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  • CAPACITY TABLE OF CONTENTS

    SECTION PAGE

    1 GENERAL INFORMATIONSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8Engine and Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . .1-10

    2 PREVENTIVE MAINTENANCEPre-Operational Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Suggested Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Weekly or 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2200 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Quarterly or 500 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 Years or 2000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Engine Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Years or 6000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Daily Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3Maintenance Procedures - 250 Hours or 3 Months . . . . . . . . . . . . . . . . .2-5Maintenance Procedures 500 Hours of Operation . . . . . . . . . . . . . . . . . .2-6Maintenance Procedures 5000 Hours or 1 Year . . . . . . . . . . . . . . . . . .2-12Maintenance Procedures 2000 Hours or 2 Years . . . . . . . . . . . . . . . . . .2-16Recommended Lubrication and Capacities . . . . . . . . . . . . . . . . . . . . . .2-20Cooling System Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20Tire Pressure Maximum Recommendations . . . . . . . . . . . . . . . . . . . . . .2-20Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

    3 ELECTRICAL SYSTEMTerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . . .3-1Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Power Distribution Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Relay Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6Wiring Diagrams & Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

  • CAPACITY TABLE OF CONTENTS

    SECTION PAGE

    4 TRANSMISSIONTerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . . .4-1(Refer to RDS3000 Allison Transmission Manual)

    5 FRONT AXLE & STEERINGTerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . . .5-1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4TAS Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5Front End Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19Disassembly, Overhaul and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

    6 REAR AXLE & DURA RIDETerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . . .6-1Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4Disassembly & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8Ride Height Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8Ride Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12Leveling Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13A-Frame Pivot Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

    7 AIR SYSTEMTerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . . .7-1Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3Automatic drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4Air Brake System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

  • CAPACITY TABLE OF CONTENTS

    SECTION PAGE

    8 ABS/ATC SYSTEMTerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . . .8-1ABS Controller Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2Power Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3ABS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3ATC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4Troubleshooting ABS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5Troubleshooting Blink Codes & Diagnostic Modes . . . . . . . . . . . . . . . . . .8-7Troubleshooting Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-22Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-25Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26

    9 CHASSIS LUBRICATION SYSTEMTerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . . .9-1System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2Air Operated Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7

    10 HYDRAULIC SYSTEMTerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . .10-1Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3Hydraulic System Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3Hydraulic Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4Hydraulic System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15

    11 BOOM & FIFTH WHEELDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1Trailer Upper Coupler or Bolster Plates . . . . . . . . . . . . . . . . . . . . . . . . .11-6Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7

  • CAPACITY TABLE OF CONTENTS

    SECTION PAGE

    12 CAB LIFT SYSTEMTerminal Objective and Enabling Objectives . . . . . . . . . . . . . . . . . . . . .12-1Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6Ride Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6Leveling Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6Cab Cushion Air Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6Troubleshooting Cab Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8

  • CAPACITY GENERAL INFORMATION

    INTRODUCTIONThis manual contains information and instruc-tions for servicing, troubleshooting, mainte-nance and repair of the Trailer Jockey. Regularservicing and an established preventive main-tenance program will keep all components ofthe vehicle operating at maximum efficiencyand will promote a longer and safer service life.Follow the instructions in this manual carefullyto keep the vehicle operating properly.

    SPECIFICATIONS:

    ENGINEManufacturer . . . . . . . . . . . . . . . . . . . .Varies

    TRANSMISSIONManufacturer . . . . . . . . . . . . . . ..........Varies

    FRONT AXLEManufacturer . . . . . . . . . . . . . . . . . . . .Varies

    REAR AXLEManufacturer . . . . . . . . . . . . . . ..........Varies

    FRONT SUSPENSIONType . . . . . . . . . . . . . . . . . . . . . Leaf SpringsRating . . . . . . . . . . . . . . . . . . . . .13,200 Ibs.

    REAR SUSPENSION Dura Ride Trailing Arm,Air Spring, 30,000 lb. ratingWHEELS22.5 X 8.35 Hub Piloted, 5-hole

    CABWidth . . . . . . . . . . . . . . . . . . . . . . . . . . .51 in.Depth . . . . . . . . . . . . . . . . . . . . . . . . . .64 in.

    HEATER45,000 BTU Fresh Air with Electric Blower

    DEFROSTERType . . . . . . . . . . . . . . . . .Heater-integrated

    DASH PANELRemovable for easy maintenance with volt-meter, hour meter, oil presure, air filter restric-tion indicator, water temperature, air systempressure, fuel level gauge.

    WARNING DEVICES:Trailer ABS Fault Code . . . . . . . . . . . . .LightATC Automatic Traction Control Active .LightCharging System Indicator . . . . . . . . .LightLo-Air Air Pressure Low . . . .Light and AlarmEngine Major Fault Code . . . . . . . . . . . .LightWarning Minor Engine Fault Code . . . .LightWTS Wait to Start Warning . . . . . . . . . .LightComm J1939 Datalink Backbone failure LightTrans Temp exceeds parameters . . . . .LightCheck Trans Fault Code . . . . . . . . . . .LightRegen Icon Exhaust Regen. reqd. . . . .Light

    CAB TILTING45 Hydraulically with 90 Tilt Capability

    CAB MOUNTING . . . . . . . . .Rubber Cushion Front Cab Pivots . . . . . . . . . . . . . . .Safety Type Cab Latching

    Rear Cab Air RideDOORSHeavy Duty Design with Key-Type Lock on L.H.and Rear Sliding Door .

    HYDRAULIC SYSTEM FOR 5TH WHEELTrans. Direct Mounted Power Take-Off withDirect Mounted Gear Pump and 10 GallonReservoir

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  • CAPACITY GENERAL INFORMATION

    FIFTH WHEEL & BOOM ASSEMBLY36 Dia. 5th wheel for 2 dia. king pins withCab-Controlled air unlatch and automaticrelatch

    Dual hydraulic 5 double acting cylinders andself-aligning replaceable cylinder bushings.

    TIRESFront . . . . . . . . . .Tubeless single 11 X R22.5 . . . . . . . . . . . . . .16 Ply LRG Highway Tread

    Rear . . . . . . . . . . . .Tubeless Dual 11 X 22.5 . . . . . . . . . . . . . .16 Ply LRG Highway Tread

    STEERINGHydraulic power steering with engine mountedgear driven pump

    BRAKESFront axle . . . . . . . . . . . . . . . . . . . .ABS/ATVRear axle . . . . . . . . . . . . . . . . . . . . .ABS/ATCParking . . . . . . . . . .Spring type on rear axleEmergency . . . . . . . . . .Automatic application . . . . . . . . . . . . . . . . . . . . . .of parking brakes

    COOLING SYSTEMFin and tube radiator of heavy duty constructionmounted on rubber shock pads. System sup-plied with 50% solution of permanent typeantifreeze with transmission oil cooler in lowerradiator tank.

    FUEL TANK . . . . . . . . . .50 Gallon step tank

    FILTERSEngine air . . . . . . . . . . . .Dry type air cleanerFuel (2) . . . . .Frame mounted fuel/water sep. . . . . . . . . . . . . . . . . . . . . . . .Engine mountedHydraulic pump . . . . . . . . . .Full flow spin-on . . . . . . . . . . . . . .element with intake strainerPower steering . . . . . .Replaceable cartridge . . . . . . .type within power steering reservoir

    Engine Oil Filter . . . . . . . . . . . . . . . .SpinnerII

    AIR SYSTEM15.2 CFM compressor, 3 tank reservoir system

    ELECTRICAL SYSTEM12 Volt negative ground with circuit breakers,130 amp alternator, color coded wiring in sepa-rate removable harness.

    STARTER . . . . . . . . . . . .Nippodensa Electric

    BATTERY . . . . . . .Two12V 700CCA 31-ECO

    EXHAUST . . . . .Converter muffler and outlet . . . . . . . . . . . . . . . . .with vertical behind cab

    TRAILER EQUIPMENTAir . . . . . . . . . . . . . . . . . . . .Two air lines with . . . . . . . . . . . . . . . . . . . .glad hand receivers

    Electrical . . . . . . . . .7-wire female receptacle . . . . . . . . . . . . . . . . . . . . . . . . .at rear of cab

    VEHICLE LOAD CAPACITY (at 15 mph)GVW . . . . . . . . . . . . . . . . . . . . . . .32,200 lbs.GCVW . . . . . . . . . . . . . . . . . . . . .81,000 lbs.

    WEIGHT (average) . . . . . . . . . . . .13,500 lbs.

    TURNING RADIUS . . . . . . . . . .Standard 116 wheelbase 20 6

    DRAW BAR PULL . . . . . . . . . . . .12,702 lbs.

    GRADEABILITY . . .At capacity GCW 15.9%

    FIFTH WHEELLift Rating . . . . . . . . . . . . . . . . . . .70,000 lbs.Lift Height . . . . . . . . . . . . . . . . . . . . . . .16 in.

    DIMENSIONSHeight . . . . . . . . . . . . . . . . . . . . . . . . .120 in.Width . . . . . . . . . . . . . . . . . . . . . . . . .98.8 in.Length . . . . . . . . . . . . . . . . . . . . . . . . .192 in.Wheelbase . . . . . . . . . . . . . . . . . . . . . .116 in.

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  • CAPACITY GENERAL INFORMATION

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    NOMENCLATURE

    SPOT LIGHT

    ENGINECOMPARTMENT

    HYDRAULIC OILRESERVOIR

    AUTO-GREASER

    CAB TILT PUMPQUARTERFENDERS

    DURA-RIDESUSPENSION

    BATTERY BOX

    AIR DRYER FIFTH WHEEL& BOOM

    FUEL TANK

    TILT CAB

    FUEL FILTER

  • CAPACITY GENERAL INFORMATION

    Maintenance Procedures

    There are a number of procedures involved inmaintenance and repair that are referred tothroughout this manual. Application of theseprocedures will enable the technician to bemore efficient, better organized and capable ofperforming the various tasks properly, whichwill ensure that the service and/or repair is thor-ough and complete.

    Fasteners

    Fasteners are nuts, bolts, studs and screwsused to hold two or more parts together. Thereare a few things to keep in mind when workingwith fasteners. Almost all of them use a lockingdevice of some type, either a lockwasher, lock-nut, locking tab or thread adhesive. All thread-ed fasteners should be clean and straight, withundamaged threads and undamaged cornerson the hex head where the wrench fits.Develop the habit or replacing all damagednuts and bolts with new ones. Special locknutswith nylon or fiber inserts can only be usedonce. If they are removed, they lose their lock-ing ability and must be replaced.

    Rusted nuts and bolts should be treated with apenetrating fluid to ease removal and preventbreakage. After applying the rust penetrant, letit work for a few minutes before trying to loosenthe nut or bolt. Badly rusted fasteners mayhave to be chiseled or sawed off or removedwith a special nut breaker, available at toolstores.

    If a bolt or stud breaks off in an assembly, it canbe drilled and removed with a special tool com-monly available at tool stores.

    Flat washers and lockwashers, when removedfrom an assembly, should always be replacedexactly as removed. Replace any damagedwashers. Never use a lockwasher on any softmetal surface (such as aluminum), thin sheetmetal or plastic.

    Fastener Sizes

    For a number of reasons, automobile equip-ment manufacturers are making wider andwider use of metric fasteners. Therefore, it isimportant to be able to tell the differencesbetween standard (sometimes called U.S. orSAE) and metric hardware, since they cannotbe interchanged.

    All bolts, whether standard or metric, are sizedaccording to diameter, thread pitch and length.For example, a standard 1/2 - 13 x 1 bolt is 1/2inch diameter, has 13 threads per inch and is 1inch long. An M12 - 1.75 x 25 metric bolt is 12mm in diameter, has a thread pitch of 1.75 mm(the distance between threads) and is 25 mmlong. The two bolts are nearly identical, andeasily confused, but they are not interchange-able.

    In addition to the differences in diameter, threadpitch and length, metric and standard bolts canalso be distinguished by examining the boltheads. To begin with, the distance across theflats on a standard bolt head is measured ininches. while the same dimension on a metricbolt is sized in millimeters (the same is true fornuts). As a result, a standard wrench shouldnot be used on a metric bolt and a metricwrench should not be used on a standard bolt.Also, most standard bolts have radial gradelines on the head to denote the grade orstrength of the bolt, which is an indication of theamount of torque that can be applied to it. Thegreater the number of grade lines, the greaterthe strength of the bolt. Metric bolts have aproperty class (grade) number, rather than radi-al lines, molded into their heads to indicatedbolt strength. In this case, the higher the num-ber, the stronger the bolt.

    Strength markings can also be used to distin-guish standard hex nuts from metric hex nuts.Many standard nuts have dots stamped intoone side, while metric nuts are marked with anumber. the greater the number of dots, or the

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  • CAPACITY GENERAL INFORMATION

    1-5

    higher the number, the greater the strength ofthe nut.

    Metric studs are also marked on their endsaccording to property class (grade). Largerstuds are numbered the same as metric boltswhile smaller studs carry a geometric code todenote property class.It should be noted that many fasteners, espe-cially grades 0 through 2, have no distinguish-ing marks on them. When such is the case, theonly way to determine whether it is standard ormetric is to measure the thread pitch or com-pare it to a known fastener of the same size.

  • CAPACITY GENERAL INFORMATION

    Standard fasteners are often referred to asSAE, as opposed to metric. However, it shouldbe noted that SAE technically refers to a non-metric fine thread fastener only. Coarse threadnon-metric fasteners are referred to as USSsizes.

    Since fasteners of the same size (both stan-dard and metric) may have different strengthratings, be sure to reinstall any bolts, studs ornuts removed in their original locations. Also,when replacing a fastener with a new one,make sure that the new one has a strength rat-ing equal to or greater than the original.

    Tightening sequences and procedures

    Most threaded fasteners should be tightened toa specific torque value (torque is the twistingforce applied to a threaded component such asa nut or bolt). Overtightening the fastener canweaken it and cause it to break, while under-tightening can cause it to eventually comeloose. Bolts, screws and studs, depending onthe material they are made of and their threaddiameters, have specific torque values. Besure to follow the torque recommendationsclosely. For fasteners not assigned a specifictorque, a general torque value chart is present-ed here as a guide. These torque values arefor dry (unlubricated) fasteners threaded intosteel or cast iron (not aluminum). As was pre-viously mentioned, the size and grade of a fas-tener determines the amount of torque that cansafely be applied to it. Higher grades can toler-ate higher torque values.

    Fasteners laid out in a pattern, such as cylinderhead bolts, oil pan bolts, differential cover bolts,etc., must be loosened or tightened insequence to avoid warping the component.This sequence will normally be shown in theappropriate section. If a specific pattern is notgiven, the following procedures can be used toprevent warping.

    Initially, the bolts or nuts should be assembled

    finger tight only. Next, they should be tightenedone full turn each, in a criss-cross or diagonalpattern. After each one has been tightened onefull turn, return to the first one and tighten themall one-half turn, following the same pattern.Finally, tighten each of them one-quarter turn ata time until each fastener has been tightened tothe proper torque. Too loosen and remove thefasteners, the procedure would be reversed.

    1-6

  • CAPACITY GENERAL INFORMATION

    1-7

    TORQUE CHART

    NOTE: This chart is intended as a guide for the wrench torque that should be applied to tighteningnuts and bolts or studs, or capscrews when no torque is specified on the assembly print or sepa-rate instructions.

    When tightening a bolt with a castellated nut, torque to the low value shown on the chart. Then con-tinue to tighten until the hole in the bolt and the slot in the nut become aligned. Nuts must be of thesame SAE grade as the bolts on the chart. When nuts and bolts are of different grades, use thetorque value for the lower of the two.

    This chart is not intended for use in seating a stud in a housing. These values were calculated onapproximately 75% of the proof-load for dry unplated bolts, and should be reduced by approximate-ly 25% for lubricated fasteners.

  • CAPACITY GENERAL INFORMATION

    1-8

  • CAPACITY GENERAL INFORMATION

    1-9

  • CAPACITY GENERAL INFORMATION

    Engine Dataplate

    The engine data plates show specific informa-tion about your engine. The engine serial num-ber (1) and Control Parts List (CPL) (2) provideinformation for ordering parts and serviceneeds

    NOTE: The engine dataplate must not bechanged unless approved by Cummins EngineCompany, Inc.

    Transmission Nameplate

    The transmission nameplate is located on theright rear side of the transmission. the name-plate shows the transmission serial number,part number (assembly number), and modelnumber. All three of these numbers must beprovided when ordering replacement parts orrequesting service information.

    1-10

    Engine and Transmission Identification

  • CAPACITY PREVENTIVE MAINTENANCE

    PRE-OPERATIONAL AND SAFETY INSPECTION

    _______ Check engine oil level_______ Check engine coolant level_______ Check power steering fluid level_______ Check charge air cooler connections for security and leaks_______ Check hydraulic fluid level, boom down_______ Drain moisture from air tanks_______ Check tires for condition and proper inflation_______ Check cab holddown latches for proper operation_______ Check to ensure cab tilt pump selector is in cab lower position_______ Check cab door(s) for proper operation - ensure door latches operate properly_______ Check windshield wiper and washer for proper operation_______ Check accelerator for proper operation - accelerator must move freely through

    range of operation_______ Check rear view mirrors and adjust as necessary_______ Inspect trailer hoses and electrical cable for security and condition_______ Clean all windows_______ Check neutral lockout system for proper operation_______ Check fifth wheel control lever for proper operation_______ Check fifth wheel secondary lock - lock should be disengaged_______ Check fifth wheel plate for proper lubrication_______ Check horn for proper operation_______ Check steering system for proper operation_______ Check all gauges/indicators for proper operation_______ Check parking and service brakes for proper operation_______ Check lube lever in auto lube system reservoir - if less than half, refill_______ Check fuel tank level - fill if necessary_______ Adjust seat as necessary_______ Check air compressor for proper operation - compressor cut-out pressure should

    be 120 PSI - cut-in pressure should be between 90-110 PSI_______ Check electrical system for proper operaion - all lights acc. should be on_______ Check all lights for proper operation:

    (a) Headlights, 1. High, 2. Low(b) Turn signals, 1. Right, 2. Left(c) Parking and clearance lights(d) Brake lights(e) Hazard lights

    _______ Check transmission fluid level with engine running at idle_______ Perform final walk around inspection and check for (a) fluid leaks - engine,

    transmission and axles. (b) air leaks, (c) check exhaust system for damage andleaks (d) check cab and frame for damage.

    DAMAGE REPORT (Circle or markany damaged location)

    Report all discrepancies to yoursupervisor

    2-1

  • CAPACITY PREVENTIVE MAINTENANCE

    2-2

    SUGGESTED PREVENTIVEMAINTENANCE

    DailyRecord hourmeter readingCheck coolant level and add coolant if neces-sary (Use caution)Check transmission oil level and add oil if nec-essary (engine running)Check engine oil level (engine stopped)Check power steering oil level and add oil ifnecessaryCheck all belts for tension and conditionCheck hydraulic oil level and add oil if neces-sary (boom down)Drain water from all air tanksCheck tire pressure and conditionCheck for leaks, broken or damaged partsCheck lights working and cleanCheck mirrors clean, tight and unbrokenCheck exhaust system for leaks or damageDrain Fuel/Water SeparatorCharge air connectionsTransmission filter indicators

    Weekly or 50 Hours of OperationPerform all daily checksCheck auto lubeCheck oil in rear axle

    200 Hours of OperationInitial change of RDS3000 main filter

    Quarterly or 500 Hours of Operation

    CAUTION - Never service air cleanerwith engine running to prevent dirt from beingdrawn into intake.

    Service air cleaner when indicator shows redChange hydraulic oil filterCheck wheel nut torqueCheck fuel filters when fuel reaches 1/2 fromtop of clear bowlCheck adjustment on all brakesCheck air compressor mountingCheck charge air coolerCheck fuel pump mounting

    Change engine oil and filerCheck wheel bearing oilCheck brake linings for wear and adjust camsor replace linings if necessaryCheck oil in rear axleCheck oil in transmission(Oil sampling analysis recommended)

    DURA RIDE:Check center bearingCheck air bagsCheck height adjustment

    2 Years or 2000 Hours of OperationCheck vibration damperCheck vibration damper rubberDrain and flush cooling system

    3000 Hours of OperationChange internal transmission filter and changefluid(Oil sampling analysis recommended)Change steer reservoir filter and fluidChange hydraulic oil and clean strainerCheck air dryer cartridgeCheck and adjust 5th wheel jamsChange cab tilt pump fluidRepair FacilityCheck and clean automatic drain valves on airtank.

    Engine Valve AdjustmentInitial valve adjustment at 5000 hours.Subsequent valve adjustments at 50,000 miles.Annual inspection or lube of hydraulic pumpand PTO shafts.

    3 Years or 6000 Hours of OperationChange oil in rear axleChange oil in wheel bearingsChange oil in transmissionChange air dryer cartridgeChange brake linings

  • CAPACITY PREVENTIVE MAINTENANCE

    2-3

    Oil Level - Check

    Never operate the engine with the oil levelbelow the L (Low) mark or above the H(High) mark. Wait at least 15 minutes aftershutting off the engine to check the oil. Thisallows time for the oil to drain to the oil pan.

    NOTE: The vehicle must be level when check-ing the oil level to make sure the measurementis correct.

    Coolant Level - Check

    WARNING: Do not remove theradiator cap from a hot engine. Wait untilthe temperature is below 120 F. beforeremoving the pressure cap. Failure to do socan result in personal injury from heatedcoolant spray or steam. Remove the fillercap slowly to relieve coolant system pres-sure.

    NOTE: Never use a sealing additive to stopleaks in the coolant system. This can result incoolant system plugging and inadequatecoolant flow causing the engine to overheat.The coolant level must be checked daily.

    Daily Maintenance Procedures

    General Information

    Preventative maintenance begins with day-to-day awareness of the condition of the engine and itssystems. Before starting the engine, check the oil and coolant levels. Look for:

    Leaks Loose or damaged parts Worn or damaged belts Any change in engine appearance

    CAUTION: Do not add coldcoolant to a hot engine. Engine castings canbe damaged. Allow the engine to cool to below120 F. before adding coolant.

    Fill the cooling system with coolant to 1 belowthe bottom of the fill neck in the radiator fill.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-4

    Drive Belt - Inspection

    Visually inspect the belt. Check the belt forintersecting cracks. Transverse (across thebelt width) cracks are acceptable. Longitudinal(direction of belt length) cracks that intersectwith transverse cracks are not acceptable.Replace the belt if it is frayed or has pieces ofmaterial missing.

    Cooling Fan - Inspection

    Warning. Personal injury can resultfrom a fan blade failure. Never pull or pryon the fan. This can damage the fanblade(s) and cause fan failure.

    NOTE: Rotate the crankshaft by using theengine barring gear.

    A visual inspection of the cooling fan is requireddaily. Check for cracks, loose rivets, and bentor loose blades. Check the fan to make sure itis securely mounted. Tighten the capscrews ifnecessary. Replace any fan that is damaged.

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    2-5

    Maintenance Procedures - 250 Hours or 3 Months

    General Information

    All checks or inspections listed under daily or previous maintenance intervals must also be per-formed at this time in addition to those listed under this maintenance interval.

    Air Intake System - Inspection

    Inspect the intake piping for cracked hoses,loose clamps, or punctures which can allow dirtand debris to enter the engine.

    Tighten or replace parts as necessary to makesure the air intake system does not leak.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-6

    Maintenance Procedures - 500 Hours of Operation

    Check wheel bearing oil Check brake linings for wear and adjust cams or replace linings if necessary Check oil in rear axle Check oil in transmission

    (Oil sampling analysis recommended)

    Lubricating Oil and Filter ChangeInterval

    The maximum recommended oil and filterchange intervals are 250 hours or 3 months;whichever comes first. If your application accu-mulates high hours and low mileage, thechange interval is determined by hours.

    Fill the engine with clean oil to the proper level.

    Pan Capacity - 15 U.S. QuartsTotal System Capacity - 17.3 U.S. Quarts

    Operate the engine at idle to inspect for leaksat the filters and the drain plug.

    Stop the engine. Wait approximately 15 min-utes to let the oil drain from the upper parts ofthe engine. Check the oil level again.

    Add oil as necessary to bring the oil level to theH (High) mark on the dipstick.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-7

    STEER AXLE

    Description

    This steer axle is of extremely rugged construc-tion. The design prevents scuffing of the steertires.

    Lubrication

    Access for checking proper lubrication cab beattained by steering the machine first to oneside and then to the other. Lubrication isaccomplished by the automatic lubrication sys-tem which is determined by the timer adjust-ment.

    Refer to the Recommended Lubrication Chartfor type of lubricant to be used. If the machineis subjected to heavy work schedule underextreme dusty conditions, more frequent lubri-cation may be necessary.

    Front Wheel Bearings Lubrication(Oil lubricated)

    Hub caps used with oil lubricated front wheelbearings may be removed in the same manneras conventional hub caps. Care must be takento correctly install gasket since oil leakage canoccur at this point. Bolts should be torquedevenly to 24 ft lbs.

    Adding Lubricant

    The correct oil level for the front wheel bearingsis at the oil level line. It is permissible for the oillevel to be up to 1/4 inch above the oil level line.The vehicle must be level.

    When adding lubricant to front wheel hubs, waita short period of time for the lubrication to seekits level. Recheck the lubricant level, add morelubricant if necessary, and replace the fillerplug. Use lubricant as specified in section 1

    Front Wheel Bearing Service

    Wheel bearings must be correctly adjusted formaximum bearing life. Perform the followingprocedures to service and adjust the frontwheel bearings.

    a. Removal

    1. Install wheel chocks on rear wheelsto prevent movement, then place a jack underthe front axle and raise until the tire lifts off theground. Remove the wheel.

    2. Remove the capscrews (1) a n dwashers (2) from the hub cap (3).

    Front Axle

    Oil Lubricated Hub Cap

  • CAPACITY PREVENTIVE MAINTENANCE

    2-8

    100 to 150 ft. lbs. Torque 2-5/8 and larger jamnuts 100 to 200 ft. lbs. The resulting end playmust be within limits of .001 to .010 in. loose.

    6. Install hub cap (3) and gasket (4),and secure with capscrews (1) and lockwash-ers (2). Install wheel.

    7. Install brake drum (10).

    8. Install wheel then torque wheel nutsto specified value.

    3. Remove hub cap (3) and gasket (4).

    4. Remove outer bearing nut (5), lock-washer (6) and lockwasher (7).

    5. Remove inner bearing adjuster nut(8).

    6. Remove outer bearing cone (9).

    7. Remove drum (10) and hub assem-bly (11).

    8. Remove seal assembly (12) andinner bearing cone (13).

    b. Cleaning and Inspection.

    1. Clean bearings, hub and seal.

    2. Inspect the parts for wear or damage,making any necessary replacements.

    3. Coat bearings with synthetic gearlube 75W-90.

    c. Installation and Adjustment.

    1. Install the inner cone (13) and sealassembly (12) in the hub (11) using a properseal installation tool and place the hub on thefront spindle.

    2. Install the outer cone (9).

    3. Install inner adjusting nut (8). Threadthe nut against the bearing as the hub assem-bly is revolved.

    4. Using a torque wrench, tighten theadjusting nut to 50 ft. lbs. torque while rotatingdrum and hub assembly in both directions to besure all bearing surfaces are in contact.

    5. Back off adjusting nut 1/6 to 1/4 turn.Install lockwasher (7), lockwasher (6) and outerjam nut (5). Torque 1-1/8 to 2-5/8 jam nuts

    Front Wheel Bearings

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    2-9

    DRIVE AXLEDescription

    This axle is a heavy duty type with doublereduction gearing. Positive full flow lubricationassures adequate lubrication to all movingparts of the carrier under all operating condi-tions.

    Checking Oil Level

    Perform the following procedures to check oillevel and service the differential.

    NOTE

    The machine should be parked on a level sur-face when the drive axle is being serviced.Refer to the Lubrication Chart for servicingintervals and type of oil to be used.

    a. Provide a suitable container to catchoil then remove drain plug.

    b. Once oil has completely drained, rein-stall drain plug.

    c. Service differential with specified oilthrough Fill/Level plug hole until oil starts toflow from the hole.

    d. Install Fill/Level plug.

    e. Wipe away any excess oil from axlehousing then dispose of used oil in accordancewith federal and local regulations.

    DRIVE AXLEDescription

    This axle is a heavy duty type with doublereduction gearing. Positive full flow lubricationassures adequate lubrication to all movingparts of the carrier under all operating condi-tions.

    Checking Oil Level

    Perform the following procedures to check oillevel and service the differential.

    NOTE

    The machine should be parked on a level sur-face when the drive axle is being serviced.Refer to the Lubrication Chart for servicingintervals and type of oil to be used.

    a. Provide a suitable container to catchoil then remove drain plug.

    b. Once oil has completely drained, rein-stall drain plug.

    c. Service differential with specified oil

    Rear Wheel Bearings

  • CAPACITY PREVENTIVE MAINTENANCE

    and seals must be manually supplied with ade-quate lubricant or they will be severely dam-aged before the normal motion of the vehiclecan supply lube to the hub ends of the housing.

    To avoid the risk if premature damage to wheelbearings and seals, they must be prelubedany time the wheel equipment is beinginstalled.

    1. Fill axle with lube through axle housingcover filler hole.

    2. Jack up left side of axle. Maintain this posi-tion for one minute to allow lube to flow intowheel ends at right side.

    3. Jack up right side of axle. Maintain this posi-tion for one minute to allow lube to flow intowheel ends at left side.

    4. With vehicle level again, add lube throughaxle housing cover filler hole The axle shouldrequire two additional pints of lube to bring levelup to bottom of filler hole.

    Rear Wheel Bearing Service

    Wheel bearings must be correctly adjusted toachieve maximum bearing life. Perform the fol-lowing procedures to service and adjust therear wheel bearings.

    a. Removal.

    1. Install wheel chocks to prevent move-ment then place a jack under the rear axle andraise until the tires lift off the ground. Adjustbrake shoes until there is no drag on thewheels.

    2. Remove the nuts (1) to remove thewheels and drum (2).

    3. Place a suitable container under theend of the axle to catch lubricant.

    4. Remove the nuts (3), lockwashers(4), axle shaft (5), gasket (6), outer seal (7),gasket (8) and wiper (9).

    5. Remove the nut (10), lockwasher(11), nut (12) and bearing cone (13).

    6. Carefully pull the hub (14) from theaxle housing (19).

    7. Remove the seal (15) and bearingcone (16). Remove the bearing cups (17 and18) only if they require replacement.

    b. Cleaning and Inspection

    1. Clean old lubricant from bearings,hub and seals.

    2. Inspect the parts for wear or damage,making any necessary replacements. Repackthe hub and bearings with manufacturers spec-ified lubricant.

    c. Installation and Adjustment.

    1. If bearing cups (17 and 18) wereremoved, install the bearing cups making surethey are seated squarely in their bores.

    2. Install the bearing cone (16) andgrease seal (15) then, slide the hub (14)assembly onto the axle housing (19).

    3. Install the bearing cone (13) and nut(12). Thread the adjusting nut against the bear-ing as the hub is rotated.

    4. Tighten nut (12) to 50 ft. lbs. torquewhile rotating the hub in both directions. Thewheel should turn easily.

    5. Install spindle washer (11) engagingnut dowel pin with hole in washer.

    2-10

  • CAPACITY PREVENTIVE MAINTENANCE

    NOTE

    If dowel pin and washer hole are not aligned,remove washer, flip over and reinstall. For fur-ther alignment, the nut can be moved slightly.However, do not back off more than 1/3 turn.

    6. Repeat rotation of the wheel in bothdirections. The wheel should rotate freely andbe within limits of 0.001 (.020 mm) end play.

    7. With adjustment complete, installouter nut and torque to 300-400 ft. lbs.

    8. Install gasket (8), outer seal (7), gas-ket (6), wiper (9) and axle shaft (5). Securewith lockwashers (4) and nuts (3).

    2-11

  • CAPACITY PREVENTIVE MAINTENANCE

    2-12

    Maintenance Procedures at 5000 Hours or 1 Year

    General Information

    All checks or inspections listed under daily or previous maintenance intervals must also be per-formed at this time in addition to those listed under this maintenance interval.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-13

  • CAPACITY PREVENTIVE MAINTENANCE

    2-14

  • CAPACITY PREVENTIVE MAINTENANCE

    2-15

  • CAPACITY PREVENTIVE MAINTENANCE

    2-16

    Maintenance Procedures at 2000 Hours or 2 Years

    Cooling System Maintenance -Coolant Draining

    CAUTION: Avoid prolongedand repeated skin contact with usedantifreeze. Such prolonged repeated con-tact can cause skin disorders or other bod-ily injury.

    Avoid excessive contact - wash thorough-ly after contact.

    Keep out of reach of children

    Protect the environment: Handling and dis-posal of used antifreeze can be subject tofederal, state, and local law regulation. Useauthorized waste disposal facilities, includ-ing civic amenity sites and garages provid-ing authorized facilities for the receipt ofused antifreeze. If in doubt, contact yourlocal authorities or the EPA for guidance asto proper handling of used antifreeze.

    Drain the cooling system by opening the drainvalve on the radiator and removing the plug inthe bottom of the water inlet. A drain pan witha capacity of 10 U.S. gallons will be adequatein most applications.

    Check for damaged hoses and loose or dam-aged hose clamps. Replace as required.Check the radiator for leaks, damage and buildup of dirt. Clean and repair as required.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-17

    Cooling System Flushing

    CAUTION: During filling, airmust be vented from the engine coolant pas-sages. The air vents through the jiggle pinopenings to the top radiator hose and out the fillopening.

    NOTE: Adequate venting is provided for a fillrate of 5 U.S. gallons/minute.

    Fill the system with a mixture of sodium carbon-ate and water (or a commercially availableequivalent).

    NOTE: Use 1.0 pounds of sodium carbonatefor every 6 U.S. gallons of water.

    CAUTION: Do not install theradiator cap. The engine is to be operatedwithout the cap for this process.

    Use a mixture of 50 percent water and 50 per-cent propylene glycol antifreeze to fill the cool-ing system.

    CAUTION: Never use wateralone for coolant. Damage from corrosioncan be the result of using water alone forcoolant.

    Install the pressure cap. Operate the engineuntil it reaches a temperature of 180 F. andcheck for coolant leaks.

    Check the coolant level again to make sure thesystem is full of coolant.

    WARNING: Before removingthe pressure cap, wait until the coolant tem-perature is below 120 F. Failure to do socan cause personal injury from heatedcoolant spray.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-18

    Vibration Damper (Rubber) -Inspection

    Check the index lines (A) on the damper hub(B) and the inertia member (C) If the lines aremore than 1/16 inch out of alignment, replacethe damper.

    Inspect the rubber member for deterioration. Ifpieces of rubber are missing or if the plasticmember is more 1/8 inch below the metal sur-face, replace the damper.

    NOTE: Also look for forward movement of thedamper ring on the hub. Replace the damper ifany movement is detected.

    Air Compressor - Inspection

    NOTE: All air compressors have a smallamount of lubricating oil carry over which lubri-cates the piston rings and moving parts. Whenthis lubricating oil is exposed to normal air com-pressor operating temperatures over a periodof time, the lubricating oil will form varnish orcarbon deposits. If the following inspectionsare not done, the air compressor piston ringswill be affected by high operating temperaturesand pressures and will not seal correctly.

    Air Compressor Discharge Inspection

    Drain the air system wet tank to release thesystem air pressure. Remove the air dischargeline from the air compressor.

    Measure the total carbon deposit thicknessinside the air discharge line as shown. If thetotal carbon deposit (X + X) exceeds 1/16 inch,clean and inspect the cylinder head, the valveassembly, and the discharge line. Replace ifnecessary.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-19

    If the total carbon deposit exceeds specifica-tions, continue checking the air discharge lineconnections up to the first tank until total car-bon deposit is less than 1/16 inch. Clean orreplace any lines or connections that exceedthis specification.

    Inspect air dryer, spitter valves and pressurerelief valves for carbon deposits or malfunction-ing parts. Inspect for air leaks.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-20

    RECOMMENDEDLUBRICANTS ANDCAPACITIES

    ENGINE OIL . . . . . . . . . . . . . . . . . . .17.3 qts. . . . . . . . . . . . . . . SAE 15W40 - Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . .(API C1-4)

    TRANSMISSION OIL . . . . . . . . . . . . .23 qts. . . . . . . . . . . . . .Synthetic Transmission Fluid . . . . . . . . . . . . . . . . . . . . . .Castrol Transynd

    DRIVE AXLES OIL . . . . . . . . . . . . . . .41 pts. . . . . . . . . . . . . .Synthetic Gear Lube 75W-90 . . . . . . . . . . . . . . . . . . . . . . . . .Chevron RPM

    POWER STEERING . . . . . . . .4 Qt. Dexron . . . . . . . . . . . .Automatic Transmission Fluid

    HYDRAULIC SYSTEM . . . . . . . . . . . .10 Gal. . . . . . . . . . . . . .Anti-Wear, AntiFoam (AW46)

    FUEL TANK . . . . . . . . . . . . . . . . . . . .50 Gal. . . . . . . . . . . . . . . . . . . . . . .No. 2 Diesel Fuel

    CHASSIS FITTINGS . . . . . .NLGI-00 Grease

    AUTO LUBE PUMP RESERVOIR . . . .6 Lbs.

    FRONT WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . .Synthetic Gear Lube 75W-90 . . . . . . . . . . . . . . . . . . . . . . . . .Chevron RPM

    CAB TILT PUMP . . . . . . . .2 Qts. Dextron III . . . . . . . . . . . .Automatic Transmission Fluid

    COOLING SYSTEMRECOMMENDATIONS

    41 Qt. - Use 50/50 solution of Ethylene Glycolpermanent antifreeze and softened water inwinter.

    TIRE PRESSURE MAXIMUMRECOMMENDED

    FRONT . . . . . . . . . . . . . . . .11R X 22.5-16PR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 PSI

    REAR . . . . . . . . . . . . . . . . .11R X 22.5-16PR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 PSI

    FUEL REQUIREMENTS

    GENERAL FUEL CLASSIFICATIONWinter . .No. 1-D or 2-D Blended (Winterized)Summer . . . . . . . . . . . . . . . . . . . . . . .No. 2-D

    FINAL BOILING POINT . . . . . . . . . . . . . . . . . . . . . . . . . .675 F. Max.

    CETAIN NO.Winter . . . . . . . . . . . . . . . . . . . . . . . . .45 Min.Summer . . . . . . . . . . . . . . . . . . . . . . .40 Min.

    SULFUR CONTENT . . . . . . . . . .05% Max.

  • CAPACITY PREVENTIVE MAINTENANCE

    2-21

    ALL CHANGE PERIODS OUTLINED IN SECTION 1 ARE RECOMMENDATIONSBASED ON AVERAGE CONDITIONS. LUBRICANTS SHOWING SIGNS OFEXCESSIVE HEAT, OXIDATION OR DIRT, SHOULD BE CHANGED OFTENENOUGH TO PREVENT THESE CONDITIONS FROM OCCURRING. CHANGEPERIODS MUST BE ESTABLISHED ON THE BASIS OF INDIVIDUAL JOB CONDI-TIONS.

  • CAPACITY ELECTRICAL SYSTEM

    TOPIC 3 ELECTRICAL SYSTEM

    Terminal Objective:

    Upon completion of this unit, the student will be knowledgeable in the location, identifica-tion, procedures, diagnostics and repairs of the electrical system found on Capacity spot-ters.

    Enabling Objectives:

    Locate, identify and define wire coding, usage, and circuit protection. Identify andrepair electrical connectors and terminals used on these vehicles.

    Read and interpret vehicle wiring diagrams. Identify, locate and trace circuitsusing the vehicle wiring diagrams.

    Locate and identify the electrical system components, harnesses, electrical panels,bulkhead connectors, electronic control modules and other related componentsused on these vehicles.

    Understand the operation and diagnosis of circuit protection devices used onthese vehicles.

    3-1

  • CAPACITY ELECTRICAL SYSTEM

    3-2

    DESCRIPTION

    The electrical system consists of a battery, abattery charging alternator with voltage regula-tor, ignition and starter switch, starter, anddiaphragm valve. The remainder of the electri-cal system consists of instruments, switches,sending units, wiring, circuit breakers, etc., nec-essary for operation of the electrical system.Equipment selected by the customer will deter-mine the electrical equipment to be installed inaddition to the standard electrical system.

    Battery

    There are two 12V 700CCA 31-ECO batteries.They are maintenance-free. Water does nothave to be added at any time. If a maintenancetype battery is installed at any time, the waterlevel should be checked periodically.

    CAUTION

    Overfilling can cause poor performance or earlyfailure.

    a. Keep the top of the batteries, termi-nals and cable clamps clean. When necessary,wash them with a solution of baking soda andwater, and rinse with clean water.

    CAUTION

    Do not allow the soda solution to enter thecells.

    b. Inspect the cables, clamps and hold-down brackets regularly. Replace any damagedparts. Clean and re-apply a lightcoating of grease to the terminals and cableclamps when necessary.

    c. Check the electrical system if the bat-tery becomes discharged repeatedly.

    d. Use the following quick in-the-unitcheck as an indication of faulty components in

    the battery charging circuit

    (1 ) A fully charged battery and lowcharging rate indicates normal alternator-regu-lator operation.

    (2) A low battery and high charging rateindicates normal alternator-regulator operation.

    (3) A fully charged battery and a highcharging rate usually indicates the voltage reg-ulator is not limiting the alternator output.

    CAUTION

    A high charging rate on a fully charged batterywill damage the battery and other components.

    (4) A low battery and low or no chargingrate could be caused by loose connections,damaged wiring, defective alternator, improperregulator operation, or defective alternator.

    NOTE

    If the machine is to be inoperative or idle formore than 30 days, remove the batteries. Thebatteries should be stored in a cool dry place.

    Alternator

    The alternator can be expected to give long,trouble-free service; however, the diodes andtransistors in the alternator circuit are very sen-sitive and can be easily destroyed. The follow-ing precautions should be observed whenworking on or around the alternator.

    Avoid grounding the output wires or the fieldwires between the alternator and regulator.

    Never run an alternator on an open circuit.

    Grounding an alternator's output wire or termi-nals, which are always hot regardless ofwhether or not the engine is running and acci-dentally reversing the battery's polarity will

  • CAPACITY ELECTRICAL SYSTEM

    3-3

    destroy the diodes. Grounding the field circuitwill also result in the destruction of the diodes.Some voltage regulators provide protectionagainst some of these circumstances; however,it is recommended that extreme caution beused.

    Accidentally reversing the battery connectionsmust be avoided. If a booster battery is to beused, the batteries must be connected positive(+) to positive (+), and negative (-) to negative(-).

    Never disconnect the batteries while the alter-nator is in operation. Disconnecting the batter-ies will result in damage to the diodes, causedby the momentary high voltage and currentinduced by the instantaneous collapse of themagnetic field surrounding the field windings.

    NOTE

    Cummins engines use an automatic springloaded belt tensioner on the water pump andalternator belt. No belt tension adjustment isnecessary on this belt.

    Drive Belt Tension - Check

    Measure the belt deflection at the longestspan of the belt.

    Maximum deflection: 3/8 to 1/2 inch.

  • CAPACITY ELECTRICAL SYSTEM

    Power Distribution Center

    1 Electronic Board Assembly2 Flasher onlyNS Flasher bracket

    2

    3-4

  • CAPACITY ELECTRICAL SYSTEM

    Relay Bank

    1 105 amp man reset breaker . . . . . . . . . . . . . . . . . . . . . . . . . . .42 75 amp relay with diode . . . . . . . . . . . . . . . . . . . . . . . . . . .33 12V solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .2

    1

    3

    2

    3

    3-5

  • CAPACITY ELECTRICAL SYSTEM

    Item No. Name Function

    1 Voltmeter Indicates current within electrical system

    2 Hourmeter Indicates total time the engine has beenoperating in hours and tenths of hours.This is vital to good maintenance proce-dures and to keep records on theTrailer Jockey

    3 Engine Oil Pressure Indicates pressure within engine lubri-Gauge cation system in PSI and KPa. Normal

    reading 40 to 60 PSI.

    4 Engine Water Temperature Indicates temperature of engine coolant indegrees F. and Celsius. Normal operatingtemperature 170-195 F.

    5 Air Filter Restriction Indicates need to change air filter.Indicator

    6 Emergency Flasher Pull knob out to activate emergency flashers.Control Push knob in to deactivate.

    7 Turn Signal/High Beam Move lever FORWARD to indicate rightControl turns, or BACK to indicate left turns.

    Lift lever to switch from low to high beams,lift again to switch back to low beam

    1

    2

    3 45

    67

    INSTRUMENTATION

    3-6

  • CAPACITY ELECTRICAL SYSTEM

    Item No. Name Function

    8 Horn Button Depress in center of steering wheel to soundhorn.

    9 Air System Pressure Indicates pressure within air brake systemGauge in PSI and KPa. Normal maximum operating

    pressure is approximately 120 PSI. A warningbuzzerwill sound if air pressure drops below 60 PSI.

    10 Speedometer Indicates speed vehicle is traveling in milesper hour and kilometers per hour.

    11 Fuel Level Gauge Indicates level of fuel remaining in fuel tank.

    12. Ignition Switch Key operated, 3 position switch.Anti-Restart OFF position - electrical system de-energized

    key can be removed.ON position - electrical system energized.START position - spring loaded position.This position engages and activates theengine starter motor. When key is released,switch will return to ON position.Key must be turned to OFF positionbefore trying to restart again.

    8

    9

    10 11

    12

    3-7

  • CAPACITY ELECTRICAL SYSTEM

    WIRING DIAGRAMS

    Since it isnt possible to include all wiring infor-mation on one wiring diagram, smaller individ-ual wiring diagrams are provided for clarity.

    Prior to troubleshooting any electrical circuitcheck the circuit breaker to make sure they arein good condition. Make sure that the battery isproperly charged and that the battery cableconnections are clean and in good condition.When checking a wiring circuit, make sure thatall connectors are clean with no broken orloose terminals. When unplugging a connec-tor, do not pull on wires. Pull only on the con-nector housings themselves.

    Electrical Troubleshooting - GeneralInformation

    A typical electrical circuit consists of an electri-cal component, switches, relays and circuitbreakers related to that component and thewiring and connectors that link the componentto both the battery and the chassis. To helppinpoint an electrical circuit problem, wiring dia-grams are included in this section.

    Before tracking any troublesome electrical cir-cuit, first study the appropriate wiring diagramto get a complete understanding of what makesup that individual circuit. Trouble spots, forinstance, can often be narrowed down by not-ing if other components related to the circuit areoperating properly. If several components orcircuits fail at the same time, chances are theproblem is in the circuit breaker or ground con-nection.

    Electrical problems usually stem from simplecauses, such as loose or corroded connec-tions, bad relay and/or circuit breaker. Visuallyinspect the condition of circuit breakers, wiringand connections in the problem circuit beforetroubleshooting it.

    If testing instruments are going to be utilized,use the wiring diagrams to plan ahead of timewhere you will make the necessary connec-tions in order to accurately pinpoint the troublespot.

    The basic tools needed for electrical trou-bleshooting include a circuit tester or voltmeterand a continuity tester.

    Voltage Checks

    Voltage checks should be performed in a circuitthat is not functioning properly. Connect onelead of a circuit tester to either the negative bat-tery terminal or a known good ground. Connectthe other lead to a connector in the circuit beingtested. If the bulb in the tester lights, voltage ispresent, which means that part of the circuit isproblem free. Continue checking the rest of thecircuit in the same fashion. When you reach apoint at which no voltage is present, the prob-lem lies between that point and the last testpoint with voltage. Most often the problem canbe traced to loose or bad connections.

    NOTE: Keep in mind that some circuits receivevoltage only when the ignition switch is in therun position.

    Locating a Short

    One method of finding a short in a circuit is toremove the circuit breaker and connect a testlight or voltmeter to the breaker terminal. Thereshould be no voltage present in the circuit.Move the electrical harness from side to sidewhile watching the test light. If the light comeson, there is a short to ground somewhere inthat area, probably where the insulation hasrubbed through. The same test can be per-formed on each component in the circuit includ-ing the switch.

    3-8

  • CAPACITY ELECTRICAL SYSTEM

    Ground Check

    Perform a ground test to check whether a com-ponent is properly grounded. Disconnect thebattery and connect one lead of a self poweredtest light or continuity tester to a known goodground. Connect the other lead to the wire orground connection being tested. If the lightcomes on, the ground is good. If the light doesnot come on the ground is bad.

    Continuity Check

    A continuity check is done to determine if thereare any breaks in a circuit. With the circuit off(no power in the circuit) a self powered continu-ity tester can be used to check the circuit.Connect the test leads to both ends of the cir-cuit (or to the power end and a good ground)and if the test light comes on the circuit is pass-ing current properly. If the test light does notcome on, there is a break somewhere in the cir-cuit. This same procedure can be used to testa switch, by connecting the continuity tester tothe switch terminals. With the switch turned on,the test light should come on.

    Finding an Open Circuit

    When diagnosing for possible open circuits, it isoften difficult to locate them by sight becauseoxidation or terminal misalignment are hiddenby the connectors. Merely wiggling a connec-tor on a sensor or in the electrical harness maycorrect the problem. Remember this when anopen circuit is indicated when troubleshooting acircuit. Intermittent problems may also becaused by oxidation or loose connections.

    Electrical troubleshooting is simple if you keepin mind that all electrical circuits are basicallyelectricity running from the battery, through thewires, switches, relays and circuit breaker toeach electrical component (light bulb, motor,etc.) and to ground, from which it is passedback to the battery. Any electrical problem is aninterruption in the flow of electricity to and fromthe battery

    3-9

  • CAPACITY TRANSMISSION

    TOPIC 4 ALLISON TRANSMISSION(Refer to Allison RDS3000 Allison Transmission Manual)

    Terminal Objective:

    Upon completion of this unit, the student will be knowledgeable in the identification, con-struction, operation, diagnostics, troubleshooting and repairs of the ALLISON RDS-3000Transmission found on Capacity spotters.

    Enabling Objectives:

    Identify the Allison transmission and identify it as an assembly or in componentsform.

    Understand basic operation, locate external and internal electronic components,decode Identification Plate and identify fluid levels.

    Identify components of the cooling system. Understand electronic controls and operation such as inputs, outputs, TCM and

    J1939. Perform system diagnostics and troubleshooting.

    4-1

  • CAPACITY FRONT AXLE & STEERING

    TOPIC 5 FRONT AXLE & STEERING

    Terminal Objective:

    Upon completion of this unit, the student will be knowledgeable in the identification, pro-cedures and repairs of the front axle & steering system found on Capacity spotters.

    Enabling Objectives:

    Identify the TAS steering and identify it as an assembly or in components form. Understand basic operation, procedures for tow-in adjustments, axle stops and

    components of the steering column.

    5-1

  • CAPACITY FRONT AXLE & STEERING

    INTRODUCTION

    The following paragraphs outline the proce-dures to remove and replace various compo-nents of the hydraulic power steering system.Each of the components may be serviced indi-vidually. Perform only the steps necessary toeffect the desired repair. Refer to the figures asindicated for location and identification of partswhile performing these procedures.

    NOTE:

    Many power steering problems are due to lackof pressure or insufficient flow. In the event anyproblem occurs, always check first for low oillevel, restricted lines, loose fitting and pluggedfilters. Use the following procedures to testpressure and flow. (See Steering CircuitHydraulic Tests illustration, Figure 11-1)

    1. Install a pressure gauge and a shut off valvein the line from the pump outlet to gear inlet.Install a flow meter in the line from the gear out-let to reservoir. Place a thermometer in thereservoir.

    2. With the shut off valve open, start the engineand steer the wheels to lock several times toheat the system fluid to approximately 130 F.

    3. Steering Pump Pressure Test.

    a. Operate the engine at approximately1000 RPM.

    NOTE: Test at 1000 RPM. Pump flow (nopressure) should be 4.5 GPM +/- .5 GPM.Pump flow (at 1000 PSI) should be 4.0 GPM.Relief pressure 1300 PSI (no flow).

    CAUTION

    Do not keep the shut off valve closed over fiveseconds to avoid damage to the pump.

    b. Close the shut off valve and read thepressure gauge.

    c. If the pressure is below 1250 PSI orabove 2000 PSI, repair or replace the pump.

    NOTE:

    Closing of the valve will cause the fluid temper-ature to increase significantly. Allow the fluid tocool to 130 F. before continuing tests.

    4. Steering Pump Flow Test.

    a. Operate the engine at idle speed andslowly close the shut off valve until the pressuregauge indicates 1000 PSI. Record the flowrate shown on the flow meter. (Min. 3 GPM,Max 8 GPM) Open the shut off valve.

    NOTE:

    If fluid temperature has risen, allow it to cool to130 F.

    b. Increase engine speed to 1200 -1300 RPM. Read and record the flow rate.Slowly close the shut off valve until the pres-sure gauge reaches 1000 PSI and again recordthe flow rate.

    c. The reduction from the first reading tothe second reading should not exceed 20%.

    5. Steering Gear Internal Leakage Test.

    a. Place a long steel spacer block (1inch square by 6 inches long) between the axlestops as shown (see illustration InternalLeakage Test , Figure 11-2)

    5-2

  • CAPACITY FRONT AXLE & STEERING

    5-3

    Figure 11-1

    PUMP FLOW RATE VS ALLOWABLEINTERNAL LEAKAGE

    VARIOUS SPEEDS OF STEERING AS NOTED

    FOR 2 HWT/SEC

    FOR 1.5 HWT/SEC

    FOR 1.0 HWT/SEC

    FLOW RATEFROM [email protected] 1000 PSI& ENGINEIDLE (GPM)130 F.

    F = FAHRENHEITGPM = GALLONS PER MIN.HWT = HAND WHEEL TURNSPSI = POUNDS PER SQ. IN.

    ALLOWABLE INTERNAL LEAKAGE (GPM)@ STEERING GEAR 130 F.

    Figure 11-2 Figure 11-3

  • CAPACITY FRONT AXLE & STEERING

    5-4

    b. Turn the steering wheel until the linkage bot-toms out on the spacer block.

    NOTE:

    Apply at least 20 lbs. to the rim of the steeringwheel during this test to be sure the steeringgear control valve is closed.

    c. Pressure gauge should now read sys-tem relief pressure as noted in pump pressuretest. Steering gear internal leakage can beread on the flow meter.

    CAUTION

    Do not hold the steering wheel in the maximumturn position longer than five to ten seconds ata time to avoid pump damage.

    d. If leakage is greater than 1.5 GPMthe gear should be repaired or replaced. Ifleakage is less, refer to the Allowable LeakageChart below to determine the allowable leak-age. Use the flow rates recorded during pumpflow tests. (Figure 11-3)

    e. Repeat procedure for opposite direc-tion of turn.

    SERVICING

    a. Maintain the proper level of fluid in thereservoir.

    b. Check all hoses and fittings for sign ofleakage.

    c. The power steering filter requires peri-odic replacement. Refer to the PeriodicMaintenance Chart for the intervals betweenpower steering filter changes.

    d. Change the power steering filter byperforming the following:

    (1) Refer to Figure 11-4 and remove thewingnut (1) and gasket (3) to release the cover(4) and gasket (5).

    (2) Remove the spring (6) and cap (7) torelease the filter element (8).

    (3) Position the replacement filter ele-ment (8) place in the reservoir (9) then, installcap (7) and spring (6).

    (4) Install the gasket (5), cover (4), gas-ket (3) and wing nut (1).

    CAUTION

    Do not mix power steering fluids. Seal damagemay result.

    (5) Fill the reservoir to the FULL mark onthe dipstick (2) with the grade of oil listed in theRecommended Lubricants chart in the front ofthis manual.

    Figure 11-4

  • CAPACITY FRONT AXLE & STEERING

    5-5

    TAS STEERING GEAR

    General Operation

    What Happens During a SteeringManeuver

    When the driver turns the steering wheel, hetransmits force from the steering wheel to thesteering gear input shaft. A torsion bar, pinnedat its one end to the input shaft and at its otherend to the worm shaft, turns with the input shaftand exerts a rotational force on the worm shaft.In response to this rotational force, the wormshaft, acting through the recirculating ballmechanism, tries to move the rack piston axial-ly through the gear housing cylinder bore.

    The rack pistons axial movement is resisted byits engagement to the sector shaft, which isconnected by linkage to the steered wheels.Because of this resistance, the torsion bar istwisted by the input shaft, thereby actuating thecontrol valve. Pressurized fluid, directed by thecontrol valve, assists in moving the rack pistonaxially through the cylinder bore. The rack pis-ton then turns the sector shaft to steer the vehi-cle.

    Shock Loads to the Gear

    If the steered wheels receive a shock load, theshock forces are transmitted through the sectorshaft to the rack piston, and on to the wormshaft. The internal geometry of the steeringgear causes the control valve to send high-pressure fluid to the correct cylinder cavity toresist the shock forces. By absorbing the shockforces hydraulically, the steering gear preventsobjectionable kickback at the steering wheel.

    Unloading (Poppet) Valves

    The steering gear is equipped with two unload-ing valves, one at each end of the rack piston.

    One valve or the other, depending on the direc-tion of turn, will trip as the steered wheelsapproach the axle stops (which must be setaccording to manufacturer's specification). Thetripped valve reduces pressure in the gear andhelps to reduce heat generated by the pump. Atthe same time, the valves also reduce forceson the steering linkage. These valves are auto-matically set to axle stops after installation invehicle at first full right and left turn.

    The procedure for air bleeding follows in thismanual. Replacement of damaged automaticbleed plugs, and manual bleed screws isdescribed in a later section.

    General Design

    Integral Power Steering

    TAS power steering gear is the latest design inthe TRW Commercial Steering Division familyof integral hydraulic power steering gears.Integral hydraulic power steering means thatthe gear contains a manual steering mecha-nism, a hydraulic control valve, and a hydraulicpower cylinder, all in a single, compact pack-age.

    Rotary Control Valve

    The rotary control valve combines simplicity ofconstruction with desirable performance char-acteristics. The speed at which the driver canturn the steering wheel with power assist isdependent upon the pump flow (measured ingallons per minute) directed to a cylinder cavi-ty. The control valve controls flow through thesteering gear.

    The pressure (measured in pounds per squareinch) required for the gear to steer the vehicleis created by the power steering pump to over-come resistance at the steered wheels. Thecontrol valve senses these requirements and

  • CAPACITY FRONT AXLE & STEERING

    5-6

    directs fluid to the appropriate cylinder cavity inthe steering gear at the proper flow rate andpressure.

    Pressure Means Work, Flow MeansSpeed

    The higher pressure a steering gear can with-stand, the more work it can perform. The maxi-mum operating pressure gears is 2,175 psimaximum flow rate is 8 gal/min.

    The TAS series gears can steer a vehicle with-in its front end weight rating through a turn atlow speed and engine idle. As the driver turnsthe steering wheel faster or slower, more orless fluid will be required by the gear.

    Approved Hydraulic Fluids

    Automatic Transmission Fluid Dexron IIMobil ATF 210Automatic Transmission Fluid Type "E" or FMobil Super 10W-40 Motor OilChevron 10W-40Shell Rotella T30WChevron Custom 10W-40 Motor OilShell Rotella T SAE 30Chevron Torque 5 FluidTexaco 10W-40Exxon Nuto H32 Hydraulic FluidTexaco TL-1833 Power Steering FluidFleetrite PSF (Can #990625C2)Union 10W-40Ford Spec. M2C138CJUnion 15W-40Mack EO-K2 Engine OilUnocal Guardol 15W-40 Motor Oil

    The steering system should be kept filled withone of the above fluids.

    WARNING

    Completely flush the steering system with oneof the recommended fluids above only. Do notmix oil types. Any mixture or any unapprovedoil could lead to seal deterioration and leaks. Aleak could ultimately cause the loss of fluid,which could result in a loss of power steeringassist.

    Initial TAS Installation

    Bolt gear to frame, torque to vehicle manufac-turer's recommendation.

    Connect return line to steering gear returnport.

    Connect hydraulic line from pump to pressureport in steering gear unit.

    Connect steering column to input shaft, torquepinch bolt to recommendation.

    Install pitman arm on output shaft, torque boltto recommendation.

    Initial Poppet Setting

    For this procedure to work correctly, you musthave: A new gear received from TRW or yourvehicle manufacturer's aftermarket system, or aused gear on which poppet seats have beenreplaced or reset during gear disassembly pro-cedures. ALSO: Fixed stop screw installed inhousing, or poppet adjusting screw installed sothat it duplicates fixed stop screw length.

    CAUTION

    The axle stops and all steering linkage must beset according to vehicle manufacturer's specifi-cations, and the pitman arm must be correctlyaligned on the sector shaft for poppets to be setcorrectly.

  • CAPACITY FRONT AXLE & STEERING

    5-7

    Full turn in one direction

    1. With the engine at idle and the vehicleunloaded, turn steering wheel to full travel inone direction until axle stop contact is made.Maximum input torque to be applied during thisprocedure is 40 lb. rim pull on a 20 in. diametersteering wheel.

    NOTE: If you encounter excess rim pull effort,allow vehicle to roll forward or jack up the vehi-cle at the front axle.

    Full turn in other direction

    2. Follow the same procedure while turning thesteering wheel in the other direction. The pop-pets are now positioned to trip and reducepressure as the steered wheels approach theaxle stops in either direction.

    Maintenance Tips

    Never high-pressure wash or steam clean apower steering gear while on or off the vehicle.Doing so could force contaminants inside thegear and cause it to malfunction.

    Make sure vehicle wheel cut or clearancesmeet manufacturer's specifications, and makesure pitman arm timing marks are aligned prop-erly to prevent internal bottoming of the steer-ing gear.

    Regularly check the fluid and the fluid level inthe power steering reservoir.

    Keep tires inflated to correct pressure.

    Never use a torch to remove pitman arm.

    Investigate and immediately correct the causeof any play, rattle, or shimmy in any part of thesteering system.

    Make sure the steering column is aligned prop-erly.

    Encourage drivers to report any malfunctions oraccidents that could have damaged steeringcomponents.

    Do not attempt to weld any broken steeringcomponent. Replace the component with origi-nal equipment only.

    Do not cold straighten, hot straighten, or bendany steering system component.

    Always clean off around the reservoir filler capbefore you remove it. Prevent dirt or other for-eign matter from entering the hydraulic system.

    Investigate and correct any external leaks, nomatter how minor.

    Replace reservoir filters according to require-ments.

    If you feel the vehicle is developing excessive-ly high hydraulic fluid temperatures, determinethe cause immediately.

    Maintain grease pack behind the output shaftdirt and water seal as a general maintenanceprocedure at least twice a year, in the Springand Fall. Grease fitting is provided in housingtrunnion. Use only NLGI grade 2 or 3 multipur-pose chassis lube, and use only a hand operat-ed grease gun on fitting. Add grease until itbegins to extrude past the sector shaft dirt andwater seal.

  • CAPACITY FRONT AXLE & STEERING

    5-8

    Filling and Air Bleeding theSystem

    TOOLS REQUIRED - 5/16 SocketLbfin. Torque wrench

    MATERIALS REQUIRED - Hydraulic fluid

    CAUTION

    Make sure poppets are set correctly beforebeginning this procedure.

    Run engine for 10 seconds, turn off and fillreservoir

    1. Fill the reservoir nearly full. Do not steer.Start and run the engine for 10 seconds, thenshut it off. Check and refill the reservoir. Repeatat least three times, checking the reservoireach time.

    CAUTION

    Do not allow the fluid level to drop significantlyor run out of the reservoir. This may induce airinto the system.

    Run engine for 2 minutes, turn off and fillreservoir

    2. Start the engine and let it idle for 2 minutes.Do not steer. Shut off the engine and check thefluid level in the reservoir. Refill as required.

    Steer vehicle

    3. Start the engine again. Steer the vehiclefrom full left to full right several times. Add fluid,as necessary, to the full line on the dip stick.

    Automatic bleed systems should now be freefrom trapped air. Manual bleed systems contin-ue with step 4.

    Allow air to bleed out from bleed screw

    4. With engine idling, steer from full left turn tofull right turn several times. Stop steering andloosen the manual bleed screw about one turn.Allow air and aerated fluid to "bleed out" untilonly clear fluid is seen. Close the bleed screw,refill the reservoir if required.

    Repeat step 4 three to four times until all the airis discharged. Torque manual bleed screw to30 Ibf~in.

    CAUTION

    Do not turn steering wheel with bleed screwloosened.

  • CAPACITY FRONT AXLE & STEERING

    5-9

    Disconnect return line

    1. Disconnect return line from the steering gear and plug theline. Also cap the return port of the gear with a high pressurefitting.

    Disconnect column

    2. Remove the steering column from the gear input shaft.

    Remove dirt & water seal

    3. Remove the dirt and water seal from the steering gear.

    Remove retaining ring

    4. Wipe out the grease and the~ remove the spiral retainingring. Use a screwdriver inserted into the notch formed in theend of the ring. Be careful not to scratch the bore with thescrewdriver.

    Input Shaft Seal Replacement

    TOOLS REQUIRED - Hammer, J37073,Screwdriver

    MATERIALS REQUIRED - Clean cloth, Drip pan,High pressure fitting, Hydraulic fluid, Plug, Shoptowel.

    This procedure uses the vehicles powersteering pump to force out the input shaftseal. To use this procedure, the power steer-ing pump should have a minimum of 1,500PSI available.

  • CAPACITY FRONT AXLE & STEERING

    5-10

    Replace column

    5. Slip the steering column back onto the input shaft with thepinch bolt installed, but no tightened.

    Wrap exposed area

    6. Tie or wrap a shop towel around the input shaft area andplace a drip pan under the vehicle to catch oil.

    Fill reservoir

    7. Add fluid as necessary to the full line on the dipstick. Donot mix fluid types.

    WARNING - Any mixture of fluid types, or useof any unapproved fluid could lead to seal deterioration andleaks. A leak could ultimately cause the loss of fluid, whichcould result in a loss of power steering assist.

    Force out seal

    8. With the vehicle in neutral, momentarily turn the starter(quickly turn off the engine if it starts).

    Remove input shaft seal

    9. Remove the shop towel. Disconnect the steering column,and remove the input shaft seal.

    Input Shaft Seal Replacement (Cont.)

  • CAPACITY FRONT AXLE & STEERING

    5-11

    Inspect seal area

    10. the seal area of the valve housing for any seal frag-ments. Remove any that are found.

    Inspect old seal

    11. Check the seal for heat damage. If the seal is stiff andbrittle, and not pliable like the new seal, it is probably heatdamaged. Determine and fix the cause of excessive heat inthe vehicle.

    Install new seal

    12. Put clean grease (Mobil Temp 1 or 2 or equivalent) on theinside dia. of the new input shaft seal, and place it over theinput shaft. With the small dia. of tool J37073 against theseal, tap the tool until the tool shoulder is square against thevalve housing. Remove any seal material that may havesheared off in the seal bore or retaining ring groove.

    CAUTION: Do not use a socket to install sealbecause you will not be able to control seal installation depth,possibly causing a leak.

    Install retaining ring

    13. Insert new retaining ring into the groove.

    Install dirt & water seal

    14. Pack the end of the sing bore around the input shaft withclean, high temperature industrial grease (Mobile Temp 1 or2 or equivalent). Apply more of the grease to a new dirt &water seal and install it over the input shaft. Seat it in thegroove behind the serrations and against the valve housing.

    Input Shaft Seal Replacement (Cont.)

  • CAPACITY FRONT AXLE & STEERING

    5-12

    Reconnect column

    15. Reconnect the steering column to the input shaft andtighten the pinch bolt to torque level specified.

    Reconnect return line

    16. Reconnect the return line to the steering gear return port.

    Air bleed system

    17. Air bleed the system using the air bleeding procedure inthis section.

    Input Shaft Seal Replacement (Cont.)

  • CAPACITY FRONT AXLE & STEERING

    5-13

    Center the sector shaft

    1. With the engine off, rotate the steering wheel (input shaft)until the timing mark on the sector shaft lines up with themark on the housing. The line on the sector shaft should beat a 90 angle from the input shaft. The sector shaft is nowon its center of travel.

    Remove the drag link

    2. Remove the drag link from the pitman arm.

    CAUTION: To avoid resetting the poppets, donot rotate the input shaft more than 1-1/2 turns from the cen-ter of travel position while the drag link is disconnected.

    Check for sector shaft lash

    3. From the center of travel position, grasp the pitman armand gently try to rotate it. If looseness or lash is felt at thispoint, the sector shaft is out of adjustment.

    Loosen jam nut

    4. Loosen the jam nut.

    Sector Shaft Adjustment

    TOOLS REQUIRED - Screwdriver, 3/4 Socket,3/4 Open end wrench

    This adjustment can only be completed on thevehicle if the adjusting screw jam nut is acces-sible. This nut is located on the side cover.

    Photos in this section were taken on a mockframe rail for clarity.

  • CAPACITY FRONT AXLE & STEERING

    5-14

    Position adjusting screw

    5. If no lash was detected in step 3, turn the shaft adjustingscrew counterclockwise until you feel lash at the output shaft.

    Adjust shaft

    6. Slowly turn the shaft adjusting screw clockwise until youfeel no lash at the output shaft without using more than 10lbfft of torque. From this position, turn the screw clockwise1/8 to 3/16 of a turn more. Hold the adjusting screw in place,and tighten the jam nut. Final torque 43 lbfft.

    Recheck for lash

    7. Turn the steering wheel 1/4 turn each side of center, thenback to center and recheck the pitman arm for lash. Youshould feel no lash; if there is lash, repeat steps 4, 6 and 7.

    Connect drag link

    8. Reconnect the drag link to the pitman arm.

    CAUTION: Maintain grease in the sector shaftbearing through the grease fitting in the housing using only ahand operated grease gun. Add grease until it begins toextrude past the dirt and water seal. Do not use a powergrease gun because it will supply grease too fast; this couldadversely affect the high pressure seal and contaminate thehydraulic fluid.

    Sector Shaft Adjustment (Cont.)

  • CAPACITY FRONT AXLE & STEERING

    Set axles stops, warm-up system

    1. Set the axle stops to provide a 5/8 minimum clearance ofthe tire with any chassis component.

    Start the engine and allow the vehicle to idle for 5-10 minutesto warm the hydraulic fluid. Shut off the engine.

    Assemble adjusting screw into nut

    2. If a new poppet adjusting screw and nut are being used,turn the screw into the non-sealing end of the jam nut untilthe drive end of screw is flush with the nut.

    Your steering gear will have either fixed stop bolt or anadjusting screw. If the adjusting screw is already part of thesteering gear, back the nut off of the adjusting screw until it isflush with the end of the adjusting screw.

    Remove poppet stop bolt

    3. Make sure the engine is off and the road wheels are instraight ahead position. Remove and discard the poppetfixed stop bolt (if equipped) and washer (if equipped) from thelower end of the housing.

    If the unit has a poppet adjusting screw and sealing nut thatneed to be replaced, remove and discard them.

    Turn adjusting screw assembly into housing

    4. Turn the adjusting screw and sealing nut assembly, with-out rotating the nut on the screw, into the housing until the nutis firmly against the housing using a 7/32 allen wrench.Tighten the sealing nut against the housing.

    CAUTION: If the drive end of the screw isbelow the face of the nut, the poppet seat flange will breakduring step 7d.

    Poppet Readjustment

    TOOLS REQUIRED - 7/32 allen wrench, 5/8open end wrench, 3/4 open end wrench, 3/4socket, lbflb torque wrench.

    MATERIALS REQUIRED - hydraulic fluid, jack

    This resetting procedure will work in mostcases with at least 1-3/4 hand-wheel-turnsfrom each side of center. If youre making alarge reduction cut and this procedure doesnot work, you may have to replace or internal-ly reset the poppets.

    5-15

  • CAPACITY FRONT AXLE & STEERING

    Refill reservoir

    5. Refill the system reservoir with approved hydraulic fluid.

    CAUTION: Do not mix fluid types. Mixing oftransmission fluid, motor oil, or other hydraulic fluids willcause seals to deteriorate faster.

    Jack up vehicle

    6. Place a jack under the center of the front axle and jack upthe front end of the vehicle so the steer axle tires are off theground.

    Push upper poppet out to prepare it for setting

    7. a. Start the engine and let it run at idle speed.

    b. Note which output shaft timing mark is nearest the hous-ing piston bore.

    c. Turn the steering wheel in the direction that makes thistiming mark move toward the adjusting screw just installed inthis direction until axle stop contact is made.

    d. Pull hard on the steering wheel (put up to 40 lb rim pull ona 20 dia. steering wheel) after the axle stop is contacted.

    Set upper poppet

    8. a. Turn the steering wheel in the opposite direction (endof timing mark away from adjusting screw)until the other axlestop is contacted.

    b. Pull hard on the steering wheel (put up to 40 lb rim pull ona 20 dia. steering wheel).

    c. Release the steering wheel and shut off the engine.

    Back out adjusting screw

    9. Loosen the sealing nut and back out the adjusting screwuntil 1 is past the nut. Tighten the sealing nut against thehousing.

    CAUTION: Do not hold the steering wheel atfull turn for more than 10 seconds at a time; the heat build-upat pump relief pressure may damage components.

    5-16

  • CAPACITY FRONT AXLE & STEERING

    5-17

    Set lower poppet

    10. a. Start the engine and let run at idle speedb. Turn the steering wheel in the original direction (end oftiming mark toward adjusting screw), until axle stop contactis made.

    b. Hold the steering wheel in this position (with up to 40 lbrim pull) for 10 seconds, then release. Repeat this holdand release process as many times as necessary whilecompleting step 11l.

    Position adjusting screw

    11. a. With steering wheel held tightly at full turn loosenthe jam nut and hold it in place with a wrench.

    b. Turn the adjusting screw in (clockwise) using finger-pressure only (dont use a ratchet), until the allen wrenchstops. Do not attempt to turn it in further. Pause the turn-ing-in process each time the driver releases the steeringwheel; continue turning only while the wheel is held at fullturn.

    c. Back off the adjusting screw 3-1/4 turns and tighten thesealing nut. Torque sealing nut to 35 lbft.

    The procedure is complete

    12. The poppets have now been completely reset. Lowerthe vehicle. Check the reservoir and fill if required.

    WARNING: The length of the adjusting screwbeyond the nut must be no more than 1-1/16 for properthread engagement.

    NOTE: The length of adjusting screw beyond the sealingnut may be different for each vehicle.

    Poppet Readjustment (Cont.)

  • CAPACITY FRONT AXLE & STEERING

    5-18

    TAS Steering DesignFeatures

    1. Rotary Valve - This device provides respon-sive steering control.

    2. Poppets - These unloading valves are auto-matically set to furnish power steering pumpprotection and reduce pressure to unload steer-ing linkage at vehicle axle stop settings.

    3. Recirculating Balls - Combine highmechanical efficiency with smooth operation.

    4. Dirt & Water Seals - Lip-type seals on bothinput and output shafts.

    5. Torsion Bar