Body Installation Manual

Size: px
Start display at page:

Download "Body Installation Manual"

Transcription

1 Click here for link to Contents MD T Body Installation Manual MKB8E Series PKC8E Series PDC8E Series PWC8E Series Issued Date: 16 Jan 2017 Please ensure you have the latest revision of this manual by checking the UD Trucks website:

2

3 FOREWORD This body installation manual presents the basic data and describes precautions involved in designing and manufacturing the body and general equipment to be installed on the UD Trucks forward control 4x2 MKB8E series, 4x2 PKC8E series, 6x2 PDC8E and 6x4 PWC8E series of medium-duty trucks. The body manufacturer is requested to install a quality vehicle body which satisfies the customer s requirements by observing the precautions outlined in this manual. It is the responsibility of the body manufacturer or the modification company, to make sure that the completed vehicle, with body and equipment, or after modification, confirms to all Federal regulations and applicable laws and regulations of the State or Territory in which the vehicle is to be registered. IMPORTANT NOTICE The information contained herein is based on the latest product information at the time of publication. The information described in this manual is general and nothing contained herein is to be regarded as authorisation by UD Trucks of the assembly or modification of any particular vehicle. UD Trucks is constantly working to improve its products and reserves the right to make changes in design, materials, equipment, information, specifications and models, and to discontinue models or equipment at any time without prior notice. UD Trucks Level 1/20 Westgate Street Wacol QLD 4076 Volvo Group Australia Pty Ltd ABN

4 LIST OF ABBREVIATIONS USED IN THIS MANUAL ABS Anti-Lock Braking System ACM Aftertreatment Control Module ADR Australian Design Rules AS Australian Standard AS/NZS Australian Standard/New Zealand Standard ATM Aggregate Trailer Mass AVSR Australian Vehicle Standards Rules 1999 CML Concessional Mass Limits DoIT Department of Infrastructure and Transport (formerly DoTaRS) EHS Easy Hill Start GCM Gross Combination Mass GVM Gross Vehicle Mass LRG Load Restraint Guide MSDS Material Safety Data Sheet PCD Pitch Circle Diameter PCV Partially Completed Vehicle PTO Power Take Off RHS Rolled Hollow Section RTC Rated Towing Capacity SCR Selective Catalytic Reduction (AdBlue system) SSM Second-Stage-of-Manufacture SSMM Second-Stage-of-Manufacture, Manufacturer T/M Transmission UDT UD Trucks Volvo Group Australia Pty Ltd UDTC UD Trucks Corporation (Japan) VIN Vehicle Identification Number (refer to the Owner s Manual for location on the vehicle) VSB Vehicle Standards Bulletin > Greater than Equal to or greater than < Less than Equal to or less than MODEL CODING This manual uses the UDTC model code designations that appear on the trucks ADR Identification (compliance) Plate, Vehicle Plate (PK, PD and PW models) and in the UDTC Service Manuals. Note VIN Decode Tables: Refer to the Vehicle Specifications section of this manual. These UDTC model code designations vary from the general sales model description, as used in the Australian market. Please refer to the following cross reference table. Australian Market: Sales Model Description MK MK PK PK PK PD PW UDTC: Model Code Designation MKB8E PKC8E PDC8E PWC8E

5 CONTENTS FOREWORD LIST OF ABBREVIATIONS USED IN THIS MANUAL MODEL CODING VEHICLE SPECIFICATIONS MK Series PK Series PD Series PW Series KOLA VIN Structure GUIDELINES LEGISLATION GENERAL OVERVIEW AUSTRALIAN DESIGN RULES (ADR) CERTIFICATION Vehicle Manufacturer Second-Stage-of-Manufacture Vehicle Standards Bulletin No. 6 MANUFACTURER S GUIDELINES Weight Distribution Calculations Maximum Aggregate Trailer Mass ( ATM ) Rigid Truck with Trailer Front Underrun Protection System (FUPS) UDTC Service Manual OTHER LEGISLATION Australian Vehicle Standards Rules 1999 Load Restraint Guide Concessional Mass Limits Performance Based Standards State/Territory Registration Authorities ADR SUMMARY Applicable to 11 M/Y SSM AND BODY BUILDERS ADR CHECK LIST Positioning of Lamps and Reflectors: Supplied by UDT Items Supplied at SSM GUIDELINES BODY INSTALLATION SUB-FRAME AND BODY INSTALLATION 1. Sub-Frame Shape and Mounting 2. Front End Shape 3. Positions of Front-End Reinforcement 4. Mounting Brackets 5. Location Plates 6. Combination with Chassis Frame (1) U-Bolt Mounting (2) Preventing Fore-and-Aft Movement (3) Sub-Frame Connecting Devices - Location 7. Long Wheelbase Truck CHASSIS FRAME 1. Drilling the Frame 2. Riveting MECHANICAL CONNECTIONS BETWEEN VEHICLES 1. Towbars, Tow Couplings and Fifth Wheels LIFTING DEVICES 1. Cranes 2. Tailgate/Platform Loader PRECAUTIONS DURING ELECTRIC WELDING PRECAUTIONS ON VEHICLES EQUIPPED WITH: ABS EHS (MK, PK and PD manual t/m models) PRECAUTIONS FOR THE SRS AIRBAG SYSTEM Condor Issued Date: 16 Jan 2017

6 CONTENTS PRECAUTIONS FOR BODY INSTALLATION - AdBlue SCR SYSTEM REMODELING THE EXHAUST SYSTEM Precautions when Installing Equipment near Exhaust System Components ALLISON AUTOMATIC TRANSMISSIONS PRECAUTIONS & OPTIONAL FEATURES OTHER TIGHTENING TORQUE OF GENERAL CHASSIS BOLTS CHASSIS LAYOUT MKB8EL-E (L = Steel leaf suspension) MKB8EL-F MKB8EL-K MKB8EL-L MKB8EL-N MKB8EL-E Tipper PKC8EL-H (L = Steel leaf suspension) PKC8EL-K PKC8EL-N PKC8EL-R PKC8EL-S PDC8EC-V (C = Air suspension) PWC8EL-P (L = Steel leaf suspension) MASS CHASSIS CAB MKB8E PKC8E PDC8E PWC8E FRAME ASSEMBLY MKB8E PKC8E PDC8E PWC8E SECTION MODULUS MKB8EL - E~L (L = Steel leaf suspension) MKB8EL - N PKC8EL (L = Steel leaf suspension) PDC8EC (C = Air suspension) PWC8EL-P (L = Steel leaf suspension) MKB8EC-F (C = Air Suspension) MKB8EC-K MKB8EC-L MKB8EC-N PKC8EC-H (C = Air suspension) PKC8EC-K PKC8EC-N PKC8EC-R PKC8EC-S PWC8EC-W (C = Air suspension) MKB8EC - F~L (C = Air suspension) MKB8EC - N PKC8EC (C = Air suspension) PWC8EC-W (C = Air suspension) ALLOWANCE FOR REAR AXLE, SUSPENSION & TYRE ARTICULATION ALLOWANCE FOR BODY CLEARANCE, CAB TILT & SUSPENSION MOVEMENT PTO PTO LOCATION REAR ENGINE PTO Layout Drive Shaft Installation Specifications Parts List Installation PTO Assembly Oil Pipes Air Tubes Sequence Condor Issued Date: 16 Jan 2017

7 CONTENTS TRANSMISSION PTO UDTC Factory Option: High output torque PTO MLS63B transmission PTO Circuit: Manual Transmission Models PTO Circuit: Automatic Transmission Models Harness and Connector Location: PTO & External Engine Control Lever ENGINE CONTROL SYSTEM Explanation of the Functions of Engine Control Parts and Installation a. Junction Connection Patterns Connection Pattern STANDARD CHASSIS-CAB (ex, UDTC production) End of Line Programming (EOLP) Parameters Connection Pattern When ENGINE PTO is Installed When TRANSMISSION PTO is Installed b. External Engine Control Lever Unit c. PTO Switch d. Parts to be Prepared when the External Control Lever is Retrofitted ELECTRICAL SYSTEM CAUTION: Battery Disconnection HARNESS FOR REAR LAMPS Wiring and Installation of Rear Combination and Registration Plate Lamps Position of Rear Combination, Reversing and Registration Plate Lamps LOCATION OF RELAY, FUSE BOX, AND OTHER ELECTRICAL UNITS USING THE ADDITIONAL POWER SOURCES 1. Additional Power Source Cab Interior 2. Battery Relay Box 3. Battery Terminal GENERAL PRECAUTIONS ON ELECTRICAL WIRING CAB Routing of Additional Harness into the Cab Allowance for Cab Tilt and Suspension Movement HARNESS AND ELECTRICAL COMPONENT LAYOUT AIR SYSTEM Discharge of Air Preferential Charging of the Air System Installation and Removal of Nylon Tube for Air Piping and Connector AIR PIPING DIAGRAMS MKB8E STANDARD GCM with ABS and EHS (Manual T/M models) MKB8E STANDARD GCM with ABS (Auto T/M models) PKC8E STANDARD GCM PDC8E STANDARD PWC8E STANDARD PAINTING PRECAUTIONS ON PAINTING Painting of Cabs Exterior Parts recommended to be REMOVED before Painting Precautions on Painting Resin (plastic) Parts Precautions for Polypropylene (PP) Resin based Parts that SHOULD NOT be Painted Attachment of Decals ALLOWABLE TEMPERATURE LIMITS OF MAJOR PARTS BOUNDARIES OF CAB PAINTING PRECAUTIONS ON PAINTING THE DISC WHEEL APPENDIX Condor Issued Date: 16 Jan 2017

8 CONTENTS Condor Issued Date: 16 Jan 2017

9 VEHICLE SPECIFICATIONS MK Series MK (including Tipper) MK Model Code MKB8E Engine GH7TA (180 kw) GH7TB (206 kw) Transmission MLS63B Allison 2500 MPS63B Suspension Leaf Air Leaf Air Leaf Air Wheelbase (mm) E F K L N Frame Width 860 mm Height x Width x Thickness Tensile Strength Yield Point Section Modulus Tyre size Tyre size Brake system E~L w/base 234 x 70 x 7.0 mm N w/base 234 x 80 x 7.0 mm 539 MPa {55 kgf/mm²} 372 MPa {38 kgf/mm²} E~L w/base 3.22 x 10 5 mm³ N w/base 3.53 x 10 5 mm³ STD 235/75R /75R17.5 OPT 245/80R Air Over Hydraulic (AOH) with ABS and *EHS (*manual t/m models only) Suspension MKB8EL (Leaf) MKB8EC (Air) Front Rear Dimensions Spring Constant Dimensions/Type Spring Constant 1300 x 70 x 11 mm 8 leaf 244 N/mm (24.9 kgf/mm) Main: 1300 x 70 x 11 mm 7 leaf HAS 200 air suspension with air dump Helper: 980 x 70 x 11 mm 7 leaf control Main: 216 N/mm (22.0 kgf/mm) Chassis Cab Fully Laden Total: 985 N/mm (100.4 kgf/mm) 118 (12.0) 343 (35.0) N/mm (kgf/mm) VIN Structure (typical example MKB8EL-E) JNB M K B 8 E L 00 E Character Description 13~17 Chassis Serial Number 12 Wheelbase (refer above table, E = 3770 mm etc.) 10~11 Filler (no relevance) 9 Rear Suspension C = Air L = Steel Leaf 8 Emission Level (E = Euro 5) 7 6 Engine Model (8 = GH7) Model Variant 5 4 Axle Configuration (K = 4x2) Vehicle Product Line 1~3 World Manufacturer Indicator (JNB = UDTC) Up to VIN N

10 VEHICLE SPECIFICATIONS PK Series PK PK PK Model Engine Transmission GH7TA (180 kw) Allison 2500 MPS63B Allison 3000 PKC8E ES11109 GH7TB (206 kw) MPS63B Suspension Leaf Air Leaf Air Wheelbase (mm) Allison 3000 ES11109 H K N R S Frame Width 860 mm Height x Width x Thickness Tyre size Tensile Strength Yield Point Section Modulus Rim and wheel Brake system STD OPT 275/70R22.5 Outer 250 x 80 x 8.0 mm Inner H~K w/base 234 x 72 x 3.2 mm N~S w/base 234 x 72 x 6.0 mm 539 MPa {55 kgf/mm²} 372 MPa {38 kgf/mm²} H~K w/base 5.50 x 10 5 mm³ N~S w/base 6.70 x 10 5 mm³ Front 295/80R22.5 Rear 11R /70R x 8.25 offset 165 mm, 10 stud (ISO) Full Air, Taper Roller with ABS and *EHS (*manual t/m models only) Suspension PKC8EL (Leaf) PKC8EC (Air) Front Rear Dimensions Spring Constant Dimensions/Type Spring Constant Main: 1600 x 80 x 13 mm 4 leaf 14 mm 5 Helper: 1100 x 80 x 12 mm 8 leaf Main: 325 N/mm (33.2 kgf/mm) Total: 1103 N/mm (112.5 kgf/mm) 1400 x 80 x 20 mm 1 leaf 22 mm N/mm (35.0 kgf/mm) HAS 230 air suspension with WABCO remote electronic, programmable and adjustable height control RFCN: RF2022 Chassis Cab Fully Laden 125 (12.8) 317 (32.3) N/mm (kgf/mm) VIN Structure (typical example PKC8EL-H) JNB P K C 8 E L 00 H Character Description 13~17 Chassis Serial Number 12 Wheelbase (refer above table, H = 4500 mm etc.) 10~11 Filler (no relevance) 9 Rear Suspension C = Air L = Steel Leaf 8 Emission Level (E = Euro 5) 7 6 Engine Model (8 = GH7) Model Variant 5 Axle Configuration (K = 4x2) 4 Vehicle Product Line 1~3 World Manufacturer Indicator (JNB = UDTC) Up to VIN K

11 VEHICLE SPECIFICATIONS PD Series PD Model Engine PDC8E GH7TB(206 kw) Transmission Allison 3000 ES11109 Suspension Wheelbase (mm) V 6710 Frame Width 860 mm Height x Width x Thickness Tensile Strength Yield Point Section Modulus Tyre size Rim and wheel Brake system Air Outer 250 x 80 x 8.0 mm Inner 234 x 72 x 6.0 mm 539 MPa {55 kgf/mm²} 372 MPa {38 kgf/mm²} 6.70 x 10 5 mm³ Front 295/80R22.5 Rear 11R x 8.25 offset 165 mm, 10 stud (ISO) Full Air, Taper Roller with ABS and *EHS (*manual t/m models only) Suspension Dimensions Front Spring Constant Dimensions/Type Rear Spring Constant PDC8EC (Air) 1400 x 80 x 20 mm 1 leaf 22 mm N/mm (35.0 kgf/mm) HAS 460 air suspension with WABCO remote electronic, programmable and adjustable height control RFCN: RF2005 Chassis Cab Fully Laden 125 (12.8) 317 (32.3) N/mm (kgf/mm) VIN Structure (typical example PDC8EC-V) JNB P D C 8 E C 00 V Character Description 13~17 Chassis Serial Number 12 Wheelbase (refer above table, V = 6710 mm etc.) 10~11 Filler (no relevance) 9 Rear Suspension C = Air L = Steel Leaf 8 Emission Level (E = Euro 5) 7 6 Engine Model (8 = GH7) Model Variant 5 Axle Configuration (D = 6x2) 4 Vehicle Product Line 1~3 World Manufacturer Indicator (JNB = UDTC) Up to VIN V

12 VEHICLE SPECIFICATIONS PW Series PW Model Engine PWC8E GH7TB(206 kw) Transmission Allison 3500 Suspension Trunnion Suspension Air Wheelbase (mm) P W Frame Width 860 mm Height x Width x Thickness Tensile Strength Yield Point 250 x 80 x 8.0 mm 539 MPa {55 kgf/mm²} 372 MPa {38 kgf/mm²} Outer 250 x 80 x 8.0 mm Inner 234 x 72 x 6.0 mm Section Modulus 5.50 x 10 5 mm³ 6.70 x 10 5 mm³ Tyre size Rim and wheel Brake system Front 295/80R22.5 Rear 11R x 8.25 offset 165 mm, 10 stud (ISO) Full Air, Taper Roller(Front), S-Cam(Rear) with ABS Suspension PWC8EL (Leaf) PWC8EC (Air) Front Rear Dimensions 1400 x 80 x 20 mm 1 leaf 22 mm 2 Spring Constant 343 N/mm (35.0 kgf/mm) Dimensions/Type 1320 x 90 x 20-2, 22-2, 20-2, 18-2 HAS 460 air suspension RFCN: RF2005 Spring Constant 2344 {239} N/mm {kgf/mm} Chassis Cab Fully Laden 125 (12.8) 317 (32.3) N/mm (kgf/mm) KOLA VIN Structure (ALL MODELS after W1537 Production) - 4 -

13 GUIDELINES - LEGISLATION GENERAL OVERVIEW This manual has been prepared to provide intermediate and final stage manufacturers with basic data, such as specifications and dimensions, of the chassis-cab manufactured by UD Trucks Corporation, Japan ( UDTC ). This manual is not intended to provide instructions or authorisation by UDTC for modification, alteration or completion of any vehicle and nothing contained herein is to be regarded as providing any such instructions or authorisation. UDTC and UD Trucks ( UDT ) shall not be responsible for any modification, alteration or completion of the vehicle which shall be the responsibility of subsequent Second-Stage-of-Manufacture ( SSM ) manufacturers ( SSMM ). The chassis-cab manufactured by UDTC, and supplied by UDT, is designed to comply with all applicable Australian Design Rules ( ADR ) for a Partially Competed Vehicle ( PCV ) at the time of manufacture. ADR compliance of the chassis-cab manufactured by UDTC is granted by the Department of Infrastructure and Regional Development. Proof of compliance of an individual PCV is shown by UDT s fitment of an ADR Identification (compliance) Plate. Various regulations relating to vehicle performance, equipment, and safety have been issued by government organisations. These regulations include, but are not limited to the Department of Infrastructure and Regional Development regulations. Other Federal, State, Territory and local regulations may also apply. SSMM, body builders and motor carriers are responsible for knowing and complying with all regulations that may apply to the vehicle. A finished vehicle may also require devices that are not specified in the regulations. SSMM, body builders and motor carriers must determine what safety devices are necessary for the safe operation of the vehicle. Nothing in this manual should be taken as a representation that all equipment necessary for the safe operation of the vehicle in its intended use has been installed on the partially completed chassis-cab. All illustrations and specifications in this Body Installation Manual are based on the latest information and believed to be correct at the time of publication. The numerical values used herein are for standard specifications and dimensions. Occasionally, vehicle assembly tolerances may produce some variance in the actual vehicle. UDTC and UDT reserve the right to make changes in design, materials, equipment, information, specifications and models and to discontinue models or equipment at any time without notice and without incurring any obligation. Additional copies of the latest revision of this manual may be obtained from the UDT website: Condor Issued Date: 16 Jan 2017

14 GUIDELINES - LEGISLATION AUSTRALIAN DESIGN RULES (ADR) CERTIFICATION VEHICLE MANUFACTURER In accordance with the Motor Vehicle Standards Act 1989, it is the responsibility of UDTC to ensure vehicles supplied by UDT in chassis-cab (i.e. PCV) configuration conform to the conditions specified in the ADR Identification (compliance) Plate Approvals issued by the Department of Infrastructure and Regional Development. ADR Circular , Certification of Chassis-Cab Vehicles, clause 4.1 permits the vehicle manufacturer to supply a PCV in the nature of a chassis-cab that may not fully comply with certain ADR s, as follows The Position requirements of ADR 13/00 for the following Lighting and Light Signalling devices:- Reversing Lamp (ADR 1/00) as per ADR 13/00 Appendix A clause Rear Direction Indicators (ADR 6/00) as per ADR 13/00 Appendix A clause Rear Reflex Reflectors (ADR 47/00) as per ADR 13/00 Appendix A clause Devices for Illumination of Rear Registration Plates (ADR 48/00) as per ADR 13/00 Appendix A clause Rear Position (Side Lamps) (ADR 49/00) as per ADR 13/00 Appendix A clause Stop Lamps (ADR 49/00) as per ADR 13/00 Appendix A clause Wheel Guards (Mudguards) for the rearmost wheels as per ADR 42/04 clause Provision for Rear Registration Plate as per ADR 61/02 clause Link to ADR s: SECOND-STAGE-OF-MANUFACTURE (SSM) ADR Circular 0-4-6, Certification of Vehicles Which Have Undergone a SSM, clause 3.3 states:- The SSM IPA (Identification Plate Approval) arrangements are available to new vehicles subject to addition and/or modification, except where the nature of the addition and/or modification does not impact on the ADR certification of the first-stage vehicle, or when the impact is considered to be minor, and readily examined by the State/Territory registration authorities. Examples of additions/modifications considered to be a State/Territory responsibility are:- Where the original rearward facing lamp units of a new chassis-cab are relocated with the adding of an otherwise non-adr impacting goods carrying body. Where the original external rear vision mirrors of a new chassis-cab are relocated to accommodate added goods carrying bodies of variable width. Where additional Side-Marker lamps are added to a commercial vehicle chassis-cab. Non-ADR relevant body added to a commercial vehicle chassis-cab. A heavy goods vehicle wheelbase extension. Note: Vehicle Standards Bulletin VSB.6, Heavy Vehicle Modifications, applies to modifications to heavy vehicles with a GVM greater than 4.5 tonnes, or heavy trailers with an ATM greater than 4.5 tonnes. Link to ADR Circulars: then select Administrator s Circulars icon in the LH side panel VEHICLE STANDARDS BULLETIN No.6 ( VSB 6 ) HEAVY VEHICLE MODIFICATION VSB 6 is a National Code of Practice and applies to modifications to heavy vehicles both prior to their first sale in Australia (new vehicles) and after their first sale in Australia (vehicles in service). Although it provides detailed requirements and examples of acceptable practice for a range of common modifications, we draw your attention to Section A clause 4.4, Precedence of ADR s and Manufacturer s Guidelines, that states:- It is important to note that the requirements of the ADR s and the original manufacturer s modification guidelines take precedence over this National Code of Practice. Person s modifying or certifying modifications to heavy vehicles must ensure that all applicable manufacturer s recommendations are complied with and that no ADR compliance is invalidated, even as an unintended result of complying with this Code of Practice. Link to VSB 6: Condor Issued Date: 16 Jan 2017

15 MANUFACTURER S GUIDELINES GUIDELINES - LEGISLATION WEIGHT DISTRIBUTION CALCULATIONS It is recommended that: Wheelbase, rear overhang, body length and weight distribution should take into account the intended vehicle application and operating load conditions (i.e. from unladen to fully laden to unladen) of the vehicle. The effect of diminishing loads should also be taken into consideration. The axle load conditions detailed in the Load Restraint Guide are complied with. In the absence of known load and operating conditions, as an alternative, the above may be determined using water level load conditions. The vehicle must always be operated within the lesser of: a) The statutory legal load limits, or, b) The manufacturers GVM, GCM and axle load ratings. MAXIMUM AGGREGATE TRAILER MASS ( ATM ) Rigid Truck with Trailer 1) The rigid truck and trailer combination must always be operated within the manufacturers approved GCM. 2) The combination must always be operated in accordance with the relevant State/Territory legislation with respect to towing limits. Always check with the appropriate authority to ensure local requirements are met. 3) In the absence of any State/Territory legislation it is recommended that the maximum ATM shall be; The lesser of:- a) The GVM, or, b) 50% of the GCM, or, c) The maximum rated capacity of the towbar. Note: Any towbar or tow coupling fitted must conform to all the requirements of ADR 62/--, Mechanical Connections Between Vehicles. This is the responsibility of the SSMM, body builder or dealer. FRONT UNDERRUN PROTECTION SYSTEM (FUPS) Where a vehicle is fitted with a Front Underrun Protection System, this safety device must not be modified or removed. To do so will void the vehicles ADR84/00 (ECE-R93) Front underrun Protection System compliance. UDTC SERVICE MANUAL (MKB8E, PKC8E, PDC8E & PWC8E Series) Format: Electronic Source: Contact your UD Trucks dealer Condor Issued Date: 16 Jan 2017

16 GUIDELINES - LEGISLATION OTHER LEGISLATION AUSTRALIAN VEHICLE STANDARDS RULES 1999 ( AVSR ) The AVSR s set standards that vehicles must comply with to be driven on roads and road-related areas. The ADR s are rules for designing and building vehicles. Imported vehicles must also comply with the ADR s. The AVSR s require a vehicle that is subject to an ADR when built or imported to continue to comply with the ADR. The AVSR s also apply certain other standards (adopted standards) that are intended to complement the ADR s. The AVSR does not apply to a vehicle if: a) the provision is inconsistent with the requirements of an ADR applying to the vehicle; and b) the vehicle complies with the ADR requirement. Web Site: then Safety & Compliance/AVSR/Model Laws and Policy Library/AVSR (pdf file), or, LOAD RESTRAINT GUIDE ( LRG ) The LRG provides transport drivers, operators, and other participants in the transport chain such as freight consignors, as well as vehicle and equipment manufacturers and suppliers with basic safety principles which should be followed for the safe carriage of loads on road vehicles. Note: The listed items in the LRG are required to be consulted when SSMM, body builders and dealers are specifying vehicles and their associated body installation and equipment. Part 1 Part 2 Web Site: SECTION B ARRANGING LOADS ON VEHICLES Selecting the Vehicle Positioning the Load SECTION G VEHICLE STRUCTURES 13. Load Distribution then Safety & Compliance/LRG, or, CONCESSIONAL MASS LIMITS ( CML ) CML s provide mass benefits for operators accredited under the National Heavy Vehicle Accreditation Scheme ( NHVAS ) Mass Management module from 1-Jul-06. Web Site: then road access, mass dimension and loading, CML or, PERFORMANCE BASED STANDARDS ( PBS ) The Performance-Based Standards (PBS) Scheme offers the heavy vehicle industry the potential to achieve higher productivity and safety through innovative and optimised vehicle design. Web Site: STATE/TERRITORY Registration Authorities Web Sites: QLD NSW ACT VIC TAS NT SA WA Condor Issued Date: 16 Jan 2017

17 GUIDELINES - LEGISLATION ADR SUMMARY - Applicable to 11 M/Y and onwards Applicable UDT Models PKC8E MKB8E PDC8E PWC8E ADR Category ADR NB2 NC ADR Title 1/00 FC FC Reversing Lamps 3/03 FC FC Seats and Seat Anchorages 4/05 FC FC Seatbelts 5/05 FC FC Anchorages for Seatbelts 6/00 FC FC Direction Indicators 8/01 FC FC Safety Glazing Material 13/00 X X Installation of Lighting and Light Signalling Devices on other than L-Group Vehicles 14/02 FC FC Rear Vision Mirrors 18/03 FC FC Instrumentation 30/01 FC FC Smoke Emission Control for Diesel Vehicles 35/04 FC FC Commercial Vehicle Braking Systems 42/04 X X General Safety Requirements 43/04 X X Vehicle Configuration & Dimensions 45/01 FC FC Lighting & Light-signalling Devices not covered by ECE Regulations 46/00 FC FC Headlamps 47/00 FC FC Retroreflectors 48/00 FC FC Devices for Illumination of Rear Registration Plates 49/00 FC FC Front and Rear Position (Side) Lamps, Stop Lamps and End-outline Marker Lamps 50/00 FC FC Front Fog Lamps 51/00 FC FC Filament Lamps 52/00 FC FC Rear Fog Lamps 61/02 X X Vehicle Markings 62/02 FC FC Mechanical Connections between Vehicles 65/00 FC Maximum Road Speed Limiting for Heavy Goods Vehicles and Heavy Omnibus 74/00 FC FC Side Marker Lamps 75/00 FC FC Headlamp Cleaners 76/00 FC FC Daytime Running Lamps 80/03 FC FC Emission Control for Heavy Vehicles 83/00 FC FC External Noise 84/00 FC Front Underrun Impact Protection Other Legislation FC FC voluntary code of practice for electromagnetic compatibility (emc) of motor vehicles FC(a) VSB 11 Certification of Road-Friendly Suspension Systems FC ECE R29 Cab Strength Requirements Legend FC Full Compliance X PCV Compliance only, refer SSM and Body Builders ADR Check List (a) PKC8EC, PDC8EC & PWC8EC (air suspension) models only Condor Issued Date: 16 Jan 2017

18 SSM AND BODY BUILDERS ADR CHECK LIST GUIDELINES - LEGISLATION ITEM REQUIREMENT COLOUR ADR Clause Appendix FRONT 1. Main (High) Beam Headlamps M White 13/00 A Dipped (Low) Beam Headlamps M White 13/00 A Front Position (Side) Lamps M { Visibility of these lamps White 13/00 A Direction Indicator Lamps M { must not be restricted Amber 13/00 A Hazard Warning Signals M { by bull bar fitment. Amber 13/00 A End-Outline Marker Lamps M on vehicles over 2.1 m OW. White or Amber 13/00 A Fog Lamps O White or Yellow 13/00 A External Cabin Lamps O on vehicles over 2.1 m OW. Amber 13/ LH & RH SIDE 1. Side Repeating Direction Indicator Lamps M Amber 13/00 A Side Retro-Reflectors MS on vehicles over 6.0 m TL. Amber 13/00 A Side Marker Lamps MS on vehicles over 2.1 m OW and Amber to Front 13/ a TL over 7.5 m. Red to Rear REAR 1. Rear Position (Side) Lamps MP Red 13/00 A Stop Lamps MP Red 13/00 A Rear Retro-Reflectors MP Red 13/00 A Direction Indicator Lamps MP Amber 13/00 A Hazard Warning Signals MP Amber 13/00 A Reversing Lamps MP White 13/00 A Rear Registration Plate Lamp MP White 13/00 A 6.8, End-Outline Marker Lamp MS on vehicles over 2.1 m OW except flat tray and tipper type bodies. Red 13/00 A Fog Lamps O Red 13/00 A Rear Registration Plate Mount MS n/a 61/ , Visibility of Tray MS { on vehicles 2.2 m or more in White or Silver 61/ Visibility of Wheel Guards MS { OW except when Rear White or Silver 42/ { Marking Plates are fitted. Yellow/Red 13. Rear Marking Plates MS on vehicles over 12.0t GVM. Ref. AVSR 1999 item 119 & VSB 12 GENERAL ITEMS 1. Vehicle Configuration and M Turning Circle 43/04 5 Dimensions MS TL, ROH, OH, GC and OW 6 2. General Safety Requirements M Electrical Wiring, Connectors & Installations 42/04 9 M Exhaust Outlets 10 M External or Internal Protrusions 11 M Field of View 12 MS Wheel Guards (Mudguards) 14 M Brake Tubing and Brake Hoses 15 O Sleeper Berths 17 O Television and Visual Display Units 18 M Warning Devices - Audible Brake Air Systems O Trailer Brake Controls: - Couplings 35/ Compatibility 7.13 M Preferential Charging: When additional air operated items are fitted (i.e. air horns, trailer brake controls, PTO s etc.) air supply must be taken from the delivery (outlet) side of the air system Multi Protection Valve (MPV) M Actuation Timing: Wheelbase extensions Mechanical Connections O Towbar, Tow Coupling and Fifth Wheel design and 62/02 Between Vehicles installation requirements 4. Trailer Braking System O Design, performance and compatibility requirements 38/ , 9 Note: If items marked M or O are either supplied or modified the SSMM or Body Builder has the responsibility for ensuring the vehicles ongoing compliance. LEGEND GC Ground Clearance M Mandatory (PCV as supplied by UDT has full compliance) m Metres MP Mandatory (SSMM, Body Builder has responsibility for positioning) MS Mandatory (SSMM, Body Builder has responsibility for supply and positioning) O Optional OH Overall Height OW Overall Width (excluding mirrors, signalling devices and side mounted lamps) ROH Rear Overhang TL Total Length Condor Issued Date: 16 Jan 2017

19 GUIDELINES - LEGISLATION POSITIONING of LAMPS and REFLECTORS: Supplied by UDT 1. Rear Combination Lamp Assembly Presence Mandatory and includes the; A. Rear position lamp B. Stop lamp C. Rear and side retro-reflectors D. Direction indicator lamp E. Hazard warning signal. Position Width (W): Height (H): The outer edge of the light-emitting surface of the indicator lamp must not be more than 400 mm from the extreme outer edge of the vehicle. Not less than 350 mm or more than 900 mm above the ground. If the structure of the vehicle does not permit installation within these limits, it is permissible to increase the upper limit to not more than 1500 mm. Geometric Visibility Horizontal: 45 inboard and 80 outboard. Vertical: 15 above and below the horizontal. Note: The distance between the rearmost side retro-reflectors and the rear of the body or equipment must not exceed 1000 mm. 2 Reverse Lamp Presence Position Width: Height: Length: Geometric Visibility Horizontal: Vertical: Mandatory Note: ADR 13/00, Appendix A clause states: One device mandatory and a second device optional on motor vehicles of category M1 and on all other vehicles with a length not exceeding 6,000 mm Two devices mandatory and two devices optional on all vehicles with a length exceeding 6,000 mm, except vehicles of category M1. No special requirement. Not less than 250 mm and not more than 1200 mm above the ground. At the rear of the vehicle. 45 to the right and 45 to the left. 15 above and 5 below the horizontal Condor Issued Date: 16 Jan 2017

20 GUIDELINES - LEGISLATION 3 Rear Registration Plate Lamp Presence Mandatory and positioned so that the device illuminates the site of the registration plate. Note: ADR 13/00, Appendix A clause states:- For the visibility of white light (excludes the reverse lamp) towards the rear, there must be no direct visibility of the apparent surface of a white lamp if viewed by an observer moving within Zone 2 (height 1.0~2.2 m above the ground and 15 left to right) and in a transverse plane situated 25.0 m behind the vehicle. Rear Registration Plate Position (ADR 61/02) - All N (truck) category vehicles: provision must be made for mounting a registration plate to be affixed to the rear of the vehicle so that no part of such plate is more than 1300 mm from the ground no part of a vehicle, including its standard equipment, regular production options or Equipment must be so located as to obscure any part of the registration plate. Note: State/territory regulations require a minimum geometric visibility of 45 right to left and 45 upwards. ITEMS SUPPLIED at SSM In accordance with ADR circular and the respective regulations the supply and positioning of the following items, where required, is the responsibility of the SSMM or Body Builder. Additional side retro-reflectors Side marker lamps Rear end-outline marker lamps Rear registration plate mount (mandatory) Visibility of tray and wheel guards Rear marking plates (mandatory on vehicles over 12.0t GVM). Additional reverse lamp on all vehicles with a length exceeding 6,000 mm, except vehicles of category M Condor Issued Date: 16 Jan 2017

21 SUB-FRAME AND BODY INSTALLATION GUIDELINES BODY INSTALLATION The rear body must be mounted to the chassis frame using a sub-frame. Mounting of the sub-frame must conform to the following: 1. SUB-FRAME SHAPE AND MOUNTING The sub-frame should form a continuous longitudinal channel or RHS. The width of the flange should be 70~100% of the flange width of the chassis frame (Fig.1). Timber should not be used as a sub-frame due to the possibility of shrinkage and warping. (1) The lower sub-frame flange must be mounted flush with the upper flange of the chassis frame. Do not mount the sub-frame at an angle to the chassis frame. Connect the right and left sub-frame to each other by crossmembers, bolsters, or the body proper. Sliding stoppers should be attached to the sub-frame if necessary (Fig.2). (2) The sub-frame channel openings should face inward toward the vehicle longitudinal centreline. (3) Align the sub-frame web surface with that of the chassis frame (Fig.3)

22 GUIDELINES BODY INSTALLATION 2. FRONT-END SHAPE The sub-frame when combined with the chassis frame may have a point where the rigidity suddenly changes, increasing the possibility of stress concentration on the chassis frame. To reduce the possibility of stress concentration, shape the front end of the sub-frame so that its rigidity gradually decreases. Also extend the front end of the sub-frame as far forward as possible. See Figs. 4, 5, 6 and 7 for examples of sub-frame front-end shapes. It is recommended that the sub-frame shown in Fig. 4, 5 or 6 be used wherever possible. If the body design or other factors preclude the use of these, Fig. 7 should be used. When mounting a tank body or other highly rigid body, use one of the shapes in Fig. 4, 5 or 6. Use a steel spacer to compensate for any uneven surface such as that caused by a gusset on the chassis frame. Avoid using semi-elastic spacer material. When using a spacer between the frame and chassis-frame, install the spacer as shown in Fig

23 3. POSITIONS OF FRONT- END REINFORCEMENT GUIDELINES BODY INSTALLATION The points of the chassis frame where its rigidity changes (e.g., crossmember, gusset and reinforcement) must not be located with the front end (contact point) of the sub-frame or the head and tail of any reinforcement (Fig. 11)

24 GUIDELINES BODY INSTALLATION 4. MOUNTING BRACKETS The use of mounting brackets to secure the sub-frame is preferred to U-bolts. If a highly rigid body such as a tank body or closed van body is to be mounted, it is strongly recommended that spacers be used in combination with mounting brackets (Fig. 12). Sufficient spring washers should be used with the connecting bolt. Install the mounting brackets to the chassis frame using bolt nut or rivet attachments at sufficient intervals. Do not weld. 5. LOCATION PLATES The sub-frame cannot be securely mounted to the chassis frame using locating plates only. When employing locating plates use U-bolts or mounting brackets. Closely align the front of the sub-frame with the chassis frame using the U- bolts or mounting brackets (Fig. 12). Do not use locating plates for mounting a body having a high centre of gravity or concentrated load. Never use a locating plate for sub-frame mounting of a tank body, dump body, concrete mixer body, van body, etc. Locating plates are not recommended for vehicles operating on rough or winding roads. Note: VSB 6 section J requires, The body must be located fore and aft on the frame and prevented from moving during violent braking by the use of at least four outrigger brackets or fishplates (i.e. location plates). A bracket or fishplate must be located at the front and rear of the body on both sides of the vehicle

25 6. COMBINATION WITH CHASSIS FRAME GUIDELINES BODY INSTALLATION To be effective, the sub-frame must be securely attached to the chassis frame. U-Bolts, mounting brackets, locating plates, etc. are normally used to connect the sub-frame to the chassis frame (Fig. 14). Never affix flanges directly to each other by welding or by bolt-nut attachment. (1) U-Bolt Mounting A simple method that is frequently used for attaching the body is U-bolts. When using this method for body mounting the following points should be considered: The load is carried on the top flange, not the web. The runner stiffens the frame thus reducing the flexibility along part of the frame length. The U-bolts holding the runners are often over tightened causing the frame flange to buckle. Once buckled, the flanges have their strength greatly reduced. When the metal spacers are positioned between the top and bottom flanges to stop the flange buckling, local stiffening occurs with resultant loss of flexibility. Fixing of the body relies on friction and high clamping forces, with no positive location. However tight the U-bolts are when fitted, they work loose and the body is then free to slide on the frame. Spacer shrinkage and wear over a period of time can occur and the body mounting becomes loose. Often U-bolts are over tightened at this time to prevent recurrence and frame distortion results

26 GUIDELINES BODY INSTALLATION If U-bolt mounting is to be used, then installation must satisfy the following conditions: 1) The No.1 U-bolt must not be installed forward of points L2 and L3 in the diagram below. to C/Line of front axle: MK 2005 PK 2020 PD 2020 PW ) The frame (particularly flanges) must not be distorted. If the vehicle does not have a box type frame, metal spacers must be inserted between the top and bottom flanges of the chassis frame rail to prevent distortion when the U- bolts are tightened. The spacers should be secured in place by the U-bolts as shown in Fig ) The body must be located fore and aft on the frame and prevented from moving during violent braking by the use of at least four (4) location plates. A location plate must be located at the front and rear of the body on both sides of the vehicle. 4) A minimum of three (3) U-bolts per side of the chassis shall be used with the maximum pitch spacing of 1750 mm. Installation of U-bolts must conform to the following: Lock the nuts. Install the U-bolt vertically to the frame. Do not install a U-bolt in a tapered portion of the frame (where the web changes in width). 5) Minimum U-bolt diameters shall be: Bodies up to 2 tonne capacity 12 mm Bodies over 2 tonne capacity 16 mm. 6) Class 4.6 steel U-bolts are recommended

27 (2) Preventing Fore-and-Aft Movement GUIDELINES BODY INSTALLATION U-bolts and vertically installed mounting brackets do not prevent fore-and-aft movement of the sub-frame. To reduce the possibility of fore-and-aft movement use locating plates as shown in Fig. 16. The frame flanges of dump trucks having a short rear overhang can be connected at the rear end using bolts and nuts. See Fig. 16-(3). Note: VSB 6 section J requires, The body must be located fore and aft on the frame and prevented from moving during violent braking by the use of at least four outrigger brackets or fishplates (i.e. location plates). A bracket or fishplate must be located at the front and rear of the body on both sides of the vehicle

28 (3) Sub-Frame Connecting Devices Location GUIDELINES BODY INSTALLATION When installing sub-frame connecting devices, avoid damage to wiring harnesses, hoses, tubes, pipes, etc., which are on or near the chassis frame. To reduce stress concentration, do not connect the chassis frame to the front of the sub-frame (Fig. 17). Avoid connecting the sub-frame in the shaded areas shown in Fig. 18. When making holes and welding the chassis frame for mounting brackets and locating plates installation, follow the procedure described under the captions entitled Drilling the Frame and Riveting - 8 -

29 7. LONG WHEELBASE TRUCK GUIDELINES BODY INSTALLATION A highly rigid sub-frame should be used on long wheelbase trucks to avoid deflection. Channel steel, lip channel steel and RHS can be utilized. DO not use a wooden sub-frame. When a side gate centre pillar is installed on a drop side gate body, the pillar should be located ahead of the centre of the rear wheels, by at least 760 mm to prevent rear overhang deflection (Fig.19)

30 GUIDELINES BODY INSTALLATION CHASSIS FRAME When drilling the chassis frame to mount a rear body or special equipment, the following precautions must be taken to avoid serious damage to the vehicle or reducing frame strength. Mounting should not cause stress concentration in the frame such as may occur from improper location, size or finishing of holes or by improper riveting. 1. DRILLING THE FRAME When drilling the frame, use an ordinary twist drill. Do not use a torch (Fig. 20). All holes must be finished after drilling to help reducing the possibility of stress concentration. Chamfer all holes for fitted bolts on both bolt head and nut faces (Fig. 21)

31 GUIDELINES BODY INSTALLATION Observe the following precautions in drilling holes. Refer to (Fig. 22): 1) Do not notch the upper and lower flanges of the side rail, gusset, and crossmember Fig. 22 (b). 2) Do not drill holes in crossmembers Fig. 22 (b). 3) Do not drill holes in the upper and lower flanges of the side rails except, (a) holes to install the end crossmember and (b) holes near the frame end to install bolts to reduce fore-and-aft movement of the sub-frame. 4) Do not drill holes in the upper and lower portions of the side rail web. No part of the holes is to be within 18% of the frame height Fig. 22 (a). 5) Holes must not be drilled within 80 mm of the perpendicular bending lines of the side member Fig ) The maximum hole diameter should be as follows: Model MK Series PK Series PD Series PW Series Max Diameter 13 mm 15 mm 15 mm 15 mm 7) The pitch between two hole centres should be at least 55 mm or 4.5 times the diameter of the larger hole, whichever is greater. This rule should also be applied to the pitch between a new and the existing hole Fig. 22 (a). 8) The edge of any hole should be more than 30 mm from any weld. 9) No more than three holes in a series should be drilled in a vertical line. lf three holes are required in a vertical line; the maximum diameter should be 11 mm for MK Series and 13 mm for PK / PD / PW Series models. Avoid a series of holes in a horizontal line whenever possible Fig. 22 (a). 10) Drill all holes perpendicular to the face to be drilled. 11) When drilling a hole in the gusset for U-bolt sub-frame mounting, the hole diameter should be 20 mm or less and the distance from the edges should be more than 30 mm Fig. 22 (b). 12) Drill the holes as far as possible from existing holes in the flange, welds and the end portion of the gusset

32 GUIDELINES BODY INSTALLATION 2. RIVETING Cold hydraulic riveting, rather than hot riveting, is strongly recommended (Scale produced during hot riveting remains on the surface or a gap is made in the rivet hole, which may cause loosening.). When hot or manual riveting is necessary, carefully inspect the finish after tightening the rivet. Always use rivets on areas of the chassis-frame subject to shearing force. Protect rivets from direct tension. When rivets are used extensively on the vehicle frame, jointly drill the frame and parts to be installed. Rivet holes should be staggered, and not in a vertical line (Fig. 23)

33 GUIDELINES BODY INSTALLATION MECHANICAL CONNECTIONS BETWEEN VEHICLES 1) Towbars, Tow Couplings and Fifth Wheels The design, installation and marking must conform to the listed ADR s and their associated Australian Standards: ADR Title Requirements 35/05 Commercial Vehicle Braking Systems Section 4, clause Brake Line Couplings Section 7.13 Service Brake Compatibility 42/04 General Safety Requirements Section 9, clause 9.2 Electrical Connections. 62/02 Mechanical Connections Between Vehicles Installation of Tow Coupling/Fifth Wheels For installation guidelines, refer to VSB 6; section P Tow Coupling/Fifth Wheels Note: Effective Jan-09, the AS/NZS standards quoted in ADR 62/02 take precedence over the AS standards quoted in VSB 6. LIFTING DEVICES 1) Cranes Refer to VSB 6; section Q Vehicle Mounted Lifting Systems Slewing. 2) Tailgate/Platform Loader Refer to VSB 6; section R Vehicle Mounted Lifting Systems Non-Slewing

34 PRECAUTIONS DURING ELECTRIC WELDING GUIDELINES BODY INSTALLATION 1. Protection of Electronic Equipment Units such as a tacho graph, radio or Sat-Nav with a built in clock are directly connected to the battery, and many electronic devices that have a low resistance against high voltage are used for the controllers such as engine, ABS, EHS, and Automatic transmission. When performing electric welding, there is the danger that electric current from the welding machine may flow back through the grounding circuit and damage these components. Be sure to follow the procedure below when performing electric welding. 1) Turn the ignition switch to OFF. 2) As the SCR Urea Dosing system operates for approximately 2 minutes after the ignition switch is turned to the OFF position, wait for more than 2 minutes before disconnecting the battery ( ) terminal. Be sure to insulate the removed terminal from the (+) terminal to prevent a short. 3) It is also recommended to disconnect all ECU s in the vehicle Vehicle ECU: Under LH side of dash panel. Engine ECU: LH side of engine. AdBlue SCR ACM: LH Cab support bracket. Brake ABS: Under LH side of dash panel. Air Suspension ECU (PK/PD/PW): Under LH seat. Auto Transmission ECU: Under LH seat. 4) Establish the grounding for the welding machine near the portion to be welded. 5) After welding, reconnect the ECU s and battery (-) terminal in the reverse sequence of removal. 2. Welding Electrode A low hydrogen electrode conforming to either the AWS A5.1 E H4~H8 or AS/NZS E H5~H10 standard and suitable for welding the listed frame material is recommended. MK PK/PD/PW SPFH540 High tension steel plate having a tensile strength of 539 MPa {55 kgf/mm²} Typical commercially available products are the BOC Smootharc 16, Cigweld Ferrocraft 16TXP-HS, Lincoln Conarc 51 and WIA Austarc 16TC manual arc welding electrodes. 3. Welding Procedure To be conducted in accordance with the guidelines and Australian Standards nominated in VSB 6, section H Chassis, items 5.7 General Precautions Welding of Frame Rails, and 5.8 Welding Requirements and the following manufacturers guidelines. (1) General The chassis frames of UD trucks are of a riveted and/or bolted construction. Therefore, avoid welding any equipment to the frame thoughtlessly. Caution should be given to a frame of high tensile steel which is easily affected by heat and may decrease in strength if improper welding is done. Electric arc welding should be used for welding the frame and the following precautions should be exercised. 1. Do not perform tack welding to temporarily attach equipment. Cracks appear easily, and the occurrence of stress concentration is possible. 2. The welding surface should be well cleaned beforehand. Grease, paint, water, rust, dust and any other foreign matter left on the welding surface could easily make blowholes and cracks. 3. Welding slag on each layer should be completely eliminated. Slag inclusion will cause a decrease in welding strength and fatigue resistance. 4. Select an appropriate welding electrode, welding current and welding speed so that any defective welding is prevented. Some typical defects of electric arc welding are shown in the next table. Corrective measures to be taken are also shown for reference. Defect Possible Cause Corrective Measure 1) Inappropriate welding electrode moving speed. Make the welding speed appropriate, and prevent slag from getting ahead of the molten pool or arc. Incomplete 2) Welding current is too low. Select the correct current for the welding condition. penetration 3) Groove angle is narrow. Enlarge the groove angle, or select an electrode diameter according to the angle. 1) The welding electrode inclination or the electrode Maintain the proper electrode angle and operation. Undercut operating speed is inappropriate. Decrease the electrode operation speed. 2) Welding current is too high. Decrease the weld current. 3) Improper welding electrode. Select the most appropriate electrode for the welding condition. Slag Inclusion 1) Imperfect removal of slag from the previous Completely remove the slag from the previous layer. layer. 2) Improper electrode operation. Increase the current a little, and operate the electrode properly. 3) Defective design. Redesign for easy welding operation

35 GUIDELINES BODY INSTALLATION Bead poor in appearance Blowhole Crack 1) Welding current is too high and the electrode diameter is too large. Select a current and electrode diameter according to the parent metal. 2) Poor weld sequence, thick weld bead. Follow the proper welding sequence, operate the electrode correctly. 3) Electrode operation speed is improper. Select an electrode operation speed enabling slag to grow from under the molten pool. 4) Slag is improper in covering weld metal Select an electrode with viscous slag. 5) Improper electrode is selected. Select the most appropriate electrode for the welding condition. 1) Excessive current and improper electrode Make the arc longer, and perform proper weaving (max. weaving is operation. 3 times as large as the electrode core diameter). 2) Parent metal is too thick or quickly cooled Perform proper preheating. 3) Oil, paint or rust is on the welded joint. Clean the welded joint well. 4) The electrode is humid. Store electrodes in a dry condition and pre-condition in accordance with the manufacturers recommendations. 5) Material galvanised Due to oxidising zinc, weld with an electrode using a flux of ilmenite or cellulose. For complete removal of the blowholes, remove all plating from the groove and parent metal adjacent to the weld face beforehand. 1) Parent metal contains a high degree of alloy Preheat, post heat and ensure a low hydrogen electrode is being elements such as manganese. used. 2) Welded joint is too rigid Perform preheating and peening. 3) Welding electrode is defective or humid. Use a correct electrode, that has been stored and pre-condition in accordance with the manufacturers recommendations 4) Welding performed with excessive current or an Perform welding at the proper current and at the proper speed. excessively high speed. 5) Material is too thick or quickly cooled. Preheat, post heat and ensure a low hydrogen electrode is being used. 6) Parent metal containing too much sulphur. Use a welding electrode of low sulphur 1) Parent metal containing too much carbon and/or Use a welding electrode of similar alloy to parent metal. manganese. Pit 2) Parent metal is too thick or quickly cooled. Perform preheating and post heating. 3) Parent metal containing too much sulphur. Use a welding electrode of low sulphur 5. The desirable power for electric arc welding is DC electrode positive. In manual welding, by the use of the AC conformable coated electrode, AC is acceptable. 6. In order to minimise the welding residual stress, perform preheating (warm the parent metal up to approximately 100 C with a burner). It is recommended that peening with a peening hammer be performed after welding, post heating should also be used when the ambient temperature is below 20 C. (2) Positions to be Welded Chassis Frame In any UD vehicle, welding should be performed as far away as possible from the positions liable to high bending moment, high bending stress, or stress concentration (e.g. crossmember end, gusset end, spring bracket, and group of holes). Welding to any gusset or crossmember is prohibited. 1. It is strictly prohibited to weld anything to the under surface of the lower flange of the side rail within the wheelbase

36 GUIDELINES BODY INSTALLATION 2. A short weld zone is liable to harden, due to quick cooling and potentially crack. Therefore, the bead length should be at least 30 mm. Defects can occur easily at the starting and ending points of welding; Thus, caution should be taken. A corner of the object to be welded must not coincide with the starting and ending points of the welding (Fig. 3-13). (3.1) Extension of Chassis Frame Rear Overhang If the load space projects more than 1.5 the times final chassis depth and unless the body structure is self supporting at full load, extend the chassis frame. It is important to consider the weight distribution and prevent overloading the rear axle. The thickness, shape and material quality of the extension material used should be similar to that of the chassis frame. If the extension exceeds the frame height or the extension is under concentrated load, reinforcement is necessary. The reinforcement should be similar to the frame in quality. When joining the extension material to the original frame, perform continuous butt-welding by following the procedures described below. When welding portions in an overhead position, be careful to prevent a shortage of weld penetration. 1. Groove shape In order to minimise thermal deformation and penetration shortage, it is recommended that an X type groove be used and that welding be performed on both the front and back sides. When a V type groove is adopted, back chipping is strongly recommended unless welding a double frame. 2. Finishing On a butt-welded portion, provide weld reinforcement. After completing the welding, perform the finishing work. Use a grinder to finish the welded portion smoothly in order to make it even with the parent metal and with no undercutting. Illustration below shows the area where finishing is required

37 GUIDELINES BODY INSTALLATION When the extension amount is within the frame height (l < h) Follow the directions given in Fig When a concentrated load is not applied, reinforcement is not necessary. 3. Follow the directions given in Fig when reinforcement is required (l > h) 4. With the double frame It is strictly prohibited to weld the inner channel and the outer channel at the same place. In providing the extension, follow the directions given in the illustration below. The inner and outer extension materials should be joined at the web by rivets or plug welds

38 GUIDELINES BODY INSTALLATION (3.2) Cutting of the Rear Overhang When it is inevitable, in mounting the rear body or a fifth wheel, cut the rear overhang accordingly giving consideration to weight distribution. If the frame is cut by gas, the cut portion will be extremely hot; so be careful it does not damage anything surrounding it. It is important not to leave the cut surface as it is, but finish the surface smoothly with a grinder. Be sure to install an end crossmember. For its installation, use rivets or M12 (7T) bolts and nuts tightened to the correct torque specification. (3.3) Reinforcement of the Side Member Generally, when installed with a sub-frame the chassis frame does not require any reinforcement. However, when mounting a specific body or meeting a specific user condition that requires reinforcement to be added to the chassis side members, follow the instructions below: 1. The standard section of the reinforcement plate should be Shaped ; the thickness should be less than that of the side member but more than 40% of its thickness. Reinforcement using an ] shaped section is capable of improving strength. However, if its installation is not precise, it may create a gap on the side member flange and cause a severe defect. Thus this type of reinforcement is not recommended. 2. For prevention of stress concentration, the end of the reinforcement plate must be cut off to less than 45 so that the section undergoes a gradual change (Fig. 3-19). 3. Use a reinforcement material similar to the side member quality. 4. In principle, the L shaped reinforcement should be installed on the flange with tensile stress. (Within the wheelbase, the tensile side is the lower flange.) 5. The end of the reinforcement should not be aligned with any existing chassis frame rigidity changing point (end of existing reinforcing) or a concentrated load input point. In other words, the starting and ending points of the reinforcement should be sufficiently separated from, or sufficiently overlapped with, the existing reinforcement end, crossmember end, spring bracket, cab back, and sub-frame starting point, etc. (Fig. 3-20) 6. The reinforcement should be desirably installed so that it is joined on the web by riveting. The standard rivet and rivet hole diameters are as follows Model Rivet Diameter Rivet Hole Diameter MK, PK, PD, PW Series 11 mm 12 mm The edge distance between the rivet hole and the reinforcement plate end should be at least 25 mm, and the rivet pitch should be 70~150 mm

39 GUIDELINES BODY INSTALLATION 7. When riveting is difficult, perform welding on the web surface. It is desirable to do plug welding by making holes in the reinforcement. The welding hole should be 20~30 mm in diameter. The edge distance between the welding hole and the reinforcement end should be at least 25 mm, and the hole pitch should be 100~170m. If the specified pitch cannot be satisfied, fillet welding may be applied. For prevention of thermal deformation, the welding zone should be separated from a bolt hole or rivet hole as much as possible (at least 30 mm). 8. Curvature of reinforcement Outer: The inside radius Ro (reinforcement) must be smaller than the outside radius ri (frame). Inner: The outside radius ro (reinforcement) must be larger than the inside radius Ri (frame)

40 GUIDELINES BODY INSTALLATION 4 Protection of Equipment During Welding To prevent the effect of welding spatter on the equipment around the welding portion, or damage by welding heat, be sure to take the following protective measures before welding. 1) When welding in the vicinity of hoses, steel tubes, nylon tubes, harness, electrical parts, and chassis parts, cover them to protect them from welding spatters and heat. 2) Before doing welding operations in front of the engine, cover the radiator and engine to prevent damage by welding spatters and heat. 3) Before doing welding operations around the cab, cover the cab to prevent damage by welding spatters and heat. 4) Before doing welding operations around the chassis suspension, cover the suspension to protect it from welding spatters and heat. 5) When welding the outside of the frame, check for the presence, or absence of tubes inside the frame. If tubes exist in the frame, put an insulating shield between the frame and the tubes to block heat and weld splatter. Especially, nylon tubes as they can be easily damaged or deformed by heat. 5. Other precautions 1) Avoid welding excessively in one area, or adjacent areas when possible (stagger weld sequence). 2) The welding length should be kept short, however not less than 30 mm. 3) Be careful not to cause welding defects such as incomplete welding, undercut, slag inclusion, blowhole, and crack

41 GUIDELINES BODY INSTALLATION PRECAUTIONS ON VEHICLES EQUIPPED WITH ABS The ABS is a brake control mechanism which contains electronic circuits processed by a microcomputer. Therefore, when installing the body near ABS components or remodelling vehicles equipped with ABS, it is necessary to pay attention to the brake control equipment or electronic parts. Especially when body installing or remodelling using electric welding, incorrect operations could adversely affect the parts or equipment. Be sure to observe the following precautions. 1. Prohibited matters 1) Modification of the brake system component parts is prohibited. 2) Use of tyres other than those specified is prohibited. 3) Relocation or remodelling of the ABS unit (modulator, control unit, sensor, etc.), brake piping and ABS harness is prohibited. Note: Do not take power for audio system, auxiliary lights, etc. from the ABS harness. 2. Precautions for body installation 1) When installing the following parts, keep them 100 mm or more away from the modulator, control unit, sensors and ABS harness. Radio wave transmitters and receivers and related antennas and harness. Motors, relays, etc. which produce electrical noise. 2) When electric welding is used at the body installation, turn the ignition switch to OFF and disconnect the ECU s and battery (-) terminal. 3) After finishing the body installation, carefully check the piping and harness for damage. 4) Perform the normal ABS inspection. For procedures of the ABS inspection, refer to the UDTC Service Manual. The main procedure is as follows: Check with a self diagnosis function. Drive the vehicle on four free rollers or drive on actual roads, and apply brakes to check for the operation of ABS. 5) Other inspections If the vehicle is equipped with electrical equipment such as radio transmission devices etc. which are used during driving, perform ABS inspection while the equipment is operating. If the vehicle is equipped with electrical equipment such as a tailgate lifter etc. which is used while the vehicle is at a stop, operate the equipment with the ignition switch turned ON or the engine operating and check the ABS for incorrect operation or the warning light for illumination. PRECAUTIONS ON VEHICLES EQUIPPED WITH EHS (MK, PK, PD manual t/m models) The EHS is a brake control mechanism which contains electronic circuits processed by a microcomputer. Therefore, when installing the body near EHS components or remodelling vehicles equipped with EHS, it is necessary to pay attention to the brake control equipment or electronic parts. Especially when body installing or remodelling using electric welding, incorrect operations could adversely affect the parts or equipment. Be sure to observe the following precautions. 1. Prohibited matters 1) Modification of the brake system component parts is prohibited. 2) Relocation or remodelling of the EHS control unit, solenoid valve, sensors, brake piping and EHS harness is prohibited. Note: Do not take power for audio system, auxiliary lights, etc. from the EHS harness. 2. Precautions for body installation 1) When installing the following parts, keep them 100 mm or more away from the EHS control unit, solenoid valve, sensors and EHS harness. Radio wave transmitters and receivers and related antennas and harness. Motors, relays, etc. which produce electrical noise. 2) When electric welding is used at the body installation, turn the ignition switch to OFF and disconnect the ECU s and battery (-) terminal. 3) After finishing the body installation, carefully check the piping and harness for damage. 4) Perform the following EHS operational condition check (steps 1~3 and steps a~f) after body/equipment installation, welding, battery or ECU disconnect/connect, etc:

42 GUIDELINES BODY INSTALLATION EHS Brake - Applied: Determined by the control unit Ignition Switch: ON or START Vehicle Speed: Stopped (0 km/h) Doors: Closed EHS OFF Switch: Lamp OFF (i.e. system activated) Service Brake: Apply for 1 second or more Clutch/Gearshift: a) Clutch depressed, gear selected, or b) Gearshift in N position Park Brake: Released Note: When all conditions are satisfied, the control unit operates the EHS valve Electrical signal from ECU EHS Valve: Operated EHS Lamp: Illuminated EHS Brake: Activated EHS Brake - Conditions of Release: 1. Release by normal starting operation Gearshift: Start gear engaged Clutch (sensor output signal): Half clutch pedal engagement travel EHS Valve: Not operated EHS Lamp: OFF EHS Brake: Released 2. Release by operation of the park brake (apply the park brake). 3. Release by turning the EHS switch to the OFF position (Note: the EHS switch lamp is now ON, indicating the EHS system is deactivated) or by turning the ignition switch to either the ACC or LOCK position. WARNING Conditions a. DOOR OPEN WARNING: When either the driver s door or passenger door is opened while the EHS is engaged and the park brake is released. b. LONG TIME WARNING: When stopped for an extended period (over 7~8 minutes) with the EHS engaged. c. MOVEMENT WARNING: When the vehicle begins to move whilst the gear lever is in the N position and the EHS engaged. d. NON-ADJUSTMENT WARNING: When the EHS RESET switch is pushed, or when either the battery terminal has been disconnected, the fuse replaced or the EHS ECU unit disconnected and the release position is required to be reset. Warning Lamp Illuminates Flashes Flashes Buzzer Sounds continuously Sounds continuously Sounds short beeps Measures to be Taken Apply the park brake before exiting the vehicle. Either apply the park brake or depress the brake pedal to reset the EHS system. (If the above measures stop the warning, there is no malfunction.) Conduct an initial adjustment as follows; 1. Stop the vehicle on level ground, confirm there is no obstruction or persons ahead of the vehicle, and chock the wheels. 2. Apply the park brake. 3. Confirm the engine is running and that the air pressure is fully charged. 4. Confirm the EHS OFF switch in is the lamp ON (deactivated) position. 5. Depress the clutch pedal fully, select 3 rd gear, and push the EHS RESET switch. 6. Release the clutch pedal slowly, until the engine speed reduces by approx. 50 rpm lower than the idling speed, then push the ADJUST switch (either FAST or SLOW). 7. Shift the gear to the N position, and slowly release the clutch pedal. e. IGNITION SWITCH POSITION WARNING: When the ignition switch is turned from the ON to either the ACC or LOCK position without applying the park brake while the EHS is engaged. f. FAULT WARNING: When the EHS lamp or buzzer operates for a reason other than the above. OFF Flashes Flashes Illuminates Sounds beeps for approx. 10 seconds Sounds twice None Sounds continuously Apply the park brake. Safely stop the vehicle, push the EHS OFF switch to the lamp ON position to deactivate the EHS operation

43 GUIDELINES BODY INSTALLATION PRECAUTIONS FOR THE SRS AIRBAG SYSTEM The SRS airbag system and the seatbelt pretensioner operate on electronic circuits, which are based on a microprocessor. Therefore, when mounting a body or remodelling a vehicle equipped with an SRS airbag system, it is necessary to pay attention to the electronic parts and to observe the following precautions. Incorrect work may prevent proper operation of the system, or cause an accidental deployment. A failure due to incorrect handling may be stored in the SRS airbag system control unit memory as the cause of any abnormal operation or non-operation that may occur while the vehicle is in operation. (SRS stands for Supplemental Restraint System, which means an additional restraint system to the seat belt.) 1. Precautions required when electric welding 1) Turn the ignition switch "OFF," disconnect the battery negative (-) terminal and leave it for three minutes. This is to let the electricity drain from the backup power circuit in the SRS airbag system control unit. 2) For other precautions, refer to "Precautions during Electric Welding" on page 14 of this section. 3) Be sure to observe Precautions for mounting the body on page 24 of this section when performing welding work. 4) After completion of the welding work, connect the battery negative (-) terminal, turn the ignition key switch to the ON position and check that the warning lamp illuminates for approximately 6 seconds and then goes out. If the SRS airbag system warning lamp does not illuminate for 6 seconds or fails to go out, consult your nearest authorized UD Trucks dealer

44 GUIDELINES BODY INSTALLATION 2. Precautions for mounting the body 1) SRS airbag system parts are installed around the steering system, around the pedal bracket, and to the seat belt retractor. Do not apply shock to SRS airbag system parts by hitting the surrounding areas, etc. 2) Do not remove SRS airbag system parts. (Except for the control unit cover and the connectors as specified in "Precautions required when electric welding" on page 23 of this section.) 3) SRS airbag system connectors are yellow in colour. Never attempt to modify harnesses or connectors. Do not change the routing, fixing positions or fixing methods of the harnesses. Do not remove connectors other than those specified. Do not bind harnesses of other systems to the SRS airbag system harness or the pretensioner harness. 4) Never use an electrical tester to inspect the electrical circuit of the SRS airbag system. 5) Remove the steering wheel before carrying out repair or adjustment of the steering system. Refer to the service manual for the work procedure. 6) Be careful not to spill water, oil, etc. on the SRS airbag system parts. Keep these parts from contact with water, oil, etc. 7) Observe the "Precautions for the SRS airbag system" in the instruction manual when handling SRS airbag system parts. 8) Always consult the dealer when discarding a gas generator or scrapping the vehicle

45 GUIDELINES BODY INSTALLATION PRECAUTIONS FOR BODY INSTALLATION AdBlue (urea water solution) SCR SYSTEM Installation of Body and/or Equipment When installing a body and/or equipment around the AdBlue tank, be careful not to cover the AdBlue filling hole (cap) with the body and/or equipment. Provide a clearance around the filler cap as shown in the figure below to allow the filler cap to be removed and replaced and the filling nozzle to be inserted. A. AdBlue Tank AdBlue Tank, Piping, Supply Module, Dosing Module and SCR Catalyst/Muffler Assembly The AdBlue tank, piping parts, supply module, dosing module and SCR catalyst/muffler assembly are installed for the purpose of making the vehicle compliant to the emission gas regulations (ADR 80/03). B. Supply Module C. Dosing Module WARNING: DO NOT relocate any parts or modify their connecting piping hoses in any way or for any reason. To do so will void the vehicles ADR emission compliance (ADR 80/03). Link to AdBlue MSDS: then select the Safety Data Sheet icon in the RH side panel. Air1 (Yara Australia Pty Ltd)

46 GUIDELINES BODY INSTALLATION Procedure of AdBlue Hose Removal and Installation CAUTION Electrical Connectors/Wiring: When handling AdBlue solution it is important that any disconnected electrical connectors are well protected by sealing them in a plastic bag. Otherwise there is a risk that the AdBlue solution, which quickly oxidises metal, will permanently damage the exposed connector/wiring. If a connector comes into contact with AdBlue solution it must be replaced immediately as capillary action will draw the AdBlue solution further into the copper wiring, at a speed of approximately 60 cm/hr, rendering the wiring harness non-serviceable. Cleaning with water or compressed air does not help, as the oxidisation process is immediate. 1) Removal Remove the tie straps around the AdBlue hoses. Mark the AdBlue hoses so that they can be correctly refitted. Whilst pushing down on the AdBlue hose connector, gently squeeze the release plug and remove the AdBlue hose. Plug the AdBlue hoses and connections to prevent dirt getting into the AdBlue system and the crystallisation of the AdBlue solution. 2) Installation Fit the AdBlue hose by aligning the connector, and then gently apply a force in the direction shown below. Check that the AdBlue connection locks into place. Secure with a new cable tie. Check there is no leakage

47 REMODELING THE EXHAUST SYSTEM GUIDELINES BODY INSTALLATION The remodelling of the SCR catalyst/muffler assembly, front engine pipe and ADR 83/00 noise reduction shields is prohibited. To prevent a fire, adverse effects on the SCR catalyst/muffler assembly and non conformance to emission regulations the remodelling of the exhaust system except the tail pipe is prohibited. 1. Remodelling the tail pipe When modifying or remodelling the tail pipe, observe the following precautions. 1) The tail pipe shall have the same material (stainless), diameter, surface treatment, etc. as those of the UDTC genuine parts. 2) Extension or further bending of the pipe may cause an increase in exhaust resistance, reduction of engine output, increase of fuel consumption, increase in the concentration of exhaust gas, etc. Exhaust back pressure must not be increased above that of the standard vehicles exhaust system. The bending radius of the pipe should be more than twice the pipe diameter as shown in the figure below, and the number of bending portions should be three at maximum. 3) Adopt an elastic support for supporting the tail pipe and use the same support method as the standard vehicle. 4) For the direction of the tail pipe opening, strictly observe the respective ADR, State and Territory regulations. 5) Do not install a spark arrestor, because it substantially increases the exhaust pressure and adversely affects the muffler/catalytic converter assembly and engine. 6) Any modification of the vehicles tail pipe will effect the vehicles noise compliance (ADR 83/00). It is the responsibility of the modifier to ensure the vehicles continued compliance with ADR 83/00. Handling of the SCR Catalyst/Muffler Assembly The SCR catalyst/muffler assembly is equipped with exhaust temperature sensors, NOx sensors, pressure sensors and the dosing module. Harnesses are connected to the sensors of the unit and hoses are connected to the dosing module. During body installation, exercise due care to the harnesses and the hoses. Damage to those components may result in a failure of the exhaust emission control devices. Caution: Do not touch water emitted from the exhaust system as it may be slightly acidic. It if makes contact with skin or clothes, flush the area generously with water. Precautions when Painting around the SCR Catalyst/Muffler Assembly and Supply Module Painting of the SCR catalyst/muffler assembly, exhaust pipes, sensors, dosing module, harness and hoses or the supply module is prohibited

48 GUIDELINES BODY INSTALLATION Precautions when Installing Equipment near Exhaust System Components Above the SCR Catalyst/Muffler (Heat Shield + Insulator) Assembly Refer to the following table for the heat-resistant temperature of the equipment to be installed and the required distance from the heat shield. Heat-Resistant Temperature of Equipment Distance from Exhaust System Components 80ºC 20 mm or more 70ºC 60 mm or more SCR Catalyst/Muffler Assembly Except Above the SCR Catalyst/Muffler Assembly and other Exhaust System Components Refer to the following table for the heat-resistant temperature of the equipment to be installed and the required distance from the exhaust system components. Heat-Resistant Temperature of Equipment Distance from Exhaust System Components 100ºC 150 mm or more 80ºC 200 mm or more CAUTION: When it is not possible to provide sufficient clearance for the equipment s heat-resistant temperature, ensure that the necessary measures such as adding a heat insulation panel or heat insulation material are installed

49 GUIDELINES BODY INSTALLATION ALLISON AUTOMATIC TRANSMISSIONS PRECAUTIONS & OPTIONAL FEATURES 1. APPLICATION: MK/PK Models with Allison 2500 Series Transmission The base chassis-cab models, as supplied by UDT, are approved for on highway distribution (i.e. typical tray or van type body) applications only and if subjected to heavy duty applications such as a refuse compactor, street sweeper, off road or site work MUST be equipped with an additional heavy duty transmission oil cooler kit. Consult your local UD Trucks Dealer for further information. 2. COOLING SYSTEM: PKC8E, PDC8E Models with Allison 3000 Series Transmission PWC8E Models with Allison 3500 series Transmission Adopt an oil to water heat exchanger, located to the front chassis cross member, in lieu of the previous oil to air radiator assemblies mounted to the RH chassis rail. Allison 3000 Oil to Water Heat Exchanger 3. LUBRICANT: Allison 2500, 3000 and 3500 Series Transmissions The transmission is filled with Allison TRANYSND fluid during UDTC production. For in service top up or replenishment, Allison TRANSYND fluids or TES-295 approved fluids are the only fluids recommended. The use of fluids other than those recommended WILL VOID the transmissions warranty. 4. DRIVELINE MODIFICATION: Allison 2500, 3000 and 3500 Series Transmissions Any modifications to the driveline MUST be carried out in accordance with the Allison publication BASIC DRIVELINE DESIGN. A current copy of this publication can be obtained from either your Allison Transmission dealer or by ing a request to dave.baxter@allisonpacific.com 5. BREATHER PROTECTION: Allison 2500, 3000 and 3500 Series Transmissions To prevent any potential spillage from a body or tank containing liquid (particularly water) mounted to the chassiscab directly above the transmission, being ingested by the transmission, it is recommended that the transmission breather be raised and extended to a protected position under the cab structure Series 3000 Series

50 GUIDELINES BODY INSTALLATION 6. OPTIONAL FEATURE: Reprogramming of Allison 2500, 3000 and 3500 Series Transmissions To accommodate customer preferences or specific application requirements, the subject model t/m ECU s can be reprogrammed, by your Allison Transmission dealer, to remove the standard shift calibration program that includes the feature nominated in the table below. The costs associated with this reprogramming are the responsibility of the UDT Dealer or customer. MKB8E PKC8E PKC8E PDC8E PWC8E UD Trucks Model /3500 Allison Transmission Series Standard Feature A5300YZL A5300YZK Shift Calibration No. EBI: (exhaust brake interface) Yes Yes Recommended for general duty cargo/distribution truck, reduces reliance on the service brakes EBI: When the exhaust brake is turned ON the t/m is forced to downshift; 2500 Series: From 5 th 4 th 3 rd 2 nd gear (alternate preselect 2 nd range) at approximately 1300 rpm, providing increased engine braking performance. 3000/3500 Series: Quickly from 6 th 5 th 4 th gear (standard preselect 4 th range) and thereafter the 4 th 3 rd 2 nd gear (alternate preselect 2 nd range) shifts occur at approximately 1300 rpm, providing increased engine braking performance. When the exhaust brake is turned OFF, downshifts occur at approximately 1050 rpm refer note below. Note: When the EBI is disabled, the calibration program downshifts the t/m at approximately 1050 rpm, irrespective of the exhaust brake function being turned either OFF on ON. 3000/3500 Series: Should the customer require any additional optional features, such as those listed below enabled or disabled, the Allison dealer should be made aware of this whilst reprogramming the vehicle. AFRI (auxiliary function range inhibit): Prevents the t/m from being shifted from N to either a forward or reverse driving range without depressing the brake pedal. DCE (direction change enable): Prevents the t/m from being shifted from either a forward to reverse or a reverse to forward driving range without depressing the brake pedal. RDCI (rolling direction change inhibit): Prevents the t/m from being shifted from either a forward to reverse or a reverse to forward driving range unless the vehicle is stationary. Note: The AFRI, DCE, and RDCI optional features are recommended for additional t/m protection where the vehicle application incorporates a high degree of forward/rearward direction changes. Location Allison Transmission Diagnostic Plug (RH side of steering column/pedal bracket)

51 GUIDELINES BODY INSTALLATION OTHER Refer the following sections of this manual for guidelines relating to: Chassis Layout PTO Specifications Electrical System Air System Painting

52 GUIDELINES BODY INSTALLATION TIGHTENING TORQUE OF GENERAL CHASSIS BOLTS The tightening torque of the bolts and other fasteners that secure the major components parts is specified in the UDTC Service Manual. In the case where there is no mention of tightening torque, general chassis bolts and fasteners should be tightened according to the following tables of bolt standard tightening torque. NOTE: All bolts and nuts are sized using the metric system. Do not use parts other than those designated. Standard Tightening Torque: Nm (without lubricant) Nominal Bolt Ø Pitch Standard Bolt Bolt with Flange Size mm mm 4T 7T 9T 4T 7T 9T M M M M M M M M M M M M M M NOTE Special parts are excluded. This standard above is applicable to bolts having the following marks embossed on the bolt head. Material Code 4T 7T 9T Mark 4 or 40 7 or 70 9 or 90 Flange Bolt (Mark F) Nominal Size Bolt Ø mm Pitch mm Recommended Tightening Torque: Nm M M M

53 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EL-E (Steel leaf suspension) MKB8EL-E (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 235/75R17.5 OH 2526 FHF 758 HEIGHT FHR 844 GC

54 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EL-F (Steel leaf suspension) MKB8EL-F (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 235/75R17.5 OH 2526 FHF 758 HEIGHT FHR 844 GC

55 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EC-F (Air suspension) MKB8EC-F (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 235/75R17.5 OH 2526 FHF 758 HEIGHT FHR 800 GC

56 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EL-K (Steel leaf suspension) MKB8EL-K (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 235/75R17.5 OH 2526 FHF 758 HEIGHT FHR 843 GC

57 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EC-K (Air suspension) MKB8EC-K (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 235/75R17.5 OH 2526 FHF 758 HEIGHT FHR 800 GC

58 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EL-L (Steel leaf suspension) MKB8EL-L (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. Unit: mm TYRE SIZE 235/75R17.5 OH 2525 HEIGHT FHF FHR GC

59 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EC-L (Air suspension) MKB8EC-L (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 235/75R17.5 OH 2525 FHF 757 HEIGHT FHR 800 GC

60 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EL-N (Steel leaf suspension) MKB8EL-N (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 235/75R17.5 OH 2525 FHF 757 HEIGHT FHR 840 GC

61 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EC-N (Air suspension) MKB8EC-N (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 235/75R17.5 OH 2525 FHF 757 HEIGHT FHR 799 GC

62 CHASSIS LAYOUT CHASSIS LAYOUT: MKB8EL-E Tipper (Steel leaf suspension) MKB8EL-E (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance. TYRE SIZE Unit: mm 245/70R19.5 OH 2544 FHF 776 HEIGHT FHR 862 GC

63 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EL-H (Steel leaf suspension) PKC8EL-H (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

64 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EC-H (Air suspension) PKC8EC-H (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

65 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EL-K (Steel leaf suspension) PKC8EL-K (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

66 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EC-K (Air suspension) PKC8EC-K (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

67 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EL-N (Steel leaf suspension) PKC8EL-N (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

68 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EC-N (Air suspension) PKC8EC-N (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

69 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EL-R (Steel leaf suspension) PKC8EL-R (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

70 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EC-R (Air suspension) PKC8EC-R (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

71 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EL-S (Steel leaf suspension) PKC8EL-S (Steel leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

72 CHASSIS LAYOUT CHASSIS LAYOUT: PKC8EC-S (Air suspension) PKC8EC-S (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) 275/70R22.5 OH FHF HEIGHT FHR GC WIDTH FT OW

73 CHASSIS LAYOUT CHASSIS LAYOUT: PDC8EC-V (Air suspension) PDC8EC-V (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). TYRE SIZE Unit: mm 295/80R22.5 (front), 11R22.5 (rear) OH 2731 HEIGHT FHF FHR GC 266 FT WIDTH OW

74 CHASSIS LAYOUT CHASSIS LAYOUT: PWC8EL-P (Leaf suspension) PWC8EL-P (Leaf suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) OH 2733 HEIGHT FHF FHR GC 266 WIDTH FT OW

75 CHASSIS LAYOUT CHASSIS LAYOUT: PWC8EC-W (Air suspension) PW8EC-W (Air suspension) Note: OH = Overall Height, FHF = Frame Height Front, FHR = Frame Height Rear, GC = Ground Clearance, FT = Front Track, OW = Overall Width (rear axle). Unit: mm TYRE SIZE 295/80R22.5 (front), 11R22.5 (rear) OH 2731 HEIGHT FHF FHR GC 266 WIDTH FT OW

76 CHASSIS LAYOUT MASS CHASSIS CAB: MKB8E

77 CHASSIS LAYOUT MASS CHASSIS CAB: PKC8E

78 CHASSIS LAYOUT MASS CHASSIS CAB: PDC8E AIR Rear Suspension Model Description Chassis Layout W/base (mm) PD24280VAA PDC8EC-V 6710 Transmission DRY Mass WET Mass Front Rear Total Front Rear Total 3000 Auto spd Man Note: Mass is an estimation only, based on a standard model as listed below; - DRY Mass: Includes fluids (except diesel fuel or AdBlue), STC and spare, excludes tools and driver. - WET Mass: Includes all fluids (diesel fuel 400L and AdBlue 50L), STC and spare, tools and excludes driver. STC = Spare Tyre Carrier OPTIONS (add) W/base (mm) Mass Front Rear Total Rear Engine PTO MASS CHASSIS CAB: PWC8E Steel LEAF Rear Suspension Model Description Chassis Layout W/base (mm) Transmission DRY Mass WET Mass Front Rear Total Front Rear Total PW24280PAL PWC8EL-P Auto AIR Rear Suspension Model Description Chassis Layout W/base (mm) Transmission DRY Mass WET Mass Front Rear Total Front Rear Total PW24280WAA PWC8EC-W Auto Note: Mass is an estimation only, based on a standard model as listed below; - DRY Mass: Includes fluids (except diesel fuel or AdBlue), STC and spare, excludes tools and driver. - WET Mass: Includes all fluids (diesel fuel 200L-PAL, 400L-WAA and AdBlue 50L), STC and spare, tools and excludes driver. STC = Spare Tyre Carrier OPTIONS (add) Rear Engine PTO W/base (mm) Mass Front Rear Total

79 FRAME ASSEMBLY DRAWING: MKB8E CHASSIS LAYOUT

80 FRAME ASSEMBLY DRAWING: PKC8E CHASSIS LAYOUT

81 FRAME ASSEMBLY DRAWING: PDC8E CHASSIS LAYOUT Model Susp A L1 L2 L3 L3a L4 L6 L7 ROH WB WL PDC8E-V Air VIEW B VIEW C Unit: mm

82 FRAME ASSEMBLY DRAWING: PWC8E CHASSIS LAYOUT Model Susp A L1 L2 L3 L3a L4 L6 L7 ROH WB WL PWC8E-W Air VIEW B VIEW C Unit: mm

83 CHASSIS LAYOUT SECTION MODULUS: MKB8EL - E~L W/base (Steel leaf suspension) SECTION MODULUS: MKB8EL - N W/base (Steel leaf suspension)

84 CHASSIS LAYOUT SECTION MODULUS: MKB8EC - F~L W/base (Air suspension) SECTION MODULUS: MKB8EC - N W/base (Air suspension)

85 CHASSIS LAYOUT SECTION MODULUS: PKC8EL (Steel leaf suspension) SECTION MODULUS: PKC8EC (Air suspension)

86 CHASSIS LAYOUT SECTION MODULUS: PDC8EC (Air suspension) SECTION MODULUS: PWC8EL (Leaf suspension)

87 CHASSIS LAYOUT SECTION MODULUS: PWC8EC (Air suspension) ALLOWANCE FOR REAR AXLE, SUSPENSION & TYRE ARTICULATION Unit: mm Chassis Rear Tyre Model Suspension Size Ha H1 H2 H3 S MKB8EL Steel Leaf n/a /75R17.5 MKB8EC Air n/a PKC8EL Steel Leaf 275/70R n/a 75 11R PKC8EC Air 275/70R n/a 11R PDC8EC Air 11R n/a PWC8EC Air 11R n/a n/a = not applicable

88 CHASSIS LAYOUT Air Rear Suspension Note: Ha: Applicable air rear suspension models only, suspension deflated. H2: Applicable to steel leaf rear suspension models only. Air rear suspension models must have a minimum clearance of 115 mm forward of the front suspension mounting bracket as shown above. Be careful not to cause interference when installing the body, fuel tanks, rear wheel guards, etc. When installing tyre chain, add 50 mm to H1 and H3 dimensions. Trunnion Rear Suspension The figure below shows the maximum ascending position of the upper torque rod between frames. Be careful not to cause interference when installing it to the body. CAUTION: The maximum ascending position of torque rod indicates the position where the axles are in metallic contact

89 CHASSIS LAYOUT ALLOWANCE FOR BODY CLEARANCE, CAB TILT AND SUSPENSION MOVEMENT To accommodate the moving portion of the cab (cab main body, cab tilt linkage, air intake etc.), on the cab suspension of +/- 45 mm longitudinal, 40 mm vertical and 30 mm lateral movement, when installing the rear body/equipment provide a clearance of; (1) 100 mm or more to the moving portion of the cab and (2) 40 mm or more between any fixed chassis parts (fluid reservoir, cab support, rear engine cover etc.). *When tilting the cab, be careful as the TC (tilt centre) raises a maximum of 20 mm (i.e. TC + 20 mm). Unit: mm Vehicle Model MKB8E PKC8E PDC8E PWC8E H1: Cab to Frame L1: Tilt Centre to Front Axle L2: Front Axle to Air Intake L3: Front Axle to Engine Cover TC: Tilt Centre to Frame TR: Tilt Radius

90 PTO SPECIFICATIONS PTO LOCATION Rear Engine PTO Chassis Model MKB8E PKC8E PDC8E PWC8E Engine Model GH7 Unit: mm PTO Output Torque H1 H2 M1 M2 M3 θ 343 Nm (35 kgf.m) Transmission PTO (Aust. Vendor supplied PTO s) Chassis Model MKB8E PKC8E PDC8E PWC8E Engine Model GH7TA GH7TB GH7TA GH7TB Transmission Model MLS63B (6.718~0.740) Allison 2500 (3.512~0.737) MPS63B (7.027~0.780) Allison 2500 (3.512~0.737) MPS63B (7.027~0.780) Allison 3000 (3.487~0.653) ES11109 (12.64~1.00) H1 H2 L1 θ º º Unit: mm PTO Ratio Location Max. Output Torque Refer to Local Vendor for their Australian Specifications Transmission PTO (UDTC Factory Option): High output torque type MLS63B T/M Chassis Model MKB8E Engine Model GH7TA Transmission Model MLS63B (6.718~0.740) PTO Output Torque {Reduction} 343 Nm (35 kgf.m) {1.003} Rotation Direction Clockwise when viewed from rear. Unit: mm H1 H2 H3 L1 L2 L3 L4 θ º - 1 -

91 PTO SPECIFICATIONS REAR ENGINE PTO Layout Note: This rear engine PTO is designed to be coupled to the driven unit/device only by a shaft with a splined slip joint and universal joint at each end. ANY other configuration requires UDT Engineering approval. Drive Shaft Installation When installing a drive shaft to the PTO, ensure the following instructions are adhered to; The joint angles, B1 and B2 should be kept between 0~8.5º. The angles B1 and B2 should be equal. WARNING: It is the installer s responsibility to ensure that the drive shaft, slip joint, universal joints and flanges, drive shaft angles, etc. are suitable for the speed and torque of the Rear Engine PTO and driven unit/device. It is strongly recommended that a suitable guard is constructed around the Rear Engine PTO drive shaft

92 PTO SPECIFICATIONS Specifications Drive Flange Dimensions Type 1 Type 2 (high speed) Drive Ratio: x engine speed x engine speed Performance Chart: Max. Torque Output: Direction of Rotation: Mass Note: 343 Nm (35 kgf.m) Counter clockwise when viewed from the rear 16 kg 1. Attaching Bolt Tightening Torque: 46~56 Nm. 2. Drive flange supplied with PTO assembly

93 Parts List Kit Type 1 (0.850): P/No PTO85 Kit Type 2 (1.200): P/No PTO12 PTO SPECIFICATIONS Kit Type 1 Type 2 Drive Ratio x engine speed Key No. Qty P/No s (kit contents) Part Name Power Take Off Bolt-Flange, PTO attaching Sealing, PTO bolt-flange Rubber Ring, PTO Oil Pipe Cyl. Block to Oil Distribution Housing Gasket, oil pipe (5) Oil Pipe Compressor & PTO Oil Feed 8 Bolt-Eye Distribution Housing, front end of pipe (7) Bolt-Eye PTO, rear end of pipe (7) Gasket, oil pipe (7) Z0E Tube Assembly Compressor Delivery Gasket, tube (11) Z0E Tube Assembly Compressor Unloader Gasket, tube (13) WARNING To ensure adequate oil supply to both the engine compressor and PTO assembly, it is mandatory that the following components be installed and the removed parts discarded when fitting a Rear Engine PTO unit. P/No Oil Pipe, Cyl. Block to Oil Distribution Housing (key no. 5) P/No Bolt-Eye, Distribution Housing (key no. 8) Note: Failure to do so may void both the Engine Compressor and Rear Engine PTO Warranty. Installation PTO Assembly - 4 -

94 PTO SPECIFICATIONS Installation Oil Pipes Installation Air Tubes Nominal Size TIGHTENING TORQUE OF GENERAL CHASSIS BOLTS Standard Tightening Torque: Nm (without lubricant) Pitch Standard Bolt Bolt with Flange mm Bolt Ø mm 4T 7T 9T 4T 7T 9T M M M8 8.0 M M

95 PTO SPECIFICATIONS Installation Sequence Disconnect: Battery (-) terminal. Note: Wait for approximately 2 minutes after turning the ignition key to the OFF position to allow the SCR Urea Dosing System to cease operation. Remove: (A) Rear engine cover. (B) Tube assembly compressor unloader. (C) Tube assembly compressor delivery. Note: Discard tube assemblies (B & C) but retain all attaching hardware, plus 1 x tube (C) P clip and insulator for use at item (G on MK/PK/PD/PW**280 models). (D) Bracket compressor tube support. (E) Bracket LH, compressor tubes/electrical harness support. Must be removed to allow installation of oil pipe (7). (F) PTO aperture cover plate (ensure area is clean before removal). Install: (1) Power Take Off assembly utilising; (2) 4 x Bolt-Flange, (3) 4 x Sealing, (4) 1 x Rubber ring and torque the attaching bolts to specification. Note: a. Refer parts list for key no s 1, 2, 3 & 4. b. Ensure that when torqued in place, the PTO has approximately 0.2~0.3 mm of backlash at the drive flange bolt PCD and rotates freely when checking the backlash. Relocate MK/PK/PD/PW ** 280 models: (G) To provide wiring harness clearance from the PTO drive flange, utilising the P clip and insulator retained from (C), relocate the rear of engine wiring harness from the flywheel housing to the RH lower bolt on the PTO assembly

96 PTO SPECIFICATIONS Remove: (H) Panel RH, chassis. (I) Crankcase ventilation unit (rest on top of the inlet manifold) (J) Air intake housing. Disconnect: (K) Oil pressure switch wiring harness. Remove: (L) Bolts, support bracket engine wiring harness. Note: The above is necessary to obtain sufficient clearance to remove the existing oil pipe and install the new oil pipe (7). Remove: (M) Bolt, support bracket oil pipe. (N) Oil pipe compressor oil feed. (O) Oil pipe cyl. block to oil distribution housing. Note - Discard: a. (N) Oil pipe (6.4 mm ØD), retain bolt-eye, compressor. b. (O) Oil pipe (6.4 mm ØD), retain both bolts-eye. c. (P) Bolt-eye (M10 x 18 x 4.0 mm ØD oil feed hole) from the oil distribution housing end of oil pipe (N). Install: (5) Oil Pipe Cyl. Block to Oil Distribution Housing (10.0 mm ØD) with Gaskets (6) and torque to specification. Note: a. Refer parts list WARNING. b. Refer parts list for key no s 5 &

97 Install (cont.): (7) Oil Pipe Compressor & PTO Oil Feed (10.0 mm ØD) with gaskets (10). To install the oil pipe into position, it must be fed in from the rear of the engine, to the left of the compressor and behind the LH engine wiring harness and then under the wiring harness support bracket (L). Once in position, start the bolt s-eye/bolt, support in the following sequence, (9) (Q) (8) (M) and then torque to specification. (8) Bolt-Eye Distribution Housing. (9) Bolt-Eye PTO ID Bolt-Eye (8 & 9): M10 x 22, 2 x 5.0 mm ØD radial oil feed holes. (Q) Bolt-Eye Compressor ID: 2 x radial oil feed holes. (M) Bolt, support bracket. Note: a. Refer parts list WARNING. b. Refer parts list for key no s 7, 8, 9, & 10. Install: (L) Bolts, support bracket engine wiring harness. Reconnect: (K) Oil pressure switch wiring harness. Install: (J) Air intake housing. (I) Crankcase ventilation unit. (H) Panel RH, chassis. (E) Bracket LH, compressor tubes/electrical harness support. (D) Bracket compressor tube support to PTO assembly. (11)Tube assembly compressor delivery with gaskets (12). (13) Tube assembly compressor unloader with gaskets (14). ID Bolt-eye: 4 x radial air feed holes. Note: Refer parts list for key no s 11, 12, 13 & 14. PTO SPECIFICATIONS Reconnect: Battery (-) terminal. Start the engine and check for: Oil and air leaks. PTO operation. If noisy, contact UD Trucks Service Department for guidance. Install: (A) Rear engine cover. Reset: Time in Audio Unit: Refer to the vehicle Audio Manual. Date/Time in Multi-display: ) Refer to the vehicle Owner s Manual Equipment Description and Operation EHS MK manual T/M models: ) section Multi-display Monitor Settings display, date/time and the EHS ) initial and brake release adjustment items

98 PTO SPECIFICATIONS TRANSMISSION PTO UDTC Factory Option: High output torque (343 Nm) PTO MLS63B transmission Chassis Model Part No. PTO Assembly Drive Ratio Part No. Drive Flange MKB8E Z5379 (#) x engine speed Note: (#) cannot be retrofitted to the standard production MLS63B t/m assembly. Supply Condition: a) The PTO assembly is installed to the vehicle during production, without a drive flange. b) Drive flange, P/No , can be sourced locally from UDT Parts Dept. PTO Operation: A control, as per the following circuit diagram, is installed to the vehicle during production, when ordered with the UDTC factory PTO option

99 PTO Circuit: Manual Transmission Models PTO SPECIFICATIONS All manual transmission models incorporate the above PTO circuit electrical harness and this may be utilised to operate locally supplied transmission PTO s by the addition of the listed components and reference to the Engine Control System - Junction Connection Patterns in this section of this manual. Kit PTO Control Manual T/M Models: P/No SC002 Qty P/No s (kit contents) Part Name Z00 PTO Switch Z12 PTO Relay Z000 PTO Clutch Switch A Nut, PTO Clutch Switch Z0004 Stopper, PTO Clutch Switch Z1A Magnetic Valve

100 PTO Circuit: Automatic Transmission Models PTO SPECIFICATIONS All automatic transmission models incorporate the above PTO circuit electrical harness and this may be utilised to operate locally supplied transmission PTO s by the addition of the listed components and reference to the Engine Control System - Junction Connection Patterns in this section of this manual. Kit PTO Control Auto T/M Models: P/No SC004 2 Qty P/No s (kit contents) Part Name Z00 PTO Switch Z12 PTO Relay 1 PTO Relay 2 N&P Relay Z1A Magnetic Valve

101 PTO SPECIFICATIONS Harness and Connector Location: PTO & External Engine Control Lever Main Harness Chassis Harness

102 PTO SPECIFICATIONS 3. ENGINE CONTROL SYSTEM Engine with Electronic Controlled Fuel Injection System The engine with electronic controlled fuel injection system does not have a control lever on the injection pump. This feature can be retrofitted to chassis-cab models, by the installation of an external engine control lever unit that is available from your UD Trucks dealer. The control lever unit can be installed in close proximity to and connected to the engine harness connector CL44 (refer Fig. A), or relocated to any other position by utilising an extension sub-harness, refer to item b.2. Control Lever Installation Procedure. The characteristics of the governor (driving or all-speed mode) can be switched by connecting or disconnecting the two harness connectors (called junction A and junction B) respectively, which are located at the right hand side of the steering column, adjacent to the brake pedal. Note: For connecting positions, refer to Fig. B Location of Junctions A and B, and item a. Junction Connection Patterns. Control Lever (Pt No ND00A) Fig. A External Engine Control Lever and Location of Connector CL

103 PTO SPECIFICATIONS Fig. B Location of Junctions A and B CAUTION Junctions A and B have no flags. Connect them based on the wire colours. There is a harness (with a flag in roman characters) for trouble diagnosis near the Junctions A and B. Be careful not to connect it to any of the PTO junction connectors. For connection patterns, refer to item a. Junction Connection Patterns. Note: For connector locations refer to the Harness and Connector Location" layout in this section of this manual, Illustration Main Harness Chassis Harness Connector M-185 Junction A2 M-186 Junction B2 M-187 Junction AB M-188 Junction B1 M-167 PTO switch M-174 PTO Clutch Switch CL-44 PTO accelerator sensor Explanation of the Functions of Engine Control Parts and Installation Junctions A and B...Refer to item a. Junction Connection Patterns. Engine Control Lever... Refer to item b. External Engine Control Lever Unit. PTO Switch... Refer to item c. PTO Switch. Note: Conditions where engine control by the external engine control lever is activated. Transmission change lever: Neutral position must be selected. Vehicle speed: Vehicle must be stationary

104 PTO SPECIFICATIONS a. Junction Connection Patterns Notes: 1. PTO switch (incorporates both the PTO and governor switching function)...part No Z To switch the governor characteristics from Driving to All Speed mode, the ON or OFF signal of the PTO switch is required and in addition, the following conditions must be satisfied. Accelerator pedal: Idling position. External engine control lever: Idling position (if fitted). Transmission lever: Neutral position must be selected. Vehicle speed: Vehicle must be stationary. Clutch pedal (manual t/m models): The clutch pedal must be depressed and then released, after operation of the PTO switch, to engage the PTO circuit. 3. When using ENGINE PTO connection pattern 2 both the accelerator pedal and external control lever are active, the engine speed is determined according to either the accelerator pedal opening degree or the external engine control lever opening degree, whichever can achieve a higher speed. 4. When fitted with a PTO switch, the switch must be in the OFF position before starting the engine. When the switch is in the ON position, the engine DOES NOT START and a NO Start warning message is displayed in the instrument panel Multi-Display (ref. Fig. 5). End of Line Programming (EOLP) Parameters Should during PTO operation, the vehicle application require one or more of the optional features listed in the table below to be activated, the Vehicle Electronic Control Unit (VECU) is re-programmable by UDT, via your UD Trucks dealer. VECU program MID 144 Parameter Setting Optional Feature (when PTO switch is ON) Code Standard Optional LVU Accelerator pedal function Disabled Enabled LXD Engine Idle Control (EIC) max. speed when active 980 rpm Required rpm LXJ Auto PTO Idle Speed Note: EIC must be set in the AUTO position for LXJ to function. 550 rpm Required rpm XM Parking Brake condition to activate PTO Disabled Enabled LVU Enabled: When an external engine speed control is also fitted to the vehicle, the engine speed is determined by whichever signal (i.e. accelerator pedal or external engine speed control) that can achieve the higher engine speed. LXD/LXJ Required (#) rpm: Available setting range is between idle to governed engine speed. (#) The set rpm is overridden by the accelerator pedal (LVU enabled) or external engine speed control (when fitted) if they transmit a signal that can achieve a higher engine speed than the LXD/LXJ set rpm. XM Enabled: Requires the parking brake to be applied to activate the PTO circuit. WARNING: Ensure that the PTO switch is turned OFF during driving. If the PTO switch is in the ON position, the governor characteristic is changed to the operation mode (all-speed). Driving under such a status is dangerous

105 PTO SPECIFICATIONS

106 PTO SPECIFICATIONS Note: Accelerator Pedal (active/disabled) When using ENGINE PTO connection patterns 3 and 4 or TRANSMISSION PTO connection patterns 2 and 3 and the PTO switch is turned to the ON position, the accelerator pedal function is disabled. Should the vehicle application require the accelerator pedal function to be active when using one of these connection patterns, refer to the End of Line Programming (EOLP) Parameters in this section of this manual

107 b. External Engine Control Lever Unit PTO SPECIFICATIONS 1. Specification of control lever 1) Reaction force of lever At idle: 1.02 Nm {0.104 kgf.m} At full speed: 2.00 Nm {0.204 kgf.m} 2) It is recommended that the engine speed, during PTO operation, be set to a minimum of 900~1000 rpm. Fig. 1 Engine Control Lever (Part No ND00A) CAUTION - Engine Control Lever: The adjusting bolts mounted at two points on the engine control lever (Fig 1a) have been set by UDTC during manufacture. Do not adjust them. Fig. 1a Engine Control Lever

108 PTO SPECIFICATIONS 2. Control Lever Installation Procedure 1) Install the control lever to an appropriate location taking into consideration the body installation and final vehicle application. 2) The control wire must be routed and supported by the body manufacturer. 3) Note: A mounting bracket must be manufactured by the body manufacturer. For detail concerning the control lever installation hole location and dimensions, refer to Fig. 1. Install the control lever at a position where water cannot be directly splashed upon it, including during car wash. In instances where it is not feasible to protect the control lever from water splash (at the portion A in Fig. 1), place a suitable cover on it. Do not install the control lever in the wrong direction as shown in Fig. 2. Fig. 2 Installation Direction If due to the installed location of the control lever the connection to harness requires extension, use extension sub-harness ( Z01) or equivalent. According to the GENERAL PRECAUTIONS ON ELECTRICAL WIRING in the electrical section of this manual, route/locate the sub harness and install vibration-proof fasteners where necessary. 4) The control lever harness is connected to chassis harness connector CL-44, located near the LH rear of the engine within the rear cab support. For detail concerning the harness connection, remove the rear engine cover and refer to Fig. 4 Location of Engine Control Lever Connector CL-44. The connector is equipped with a waterproof cap, and fastened to the engine harness using a binding tape. Before connecting, remove the tape and waterproof cap. (The connector is a 4-pin waterproof type.) Fig. 3 Installation Engine Control Lever

109 PTO SPECIFICATIONS c. PTO Switch Fig. 4 Location of Engine Control Lever Connector CL-44 (rear engine cover removed) If a PTO switch is to be added to a vehicle having no PTO/Governor switching function, install the switch in the space provided on the instrument panel. 1. Switch Part No Z Sequence of Installation 1) Pull the instrument cluster surround from the instrument panel to remove it. 2) Pull the escutcheon (PTO switch) forward from the instrument panel to remove it. 3) Install the PTO switch to the PTO switch installation point on the escutcheon. 4) The switch connector is connected to the S type 8 pin female connector M-167 which is taped to the subharness that branches from the main harness to the escutcheon. Remove the blue tape and pull out the connector. 5) Connect the PTO switch connector with connector M ) Install the escutcheon and instrument cluster surround in the reverse sequence of removal. Fig. 5 Instrument Panel and NO Start Warning Message 3. Precautions when Starting the Engine On a vehicle equipped with a PTO switch, be sure to turn the switch to the OFF position before attempting to start the engine. When the switch is in the ON position, the engine DOES NOT START and the Multi- Display Monitor will display a NO Start warning message (Fig. 5)

110 PTO SPECIFICATIONS d. Parts to be Prepared when the External Control Lever is Retrofitted Parts List Kit, Manual T/M Models: P/No SC001 Kit, Auto T/M Models: P/No SC003 Qty Note: The required parts can be purchased in either a kit form or individually as listed below. Manual Auto P/No s (kit contents) Part Name Remarks T/M T/M Z00 PTO Switch Install as required for the ND00A Engine Control lever selected Connection Pattern Z01 Sub-harness (3.5m) 1 PTO Relay 1 (man & auto t/m models) Z12 PTO Relay 2 (auto t/m models) N&P Relay (auto t/m models) Z000 (#) PTO Clutch Switch Refer note (a) A (#) Nut, PTO Clutch Switch Z0004 (#) Stopper, PTO Clutch Switch Z1A Magnetic Valve (air supply to T/M PTO) Not required for Engine PTO Note: a) To activate the transmission PTO circuit and the PTO ON display in the instrument panel Multi-Display:- Manual T/M Models: The PTO relay 1 and PTO clutch switch must be installed to the vehicle. (#) Rear Engine PTO Installation (i.e. without manual t/m PTO): It is permissible to delete the items marked (#) and bridge the terminals at connector M-174 PTO Clutch Switch. Caution: If bridged, apply suitable electrical insulation to connector M-174. Auto T/M Models: The PTO relays 1, 2 and the N&P relay must be installed to the vehicle. b) Refer to the Transmission PTO section of this manual for the PTO control circuit diagrams. PTO Switch (Pt No Z00) Instrument Panel - Multi-Display Monitor Relays ( LH Side under dash panel) Control Lever (Pt No ND00A) PTO Clutch Switch (Pt No Z000)

111 PTO SPECIFICATIONS

112 ELECTRICAL SYSTEM See MD-T wiring diagrams in the UDTC Service Manual for more detailed information on the electrical system. CAUTION: Battery Disconnection As the SCR Urea Dosing system operates for approximately 2 minutes after the ignition switch is turned to the OFF position, wait for more than 2 minutes before disconnecting the battery ( ) then (+) terminals. HARNESS: Wiring and Installation of Rear Combination and Registration Plate Lamps Harness for the rear combination and registration plate lamps has surplus harness that enables extension during body installation. The surplus harness is tied in bundles for shipment as shown in the figure below. At body installation, lay out the harness without sagging and install retainer clips at intervals of 300 mm (ref. General Precautions on Electrical Wiring). Tie any remaining harness in a bundle and retain it so that it does not interfere with the brake piping, fuel piping, etc. Position of Rear Combination, Reversing and Registration Licence Plate Lamps Rear combination, reversing and registration plate lamps, supplied by UDT, all have ADR approval for photometric performance however their location on the completed vehicle must meet the positional requirements of ADR 13/--, refer to the Guidelines Legislation section of this manual. Ensure that the requirements of Appendix A, clause of ADR 13/-- are also met when considering the location of the registration plate lamp

113 ELECTRICAL SYSTEM LOCATION OF RELAY, FUSE BOX AND OTHER ELECTRICAL UNITS The fuse box, relay, engine control and other electrical units are located as shown in the illustrations below. CAUTION: When welding, strictly observe the Precautions During Electric Welding instructions in the Guidelines Body Installation section of this manual. Location A: LH Side of Dash - 2 -

114 ELECTRICAL SYSTEM Location B: LH Centre of Dash Location C: RH Centre of Dash - 3 -

115 ELECTRICAL SYSTEM Location D: Steering Column LH Side RH Side Location E: Under Passenger Seat ENGINE CONTROL LH Side of Engine LH Side of Cab Rear Support Bracket Engine Control Unit AdBlue - SCR System: ACM (Aftertreatment Control Module) - 4 -

116 ELECTRICAL SYSTEM USING THE ADDITIONAL POWER SOURCES Available additional power sources and their respective terminals are listed in the following table. The available additional power sources vary depending on the vehicle model. Check the applied model for availability. Terminal No. for the power source (Product No. of Yazaki Corporation) Item No. Additional power source item Location of the terminal for the power source Maximum output capacity Terminal on the chassis side (Accessory No.) Shape Terminal for connection (prepared by the body manufacturer) Shape Applied models 1 Additional power source in the cab Upper portion of the control unit on the passenger side Direct to BAT #200W ACC #140W IGN 200W All vehicles 2 Chassis (1) Battery Relay Box - 3 Chassis (2) Battery Terminal - Battery relay terminal M8x1.25(nut) Battery terminal M8x1.25(nut) Ring terminal for automobile (Hole diameter 8.4 mm) 3 All vehicles All vehicles NOTES: The items Nos. in the above table correspond to the Item Nos. detailed in the following procedures. For Item No. 1, be sure to follow the Table 1: Additional power source output capacity of this section. The part No. indicated in the column for Terminal for connection is the Yazaki Corporation part No. that is recommended for use when the body manufacturer uses these power sources. The shapes of connectors are as shown in the figure below

117 Item No 1. Additional Power Source Cab Interior ELECTRICAL SYSTEM Maximum output Location of the terminal for the power source capacity 1. BAT #200W Upper portion of the control unit on 2. ACC #140W the passenger side 3. IGN 200W Table 1: Additional Power Source Output Capacity CAUTION: a) # Maximum combined load capacity (i.e. 1+2) is 200W due to the fuse capacity. b) Maximum combined load capacity (i.e ) is 280W. The terminals for taking out the additional power source in the cab, in series, are provided on the passenger side behind the LH lower dash panel. Additional Power Source Cab Interior 1) BAT (illustration key M-68): For additional live power source directly connected to the battery Wire code: Yellow Flag: BAT. Terminal: Female plug Output Capacity: Refer to Table 1: Additional Power Source Output Capacity in this section. Fuse: This circuit is fused using a 10A fuse inside the cab (fuse No. 7). 2) ACC (illustration key M-66): For additional power source of accessory Wire code: Red Flag: ACC. Terminal: Female plug Output Capacity: Refer to Table 1: Additional Power Source Output Capacity in this section. Actuation: Turned ON by turning the ignition switch to the ACC. position. Fuse: This circuit is fused using a 15A fuse inside the cab (fuse No. 46). 3) IGN (illustration key M-67): For additional power source from the ignition circuit Wire code: Blue Flag: IGN Terminal: Female plug Output Capacity: Refer to Table 1: Additional Power Source Output Capacity in this section. Actuation: Turned ON by turning the ignition switch to the IGN position. Fuse: This circuit is fused using a 15A fuse inside the cab (fuse No. 44). 4) Grounding (illustration key M-69): Earth Wire code: Black Flag: No marking Terminal: Female plug Capacity: 280W (ref. caution above)

118 ELECTRICAL SYSTEM Item No 2. Additional Power Source Battery Relay Box A power source can be taken from the battery relay terminal in the battery relay box. Output: 20A (Atmosphere temperature: 60 C or less). Terminal: Use a ring terminal for automobile use with the hole diameter of 8.4 mm. Harness: Use electric wire for automobile use with a minimum cross section area of 2.0 mm². Wire Routing: Cut the protruding portion of the rubber grommet attached to the side of the battery relay box, pass the additional harness through the grommet, then apply a sealing process for waterproofing. Actuation: Turned ON by turning the ignition switch to the ON position. CAUTION: An in-line fuse of appropriate capacity MUST be installed. If relocated, install the battery relay box with the water drain hole facing downwards. Additional Power Source Battery Relay Box Item No 3. Additional Power Source Battery Terminal If a power source is taken directly from the battery, connect the battery cable together with the additional harness terminal using the existing fixing nut as shown below. CAUTION: An in-line fuse of appropriate capacity MUST be installed. Additional Power Source Battery - 7 -

119 ELECTRICAL SYSTEM GENERAL PRECAUTIONS ON ELECTRICAL WIRING 1. When installing the harness, do not install a harness connector at any place that may be exposed to water or dirt. If a connector is installed unavoidably at such a place, use a water-proof connector or protect the connector with a cover. Install the harness at places where the harness will not be damaged by the accumulation of water, dust, dirt, snow, etc., freeze, or flying stones. 2. To prevent disconnection due to vibration, fix the harness connectors and harness body securely with clip bands or vinyl coated clips as shown in Fig If a harness is installed across the edges of the frame, cab, body, other components etc., protect the harness by winding corrugated tubes around the harness or installing protectors at the edges. If the portion where the harness and the edge are in contact makes relative motion, protect the harness using both methods A and B. 4. If the plug is used for connection of harness, the female connector should be used on the power source side to prevent shorting to earth when the plug is disconnected. 5. When the harness passes through the hole of a thin metal plate, use a grommet to protect the harness

120 ELECTRICAL SYSTEM 6. When laying the harness to electrical parts such as lights, install the harness at a lower position than the electrical unit to prevent rainwater from entering the unit along the surface of the harness. 7. If the harness is installed in a place where relative movement, vibration, etc. occurs (between the cab and frame or between the engine and vehicle body, for example), adjust the length of the harness appropriately to prevent the harness from being pulled or caught in. 8. Keep the harness and connector over 200 mm away from any heat source so that the temperature of the wires does not exceed the allowable temperature of 60 C. Note: If it is impossible to secure a sufficient clearance, provide an insulated shield between the harness and heat source. 9. When installing an additional wire, and there is an existing harness in the vicinity of the wiring route, tape or cable tie that additional harness along the existing harness. Do not lay the harness along any piping such as the brake piping, fuel piping, etc. (of any pipe material such as steel tube, rubber hose, vinyl hose, etc.). Provide the specified clearance between the pipes and harness as shown in the figure below

121 ELECTRICAL SYSTEM 10. A single harness must be supported/retained at intervals of 300 mm or less. 11. When extending a harness, use a wire which has the same conductor and insulator size, colour, etc. Secure the conductor connection by crimp connection or soldering and apply a complete insulation coating to the connection using a heat-shrinkable tape with adhesive. When connecting harness outside the cab, be sure to waterproof and insulate the connection. 12. When installing an additional electric device, install a protected wiring circuit via a fuse or fusible link. The fuse rating should be chosen to protect both the device and wiring circuit. Use of Transceiver and Voltage Converter If a transceiver and/or voltage converter is installed, ensure that the equipment is, NOT located in close proximity to the vehicle s existing on-board ECU s and that the grounding wire for the equipment is connected to the battery supply s negative terminal. Otherwise an induced current or noise can potentially flow in the vehicle s electrical systems disrupting the stability of the electrical equipment, particularly ECU s that control engine, transmission and braking system functions etc

122 ELECTRICAL SYSTEM CAB Routing of Additional Harness into the Cab A rubber grommet for additional harness installation is located above the harness connector box on the LH side of the cab front panel behind the front lid. Route the additional harness as shown in the following illustration. One of two sizes of additional harness can be passed through the grommet by cutting at either the cross section A- A (max. diameter of 7 mm) or B-B (max. diameter of 13 mm) of the rubber grommet. Lay the harness through the grommet as illustrated below (i.e. interior upwards, exterior downwards). If an electric unit is installed on the inside of the cab, water may enter the unit along the inner surface of the harness. To prevent this, face the terminal downwards and route the harness lower than the electric unit. CAUTION: Seal the grommet through which the harness is passed to prevent water or drafts from entering. Allowance for Cab Tilt and Suspension Movement (when installing lamps, harnesses, etc) Provide a clearance and sufficient harness length to allow for cab movement of; +/- 45 mm longitudinal, 40 mm vertical, 30 mm lateral and a *20 mm allowance for the TC (tilt centre) to rise when tilting the cab (i.e. TC + 20 mm). Unit: mm Model TR (tilt radius) TC (tilt centre) MKB8E PKC8E PDC8E PWC8E

123 ELECTRICAL SYSTEM HARNESS AND ELECTRICAL COMPONENT LAYOUT See MD-T wiring diagrams in the UDTC Service Manual for detailed information on the electrical system. SCHEMATIC DIAGRAM The schematic diagram illustrates how each harness (main harness, chassis harness, floor harness, floor upper harness, body side harness, etc.) is wired on the actual vehicle. Depending on the model, however, the arrangements of the wires and units may sometimes be different, so the respective schematic diagrams must be carefully checked to see they coincide with the arrangements in the actual vehicle

124 ELECTRICAL SYSTEM

125 ELECTRICAL SYSTEM

126 ELECTRICAL SYSTEM

127 ELECTRICAL SYSTEM Type I, Type II M-1 Chassis harness 1 (CR-1) M-2 Chassis harness 2 (CL-1) M-3 Chassis harness 3 (CR-2) M-4 Chassis harness 4 (CR-3 M-5 Chassis harness 5 (CL-2) M-6 Chassis harness 6 (CL-3) M-7 Chassis harness 7 (CL-4) M-8 Cab front harness (CF-1) M-9 Floor upper harness 3 (U-3) M-10 Floor upper harness 1 (U-1) M-11 Floor upper harness 2 (U-2) M-12 Door harness (DL-1) M-13 Earth LH M-14 Floor upper harness 4 (U-15) M-15 VECU main relay M-16 Engine main relay M-17 Starter control relay M-18 Parking relay 1 M-19 T/M PTO relay 1 M-20 Parking relay 2 M-21 Fog light relay M-22 Inter lock relay M-23 Mirror heater relay M-26 ABS relay M-28 T/M PTO relay 2 M-30 Parking relay 3 M-35 ABS control unit 1 (pneumatic) M-36 ABS control unit 2 (pneumatic) M-37 Timer unit 1 M-38 Timer unit 2 M-40 VECU 1 (blue) M-41 VECU 2 (green) M-42 VECU 3 (green) M-45 NICU 1 (orange) M-46 NICU 2 (green) M-47 NICU 3 (white) M-48 Floor under harness LH (NL-1) M-49 Warning buzzer M-50 EHS control unit 1 M-51 EHS control unit 2 M-52 Stop light relay 1 M-53 Stop light relay 2 M-54 Stop light relay 3 M-57 ACM checker M-58 CAN resister M-65 Tacho graph M-66 Option accessory M-67 Option ignition M-68 Option battery M-69 Option earth CBCC CAN bus connector C CBCD CAN bus connector D CBCB CAN bus connector B CBCG CAN bus connector G M-80 Air conditioner sub harness 1 M-81 Air conditioner sub harness 2 M-100 Fuse block 1 (30P) M-101 Reverse relay M-102 Blower motor relay M-103 Air conditioner ignition relay M-110 Fuse block 2 (30P) M-111 Tail light relay M-112 Headlight relay 1 M-113 Headlight relay 2 M-114 Accessory relay M-120 Cigarette lighter M-122 Audio M-123 Fluorescence light switch M-130 Flasher unit M-132 Keyless entry unit M-133 Low air warning buzzer M-134 Horn relay M-136 Diode B M-137 Diode C M-138 Diode D M-139 Diode E M-140 Diode G M-141 Diode H M-142 Diode J M-145 Mirror heater switch M-146 ASCD main switch M-147 LCT power mode switch M-148 Display mode switch M-149 EHS off switch M-150 Diode I M-151 Meter cluster 1 M-152 Meter cluster 2 M-153 Meter cluster 3 M-154 Meter cluster 4 M-159 Floor under harness RH (NR-1) M-160 Diagnosis tool connector M-161 Accelerator switch M-162 Accelerator sensor M-163 Combination switch 1 M-164 Combination switch 2 M-165 Spiral cable M-166 Ignition switch M-167 T/M PTO switch M-168 Idle volume M-171 Door harness 1 (DL-1) M-172 Door harness DR2 (DR-2) M-173 Body side harness (B-1) M-174 Clutch switch 1 M-175 Clutch switch 2 M-176 Clutch stroke sensor M-182 Fog light switch M-183 Plug terminal (E) of erasing trouble codes 1 (EHS) M-184 Plug terminal (E) of erasing trouble codes 2 (EHS) M-185 Junction A2 M-186 Junction B2 M-187 Junction AB M-188 Junction B1 M-189 Air bag control unit M-190 Earth RH M-191 ATM diagnosis control unit M-194 ABS diagnose connector M-196 Diagnosis switch (air bag) M-198 Brake diagnose switch M-199 Diode PTO M-200 Neutral and Parking relay M-201 High-low relay M-202 Key lock solenoid M-203 Air suspension down switch M-204 Air suspension relay

128 ELECTRICAL SYSTEM

129 ELECTRICAL SYSTEM

130 ELECTRICAL SYSTEM Type I, Type II CHASSIS HARNESS RH CR-1 Main harness CS1 (M-1) CR-2 Main harness CS3 (M-3) CR-3 Main harness CS4 (M-4) CR-6 Joint connector chassis RH1 CR-8 Joint connector chassis RH3 CR-9 Joint connector chassis RH4 CR-10 EHS magnetic valve CR-20 Chassis harness LH5 (CL-20) CR-21 Chassis harness LH1 (CL-21) CR-22 Chassis harness LH2 (CL-22) CR-23 Chassis harness LH3 (CL-23) CR-24 Bumper sub harness RH CR-25 Electric horn low CR-26 ABS modulator front RH CR-27 Frame earth 2 CR-29 ABS wheel speed sensor front RH CR-35 Frame earth 1 CR-38 Air pressure switch sub harness 2 CR-39 Air dryer CL-29 ABS sensor front LH CR-41 Air pressure switch 1 CR-42 Air pressure switch 2 CR-43 Air pressure switch 3 CR-44 Air pressure switch 4 CR-45 Brake fluid level switch CR-46 Air booster stroke switch 1 CR-47 Air booster stroke switch 2 CR-49 Air pressure switch sub harness 1 CR-50 Exhaust brake valve CR-52 Air heater relay 2 CR-53 Fusible link block 3 CR-54 Fusible link block 5 CR-56 Fusible link block 6 CR-58 Fusible link block 8 CR-59 Fusible link block 9 CR-60 Fusible link block 10 CR-61 4P fuse block 1 CR-62 4P fuse block 2 CR-63 Battery relay 4P fuse 2 CR-64 Battery relay 1 CR-65 Dosing module CR-67 Exhaust temperature sensor (DPF) CR-72 NOX sensor SCR CR-73 Battery relay 4P fuse 1 CR-74 Battery relay 4P fuse 3 CR-75 Battery relay 2 CHASSIS HARNESS LH CL-1 Main harness CS2 (M-2) CL-2 Main harness CS5 (M-5) CL-3 Main harness CS6 (M-6) CL-4 Main harness CS7 (M-7) CL-11 Joint connector chassis LH 1 CL-12 Joint connector chassis LH 2 CL-13 Joint connector chassis LH 3 CL-16 Front turn light LH CL-17 Cab panel earth 1 CL-18 Frame earth 6 CL-20 Chassis harness RH5 (CR-20) Chassis harness RH1 (CR-21) CL-22 Chassis harness RH3(PK/PD/PW) (CR-22) CL-22 Chassis harness RH2(MK) (CR-22) CL-24 Bumper sub harness LH CL-26 ABS modulator front LH CL-27 W/L sensor sub harness (Type I, Type II) CL-28 Frame earth 5 CL-29 ABS sensor front LH CL-30 Joint connector chassis LH4 CBCE CAN bus connector E CL-35 Supply module CL-40 ACM CL-41 1P fuse block CL-42 Air heater relay 1 CL-43 Air heater relay 4 CL-44 PTO Accelerator sensor Location: Refer PTO Specifications section of this manual CL-45 Engine harness CS CL-48 Frame earth 3 CL-49 Frame earth 4 CL-50 AdBlue tank sensor CL-54 Low switch CL-55 Back up switch CL-56 Neutral switch CL-58 Speed sensor CL-60 Main T/M connector LCT CL-61 Output speed sensor CL-62 Turbine speed sensor CL-63 Engine speed sensor CL-66 TM sub harness chassis 1 CL-67 TM sub harness chassis 2 CL-70 Tank gauge unit CL-71 PTO magnetic valve Location: Refer PTO Specifications section of this manual CL-75 Tail harness 1 (T-1) CL-76 Tail harness 2 (T-2) CL-77 Tail harness 3 (T-3)

131 ELECTRICAL SYSTEM

132 ELECTRICAL SYSTEM

133 ELECTRICAL SYSTEM

134 ELECTRICAL SYSTEM

135 ELECTRICAL SYSTEM EARTH POINT: CAB M-190: RH (inside cab) M-13: LH (inside cab) CL-17: Front of cab EARTH POINT: CHASSIS

136 AIR SYSTEM Discharge of Air WARNING: Prior to disconnecting any air system components or air piping, the stored energy (i.e. air pressure) must be drained from EACH air system circuit by opening each of the drain cocks provided in the lower surface of each air reservoir. Typical Drain Cock Locations Preferential Charging of the Air System When additional air operated items are installed (i.e. air horns, PTO s etc.) air supply MUST be taken from the accessories circuit (i.e. clutch booster, driver s suspension seat, exhaust brake, etc.) delivery port side (refer outlet port 24 in the air piping diagrams included in this manual) of the air system Multi Protection Valve (MPV) as per the listed clauses extracted from ADR 35/04: Where the device generating the energy for any number of Brake Power Unit 35/ supplies energy to other devices, the design shall be such that all the Brake Power Unit 35/ are preferentially charged to an energy level of not less than 0.69 E (450 kpa) In the case of Service Brake Systems incorporating Brake Power Unit 35/ the design shall be such that all Brake Power Unit 35/ must preferentially service the brake system if the energy falls below 0.69 E (450 kpa). Definition: Brake Power Unit 35/ - a device installed in a brake system that stores the energy required to actuate the brakes and provides the energy either directly or indirectly through an auxiliary device, with the operator action consisting only of modulating the energy application level. Multi Protection Valve (MPV) and Port 24 Auxiliary System Circuit (MK shown) - 1 -

137 AIR SYSTEM Installation and Removal of Nylon Tube for Air Piping and Connector 1. Precautions for Handling Nylon Tube and Connector Nylon tubes are weak against heat. Before performing welding operations for remodelling of vehicles, remove nylon tubes. Nylon tubes are weak against acid. Do not touch nylon tubes with waste cloth or work gloves containing battery fluid. When installing or removing nylon tubes, be careful not to bend them. If a nylon tube is bent, replace it with a new one. Take extra care to prevent nylon tubes from interfering with other equipment, attachments or being caught in moving components. For removal and installation procedures, refer the following instructions. When installing nylon tubes, ensure that the tube bending radius is larger than the minimum values shown in the table below. Unit: mm Tube Outside Dia. Ǿ6 Ǿ8 Ǿ10 Ǿ12 Ǿ15 Bending Radius Nylon Tube Minimum Bending Radius 2. Removal/Installation for Push-On Type Connector Typical MD-T Push-On Type Connector Assembly a. Special Tools Cutter, Nylon Tube: P/No Z0002 Push Bar: P/No Z0003 use for 6, 8, 10 and 12 mm outside diameter tube. P/No Z0004 use for 10, 12 and 15 mm outside diameter tube. Band Binding Tool: P/No Z

138 AIR SYSTEM b. Removal (Push-On type) 1. Discharge the stored energy (i.e. air pressure). Refer item Discharge of Air in this section of this manual. 2. Remove dirt and dust from the connected area before disassembly. Note: To prevent incorrect re-assembly, it is recommended that the tube and connector be identified with a tag or similar means of identification. 3. Using special tool (99886 Z0003 or Z0004) push the collet towards the connector body whilst applying a pull force to the nylon tube. CAUTION Do not push the collet with a sharp-tipped tool such as a flat-blade screwdriver to extract the nylon tube. The collet could be damaged or deformed, making it impossible to use. 4. Remove dirt and dust from the insertion surface of the nylon tube. Disconnect the connector from all other piping and blow air inside the connector to remove any foreign materials. CAUTION When removing dirt and dust from inside the connector, disconnect the connector from the piping. Be sure not to allow dirt and dust to enter the piping. Never use oil to wash the connector as grease is used on the inside rubber seal. Washing with oil will eliminate the grease. Oil may be used to wash the surface of the nylon tube

139 AIR SYSTEM c. Installation (Push-On type) 1. Make sure there is no damage, burrs, dirt or dust on the insertion area of the nylon tube. NOTE The tube may be reused even though the collet pawl mark remains at the tip of the tube. This does not affect the sealing performance. 2. Push the nylon tube into the connector until it reaches the insertion position mark. NOTE A resistance is felt twice when inserting the nylon tube. Be sure to continue to push the tube until it reaches the insertion position mark. If insertion is insufficient air leakage may result. If replacing the tube, mark the insertion length on the nylon tube in accordance with the table below and then insert the nylon tube. Marking position Unit: mm Tube Outside Dia. Ø6 Ø8 Ø10 Ø12 Ø15 Length from tube tip CAUTION Do not use a tube with a crushed cut surface or an obliquely cut tube end as, when inserted, it could damage the seal within the connector, resulting in air leakage. When cutting a tube, use a special cutter (99661 Z0002) and cut it perpendicularly. When inserting a nylon tube, do not apply sealing bond as the sealing performance will be reduced making it impossible to re-use the connector 3. After insertion, apply a pull force to the nylon tube by hand to make sure it is securely connected. 4. Use soap suds to ensure there is no air leakage

140 AIR SYSTEM 3. Inspection of Nylon Tube and Connector Check the nylon tube and connector. If one the following conditions exists, replace them. Do not allow them to contact battery fluid. If they do contact battery fluid, replace the tube with a new one. When there are scratches on the nylon tube insertion portion (scratches on the portion where the V-seal contacts the nylon tube cause air leakage). When there are cuts caused by an edged tool on the surface of the nylon tube. When there is a crease on the nylon tube caused by bending. When the collet, cap or connector inner surface is damaged or deformed. When the surface of the nylon tube is deformed due to heat. When there are pin holes on the surface of the nylon tube caused by spatter during welding

141 AIR SYSTEM 4 Installation and Removal of the Binding Band of Nylon Tubes for Air Piping 1) Precaution on binding band There are three types of binding bands for nylon tubes depending on the installation position as follows: Install or remove the C type of band according to the following procedure. A: Band for Fixing to the Frame B: Binding Band: Standard C: Binding Band: Robust Type Can be Reused Can be Reused Cannot be Reused. Use the Binding Tool to apply. Installation/removal procedure of the binding band C type Cut the binding band to remove it. The cut band cannot be reused. If the binding band is removed during maintenance or body installation, be sure to reinstall a new binding band as specified below using the recommended binding tool. Part No. Part Name Z00 Binding band Z0003 Binding tool With the use of the binding tool, the band is bound with the tightening force set by the dial and the surplus end portion of the band is automatically cut. Installation of the Binding Band using Binding Tool (P/No Z0003): 1. Tighten the binding band to some extent by hand. 2. Put the binding band end in the tool. 3. Pull the trigger. The set tightening force (1.5, refer caution) is applied to the object to be bound and the tightening band is cut. CAUTION The tightening force adjustment dial of the tool shall be set to 1.5 (Reference tightening force: 130 N {13 kgf}). If nylon tubes are tightened at a tightening force other than the specified force, the nylon tubes may be damaged. Do not use the binding tool for tightening (or cutting the surplus portion) of the type A or B band, as the tightening force applied may break the hook from the band. To add or install nylon tubes when conducting the body installation, bind the new tubes and the existing nylon tube bundle together with a new band without cutting the existing band

142 AIR SYSTEM AIR PIPING DIAGRAMS MKB8E STANDARD GCM with ABS and EHS (Manual T/M models) - 7 -

143 AIR SYSTEM MKB8E STANDARD GCM with ABS (Auto T/M models) - 8 -

144 AIR SYSTEM PKC8E STANDARD GCM - 9 -

145 AIR SYSTEM PDC8E STANDARD

146 AIR SYSTEM PWC8E STANDARD

147 AIR SYSTEM

148 PAINTING PRECAUTIONS ON PAINTING Painting of Cabs The standard finished colour of the cabin structure, ex. UDTC production, is indicated in the table below. Paint Colour Code KANSAI PAINT W33 Jumping White Locally sourced touch up paint colour matching information is available from the listed websites; DuPont: then colour retrieval icon and follow the prompts. Spies Hecker: then colour finder icon and follow the prompts. CAB White Resin/Plastic Exterior Parts Exterior Parts recommended to be REMOVED before Painting Wiper arms and shaft covers Front lid, including hinges Condor, MK/PK/PD/PW (model) and Automatic marks Corner panel to grille extensions Corner panels Front grille Blanking plugs (roof deflector mounting points) Cab end-outline marker lamps Radio antenna Rear quarter window finisher and vent outlet trim panels Front fenders and skirt rubbers Cab steps and surround panels Mirror covers and arms Door handles Door turn signal lamps Air intake duct Note: Items such as vehicle identification plates, caution plates, decals, glass, rubber components (weather strips, drip seals, cab mounts), reservoirs (clutch, coolant, windscreen washer), door hinges and general chassis parts etc. not removed should be masked to prevent paint from being sprayed on them. CAUTION End-outline marker lamps and radio antenna: To prevent water entry ensure that the original packing is refitted, a sealant is applied to the attaching screws and the screws tightened to the specified torque

Ministerial Declaration (Loaded Silage Trailer) Order 2013

Ministerial Declaration (Loaded Silage Trailer) Order 2013 Ministerial Declaration (Loaded Silage Trailer) Order 2013 Under the ROAD TRANSPORT (GENERAL) ACT 2005 I, Duncan Gay, Minister for Roads and Ports, pursuant to section 16 of the Road Transport (General)

More information

SELF-STEERING AXLE TABLE OF CONTENTS

SELF-STEERING AXLE TABLE OF CONTENTS SELF-STEERING AXLE TABLE OF CONTENTS Section 1 - Introduction Section 2 - Pre-Installation Check List Section 3 - Ride Height Adjustments Section 4 - Suspension Mount Section 5 - Axle Mount Section 6 -

More information

TECHNICAL BULLETIN. Meritor WABCO Cab Leveling Valves and Chassis Leveling Valves. How the Cab Leveling and Chassis Leveling Valves Work

TECHNICAL BULLETIN. Meritor WABCO Cab Leveling Valves and Chassis Leveling Valves. How the Cab Leveling and Chassis Leveling Valves Work Revised 02-00 TECHNICAL BULLETIN Meritor WABCO Cab Leveling Valves and Chassis Leveling Valves This technical bulletin covers both cab and chassis leveling valves manufactured by Meritor WABCO. While the

More information

James M. Pleasants Company

James M. Pleasants Company James M. Pleasants Company SUBMITTAL DATA GAINESVILLE MECHANICAL DECEMBER 20, 2013 PROJECT: GSU: J-183 HUMANITIES LAW BLDG. QUOTE NO:12116 ENGINEER: STEVENS & WILKINSON GASKETED PLATE HEAT EXCHANGER Tag:

More information

Electronically Controlled Air Suspension (ECAS) for Trucks

Electronically Controlled Air Suspension (ECAS) for Trucks $2.50 Electronically Controlled Air Suspension (ECAS) for Trucks Maintenance Manual No. 36 Issued 7-99 ECAS System for 6 x 2 and 6 x 4 Vehicles with Rear Air Suspensions Service Notes Service Notes This

More information

Installation Instructions GOOSENECK MOUNTING KIT Chevrolet/GMC 1500/2500/3500 All except 4-door Crew-Cab

Installation Instructions GOOSENECK MOUNTING KIT Chevrolet/GMC 1500/2500/3500 All except 4-door Crew-Cab GOOSENECK MOUNTING KIT Equipment Required: Fastener Kit: F Wrenches: 3/4, 7/8, 15/16 Drill Bits: 1/4 Other Tools: Drill WARNING: Under no circumstances do we recommend exceeding the towing vehicle manufacturers

More information

Titan Makina Ltd. Şti. 1160. Sok. No: 9 Ostim 06370 Ankara Tel: + 90 312 354 9977 Fax: + 90 312 385 5611 Web: www.titanltd.com.

Titan Makina Ltd. Şti. 1160. Sok. No: 9 Ostim 06370 Ankara Tel: + 90 312 354 9977 Fax: + 90 312 385 5611 Web: www.titanltd.com. IS26 Concrete Spraying Machine IS26 Concrete Spraying Machine TECHNICAL SPECIFICATIONS Manipulator Max. vertical spraying reach : Max. horizontal spraying reach : Working lights : Spraying Head Rotation

More information

Competition 4 & 6 suspension Lift Toyota Landcruiser & nissan patrol

Competition 4 & 6 suspension Lift Toyota Landcruiser & nissan patrol Competition 4 & 6 suspension Lift Toyota Landcruiser & nissan patrol Competition suspension Product Guidelines Guidelines for sale and recommendation of 4 (100mm) and 6 (150mm) Lifts for Toyota Landcruiser

More information

5 axle Lowbed Semitrailer with Automatic Steering Model ST 70-93 L3. (Lowbed length approx. 14,000 mm) Technical Specification no.

5 axle Lowbed Semitrailer with Automatic Steering Model ST 70-93 L3. (Lowbed length approx. 14,000 mm) Technical Specification no. 5 axle Lowbed Semitrailer with Automatic Steering Model ST 70-93 L3 (Lowbed length approx. 14,000 mm) Technical Specification no. ST 70-93 L3 06/02 5 axle Lowbed Semitrailer with automatic steering Model

More information

Installation Guide for the TJ LCG PRO Suspension System (Low Center of Gravity) Available 4 or 5

Installation Guide for the TJ LCG PRO Suspension System (Low Center of Gravity) Available 4 or 5 INSTALLATION GUIDE Installation Guide for the TJ LCG PRO Suspension System (Low Center of Gravity) Available 4 or 5 Take every precaution to make this installation a safe procedure. Make safety the number

More information

INSTALLATION INSTRUCTIONS. 6111 Air Spring Kit 2011+ Ford F250/F-350 Single Wheel 2WD 2011+ Ford F350 Dually 2WD IMPORTANT NOTES

INSTALLATION INSTRUCTIONS. 6111 Air Spring Kit 2011+ Ford F250/F-350 Single Wheel 2WD 2011+ Ford F350 Dually 2WD IMPORTANT NOTES INSTALLATION INSTRUCTIONS 6111 Air Spring Kit 2011+ Ford F250/F-350 Single Wheel 2WD 2011+ Ford F350 Dually 2WD Thank you for purchasing a quality Hellwig Product. PLEASE READ THIS INSTRUCTION SHEET COMPLETELY

More information

SERIES ASM NEOPRENE/EPMD FLANGED SINGLE SPHERE CONNECTOR CONNECTORS. Pressures to 225 PSIG (15.51 barg) Temperatures to 230ºF (110ºC)

SERIES ASM NEOPRENE/EPMD FLANGED SINGLE SPHERE CONNECTOR CONNECTORS. Pressures to 225 PSIG (15.51 barg) Temperatures to 230ºF (110ºC) APPLICATIONS Process Industry Weak Acids Alkalies Compressed Air Pulp & Paper MODELS ASM - Flanged Connection OPTIONS Control Rods Oil & Gas Water & Waste Pump suction & discharge Sea water Chemical lines

More information

Check for deteriorated, shifting or missing tie-down pads. Replace if needed.

Check for deteriorated, shifting or missing tie-down pads. Replace if needed. C C 0 5 C H A S S I S F R A M E Chassis Frame Overview The Blue Bird Vision s chassis frame consists of two main C-channel rails which run the entire length of the bus, and several different kinds of cross

More information

16 April 2012 1032011-F 1994-2002 Dodge Adjustable Track bar with Relocation Bracket 1

16 April 2012 1032011-F 1994-2002 Dodge Adjustable Track bar with Relocation Bracket 1 16 April 2012 1032011-F 1994-2002 Dodge Adjustable Track bar with Relocation Bracket 1 BD Adjustable Track Bar w/bracket Dodge 2500-3500 4WD Models 1994-2002 Dodge 1500 4WD Model 1994-2001 P/N# 1032011-F

More information

Cooling system components, removing and installing

Cooling system components, removing and installing Page 1 of 34 19-1 Cooling system components, removing and installing WARNING! The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate

More information

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C. R O A D M A S T E R, I N C. MOUNTING BRACKET KIT 14 8 7 4 13 5 6 ITEM QTY NAME MATERIAL 1...6...1/2" x 2 1/2" BOLT... 350099-00 2...2...1/2" x 1 1/2" BOLT... 350095-00 3...8...1/2" LOCK WASHER... 350309-00

More information

Rating when used as a weight carrying hitch without spring bars:

Rating when used as a weight carrying hitch without spring bars: BOLT-TOGETHER WEIGHT DISTRIBUTING HITCH SYSTEM Rating when used as a weight distributing hitch with spring bars: Part Number 48051 4805 48053 48054 Max Tongue Weight 550 Ibs. 750 Ibs. 1000 Ibs. 1400 lbs.

More information

REPAIR INSTRUCTIONS UNDER BODY CYLINDER (UM, UL)

REPAIR INSTRUCTIONS UNDER BODY CYLINDER (UM, UL) Table of contents 1. Introduction... 3 1.1. Scope of use... 3 1.2. General remarks... 3 1.3. Contact Hyva... 3 1.4. Precautions... 4 1.5. Spare parts... 4 1.5.1. Prior to use... 4 1.6. Recycling and Reuse

More information

-1- SPECIFICATIONS 002085 CONE SETTER PLATFORM ATTACHMENT INDEX

-1- SPECIFICATIONS 002085 CONE SETTER PLATFORM ATTACHMENT INDEX -1-002085 CONE SETTER PLATFORM ATTACHMENT INDEX I. GENERAL EQUIPMENT : A. Intent Statement B. Cone Setter Platform II. III. 1. Understructure Frame 2. Mounting Components 3. Paint 4. Basket 5. Labels 6.

More information

S&W Race Cars and Components, Inc.

S&W Race Cars and Components, Inc. S&W Race Cars and Components, Inc. 11 Mennonite Church Road Spring City, PA 19475 TECH & INFORMATION: 610-948-7303 ORDERS: 1-800-523-3353 OFFICE FAX: 610-948-7342 E-Z INFO FAX 610-792-1234 CAUTION!!! -

More information

I BEAM TRACK INSTALLATION

I BEAM TRACK INSTALLATION PDQ 0/700 FESTOON SYSTEM INSTALLATION AND MAINTENANCE INSTRUCTIONS INTRODUCTION The PDQ Festoon System was designed to run on one of three sizes of I-beams: S x., S8 x 8. and S x.. System trolleys must

More information

APPLICATION FOR ADR ROAD VEHICLE APPROVAL CERTIFICATE

APPLICATION FOR ADR ROAD VEHICLE APPROVAL CERTIFICATE APPLICATION FOR ADR ROAD VEHICLE APPROVAL CERTIFICATE Before filling in this application, please see notes on Page 8. Consult your DGSA if unclear about any aspect. (All relevant parts of this application

More information

Drive shaft, servicing

Drive shaft, servicing Volkswagen Passat B6 - Drive shaft, servicing Стр. 1 из 41 40-7 Drive shaft, servicing Drive shafts, overview I - Assembly overview: Drive axle with CV joint VL100 40-7, Drive axle with CV joint VL100,

More information

INSTALLATION INSTRUCTIONS. 6108 Air Spring Kit 2011+ Ford F250 Single Wheel 4WD 2011+ Ford F350 Dually 4WD (2011 F350 Single Wheel 4WD use p/n 6113)

INSTALLATION INSTRUCTIONS. 6108 Air Spring Kit 2011+ Ford F250 Single Wheel 4WD 2011+ Ford F350 Dually 4WD (2011 F350 Single Wheel 4WD use p/n 6113) INSTALLATION INSTRUCTIONS 6108 Air Spring Kit 2011+ Ford F250 Single Wheel 4WD 2011+ Ford F350 Dually 4WD (2011 F350 Single Wheel 4WD use p/n 6113) Thank you for purchasing a quality Hellwig Product. PLEASE

More information

GENUINE PARTS INSTALLATION INSTRUCTIONS

GENUINE PARTS INSTALLATION INSTRUCTIONS GENUINE PARTS INSTALLATION INSTRUCTIONS DESCRIPTION: Illuminated Kick Plate APPLICATION: Rogue (2011) PART NUMBER: 999G6 GX010 KIT CONTENTS: Item A B C G H QTY 1 1 1 D 1 E 1 F 3 15 6 Description Kick Plate,

More information

2010 APPLICATION REFERENCE GUIDE

2010 APPLICATION REFERENCE GUIDE 2010 APPLICATION REFERENCE GUIDE INDEX QUALITY POLICY 2 ERGO ASSIST STANDARD 4-13 CUSTOM 14-18 END EFFECTORS 19-24 LIFT ASSIST 25-41 FIXTURED TOOLS 42-53 FIXTURES 54-63 ASSEMBLY TABLES 64-72 CARTS/ DUNNAGE

More information

ReadyLift (Part# 66-5075) Strut Extension, Installation Instructions Toyota Tundra New Body Style 2WD & 4WD

ReadyLift (Part# 66-5075) Strut Extension, Installation Instructions Toyota Tundra New Body Style 2WD & 4WD SAFETY WARNING: recommends this system be installed by a professional technician. In addition to these instructions, professional knowledge of disassembly/ reassembly procedures and post installation checks

More information

STEADYfast Stabilizer Installation Notes Fifth Wheel and Travel Trailers 11/23/13

STEADYfast Stabilizer Installation Notes Fifth Wheel and Travel Trailers 11/23/13 STEADYfast Stabilizer Installation Notes Fifth Wheel and Travel Trailers 11/23/13 (See Supplemental Instructions for trailers with heavy duty round footplates and/or Power Leveling Systems) PHONE SUPPORT

More information

Rear wheel brakes, servicing. Стр. 1 из 45. Note:

Rear wheel brakes, servicing. Стр. 1 из 45. Note: Volkswagen Touareg - Rear wheel brakes, servicing Стр. 1 из 45 46-2 Rear wheel brakes, servicing Rear brakes, FN 44 brake caliper, servicing Note: After replacing brake pads, depress brake pedal firmly

More information

Table of Contents WARNING SYMBOLS AND DEFINITIONS

Table of Contents WARNING SYMBOLS AND DEFINITIONS Table of Contents SAFETY INSTALLATION OPERATION MAINTENANCE Safety... 2 Specifications... 4 Installation... 5 Operation... 8 WARNING SYMBOLS AND DEFINITIONS Maintenance... 9 Parts List and Assembly Diagram...

More information

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C. R O A D M A S T E R, I N C. 11 10 20 12 4 18 19 1 2 13 16 ITEM QTY NAME MATERIAL 1...2... 1/2" x 3 1/2" BOLT... 350103-00 2...2... 1/2" x 2" BOLT... 350097-00 3...6... 1/2" x 1 1/2" BOLT... 350095-00 4...2...

More information

Mercedes-Benz Vito. Specifications

Mercedes-Benz Vito. Specifications Mercedes-Benz Vito Specifications Mercedes-Benz Technical Data Panel Van Specification Body Style Rated output (kw @ rpm) Max torque (Nm @ rpm) Injection Fuel consumption 1 (litres/100km) Front axle load

More information

Installation instruction do88 Intercooler for Volvo S40 / V50 / C30

Installation instruction do88 Intercooler for Volvo S40 / V50 / C30 Installation instruction do88 Intercooler for Volvo S40 / V50 / C30 This instruction shows how to replace the OEM intercooler with our performance intercooler. 2. 3. 1. 4. 5. Part number: ICM-170 6. At

More information

M-9424-463V Intake Manifold INSTALLATION INSTRUCTIONS

M-9424-463V Intake Manifold INSTALLATION INSTRUCTIONS Please visit www.fordracingparts.com for the most current instruction information!!! PLEASE READ ALL OF THE FOLLOWING INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION. AT ANY TIME YOU DO NOT UNDERSTAND THE

More information

»Product» Safety Warning

»Product» Safety Warning C1200 Installation Instructions 2007-2016 Chevy/GM 1500 2/4wd 2" Strut Spacer Lift Read and understand all instructions and warnings prior to installation of product and operation of vehicle. Zone Offroad

More information

RE-3 : SOLID TOP RANGE RANGE TOP ONLY

RE-3 : SOLID TOP RANGE RANGE TOP ONLY VULCAN ELECTRIC SOlid top oven range MODEL: RE-3 - SOLID TOP oven Range RE-3T - SOLID range top only ON CABINET BASE RE-3 : SOLID TOP RANGE Model Re-3T : Solid TOP RANGE TOP ONLY Index: General Data 2

More information

FRONT SUSPENSION Click on the applicable bookmark to selected the required model year

FRONT SUSPENSION Click on the applicable bookmark to selected the required model year FRONT SUSPENSION 33A-2 FRONT SUSPENSION General Information GENERAL INFORMATION 33200010105 The front suspension on 2WD vehicles is an independent suspension system having the double wishbone combined

More information

TITAN 13 x 2 ½ BRAKES

TITAN 13 x 2 ½ BRAKES INSTALLATION INSTRUCTION AND SERVICE MANUAL Actuator/Trailer Dealer - Please provide these instructions to the consumer. Consumer - Read and follow these instructions. Keep them with the trailer for future

More information

Chapter 5 - Aircraft Welding

Chapter 5 - Aircraft Welding Chapter 5 - Aircraft Welding Chapter 5 Section A Study Aid Questions Fill in the Blanks 1. There are 3 types of welding:, and, welding. 2. The oxy acetylene flame, with a temperature of Fahrenheit is produced

More information

MGB Chrome Bumper Conversion

MGB Chrome Bumper Conversion MGB Chrome Bumper Conversion Installation Instructions For 1974 1/2-1980 MGB This kit requires cutting, welding, and painting. Professional installation recommended. Note: Every MGB body is slightly different

More information

Weld Cracking. An Excerpt from The Fabricators' and Erectors' Guide to Welded Steel Construction. The James F. Lincoln Arc Welding Foundation

Weld Cracking. An Excerpt from The Fabricators' and Erectors' Guide to Welded Steel Construction. The James F. Lincoln Arc Welding Foundation Weld Cracking An Excerpt from The Fabricators' and Erectors' Guide to Welded Steel Construction The James F. Lincoln Arc Welding Foundation Weld Cracking Several types of discontinuities may occur in welds

More information

6720616592.00-1.SD. Flat roof. Rack Mounting. Installation instructions 6 720 647 036 (2010/11) AU

6720616592.00-1.SD. Flat roof. Rack Mounting. Installation instructions 6 720 647 036 (2010/11) AU 6720616592.00-1.SD Flat roof Rack Mounting AU Installation instructions 2 Contents AU Contents 1 Key to symbols and safety instructions....... 3 1.1 Explanation of symbols................ 3 1.2 Safety

More information

2003 ACCORD - Automatic Transmission Removal

2003 ACCORD - Automatic Transmission Removal 2003 ACCORD - Automatic Transmission Removal Special Tools Required Engine support hanger, A and Reds AAR-T-12566 Engine hanger balancer bar VSB02C000019 Front subframe adapter VSB02C000016 These special

More information

ATS Overhead Table Shelf System INSTRUCTION MANUAL

ATS Overhead Table Shelf System INSTRUCTION MANUAL ATS Overhead Table Shelf System INSTRUCTION MANUAL ATS Overhead Table Shelf System Instruction Manual Warranty Newport Corporation warrants this product to be free of defects in material and workmanship

More information

2011-14 F250 6 RADIUS ARM KIT

2011-14 F250 6 RADIUS ARM KIT 92154000 Thank you for choosing Rough Country for your suspension needs. 2011-14 F250 6 RADIUS ARM KIT Rough Country recommends a certified technician installs this system. In addition to these instructions,

More information

INSTALLATION MANUAL MODEL RP-150

INSTALLATION MANUAL MODEL RP-150 INSTALLATION MANUAL FOR 24 VALVE 5.9L CUMMINS POWERED DODGE TRUCKS 2003 THROUGH 2004.5 MODEL RP-150 READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION 5400 BUSINESS 50 WEST SUITE 8 573 635-0555

More information

PIGGY BACK Delivery System. EASY HITCH Truck/Trailer 3-Position Mounting Installation Instruction Manual

PIGGY BACK Delivery System. EASY HITCH Truck/Trailer 3-Position Mounting Installation Instruction Manual PIGGY BACK Delivery System EASY HITCH Truck/Trailer 3-Position Mounting Installation Instruction Manual PIGGY BACK Delivery System EASY HITCH Truck/Trailer 3-Position Mounting Installation Instruction

More information

Vehicle Restraint Installation Manual

Vehicle Restraint Installation Manual Vehicle Restraint Installation Manual SHR-5000 9 Carriage SHR-5000 12 Carriage MADE IN U.S.A. This Manual Covers Restraints Built After Serial Numbers: 4487000001 and up PRINTED IN U.S.A. RITE-HITE PRINT

More information

TOYOTA TECHNICAL. An example of a tire pressure monitor valve sub-assembly. This mounts to a drop area in the wheel.

TOYOTA TECHNICAL. An example of a tire pressure monitor valve sub-assembly. This mounts to a drop area in the wheel. TOYOTA TIRE PRESSURE WARNING SYSTEM Toyota uses various tire pressure warning systems. Here, we ll discuss the system featured on the 2006 Land Cruiser. Combination meter warning reset switch warning reset

More information

301.7D. Mini Hydraulic Excavator

301.7D. Mini Hydraulic Excavator 301.7D Mini Hydraulic Excavator Engine Weights Gross Power (ISO 14396) 17.9 kw 24.3 hp Operating Weight with Canopy 1610 kg 3,550 lb Net Power 13.2 kw 17.7 hp Operating Weight with Cab 1720 kg 3,792 lb

More information

WARNING TO END USER, INSTALLER AND SELLER OF THIS PART!

WARNING TO END USER, INSTALLER AND SELLER OF THIS PART! WARNING TO END USER, INSTALLER AND SELLER OF THIS PART! By installing this part you are accepting full responsibility and liability for proper wheel and tire fitment after installation. It is the installer

More information

INFRARED QUARTZ WALL HEATER

INFRARED QUARTZ WALL HEATER INFRARED QUARTZ WALL HEATER MODEL NO: IQ2000 PART NO: 6939004 MOUNTING & OPERATION INSTRUCTIONS GC0715 INTRODUCTION Thank you for purchasing this CLARKE Infrared Wall Heater. Before attempting to use this

More information

4.3-inch Back-Up Camera

4.3-inch Back-Up Camera TM 4.-inch Back-Up Camera Model No.: PKC0BU4 Owner s Manual and Warranty Information Read these instructions completely before using this product. Retain this Owner s Manual for future reference. INTRODUCTION

More information

10 TON HYDRAULIC PRESS

10 TON HYDRAULIC PRESS 10 TON HYDRAULIC PRESS Model Nos. CSA10F and CSA10B OPERATING & MAINTENANCE INSTRUCTIONS 0200 SPARE PARTS and SERVICING Please contact your nearest dealer, or CLARKE International, on one of the following

More information

DiscPlus DX195 and DX225 Air Disc Brakes

DiscPlus DX195 and DX225 Air Disc Brakes Revised 11-04 Technical Bulletin Revised 1 Technical 11-04 Bulletin DiscPlus DX195 and DX225 Air Disc Brakes Inspection, Installation and Diagnostics Air Disc Brake Inspection Intervals and Procedures

More information

Cooling system components, removing and installing

Cooling system components, removing and installing Engine BHW Cooling system components, removing and installing Page 1 / 24 19-1 Cooling system components, removing and installing Warning! When doing any repair work, especially in the engine compartment,

More information

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C. R O A D M A S T E R, I N C. 6 28 1 2 "ā 1 2 " 4 8 ITEM QTY NAME PART # 1...4...1/2 x 1 1/4 BOLTS... 350094-00 2...4...1/2 LOCK WASHER... 350309-00 3...4...1/2 HEX NUT... 350258-00 4...2...SPACER PLATE...

More information

Positive Control of Truck and Trailer Movement

Positive Control of Truck and Trailer Movement Positive Control of Truck and Trailer Movement Whether the tractor remains attached to the trailer or the trailer is dropped and the tractor removed, positive action must be taken to ensure the trailer

More information

INSTRUCTIONS THOROUGHLY BEFORE BEGINNING***************

INSTRUCTIONS THOROUGHLY BEFORE BEGINNING*************** Bill of Materials: RAC0012 Green Wing Aerodynamic Skirt Kit Item Part Number Description Quantity 1 RMC0218 Gen 2 Trailer Skirt Roadside 1 2 RMC0219 Gen 2 Trailer Skirt Curbside 1 3 RMC0041 Trailer Skirt

More information

ENGLISH FORK GUIDE 2013

ENGLISH FORK GUIDE 2013 FORK GUIDE 2013 ENGLISH 1 With a brand which is synonymous with specialists in forest products handling attachments, BOLZONI AURAMO offers its expertise and market leading attachments for all requirements,

More information

Front axle components, overview

Front axle components, overview just a test. Front axle components, overview 40-1 General Information Load bearing components and parts of the suspension must not be welded or straightened. Vehicles without drive axle must not be moved,

More information

Front brakes (FN- 3), servicing

Front brakes (FN- 3), servicing j a t Front brakes (FN- 3), servicing 46-1 Front brakes, servicing Note: Install complete repair kit. After replacing brake pads and before moving vehicle, depress brake pedal several times firmly to properly

More information

3. Commercial Trailer Lighting Requirements Federal Motor Carrier Safety Regulations (FMCSR) 49 CFR, Subpart B Of FMCSR Part 393

3. Commercial Trailer Lighting Requirements Federal Motor Carrier Safety Regulations (FMCSR) 49 CFR, Subpart B Of FMCSR Part 393 FMCSR 393.9.26 3. Commercial Trailer Lighting Requirements Federal Motor Carrier Safety Regulations (FMCSR) 49 CFR, Subpart B Of FMCSR Part 393 Lighting Devices, Reflectors, and Electrical Equipment 393.9

More information

READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO INSTALLATION OF SYSTEM AND OPERATION OF VEHICLE.

READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO INSTALLATION OF SYSTEM AND OPERATION OF VEHICLE. 491 W. Garfield Ave., Coldwater, MI 49036 Phone: 517-279-2135 Web/live chat: www.bds-suspension.com E-mail: tech-bds@sporttruckusainc.com Product: GM Leaf Spring READ AND UNDERSTAND ALL INSTRUCTIONS AND

More information

Installation Instructions Avalanche XUV Cap IMPORTANT! IMPORTANT!

Installation Instructions Avalanche XUV Cap IMPORTANT! IMPORTANT! Installation Instructions Avalanche XUV Cap IMPORTANT! Read all instructions carefully before commencing any work. Always wear safety equipment. Some installation steps will require two or more installers.

More information

INSTALLATION MANUAL MODEL RP-100

INSTALLATION MANUAL MODEL RP-100 INSTALLATION MANUAL FOR 24 VALVE 5.9L CUMMINS POWERED DODGE TRUCKS 2003 THROUGH 2004.5 MODEL RP-100 READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION 5400 BUSINESS 50 WEST SUITE 8 573 635-0555

More information

GUIDELINES. for oversize and overmass vehicles and loads MAY 2006. Government of South Australia. Department for Transport, Energy and Infrastructure

GUIDELINES. for oversize and overmass vehicles and loads MAY 2006. Government of South Australia. Department for Transport, Energy and Infrastructure ESCORTING GUIDELINES ESCORTING GUIDELINES SCORTING GUIDELINES ESCORTING GUIDELINES ESCORTING ESCORTING GUIDELINES for oversize and overmass vehicles and loads Government of South Australia Department for

More information

ADDING AN ELECTRIC AUXILIARY FAN TO RADIATOR STACK ON 03 ALPINE COACH

ADDING AN ELECTRIC AUXILIARY FAN TO RADIATOR STACK ON 03 ALPINE COACH ADDING AN ELECTRIC AUXILIARY FAN TO RADIATOR STACK ON 03 ALPINE COACH The original design of the 03 Alpine Coaches (and perhaps other years as well) did not include any kind of engine fan engage mechanism

More information

R02GA. July 31, 2002. Dear Blue Bird Owner:

R02GA. July 31, 2002. Dear Blue Bird Owner: R02GA July 31, 2002 Dear Blue Bird Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Blue Bird Body Company has determined that

More information

Cross-beam scanning system to detect slim objects. 100 mm 3.937 in

Cross-beam scanning system to detect slim objects. 100 mm 3.937 in 891 Object Area Sensor General terms and conditions... F-17 Related Information Glossary of terms... P.1359~ Sensor selection guide...p.831~ General precautions... P.1405 PHOTO PHOTO Conforming to EMC

More information

This kit may void factory warranty please check with manufacturer.

This kit may void factory warranty please check with manufacturer. Mfg Company TM Thank you for purchasing a Sinister Manufacturing Company EGR delete kit. Precision manufactured using aircraft quality 304 stainless steel and billet aluminum; this EGR kit is designed

More information

UB1 AIR CONDITIONING UNIT INSTALLATION INSTRUCTIONS

UB1 AIR CONDITIONING UNIT INSTALLATION INSTRUCTIONS UB1 AIR CONDITIONING UNIT INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS: Carefully read these instructions before installing your new air-conditioner. AUSTRALIAN AUTOMOTIVE AIR AL00500054E 1 Table

More information

1993 SUSPENSION Volkswagen Front. EuroVan

1993 SUSPENSION Volkswagen Front. EuroVan Article Text ARTICLE BEGINNING 1993 SUSPENSION Volkswagen Front EuroVan DESCRIPTION FWD independent suspension is an double-wishbone type with torsion bars mounted on upper control arm. Wheel is supported

More information

SLACK PERFORMANCE KARTS

SLACK PERFORMANCE KARTS SLACK PERFORMANCE KARTS SET UP GUIDE Thank you for purchasing a 2013 Slack Axiom Chassis. Performance Mfg. strives to provide you with the very best chassis and components on the market today. Your satisfaction

More information

VW Caddy W21-760-3503 INSTALLATION INSTRUCTIONS

VW Caddy W21-760-3503 INSTALLATION INSTRUCTIONS Unit 626 Kilshane Avenue, North West Business Park, Ballycoolin, Dublin 15, Ireland Telephone: +353 1 8612 632, Fax: +353 1 8612 647, email: sales@driveriteltd.com www.driveriteltd.com VW Caddy W21-760-3503

More information

INSTRUCTIONS AND PARTS LIST SINGLE GIRDER UNDERHUNG CRANE BRIDGE KITS 1/2 THRU 10 TON HAND GEARED AND MOTOR DRIVEN

INSTRUCTIONS AND PARTS LIST SINGLE GIRDER UNDERHUNG CRANE BRIDGE KITS 1/2 THRU 10 TON HAND GEARED AND MOTOR DRIVEN INSTRUCTIONS AND PARTS LIST SINGLE GIRDER UNDERHUNG CRANE BRIDGE KITS 1/2 THRU 10 TON HAND GEARED AND MOTOR DRIVEN JUNE, 1999 COPYRIGHT 1999, Columbus Mckinnon Corporation PART NO. 113533-71 Page 1 COLUMBUS

More information

Street-Lynx. Reilly MotorSports, Inc. Installation Manual

Street-Lynx. Reilly MotorSports, Inc. Installation Manual Street-Lynx By Reilly MotorSports, Inc. Installation Manual 1 1- Begin by removing your original rear suspension disconnect your brake lines, E-brake cables, and remove the driveshaft. To prevent fire

More information

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C. R O A D M A S T E R, I N C. ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 12 10 3 11 4 5 13 7 8 360-896-0407 fax 360-735-9300 www.roadmasterinc.com ITEM QTY NAME MATERIAL 1... 4...1/2 x 1 1/2

More information

Slide the new steering column shaft through the steering column from the driver compartment.

Slide the new steering column shaft through the steering column from the driver compartment. Slide the new steering column shaft through the steering column from the driver compartment. Push the column shaft through the steering column until the machined end is out past the column lower bushing.

More information

LUCCI AIRFUSION QUEST II CEILING FAN

LUCCI AIRFUSION QUEST II CEILING FAN LUCCI AIRFUSION QUEST II CEILING FAN WITH IR REMOTE INSTALLATION OPERATION MAINTENANCE WARRANTY INFORMATION CAUTION READ INSTRUCTIONS CAREFULLY FOR SAFE INSTALLATION AND FAN OPERATION. V1.0 QUEST II IR

More information

DANGER DANGER. General Information. Safety Is Your Responsibility. Ordering Parts. Contact Information

DANGER DANGER. General Information. Safety Is Your Responsibility. Ordering Parts. Contact Information Safety Safety Is Your Responsibility DANGER To avoid personal injury or death, carefully read and understand all instructions pertaining to the Anthony Liftgates product. Do not attempt to install, operate,

More information

INSIDE ENGINE COMPARTMENT TOYOTA AIR CONDITIONING ENGLISH EUROPE,GENERAL,AUSTRALIA

INSIDE ENGINE COMPARTMENT TOYOTA AIR CONDITIONING ENGLISH EUROPE,GENERAL,AUSTRALIA INSIDE ENGINE COMPARTMENT TOYOTA AIR CONDITIONING ENGLISH EUROPE,GENERAL,AUSTRALIA INTRODUCTION IMPORTANT NOTICE This manual has been designed for technicians who are qualified and educated in the proper

More information

SUSPENSION AND STEERING OVERVIEW

SUSPENSION AND STEERING OVERVIEW SUSPENSION SUSPENSION AND STEERING OVERVIEW The S40/V50 has a wide track and a long wheelbase for its relative size and weight. This gives the car stable and predictable driving characteristics. It also

More information

B.TECH. (AEROSPACE ENGINEERING) PROGRAMME (BTAE) Term-End Examination December, 2011 BAS-010 : MACHINE DESIGN

B.TECH. (AEROSPACE ENGINEERING) PROGRAMME (BTAE) Term-End Examination December, 2011 BAS-010 : MACHINE DESIGN No. of Printed Pages : 7 BAS-01.0 B.TECH. (AEROSPACE ENGINEERING) PROGRAMME (BTAE) CV CA CV C:) O Term-End Examination December, 2011 BAS-010 : MACHINE DESIGN Time : 3 hours Maximum Marks : 70 Note : (1)

More information

Explosion proof enclosures

Explosion proof enclosures 1 of 7 Explosion proof enclosures DE8 C 2 of 7 The Ex d enclosures are rugged and designed for harsh environment like: Oil and gas industry Chemical industry Pharmaceutical industry Agribusiness Without

More information

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C. R O A D M A S T E R, I N C. ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 8 7 1 6 15 28 1 2 "± 1 2 " MOUNTING BRACKET KIT 3 2 10 14 4 5 9 360-896-0407 fax 360-735-9300 www.roadmasterinc.com Item

More information

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C. R O A D M A S T E R, I N C. MOUNTING BRACKET KIT 12 3 6 9 5 11 ITEM QTY NAME MATERIAL 1...4...1/2" x 1 1/2" BOLT... 350095-00 2...4...1/2" x 1 1/2" CARRIAGE BOLT... 350362-00 3...8...1/2" NUT... 350258-00

More information

ASSEMBLY MANUAL SE-4S35

ASSEMBLY MANUAL SE-4S35 Automatic drive ASSEBLY ANUAL SE-4S35 AI-4S35 SG-4R35 Battery box otor unit Inter-4 hub CONTENTS WARNING 1 INSTALLATION CONITIONS Battery box Speed sensor Cable lengths and diameters otor unit Recommended

More information

TIG INVERTER INSTRUCTION MANUAL

TIG INVERTER INSTRUCTION MANUAL TIG INVERTER INSTRUCTION MANUAL Contents Warning General Description Block Diagram Main Parameters Circuit Diagram Installation and Operation Caution Maintenance Spare Parts List Troubleshooting 3 4 4

More information

REMOVAL AND INSTALLATION

REMOVAL AND INSTALLATION 303-01C-1 REMOVAL AND INSTALLATION Engine Body On Special Tool(s) Adapter For 303-D043 303-D043-02 or equivalent Special Tool(s) 303-01C-1 Turbocharger Lifting Bracket 303-1266 Wrench, Fan Clutch Nut 303-214

More information

STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER

STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER 14 14 STEERING HANDLEBAR/FRONT WHEEL/ SCHEMATIC DRAWING ------------------------------------------------- 14-1 SERVICE INFORMATION------------------------------------------------ 14-2 TROUBLESHOOTING-----------------------------------------------------

More information

SECTION G2: CABLE PROCESSOR MODULE MAINTENANCE

SECTION G2: CABLE PROCESSOR MODULE MAINTENANCE SECTION G2: CABLE PROCESSOR MODULE MAINTENANCE Cable Processor Module overview WARNING! When tipping the Cable Processor Module back, (after removing the toggle arm pin), use extreme caution not to drop

More information

Variety of Control Options Control is possible via wall switches, remote control systems or integration into building management systems.

Variety of Control Options Control is possible via wall switches, remote control systems or integration into building management systems. Breezway Altair Powerlouvre Window 35 Breezway Altair Powerlouvre Window The Powerlourve Window motor is neatly concealed within the Easyscreen TM Frame or the Component Powerlouvre Head Section. Automated

More information

Installation Instructions

Installation Instructions Installation Instructions Page 1 of 16 January 2008 Equipment Parts, Trailer Hitch Ver 3.0 Accessory Development SUBJECT TRAILER HITCH KIT (US Only) - P/N 71 60 0 413 359 MODEL X5 (E70): Select Vehicle

More information

Class 5 to 7 Truck and Bus Hydraulic Brake System

Class 5 to 7 Truck and Bus Hydraulic Brake System Class 5 to 7 Truck and Bus Hydraulic Brake System Diagnostic Guide 1st Edition * 5+0 Important Service tes The information in this publication was current at the time of printing. The information presented

More information

Volkswagen Jetta, Golf, GTI 1999, 2000 Brake System 46 Brakes - Mechanical Components (Page GR-46)

Volkswagen Jetta, Golf, GTI 1999, 2000 Brake System 46 Brakes - Mechanical Components (Page GR-46) 46 Brakes - Mechanical Components (Page GR-46) Front brakes Brake pads, removing and installing Brake pads, removing and installing FN 3 brake caliper, servicing FS III brake caliper, servicing Rear wheel

More information

BRAKE DRUM AND ROTOR SERVICE INFORMATION

BRAKE DRUM AND ROTOR SERVICE INFORMATION SERVICE INFORMATION To achieve maximum drum life and optimum performance, proper brake maintenance and brake balance are essential. Consult your truck or trailer manufacturer s maintenance manual for proper

More information

EZ-Steer Assisted Steering System

EZ-Steer Assisted Steering System EZ-Steer Assisted Steering System Installation Instructions Platform Kit P/N 53059-21 Case IH Puma 165 Puma 180 Puma 195 Puma 210 New Holland T7030 T7040 T7050 T7060 Revision A June 2007 Part Number 53345-21-EU2

More information

VOYAGER 570G. 744A Sprayer Control

VOYAGER 570G. 744A Sprayer Control VOYAGER 570G 744A Sprayer Control U S E R M A N U A L U S E R M A N U A L Table of Contents CHAPTER 1 - INTRODUCTION...1 SYSTEM CONFIGURATIONS...1 KIT CONTENTS...3 CONTROL HOUSING ASSEMBLY...5 CHAPTER

More information