem dry with filtered compressed air and place them on a clean surface forinspection.

2. Inspection and Repair

(a) Check the wearing surfaces of the body, pressure plate, ring and rotor for scoring andexcessive wear. Remove light score marks by lapping. Replace any heavily scored orbadly worn parts.

(b) Inspect the vanes for burrs, wear and excessive play in the rotor slots. Replace thevanes and rotor if the slots are worn.

(c) Check the bearings for wear and looseness. Rotate the bearings while applyingpressure to check for pitted or cracked races.

(d) Inspect the oil seal mating surface on the shaft for scoring or wear. If marks on theshaft cannot be removed by light polishing, replace the shaft.

(e) Flow Control Cover – Check the relief valve sub-assembly for free movement in thecover bore. Remove burrs from the valve by polishing, but DO NOT round off thecorners of the lands. DO NOT attempt to rework the valve bore. If the bore isdamaged, replace the cover.

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(f) Priority Valve Cover – Inspect the priority valve spool and bore for burrs. Removeburrs from the spool by light polishing with crocus or #500 grit paper. DO NOTround off sharp corners of the lands. Inspect the cover bore for scratches, wear and/ora pitted surface. DO NOT attempt to rework the bore. If the bore is damaged, replacethe cover. The priority valve spool must fit and move within the bore withoutevidence of bind. Rotate the spool through 360° while inspecting for bind. Inspect thesnap ring for damage. (V20 units only). If worn or bent, replace with a new snap ring.If the snap ring is bent, inspect the snap ring groove in the cover for sufficient depthand rounded edges of the snap ring groove. If the groove is defective, replace thecover.

(g) Integral Relief Valve – Inspect the spring. The spring ends must be parallel to preventcocking of the poppet. The poppet requires a close inspection in the seat contact area.A slight wear pattern should exist around the poppet area of seat contact. If the wearpattern is broken, a possible leakage path exists between the poppet and seat. Inspectthe seat for possible erosion or other defects. Refer to the seat removal procedure ifthe seat is defective.

D. ASSEMBLY

Coat all parts with hydraulic fluid to facilitate assembly and provide initial lubrication. Use smallamounts of petroleum jelly to hold O-rings in place during assembly.

NOTE: During handling and shipping of the precision machined cartridgeparts, it is possible to raise burrs on the sharp edges. All sharp edges on theparts of a new cartridge kit should be stoned, prior to installation.

1. Assembly of Flow Control Cover

See Figure 7-2. Assemble the snap ring in place within the bore (early design only). Seatfirmly in the groove. Insert the valve in the bore, smallest end first. Then install the spring andboth plugs. Use new O-rings if straight thread plugs are used.

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2. Assembly of Priority Valve Cover

(a) See Figure 7-2. If the relief valve seat was removed, a new seat must be pressed intothe body. Lubricate and insert the new seat chamfered end first into the coveropening. Align square and press into place. Use a short length of brass rod as apressing tool to prevent seat damage. Clean the relief valve bore to remove chips andfilings. Insert the poppet into the bore, align square and lightly tap the stem of thepoppet to mate the poppet and seat. Install the spring, shims and plug into the cover.(Later designs use a spring guide and straight thread plug with O-rings). Be sure tocheck the pressure setting of the relief valve against the model code. If the setting isout of tolerance, readjust by removing or adding shims. (Removing shims reducespressure while adding shims increases pressure.)

(b) Priority Valve – Install the snap ring within the priority valve cover bore (earlier V20series only); make sure the snap ring is seated within its groove. Insert the priorityvalve spool, small land first, into the bore. Install plugs at each end of the bore andsecure. Refer to Figure 7-2 for spool orientation.

3. Assembly of Pump

(a) See Figure 7-2. Begin assembly by pressing the shaft into the front bearing whilesupporting the bearing inner race. Install the small snap ring on the shaft.

NOTE: Before assembling the shaft seal, determine the correct position ofthe sealing lip. (See Figure 7-3.)

GarterSpring

Figure 7-3 Shaft Seal (Assemble with spring toward cover end of pump)

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(b) Seals are assembled with the garter spring toward the pumping cartridge. Press theseal firmly in place and lubricate the lip with petroleum jelly or other greasecompatible with the system fluid. Slide the drive shaft into the body until the bearingis seated. Tap lightly on the end of the shaft if necessary. Install the snap ring.

(c) Install new O-rings in the body and cover. Insert the ring locating pins in the bodyand assemble the ring so that the arrow on the perimeter points in the direction ofrotation. Check the assembly against Figure 7-4. Install the rotor on the shaft andinsert the vanes in the rotor slots. Be certain the radius edges of the vanes are towardthe cam ring.

(d) Place the pressure plate on the locating pins and flat against the ring. Place the springover the pressure plate and then install the cover with the outlet port in the correctposition. Tighten the cover screws to the torque shown in Figure 7-2. Rotate the shaftby hand to insure that there is no internal binding. Install the shaft key.

(e) If a foot mounting is used, assemble the pump to its foot mounting. If a gasket isused, be certain it is flat to avoid misalignment of the shaft.

View from Cover End

Right Hand Rotation Left Hand Rotation

Figure 7-4 Shaft and RotorPrope

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property of american airlines maintenance...any fluid shows on the dipstick, do not add transmission...

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