0 SUB DIVISION

55 Series

GENERAL INFORMATION
1
SAFETY PRECAUTIONS and VEHICLE STORAGE
2
SERVICE TOOLS
3
TORQUE TIGHTENING FIGURES
4
RECOMMENDED LUBRICANTS, FUEL OILS and FLUIDS
5

E9706
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55 Series Contents

CONTENTS Page Date

SECTION 1—GENERAL INFORMATION

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —29 . . . . . . . 9706
Approximate Dry Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —28 . . . . . . . 9706
Approximate Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —27 . . . . . . . 9706
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —20 . . . . . . . 9706 1
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —26 . . . . . . . 9706
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —13 . . . . . . . 9706
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —31 . . . . . . . 9706
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —15 . . . . . . . 9706
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —1 . . . . . . . . 9706
Frame and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —25 . . . . . . . 9706
Front Axle and Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —22 . . . . . . . 9706
Fuel Induction and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —14 . . . . . . . 9706
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —10 . . . . . . . 9706
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 1 —23 . . . . . . . 9706

E9706 1
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E9706
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0 GENERAL RECOMMENDATIONS
55 Series General information

1. GENERAL INFORMATION
ENGINE

Types:
Euro I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CS 134L and CS 156L
Euro II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CS 107M, CS 118M, CS 134M, CS 158M
and CS 173M
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged and intercooled 1
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 6
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,88 litres
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5,3,6,2,4
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 : 1
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 to 800 rev/min
Maximum governed speed (no load) . . . . . . . . . . 2 825 to 2 925 rev/min
Minimum oil pressure (engine hot):
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 bar
Normal running speed . . . . . . . . . . . . . . . . . . 2,0 bar
* Net (installed) bhp:
CS 107M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 kW (145 ps) @ 2 500 rev/min
CS 118M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 kW (160 ps) @ 2 500 rev/min
CS 134L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 kW (182 ps) @ 2 500 rev/min
CS 134M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 kW (182 ps) @ 2 500 rev/min
CS 156L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 kW (212 ps) @ 2 500 rev/min
CS 158M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 kW (215 ps) @ 2 500 rev/min
CS 173M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 kW (235 ps) @ 2 500 rev/min

* Maximum (declared) torque:

CS 107M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520 Nm (384 lbf ft) @ 1 500 rev/min
CS 118M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570 Nm (421 lbf ft) @ 1 500 rev/min
CS 134L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630 Nm (464 lbf ft) @ 1 500 rev/min
CS 156L and CS 158M . . . . . . . . . . . . . . . . . 700 Nm (516 lbf ft) @ 1 500 rev/min
CS 173M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 Nm (590 lbf ft) @ 1 500 rev/min

* ECE R24.03 and EEC 88/77 (Euro I and II Emissions)

Cooling System
Thermostat opening temperature:
Begins to open . . . . . . . . . . . . . . . . . . . . . . . . . 83°C (181°F)
Fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)

Cylinder Head
Maximum permissible distortion overall length . 0,30 mm
Maximum permissible distortion overall width . . 0,08 mm
Maximum re–face of combustion face . . . . . . . . . 1,0 mm
Minimum depth of cylinder head after re–facing . . 93,75 to 94,25 mm
Surface finish of combustion face . . . . . . . . . . . . . 1,5 to 3,2 micrometres

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General information 55 Series

Rocker Levers
Maximum worn clearance between rocker lever
and rocker shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,10 mm

Valves
1 Valve clearance (cold):
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,50 mm
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm
Valve face angle:
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve head depth from combustion face:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,52 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,00 mm
Valve rim thickness . . . . . . . . . . . . . . . . . . . . . . . . . 0,79 mm Minimum
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . 7,94 mm Minimum

Valve Guides
Valve guide bore diameter . . . . . . . . . . . . . . . . . . . 8,039 mm Maximum

Valve Seats
Valve seat angle:
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve seat face width:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,0 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5 mm
Valve seat grinding depth . . . . . . . . . . . . . . . . . . . . 0,254 mm Maximum

Valve Springs
Maximum inclination . . . . . . . . . . . . . . . . . . . . . . . . 1,00 mm
Valve spring free–length (approximate) . . . . . . . . 55,63 mm
Valve spring tension . . . . . . . . . . . . . . . . . . . . . . . . A minimum load of 290 N is required to
compress the spring to a height of 49,25 mm

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0 GENERAL RECOMMENDATIONS
55 Series General information

Service Valve Seat Insert Installation Dimensions

A — 8,029 " 0,010 mm

B — 0,38 mm Max radius

C — Inlet 10,40 " 0,10 mm 1

Exhaust 10,20 " 0,10 mm

D — Inlet 47,0 " 0,013 mm dia

Exhaust 43,65 " 0,013 mm dia

E — Inlet 48,0 " 0,13 mm dia

Exhaust 44,55 " 0,13 mm dia

F — Inlet 3,82 " 0,13 mm

Exhaust 3,63 " 0,13 mm

G — 0,40 mm Max radius

H — 3,2 micrometres surface finish

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General information 55 Series

Service Valve Guide Installation Dimensions

A — Lubricate with oil and press the guides flush to the bottom of the valve guide bores

B — 12,0 " 0,75 mm

1 C — Machine flush to top of valve guide bore as necessary

D — 8,029 " 0,010 mm

E — First machining for thin wall valve guides 11,125 " 0,013 mm
Second machining for thick wall valve guides 14,0 " 0,013 mm

NOTE: Initial machining of valve guide bores and final bore size of the valve guide inserts after reaming
must be concentric with the valve seats within 0,35 mm diameter and to be square with the combustion
face within 0,10 mm at 50,0 mm radius.

Camshaft
End–float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,12 to 0,33 mm
Gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,08 to 0,33 mm
Bearing bush (No.1 journal) . . . . . . . . . . . . . . . . . . 54,107 to 54,146 mm
Service bush available—rebore to . . . . . . . . 57,722 to 57,758 mm
Remainder of journals . . . . . . . . . . . . . . . . . . . . . . 53,962 to 54,013 mm
Maximum worn limit . . . . . . . . . . . . . . . . . . . . 54,164 mm
Service bushes available—rebore to . . . . . . 57,222 to 57,258 mm
Surface finish all journals to . . . . . . . . . . . . . . . . . . 2,3 micrometre
Camshaft lobes minimum diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47,040 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,770 mm
Lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35,500 mm

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0 GENERAL RECOMMENDATIONS
55 Series General information

Connecting rod and bearings

Big–end bearing clearance . . . . . . . . . . . . . . . . . . 0,114 mm
Small–end bush internal diameter:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,092 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,053 mm 1
Side clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1 to 0,3 mm

Crankshaft
Main journals:
Standard size . . . . . . . . . . . . . . . . . . . . . . . . . . 82,987 to 83,013 mm
Maximum worn limit . . . . . . . . . . . . . . . . . . . . 82,962 mm
Permissible re–grind undersize: Regrind to:
1st – 0,25 mm . . . . . . . . . . . . . . . . . . . . . 82,737 to 82,763 mm
2nd – 0,50 mm . . . . . . . . . . . . . . . . . . . . . 82,487 to 82,513 mm
3rd – 0,75 mm . . . . . . . . . . . . . . . . . . . . . 82,237 to 82,263 mm
4th – 1,00 mm . . . . . . . . . . . . . . . . . . . . . 81,987 to 82,013 mm
Thrust journal:
Permissible re–grind undersize: Regrind to:
0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . 82,487 to 82,513 mm diameter
37,975 to 38,025 mm width
1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . 81,987 to 82,013 mm diameter
38,475 to 38,525 mm width
Surface finish journals and thrust face of
thrust journal to . . . . . . . . . . . . . . . . . . . . . . . . 0,4 micrometre
Main journal fillet radii . . . . . . . . . . . . . . . . . . . . . . . 4,180 to 4,220 mm
Surface finish to . . . . . . . . . . . . . . . . . . . . . . . . 0,8 micrometre
Main bearing cap bearing diameter . . . . . . . . . . . 83,106 mm
Standard and oversize bearings available:
Main journal bearings . . . . . . . . . . . . . . . . . . . Standard plus 0,25, 0,50, 0,75 and 1,00 mm
Main journal thrust bearing . . . . . . . . . . . . . . Standard plus 0,50 mm and 1.00 mm

NOTE: When installing main bearings, ensure piston cooling nozzles are level with, or slightly below the
bearing saddle surface.

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General information 55 Series

Crankshaft end–float . . . . . . . . . . . . . . . . . . . . . . . . 0,13 to 0,35 mm

Crankpin (connecting rod) journals:
Standard size . . . . . . . . . . . . . . . . . . . . . . . . . . 68,987 to 69,013 mm
Maximum worn limit . . . . . . . . . . . . . . . . . . . . 68,962 mm
1 Permissible re–grind undersize:
1st—0,25 mm . . . . . . . . . . . . . . . . . . . . .
Regrind to:
68,737 to 68,763 mm
2nd—0,50 mm . . . . . . . . . . . . . . . . . . . . 68,487 to 68,513 mm
3rd—0,75 mm . . . . . . . . . . . . . . . . . . . . . 68,237 to 68,263 mm
4th—1,00 mm . . . . . . . . . . . . . . . . . . . . . 67,987 to 68,013 mm
Surface finish journals to . . . . . . . . . . . .
0,4 micrometre
NOTE: All journals must be ground in the opposite direction of rotation, anti–clockwise viewed from
front of crankshaft. Polish journals in direction of rotation, clockwise viewed from front of crankshaft.

Crankpin fillet radii . . . . . . . . . . . . . . . . . . . . . . . . . . 3,980 to 4,020 mm

Surface finish to . . . . . . . . . . . . . . . . . . . . . . . . 0,8 micrometre
Standard and oversize bearings available . . . . . Standard, 0,25, 0,50, 0,75 and 1,00 mm

Pistons
Skirt diameter of piston: Nominal Worn Limits
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101,880 mm 101,823 mm
0,5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . 102,380 mm 102,323 mm
1,00 mm oversize . . . . . . . . . . . . . . . . . . . . . . 102,880 mm 102,823 mm
Gudgeon pin bore diameter:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,025 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,006 mm
Gudgeon pin diameter—minimum . . . . . . . . . . . . 39,990 mm
Ring groove clearance—maximum:
Top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No check required
Intermediate ring . . . . . . . . . . . . . . . . . . . . . . . 0,150 mm
Oil ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,130 mm
Ring gap:
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,55 mm

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55 Series General information

Cylinder Block
Combustion deck: The combustion face of the cylinder block can be refaced twice and should be
stamped in the upper right hand corner with a single ‘X’ for the first reface and with two ‘XX’s signifying
the second reface.
First reface ‘A’ . . . . . . . . . . . . . . . . . . . . . . . . .
Second reface ‘A’ . . . . . . . . . . . . . . . . . . . . . .
0,15 mm
0,35 mm 1
Maximum reface allowed ‘A’ . . . . . . . . . . . . . 0,50 mm

Standard block ‘B’ . . . . . . . . . . . . . . . . . . . . . . 323 " 0,1 mm

Block first reface ‘B’ . . . . . . . . . . . . . . . . . . . . 322,85 " 0,1 mm
Block second reface ‘B’ . . . . . . . . . . . . . . . . . 322,50 " 0,1 mm

A surface finish of 1,5 to 3,2 micrometres must be obtained.

Distortion of combustion deck must not exceed 0,010 mm in any 50 mm diameter.
Maximum permissible bow, length and width 0,075 mm

Gaskets available for cylinder block:

Standard
0,15 mm oversize
0,50 mm oversize

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General information 55 Series

Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . 102 to 102,116 mm

Boring dimension (A):
1st re–bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102,469 mm
2nd re–bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 102,969 mm
1 Honing dimension (B) 15° to 25° cross–hatch:
Standard cylinder bore . . . . . . . . . . . . . . . . . . 102 to 102,040 mm
1st re–hone . . . . . . . . . . . . . . . . . . . . . . . . . . . 102,500 to 102,540 mm
2nd re–hone . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 to 103,04 mm
A 1,2 maximum micrometre surface finish must be obtained
NOTE: After boring use a honing stone to chamfer bore to dimension (C)
Dimension (C) . . . . . . . . . . . . . . . . . . . . . . . . . 1,25 mm x 15° approx.
Rough hone . . . . . . . . . . . . . . . . . . . . . . . . . . . Use 80 grit honing stone
Finish hone . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use 280 grit honing stone
NOTE: After honing clean bores, using a detergent solution, then dry thoroughly.

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55 Series General information

Cylinder liner installation:

When more than 1,00 mm bore oversize is required the block must be re–bored and a cylinder liner
fitted and finished bored to 102 to 102,040 mm. A standard diameter piston and ring set must now be
used.

Cylinder block re–bore for cylinder liner 1

(D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,500 to 104,515 mm
(E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,35 mm
NOTE: After boring, clean thoroughly prior to fitting liners.
Finish bore liner to . . . . . . . . . . . . . . . . . . . . . . 101,956 mm
Finish hone liner to . . . . . . . . . . . . . . . . . . . . . 102 to 102,020 mm
Use a honing stone to chamfer a lead of 1,25 mm x 15° on liner
NOTE: A 1,2 maximum micrometre surface finish must be obtained.
Liner stand–proud:
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . Zero (flush with block)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm

Flywheel Housing
Run–out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm

Oil Pump
Gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,76 to 0,45 mm

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General information 55 Series

GEARBOX

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S6–36 and S6–36/2 (Direct and Overdrive)

ZF 9S–75 (Direct drive)
Eaton 6109 (Direct drive)

ZF S6–36 and S6–36/2

1 Input torque:
S6–36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650 Nm (maximum)
S6–36/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 Nm (maximum)

Gear ratios: S6–36(/2) S6–36(/2)

(Direct) (Overdrive)
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.97:1 6.93:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22:1 3.79:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10:1 2.22:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.96:1 1.40:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33:1 1.00:1
6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 0.80:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.05:1 6.22:1
End–float
Input shaft/layshaft bearing . . . . . . . . . . . . . . 0 to 0,1 mm
Shims/circlips available:
Connection plate/input bearing shims . . . . . 1,0 to 2,0 mm in steps of 0,05 mm
Input and intermediate shaft/mainshaft distance
washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,2 mm, 4,9 mm, 4,6 mm,4,3 mm ,4,0 mm ,
3,7 mm ,3,5 mm, 3,3 mm and 3,0 mm
Input shaft split rings . . . . . . . . . . . . . . . . . . . . . . . . 3,40 mm, 3,50 mm, 3,60 mm
Input shaft circlips . . . . . . . . . . . . . . . . . . . . . . . . . . 2,00 mm and 1,7 to 1,9 mm in steps of
0,05 mm
Intermediate shaft split rings . . . . . . . . . . . . . . . . . 3,40 mm, 3,50 mm, 3,60 mm
Layshaft adjustment shims . . . . . . . . . . . . . . . . . . 2.00 mm, 2,2 mm and 1,35 to 1,75 mm in steps
of 0,05 mm

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55 Series General information

Layshaft circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3 to 1,75 mm in steps of 0,05 mm

Mainshaft output bearing circlips . . . . . . . . . . . . . 2,7 to 3,0 mm in steps of 0,1 mm
1st and 2nd speed synchronizer circlips . . . . . . . 2,3 to 2,5 mm in steps of 0,05 mm
4th speed gear bearing circlips . . . . . . . . . . . . . . . 1,9 mm 1
2,0 mm
2,1 mm
5th and 6th speed synchronizer circlips . . . . . . . 2,2 mm and 2,30 to 2,50 mm in steps of
0,05 mm

Eaton 6109 Gearbox

Maximum input torque . . . . . . . . . . . . . . . . . . . . . . 912 Nm
Gear ratios
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6:1
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.98:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.75:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53:1
6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.84:1
7th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34:1
8th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17:1

Mainshaft gear end–float (mm): Max Min

Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 0,35
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 0,35
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 0,35
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,53 0,31
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,44 0,27

Synchronsier ring/flange clearance . . . . . . . . . . . 0,5 to 1,9 mm

Layshaft bearing pre–load:

New bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 0,075 to 0,125 mm
Original bearings . . . . . . . . . . . . . . . . . . . . . . . 0,00 to 0,05 mm

3rd/4th speed synchroniser ring circlips . . . . . . . 2,02 to 2,12 mm in steps of 0,05 mm

Reverse/low speed synchroniser ring circlips . . 2,00 to 2,15 mm in steps of 0,05 mm
Layshaft circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,77 to 2,12 mm in steps of 0,05 mm
Layshaft pre–load shims . . . . . . . . . . . . . . . . . . . . 0,051 mm, 0,127 mm, 0,254 mm,
0.508 mm

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 GENERAL RECOMMENDATIONS 0
General information 55 Series

Input shaft bearing spacers: Colour code

3.70 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red, green, white
3.75 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow, green, blue
3.80 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue, green, white
1 3.85 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red, green, yellow
3.90 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green, green, white
3.95 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red, green, red

Oil muff sealing ring clearance . . . . . . . . . . . . . . . 0,178 mm (min)

Oil pump rotor clearance:

Outer rotor to pump body . . . . . . . . . . . . . . . . 0,5 mm (max)
Inner to outer pump lobes . . . . . . . . . . . . . . . 0,5 mm (max)

ZF 9S–75 Gearbox
Refer to Publication DW032002

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0 GENERAL RECOMMENDATIONS
55 Series General information

CLUTCH

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Borg and Beck 330, 350 and 380 mm

Diaphragm Spring
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic with air assistance

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 GENERAL RECOMMENDATIONS 0
General information 55 Series

FUEL, INDUCTION AND EXHAUST SYSTEMS

Injection Pump
Type:
CS 107M, CS 118M, CS 134L and
CS 134M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch VP 14

1 CS 156L, CS 158M and CS 173M . . . . . . . .

Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch P–7100
740 to 800 rev/min
Maximum governed speed . . . . . . . . . . . . . . . . . . 2 825 to 2 925 rev/min
Injection timing—Bosch VP14:
CS 107M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of injection 1,0 to 1,3 mm plunger travel
CS 118M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of injection 1,1 to 1,5 mm plunger travel
CS 134M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of injection 1,2 to 1,6 mm plunger travel
CS 134L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of injection 1,5 to 1,9 mm plunger travel

Injectors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch 7mm (6 hole) nozzles
Opening pressure:
Rotary pump application (Euro I) . . . . . . . . . 260 to 275 atm
In–line pump application (Euro I) . . . . . . . . . 300 to 308 atm
All fuel pumps (Euro II) . . . . . . . . . . . . . . . . . . 260 to 275 atm

Turbocharger
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Holset H1
Bearing housing bores . . . . . . . . . . . . . . . . . . . . . . 15,875 to 15,885 mm
Seal bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,305 to 19,330 mm
Shaft bearing diameter . . . . . . . . . . . . . . . . . . . . . . 10,97 to 10,98 mm
Shaft run–out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,008 mm
Shaft end–play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,077 mm
Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . 0,31 to 0,46 mm

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0 GENERAL RECOMMENDATIONS
55 Series General information

ELECTRICAL SYSTEM

General Data
Voltage:
Vehicle electrical system . . . . . . . . . . . . . . . . 24V (nominal)
Radio supply . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Cigar lighter supply . . . . . . . . . . . . . . . . . . . . .
Circuit polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24V (standard) or 12V (option)
Negative earth
1
Electrical storage system . . . . . . . . . . . . . . . . . . . . Two 12V ‘‘Maintenance–Free” batteries
connected in series.
Batteries:
Type:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 663
Heavy duty . . . . . . . . . . . . . . . . . . . . . . . . 655
Cold cranking:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 825
Heavy duty . . . . . . . . . . . . . . . . . . . . . . . . SAE 880
Reserve capacity:
Standard battery . . . . . . . . . . . . . . . . . . . 25 amps for 200 minutes
Heavy duty battery . . . . . . . . . . . . . . . . . 25 amps for 210 minutes
Starter motor:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prestolite
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 kW
Alternator:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magneti Marelli or Prestolite
Output (at 6000 rpm):
Magneti Marelli . . . . . . . . . . . . . . . . . . . . 35 amps
Prestolite . . . . . . . . . . . . . . . . . . . . . . . . . . 55 amps

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 GENERAL RECOMMENDATIONS 0
General information 55 Series

Circuit Protection
The vehicle electrical circuits are protected by blade type fuses. Standard circuit fuses are located in
the LH and RH instrument panel fuse boxes. Specialised circuit fuses are located in the following
positions:

1 — Cab front RH bulkhead panel (RSL primary fuse).

— Cab RH rear bulkhead panel (ABS ECU power supply).
— Instrument panel R.H. printed circuit board (ECAS enable supply).
Fuse colour codes and amperage ratings:
Violet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 amp
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 amp
Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amp
Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 amp
Natural (transparent) . . . . . . . . . . . . . . . . . . . . 25 amp
NOTE: All fuses quoted are shown with their corresponding DAF component identification number.

Instrument panel fuse boxes:

LH fuse box:

1 2 3 4 5 6 7 8

9 080825

1. E233 (15A) . . . . . . . . . . . . . . . . . . . . . . Direction indicators and hazard warning

2. E129 (15A) . . . . . . . . . . . . . . . . . . . . . . Rear fog lights, courtesy lights and box van
lamp
3. E131 (10A) ...................... Headlights (main beam)
4. E132 (10A) ...................... Headlights (dipped beam)
5. E043 (25A) ...................... ABSI (trailer)
6. E000 (10A) ...................... Side lamps (LH), instrument, switch and
tachograph llumination
7. E001 (10A) . . . . . . . . . . . . . . . . . . . . . . Side lamps (RH), front fog lights and headlight
dim–dip
8. E032 (15A) . . . . . . . . . . . . . . . . . . . . . . Electric windows
9. — .............................. Spare fuses

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0 GENERAL RECOMMENDATIONS
55 Series General information

RH fuse box:

1
10 11 12 13 14 15 16 17

18 080826

10. E134 (15A) . . . . . . . . . . . . . . . . . . . . . . Windscreen wipers/washers, heater motor

and radio
11. E091 (15A) . . . . . . . . . . . . . . . . . . . . . . Air dryer, heated mirrors and cold start
12. E133 (10A) . . . . . . . . . . . . . . . . . . . . . . Reverse lights, stop lights, ABS enable and
ECAS power supply
13. E135 (5A) . . . . . . . . . . . . . . . . . . . . . . . Engine stop solenoid and road speed limiter
(secondary fuse)
14. E035 (5A) . . . . . . . . . . . . . . . . . . . . . . . Instruments, warning lights and tachograph
recording mechanism
15. E030 (10A) . . . . . . . . . . . . . . . . . . . . . . Horn and automatic lubrication
16. E066 (5A) . . . . . . . . . . . . . . . . . . . . . . . Tachograph (clock)
17. E026 (15A) . . . . . . . . . . . . . . . . . . . . . . Cigar lighter and radio (memory supply)
18. — .............................. Spare fuses

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 GENERAL RECOMMENDATIONS 0
General information 55 Series

Cab RH Bulkhead Panel Fuses:

1 2
080743

1. E078 (4A) . . . . . . . . . . . . . . . . . . . . . . . Radio dropper unit (glass encapsulated type

fuse) *
2. E027 (3A) . . . . . . . . . . . . . . . . . . . . . . . Road speed limiter (primary fuse)

* Early models only

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0 GENERAL RECOMMENDATIONS
55 Series General information

ABS Power Supply Fuses:

2 FUSE

080742

1. E041 (15A) . . . . . . . . . . . . . . . . . . . . . . Power supply relay

2. E042 (15A) . . . . . . . . . . . . . . . . . . . . . . Voltage protection relay

Replacement Bulbs
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70/75W pre–focus halogen
Sidelights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4W
Cab marker lights . . . . . . . . . . . . . . . . . . . . . . . . . . 3W
Direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Side repeater lights . . . . . . . . . . . . . . . . . . . . . . . . . 5W
Rear light unit:
Rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Reverse light . . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W
Stop light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Direction indicators . . . . . . . . . . . . . . . . . . . . . 21W
Courtesy lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W
Instrument panel illumination . . . . . . . . . . . . . . . . . 1.2W
Warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2W
Switch illumination . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2W
Tachograph illumination . . . . . . . . . . . . . . . . . . . . . 1.2W

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 GENERAL RECOMMENDATIONS 0
General information 55 Series

BRAKES

Braking System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual circuit full air system
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic

1 Foundation Brakes — 11 to 15 tonne vehicles

Type:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perrot sliding caliper disc brake
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perrot single air wedge (SAW) drum brake
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic
Front brakes:
Maximum brake disc run–out . . . . . . . . . . . . 0,2 mm per side
Minimum brake disc thickness . . . . . . . . . . . 40 mm
Minimum brake pad thickness . . . . . . . . . . . . 0,5 mm above the base of the wear
indicator slot
Rear brakes:
Brake lining to drum clearance . . . . . . . . . . . 0,2 to 2,0 mm
Minimum brake lining thickness . . . . . . . . . . 0,5 mm above the wear indicator
slots where visible or 5,5 mm total
lining thickness.
Maximum brake drun run–out . . . . . . . . . . . . 0,2 mm
Brake drum machining tolerance . . . . . . . . . 3 mm on diameter; maximum
diameter 363,23 mm

Foundation Brakes — 17 to 18 tonne vehicles

Type (front and rear) . . . . . . . . . . . . . . . . . . . . . . . . DAF ‘S’ cam drum brakes
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic slack adjusters
Brake lining to drum clearance . . . . . . . . . . . . . . . 0,8 to 1,2 mm
Minimum brake lining thickness . . . . . . . . . . . . . . 1,0 mm above the rivet head
Brake drum machining tolerance . . . . . . . . . . . . . 3 mm on diameter

Air compressor:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single cylinder, air cooled or water cooled
Capacity:
Air cooled compressor . . . . . . . . . . . . . . 150 cm3
Water cooled compressor . . . . . . . . . . . 250 cm3

Air dryer:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knorr Bremse AD6
Pressure relief valve opening pressure . . . . 14 bar
Working pressure:
Cut–out pressure . . . . . . . . . . . . . . . . . . . 8,4 bar
Cut–in pressure . . . . . . . . . . . . . . . . . . . . 7,2 bar
Heater/thermostat operating temperature:
Cut–in . . . . . . . . . . . . . . . . . . . . . . . . . . . . +7° " 5°C
Cut–out . . . . . . . . . . . . . . . . . . . . . . . . . . . +30° " 3°C

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0 GENERAL RECOMMENDATIONS
55 Series General information

Brake actuators — 11 to 15 tonne vehicles

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single diaphragm (push–rod actuation)
Type 16, 14 or 12 dependent on vehicle
specification
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring brake actuator (tube mounted)
Type 12/20, 10.5/20, 9/20 or 7/20 dependent on 1
vehicle specification

Brake Actuators – 17/18 tonne vehicles

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single diaphragm (lever actuation)
Type 27
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring brake actuator (lever actuation)
Type 24

Switches
Air pressure switch opening pressure . . . . . . . . . 5,5 bar
Stoplight micro–switch setting . . . . . . . . . . . . . . . . 2,5 to 3 mm

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 GENERAL RECOMMENDATIONS 0
General information 55 Series

FRONT AXLE AND STEERING

Front Axle
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Albion F56 and F71
Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0°
Hub bearing end–float:

1 F56 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F71 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0,05 to 0,25 mm
0,05 to 0,25 mm
Stub axle upper bush—fitted (F71 axle only):
Internal diameter (pre–finished) . . . . . . . . . . 38,11 to 38,15 mm
Upper bush maximum worn clearance . . . . 0,127 mm
Stub axle/axle beam clearance:
F56 axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 to 0.30 mm
F71 axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 to 0,13 mm
Stub axle/axle beam maximum worn clearance 0,3 mm

Steering Gear
Type:
11 to 15 tonne vehicles . . . . . . . . . . . . . . . . . . ZF 8095
17/18 tonne vehicles . . . . . . . . . . . . . . . . . . . . ZF 8098
Maximum internal leakage . . . . . . . . . . . . . . . . . . . 2,5 litres/min
Piston assembly end–float . . . . . . . . . . . . . . . . . . . 0,01 to 0,015 mm
Piston assembly shims . . . . . . . . . . . . . . . . . . . . . . 2,3 to 2,8 mm in increments of 0,01 mm
Steering column end–float . . . . . . . . . . . . . . . . . . . 0,13 to 0,25 mm
Pressure relief valve setting . . . . . . . . . . . . . . . . . 150 to 160 bar

Steering Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF 2–Line
Nominal controlled flow . . . . . . . . . . . . . . . . . . . . . 12,6 to 16,41 l/min
Nominal displacement . . . . . . . . . . . . . . . . . . . . . . 21, l/min at 1 000 rev/min
Maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . 160 bar

Steering Linkage
Front wheel alignment . . . . . . . . . . . . . . . . . . . . . . Parallel to 1,6 mm toe–in
Drag–link/track–rod ball joint lift . . . . . . . . . . . . . . 2,03 mm maximum
Steering lock angles . . . . . . . . . . . . . . . . . . . . . . . . Front 38°, Rear 50°

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0 GENERAL RECOMMENDATIONS
55 Series General information

REAR AXLE

Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Albion 8.10, 10.20, 10.26, 10.28 and 11.26

Hubs
End–float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 to 0,2 mm

Driving Head — 8.20, 10.20, 10.26 and 11.26 Axles

1
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Albion single–speed differential unit
Differential lock available on 8.20, 10.26 and
11.26 driving heads
Ratios:
8.20/10.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31:1, 3.73:1, 4.10:1, 4.56:1 and 5.13:1
10.26/11.26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31:1, 3.73:1, 4.10:1, 4.56:1, 5.13:1, 5.71:1
and 6.33:1

Crownwheel and pinion backlash:

8.20/10.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 to 0,30 mm
10.26/11.26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 to 0,33 mm

Pinion bearing cage shims available . . . . . . . . . . 0,127 mm

0,25 mm
0,508 mm
0,76 mm
1.00 mm
Pinion bearing pre–load . . . . . . . . . . . . . . . . . . . . . 1,13 to 3,0 Nm
Spring balance reading: 31 to 88 N
Pinion bearing spacers available:
8.20/10.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,70 to 6,20 mm in steps of approximately
0,05 mm plus 14,60 mm, 15,175 mm and
15,20 mm
10.26/11.26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,70 to 6,20 mm in steps of approximately
0,05 mm, 12,20 mm to 12,24 mm and 12,76 to
12,8 mm in steps of approximately 0,0125 mm

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 GENERAL RECOMMENDATIONS 0
General information 55 Series

Driving Head — 10.28 Axle

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton single–speed differential unit with
differential lock
Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36:1, 3.70:1, 4.11:1, 4.63:1, 5.29:1
1 Crownwheel and pinion backlash . . . . . . . . . . . . . 0,20 to 0,46 mm
Pinion bearing cage shims available . . . . . . . . . . 0,08 mm
0,127 mm
0,25 mm
0,508 mm
0,76 mm
Pinion bearing pre–load . . . . . . . . . . . . . . . . . . . . . 1,7 to 4,0 Nm
Spring balance reading: 23 to 49 N
Pinion bearing spacers available . . . . . . . . . . . . . 18,16 to 18,39 mm in steps of approximately
0,025 mm

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55 Series General information

FRAME AND SUSPENSION

Front spring assembly:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taperleaf (parabolic)
Number of leaves:
11 to 12 tonne GVW vehicles . . . . . . . . One
13 to 15 tonne GVW vehicles . . . . . . . .
17/18 tonne GVW vehicles . . . . . . . . . .
Two
Three 1
Rear spring assembly:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taperleaf (parabolic)
Number of leaves (all models) . . . . . . . . . . . Two with an underslung parabolic helper spring
Rear spring assembly (Air suspension):
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taperleaf
Number of leaves (all models) . . . . . . . . . . . One
Shock absorbers:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double acting, telescopic
Open length . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 to 722 mm
Closed length . . . . . . . . . . . . . . . . . . . . . . . . . . 438 to 446 mm

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General information 55 Series

CAB

Cab Tilt Pump

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weber
Nominal pressure (nominal) . . . . . . . . . . . . . . . . . 250 bar

1 Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . 350 to 380 bar

Cab Tilt Ram

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weber
Closed length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683 to 689 mm
Open length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1133 to 1145 mm
Nominal pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 250 bar

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55 Series General information

APPROXIMATE REFILL CAPACITIES

Engine oil (including filter) . . . . . . . . . . . . . . . . . . . 16 litres

Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 litres
Gearbox oil:
ZF S6–36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF 9S–75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7,5 litres
10,5 litres 1
Eaton 6109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 litres
Power steering reservoir . . . . . . . . . . . . . . . . . . . . 0,75 litre
Rear axle:
8.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,0 litres
10.26 and 11.26 . . . . . . . . . . . . . . . . . . . . . . . 9,0 litres
10.20 and 10.28 . . . . . . . . . . . . . . . . . . . . . . . 9,4 litres

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General information 55 Series

APPROXIMATE DRY UNIT WEIGHTS

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 kg
Gearbox:
ZF S6–36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 kg
ZF 9S–75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 kg (excluding clutch housing)
1 Eaton 6109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 kg (excluding clutch housing)
Front axle:
F56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 kg
F71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 kg
Rear axle:
8.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 kg
10.20 and 10.28 . . . . . . . . . . . . . . . . . . . . . . . 380 kg
10.26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 kg
11.26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580 kg

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55 Series General information

ABBREVIATIONS

Across flats (bolt head size) . . . . . . . A.F. Kilogramme (force) . . . . . . . . . . . . . . . kgf

After bottom dead centre . . . . . . . . . . A.B.D.C. Kilogramme (mass) . . . . . . . . . . . . . . . kg
After top dead centre . . . . . . . . . . . . . A.T.D.C. Kilogramme centimetre (torque) . . . . kgf cm
Alternating current . . . . . . . . . . . . . . . . a.c. Kilogramme metre (torque) . . . . . . . . kgf m
Ampere . . . . . . . . . . . . . . . . . . . . . . . . .
Ampere–hour . . . . . . . . . . . . . . . . . . . .
A
Ah
Kilogramme per square centimetre .
Kilometre . . . . . . . . . . . . . . . . . . . . . . . .
kgf/cm2
km
1
Atmosphere . . . . . . . . . . . . . . . . . . . . . atm. Kilometre per hour . . . . . . . . . . . . . . . . km/h
Kilonewton per square metre . . . . . . kN/m2
Before bottom dead centre . . . . . . . . B.B.D.C. Kilopascal . . . . . . . . . . . . . . . . . . . . . . . kPa
Before top dead centre . . . . . . . . . . . . B.T.D.C. Kilovolt . . . . . . . . . . . . . . . . . . . . . . . . . . kV
Bottom dead centre . . . . . . . . . . . . . . . B.D.C. Kilowatt . . . . . . . . . . . . . . . . . . . . . . . . . kW
Brake horse–power . . . . . . . . . . . . . . . bhp
British Standard . . . . . . . . . . . . . . . . . . B.S. Left–hand . . . . . . . . . . . . . . . . . . . . . . . L.H.
Left–hand drive . . . . . . . . . . . . . . . . . . L.H.D.
Litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Celsius (centigrade) . . . . . . . . . . . . . . C
Low compression . . . . . . . . . . . . . . . . l.c.
Centimetre . . . . . . . . . . . . . . . . . . . . . . cm
Low tension (electrical) . . . . . . . . . . . . l.t.
Centimetres of mercury . . . . . . . . . . . cmHg
Cubic centimetre . . . . . . . . . . . . . . . . . cm3
Maximum . . . . . . . . . . . . . . . . . . . . . . . max.
Cubic inch . . . . . . . . . . . . . . . . . . . . . . . in3
Metre . . . . . . . . . . . . . . . . . . . . . . . . . . . m
Cycles per minute . . . . . . . . . . . . . . . . c/min.
Microfarad . . . . . . . . . . . . . . . . . . . . . . . mfd
Miles per gallon . . . . . . . . . . . . . . . . . . mile/gal
Decibel . . . . . . . . . . . . . . . . . . . . . . . . . dB Miles per hour . . . . . . . . . . . . . . . . . . . mile/h
Degree (angle) . . . . . . . . . . . . . . . . . . . ° Millimetre . . . . . . . . . . . . . . . . . . . . . . . mm
Degree temperature . . . . . . . . . . . . . . ° Millimetres of mercury . . . . . . . . . . . . mmHg
Deutsche Industrie Normen . . . . . . . . DIN Minimum . . . . . . . . . . . . . . . . . . . . . . . . min.
Diameter . . . . . . . . . . . . . . . . . . . . . . . . dia. Minus (of tolerance) . . . . . . . . . . . . . . –
Direct current . . . . . . . . . . . . . . . . . . . . d.c. Minute (angle) . . . . . . . . . . . . . . . . . . . ′
Minute (time) . . . . . . . . . . . . . . . . . . . . min.
Electromotive force . . . . . . . . . . . . . . . e.m.f.
Negative (electrical) . . . . . . . . . . . . . . –
Fahrenheit . . . . . . . . . . . . . . . . . . . . . . F Newton . . . . . . . . . . . . . . . . . . . . . . . . . N
Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . ft Newton Metre . . . . . . . . . . . . . . . . . . . . Nm
Figure (Illustration) . . . . . . . . . . . . . . . Fig. Number . . . . . . . . . . . . . . . . . . . . . . . . . No.

Ounce (force) . . . . . . . . . . . . . . . . . . . . ozf

Gallons (Imperial) . . . . . . . . . . . . . . . . gal
Ounce (mass) . . . . . . . . . . . . . . . . . . . oz
Gramme (force) . . . . . . . . . . . . . . . . . . gf
Ounce inch (force) . . . . . . . . . . . . . . . . ozf in
Gramme (mass) . . . . . . . . . . . . . . . . . . g
Outside diameter . . . . . . . . . . . . . . . . . o.d.
Gross combination weight . . . . . . . . . g.c.w.
Overdrive . . . . . . . . . . . . . . . . . . . . . . . O/D
Gross train weight . . . . . . . . . . . . . . . . g.t.w.
Gross vehicle weight . . . . . . . . . . . . . . g.v.w. Per cent . . . . . . . . . . . . . . . . . . . . . . . . . %
Pint (Imperial) . . . . . . . . . . . . . . . . . . . . pt
High compression . . . . . . . . . . . . . . . . h.c. Plus (of tolerance) . . . . . . . . . . . . . . . . +
High tension (electrical) . . . . . . . . . . . h.t. Positive (electrical) . . . . . . . . . . . . . . . +
Horse–power . . . . . . . . . . . . . . . . . . . . hp Potential difference . . . . . . . . . . . . . . . p.d.
Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . h Pound (force) . . . . . . . . . . . . . . . . . . . . lbf
Pound (mass) . . . . . . . . . . . . . . . . . . . . lb
Inches . . . . . . . . . . . . . . . . . . . . . . . . . . in Pound foot (torque) . . . . . . . . . . . . . . . lbf ft
Inches of mercury . . . . . . . . . . . . . . . . inHg Pound inch (torque) . . . . . . . . . . . . . . lbf in
Internal diameter . . . . . . . . . . . . . . . . . i.d. Pound force per square inch . . . . . . . lbf/in2

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General information 55 Series

Radius . . . . . . . . . . . . . . . . . . . . . . . . . . r
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . :
Revolutions per minute . . . . . . . . . . . . rev/min
Right–hand . . . . . . . . . . . . . . . . . . . . . . R.H.
1 Right–hand drive . . . . . . . . . . . . . . . . .
Root mean squared . . . . . . . . . . . . . .
R.H.D.
rms

Screw Threads:
American Standard Taper Pipe . . . N.P.T.F.
British Association . . . . . . . . . . . . . . B.A.
British Standard Fine . . . . . . . . . . . . B.S.F.
British Standard Pipe . . . . . . . . . . . B.S.P.
British Standard Whitworth . . . . . . . B.S.W.
Metric (millimetre) . . . . . . . . . . . . . . M
Unified Coarse . . . . . . . . . . . . . . . . . UNC
Unified Fine . . . . . . . . . . . . . . . . . . . . UNF
Second (angle) . . . . . . . . . . . . . . . . . . ”
Second (time) . . . . . . . . . . . . . . . . . . . . s
Society of Automobile Engineers . . . S.A.E.
Specific gravity . . . . . . . . . . . . . . . . . . . sp.gr.
Square centimetre . . . . . . . . . . . . . . . . cm2
Square inch . . . . . . . . . . . . . . . . . . . . . in2
Square metre . . . . . . . . . . . . . . . . . . . . m2
Standard wire gauge . . . . . . . . . . . . . . s.w.g.

Temperature . . . . . . . . . . . . . . . . . . . . . temp.
Tonne . . . . . . . . . . . . . . . . . . . . . . . . . . . t
Top dead centre . . . . . . . . . . . . . . . . . . T.D.C.

United Kingdom . . . . . . . . . . . . . . . . . . U.K.

Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Volume . . . . . . . . . . . . . . . . . . . . . . . . . vol.

Watt . . . . . . . . . . . . . . . . . . . . . . . . . . . . W
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . wt.

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55 Series General information

CONVERSION FACTORS

Length
1 mm = 0.039 in 1 in = 25,400 mm
1m = 3.280 ft 1 ft = 304,800 mm
1m = 1.094 yd 1 yd = 0,914 m
1 km = 0.621 mile 1 mile = 1,609 km 1
Area
1 cm2 = 0.155 in2 1 in2 = 6,452 cm2
1 m2 = 10.764 ft2 1 ft2 = 929,030 cm2
1 m2 = 1.196 yd2 1 yd2 = 0,836 m2
1 km2 = 0.386 mile2 1 mile2 = 2,590 km2

Volume
1 cm3 = 0.061 in3 1 in3 = 16,387 cm3
1 m3 = 35.315 ft3 1 ft3 = 0,028 m3 (28,32 l)
1 m3 = 1.308 yd3 1 yd3 = 0,765 m3
1 dm3 (1 l) = 61.023 in3 (0.0353 ft3)

Capacity
1l = 1.760 pt 1 pt = 0,568 l
1l = 0.220 gal 1 gal = 4,546 l

Mass
1g = 0.035 oz 1 oz = 28,350 g
1 kg = 2.205 lb 1 lb = 453,592 g
1t = 0.984 ton 1 cwt = 50,802 kg
1 ton = 1,016 t

Moment of Force (Torque)

1 kgf cm = 0.867 lbf in 1 lbf in = 1,152 kgf cm
1 kgf m = 7.233 lbf ft 1 lbf ft = 0,138 kgf m
1 Nm = 0.737 lbf ft 1 lbf ft = 1,357 Nm

Pressure
1 kgf/cm2 = 14.233 lbf/in2 1 lbf/in2 = 0,070 kgf/cm2
1 kN/m2 = 0.145 lbf/in2 1 lbf/in2 = 6,894 kN/m2
1 bar = 14.5038 lbf/in2 1 lbf/in2 = 0,0689 bar
1 atm = 14.6959 lbf/in2 1 lbf/in2 = 0,0680 atm
1 kPa = 0.145 lbf/in2 1 lbf/in2 = 6,894 kPa

Power
1 kW = 1.341 hp 1 hp = 0,746 kW

Force
1N = 0.224 lbf 1 lbf = 4,448 N
1 kgf = 2.205 lbf 1 lbf = 0,454 kgf

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General information 55 Series

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55 Series Contents

CONTENTS Page Date

SECTION 2—SAFETY PRECAUTIONS and VEHICLE STORAGE

DAF Commercial Vehicles During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 2 —5 . . . . . . . . 9706
Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 2 —1 . . . . . . . . 9706

E9706 1
2

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55 Series Safety precautions and vehicle storage

2. SAFETY PRECAUTIONS and VEHICLE STORAGE

SAFETY SYMBOL

The following universal safety symbol is used

throughout this Group to indicate information
which is essential for the health and safety of all
operating personnel.

All information indicated by the safety

symbol MUST be strictly adhered to.
2
The following list of safety precautions
against possible safety hazards is not
exhaustive and, therefore, all safety
related workshop practices and
precautions must be exercised.
— Wear clean protective clothing or apparatus
and apply barrier creams when necessary.

— Ensure all Warnings and Cautions listed in

this Workshop Manual are strictly adhered
to. Always read carefully the instructions
printed on labels or stamped on
components and obey them implicitly. Such
instructions are included for your health and
safety; do NOT disregard them.

— Do NOT run the engine in a confined space

or unventilated area. If the engine must be
run in a confined space ensure that an
exhaust extractor is used.

— Ensure that all personnel are clear of any

rotating parts or moving components.

— Do NOT use the jack as the sole means of

support; position suitable supports beneath
the chassis frame.

— Do NOT remove the coolant filler cap when

the engine is hot.

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— Extreme care must be taken when draining

engine oil; hot engine oil can cause severe
personal injury.

— Many liquids and other substances used in

commercial vehicles are highly toxic and
must not be consumed or inhaled and, as
far as possible, be kept from skin contact.
2 These substances, amongst others, include
battery acid, anti–freeze, hydraulic fluid,
lubricants, fuel, windscreen washer
additives, refrigerant and various
adhesives.

— Avoid unnecessary contact with used

engine oil. Prolonged and repeated contact
with used engine oil may cause serious skin
disorders.

— To prevent a possible fire risk, ensure that

the engine and its surrounding areas are
clean and free from leakages/spillages of
any inflammable liquids (e.g. fuel oil, engine
oil, cold start ether fluid, etc.).

— It is essential that all maintenance work is

inspected and tested after completion.
When appropriate, the vehicle should be
road tested, particularly where safety
related items are concerned.

— Always wear clean protective clothing,

goggles and face mask when working with
components containing friction material.
When renewing clutch or brake linings or
any other friction material related products,
always follow the safety instructions
provided by the manufacturer.

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55 Series Safety precautions and vehicle storage

— Do NOT inhale the dust from the clutch or

brake linings or blow the dust from the
units. Remove any dust using a damp cloth
or vacuum cleaner and dispose of used
waste, whilst damp, into a plastic waste
disposal bag. If a cleaning solvent is
required, methylated spirit should be used.

— When charging the batteries from an

external source ensure that the area around 2
the battery is well ventilated and protected
against any naked flame, spark or intense
heat source. The use of ‘boost’ chargers is
not recommended.

— Always disconnect both battery terminals

before commencing work on the vehicle,
disconnecting the negative (–) lead first and
the positive (+) lead last. When
re–connecting the battery always connect
the positive (+) lead first and the negative
(–) lead last.

— The master/start switch and steering lock

and its electrical circuits are designed to
prevent the auxiliary circuits and starter
motor from being energised while the
steering lock is engaged. Serious
consequences could result from alteration
or substitution of the master/start switch
and steering lock or its wiring. In no
circumstances must the master/start switch
be separated from the anti–theft device.

— Do NOT weld or subject the chassis frame

to a severe localized heat source. Failure to
observe this precaution may result in
irreparable damage to the material structure
of the chassis frame with a consequent loss
in chassis frame strength.

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Safety precautions and vehicle storage 55 Series

— Welding or drilling of the chassis frame

must NOT be undertaken without the prior
written consent of DAF Trucks Limited.
Unauthorised, indiscriminate welding or
drilling may adversely affect the safe
load–carrying characteristics of the chassis
frame.

2 — Synthetic rubber seals, O–rings and

gaskets which have been damaged by fire
or come into contact with direct heat, may
produce hazardous fumes and highly
corrosive chemicals. Before attempting to
work on any component containing burnt or
decomposed seals etc. ensure that the
following precautions are strictly observed:
— Before attempting any work, allow any
burnt or decomposed synthetic rubber
component to completely cool.
— Ensure that impervious protective
clothing and gloves are worn at all
times whilst handling these
components.
— Ensure that all work is carried out in a
well ventilated area when handling
these components.
In the event of skin contact/inhalation
seek medical attention immediately.

— The fitting of non DAF parts and

accessories may be dangerous and could
under certain circumstances invalidate the
terms of the vehicle warranty. In particular,
it is extremely hazardous to fit or replace
parts whose installation requires the
dismantling, modification, or addition to the
electrical system. Always consult your DAF
Dealer for advice regarding the approval of
any parts or accessories before fitting.

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DAF COMMERCIAL VEHICLES DURING STORAGE

Maintenance During Storage

To preserve the original delivery quality of DAF
trucks during storage, it is necessary that they
are thoroughly maintained, especially when
stored in the open.
Dependent on the length of storage the following
procedures should be observed.

Procedure ‘1’— Up to 2 weeks 2

1. Carefully close windows and ventilation
traps.

2. Check oil level, top–up if required.

3. Check tyre pressures.

4. Disconnect the batteries and check the

terminals, clean as necessary and apply
petroleum jelly to prevent subsequent
corrosion.

5. Check the engine coolant anti–freeze

content and concentration, see
‘Maintenance Manual’.

6. Repair any paint damage.

7. Drain any moisture contained in the air

reservoirs, fuel filter and sedimenter.

Procedure ‘2’— 2 to 4 weeks

1. Carry out procedure ‘1’.

2. Check and rectify any leakage.

3. Reconnect the batteries then take the

vehicle for a short test drive, ensuring the
engine reaches its normal operating
temperature, venting the cab as much as
possible during the trip.

4. After test drive close all windows, doors and

ventilators and disconnect the batteries.

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Procedure ‘3’— 4 to 8 weeks

1. Carry out Procedure ‘2’.

2. Remove the batteries from the vehicle and

store in accordance with ‘Instructions for
Storage of Batteries’.

3. Release the clutch plate from the flywheel

2 to prevent it becoming rust bound.

4. Chock the road wheels, release the

handbrake then manually release the spring
brake actuator, see ‘Workshop Manual’.

Procedure ‘4’— Over 8 weeks

If the vehicle is to remain in storage for periods
greater than 8 weeks the following procedure
should be carried out once a month.

1. Make parking brake and clutch operative.

2. Install temporary batteries.

3. Carry out remaining operations in

Procedures ‘1’ and ‘2’.

4. Remove the temporary batteries.

5. Release the clutch and parking brake.

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55 Series Safety precautions and vehicle storage

Battery Storage Instructions

1. Period of Storage
— When a battery has been charged it
should be put into service immediately,
however in circumstances were this is
not possible the battery must be
recharged once a month.
— If the vehicle is stored for a period not
exceeding one month the battery
terminals must be disconnected,
2
cleaned and coated with petroleum
jelly. Stored batteries whether on or off
a vehicle must be recharged at monthly
intervals.
— The maximum period of storage for
charged batteries is three months.

2. Storage System
— Batteries must be stored in an area
that is cool dry and well–ventilated.
— To prevent damage to the battery
terminals when in storage or whilst in
transport the following maximum
stacking heights must be observed:
— For storage: 3 batteries high
— For transport: 2 batteries high

General Instructions
— Avoid naked flames, sparks or smoking in
the vicinity of batteries, or a battery
charging plant for risk of explosion.

— Batteries are ‘Maintenance–Free’. If they

are damaged causing leakage of electrolyte
(sulphuric acid), serious personal injury
could result if the electrolyte comes into
skin or eye contact; wash–off immediately
with clean cold water or seek medical
attention.

— Wear protective gloves when handling

batteries and wash hands after use.

— Do NOT place tools on terminal posts, as

this may cause accidental short circuiting
and risk of explosion.

E9706 0–2–7
 GENERAL RECOMMENDATIONS 0
Safety precautions and vehicle storage 55 Series

E9706
0–2–8
0 GENERAL RECOMMENDATIONS
55 Series Contents

CONTENTS Page Date

SECTION 3—SERVICE TOOLS

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 3 —1 . . . . . . . . 9706

E9706 1
3

E9706
2
0 GENERAL RECOMMENDATIONS
55 Series Service tools

3. SERVICE TOOLS

Service tools which will assist when overhauling

the various units of DAF vehicles are available
from:

Multipart Distribution Limited

Bolton Road
CHORLEY PR7 3EL
Lancashire, England

Telephone: Chorley (01257) 265531

Facsimile: 01257 260350

IMPORTANT: Some service tools quoted in the

Workshop Manual have been superseded with
3
new DAF Part Numbers. When ordering service
tools it is essential that the current DAF Part
Number is quoted. Use the following list to
cross–reference tool numbers:

DAF No. Manufacturers No. Description Of Tool

ENGINE
0109747 — Diesel compression tester
0192492 — Injector bore brush
0192494 — Timing pin extension tool—Bosch VP 14
0484899 — Adapter—Rear crankshaft oil seal remover
0499811 — Adapter—Diesel compression tester
0499900 — Fuel injection pump gear remover
0535684 — Rear crankshaft oil seal replacer
0694928 — Slide hammer—Rear crankshaft oil seal
remover
0694942 — Front crankshaft oil seal replacer
0694972 — Adapter—Diesel compression tester

E9706 0–3–1
 GENERAL RECOMMENDATIONS 0
Service tools 55 Series

DAF No. Manufacturers No. Description Of Tool

TRANSMISSION
ZF S6–36 and S6–36/2 Gearbox
0484880 LC 105A Bearing remover—Basic tool
0484887 LC 105A–28 Adapter—remover—layshaft front bearing
0484901 LC 284–16 Adapter—remover—O/drive/selector pivot pin
0484924 LC 55–19 Input shaft oil seal replacer
0484977 LC 113A Adjustable flange holding tool (also rear axles)
0484978 LC 114B Coupling flange remover
0485034 LC 315 Oil seal replacer
0485035 LC 316 Bearing replacer
3 0485037
0485039
LC 320
LC 320–2
Push puller (Alternative to 0484820)
Adapter—remover—Input shaft bearing
0485062 LC 379 Gear train lifting device
0485063 LC 380 Output shaft oil seal replacer
0485064 LC 381 Mainshaft pilot
0485099 LC 438 Yoke remover
0499809 MS 550 Driver handle
0694858 1X56 137 219 Adapter
0694928 — Slide hammer

ZF 9S–75 Gearbox
Refer to publication DW032002

Eaton 6109 Gearbox

0484880 LC 105A Bearing remover—Basic tool
0484977 LC 113A Adjustable flange holding tool (also rear axles)
0485167 E108 Driver—main tool
0485172 E108–5 Adapter—input bearing replacer
0485173 E109 Driver—main tool
0694928 MS 284 Slide hammer
1329351 LC 105A–4 Adapter—remover—layshaft front and rear
bearings
1329352 E109–5 Selector control seal/bush installer
1329353 E109–6 Layshaft bearing race installer
1329354 E109–7 Input shaft oil seal installer
1329355 E109–8 Selector shaft bush installer
1329356 E109–9 Selector shaft blanking plug installer
1329357 E109–11 Layshaft bearing cone installer
1329358 E109–12 Rear oil seal replacer
1329359 E114 A Mainshaft guide sleeve
1329360 E116 A Lifting fixture
1329361 E116–1 Lifting fixture adapter
1329362 E117 Reverse idler shaft pin installer
1329363 E118 Sun gear retainer
1329365 E210 Adapter—reverse idler shaft remover/installer *
1329366 E211 Range–change selector shaft bush installer

* Use with slide hammer 0694928 (MS 284)

Clutch
0484966 MS 84 Clutch alignment tool

E9706
0–3–2
0 GENERAL RECOMMENDATIONS
55 Series Service tools

DAF No. Manufacturers No. Description Of Tool

FUEL, INDUCTION and EXHAUST SYSTEMS

0192492 — Injector bore brush
0192494 — Timing pin extension tool—Bosch VP 14
0192534 2801 Adapter—‘Torx’ screw wrench
0192535 TX20 ‘Torx’ screw wrench
0499900 — Fuel injection pump gear remover—Bosch VP 14

BRAKES
0484938 — Wrench–rear actuator locking ring
0485052 LC 356 Air pressure test equipment—2 off
0485097 LC 436 Manual de–adjust tool 3
Anti–lock Braking System (ABS) Test Equipment
0485052 LC 356 Air pressure test gauge
0694974 — ABS test box (cable tester)

DAF ‘S’ Cam Brake Assemblies

0694794 — Camshaft bush remover/replacer

FRONT AXLE and STEERING

F56 Front Axle

0499809 MS 550 Driver handle
0535891 — Hydraulic puller
0694767 — Puller
1310427 AA014 Gamma seal replacer *
1310428 AA015 Needle bearing replacer *
1310430 AA025 Hub oil seal replacer *
1310431 AA026 Bearing replacer *
1310432 AA027 Bearing replacer *
1310433 AA028 Swivel pin needle bearing remover *
1310486 — Thrust button *
1310488 — Centalising plate *

F71 Front axle

1310434 AA029 Swivel pin needle bearing installer *
1310435 AA030 Swivel pin needle bearing remover *
1310436 AA031 Swivel pin bush installer *
1310437 AA032 Swivel pin bush remover *

* Use with Driver Handle 0499809 (MS550)

E9706 0–3–3
 GENERAL RECOMMENDATIONS 0
Service tools 55 Series

DAF No. Manufacturers No. Description Of Tool

Steering Linkage
0485122 18G 1133 Separator—Steering ball joint
0485211 KML 3011 Ball joint lift—checking tool

Steering Gear
0192506 8090 798 051 Oil seal replacer
0192507 8090 798 001 Sealing ring guide sleeve
0192508 8090 798 651 Sealing ring compression tool
0485022 252A Hydraulic puller—Drop arm remover
0485211 KML 3011 Ball joint lift—checking tool
3 0484852
0484853
MS 815
MS 815–3
Power steering pressure test kit
Hoses for MS 815
0484857 — Needle valve assembly

Steering Pump
694968 — Bearing/oil seal remover
694969 — Protective sleeve
694970 — Bearing/oil seal replacer

REAR AXLE
0484977 LC 113A Flange holding tool

8.20 Hub
0499809 MS 550 Driver handle
0484910 LC 383 Oil seal drift
0499805 — Hub nut wrench
1310453 — Oil seal replacer *

10.20, 10.26, 10.28 and 11.26 Hubs

0485164 LC 322 Hub nut wrench
0499809 MS 550 Driver handle
1240120 — Oil seal replacer *

* Use with Driver Handle 0499809 (MS550)

E9706
0–3–4
0 GENERAL RECOMMENDATIONS
55 Series Service tools

DAF No. Manufacturers No. Description Of Tool

8.20 and 10.20 Driving head

1310405 AA001 Pinion nut socket
1310406 AA002 Nest rolling tool
1310407 AA004 Replacer, pinion oil seal
1310408 AA005 Replacer, pinion inner bearing cone
1310409 AA006 Replacer, pinion nose bearing (inner track) *
1310410 AA007 Bearing remover
1310411 AA007–1 End cap, use with 1310410
1310412 AA008 Replacer, differential case bearings
1310413
1310414
AA009
AA010
Replacer, pinion nose bearing (outer track) *
Installer, pinion housing bearing shell *
3
1310415 AA011 Installer, pinion housing bearing shell *
1310416 AA012 Installer, differential lock bush

10.26 and 11.26 Driving head

1310438 AA003 Nest rolling tool
1310439 AA016 Bearing remover
1310440 AA016–1 End cap, use with 1310410
1310441 AA017 Replacer, differential case bearings
1310442 AA018 Replacer, pinion nose bearing (outer track) *
1310443 AA019 Installer, pinion housing bearing shell *
1310444 AA020 Installer, pinion housing bearing shell *
1310445 AA021 Installer, differential lock bush *
1310446 AA022 Replacer, pinion oil seal
1310447 AA023 Replacer, pinion inner bearing cone
1310448 AA024 Replacer, pinion nose bearing (inner track) *

* Use with Driver Handle 0499809 (MS550)

FRAME AND SUSPENSION

1310478 — Air suspension height setting gauge

E9706 0–3–5
 GENERAL RECOMMENDATIONS 0
Service tools 55 Series

E9706
0–3–6
0 GENERAL RECOMMENDATIONS
55 Series Contents

CONTENTS Page Date

SECTION 4—TORQUE TIGHTENING FIGURES

Torque Tightening Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0— 4 —1 . . . . . . . . 9706

E9706 1
4

E9706
2
0 GENERAL RECOMMENDATIONS
55 Series Torque tightening figures

4. TORQUE TIGHTENING FIGURES

CAB Nm
Cab lock bracket bolts . . . . . . . . . . . . . . . . . . . . . . 50 to 60
Cab upper mounting bracket bolts . . . . . . . . . . . . 85 to 105
Cab lock–down mechanism mounting setscrews . . 46 to 58
Cab front RH mounting bush/bracket nuts (M14) . . 135 to 165
Cab front LH mounting bush/bracket
setscrews (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 105
Cab mounting centre bolt . . . . . . . . . . . . . . . . . . . . 205 to 245
Cab ram pivot nuts . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 105

Cab Mirrors
Detent plate retaining setscrews . . . . . . . . . . . . . . 7,5 to 8,5
Mirror head retaining bolt:
Class 2 and 4 mirrors . . . . . . . . . . . . . . . . . . . . 15 to 16
Class 5 mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 to 8 4
Spring clutch locknut . . . . . . . . . . . . . . . . . . . . . . . . 10

ENGINE
Front engine mounting nuts . . . . . . . . . . . . . . . . . . 50 to 60
Rear engine centre mounting bolts . . . . . . . . . . . 220 to 250
Cooling System
Belt tensioner mounting bolt . . . . . . . . . . . . . . . . . 43
Fan to viscous drive unit nuts . . . . . . . . . . . . . . . . 20 to 27
Fan assembly to crankshaft flange nuts . . . . . . . 60 to 75
Thermostat housing bolts . . . . . . . . . . . . . . . . . . . . 24
Water pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cylinder Head
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rocker lever adjusting nut . . . . . . . . . . . . . . . . . . . 24
Rocker pedestal bolt (8 mm) . . . . . . . . . . . . . . . . . 24
Cylinder head bolts:
Stage 1 — All bolts . . . . . . . . . . . . . . . . . . . . . . 90
Stage 2 — Long bolts only (rocker pedestals) 120
Final stage — All bolts . . . . . . . . . . . . . . . . . . . Angle torque a further 90°
Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . 43
Induction manifold bolts . . . . . . . . . . . . . . . . . . . . . 24

E9706 0–4–1
 GENERAL RECOMMENDATIONS 0
Torque tightening figures 55 Series

Torque Tightening Figures Nm

Crankcase assembly
Camshaft thrust plate setscrews . . . . . . . . . . . . . . 24
Compressor gear nut . . . . . . . . . . . . . . . . . . . . . . . 126
Compressor mounting nuts . . . . . . . . . . . . . . . . . . 78
Connecting rod bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Final stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Crankshaft damper/pulley bolts . . . . . . . . . . . . . . 137
Crankshaft main bearing cap bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Final stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive belt tensioner centre bolt . . . . . . . . . . . . . . .
175
43
Fan assembly to crankshaft flange nuts . . . . . . . 60 to 75
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Flywheel housing bolts . . . . . . . . . . . . . . . . . . . . . . 60
Front gear cover and housing setscrews . . . . . . 24
Oil cooler setscrews . . . . . . . . . . . . . . . . . . . . . . . . 24
Oil pressure regulator plug . . . . . . . . . . . . . . . . . . 80
Oil pump retaining bolts . . . . . . . . . . . . . . . . . . . . . 24
Oil suction pipe and support bracket setscrews . . 24
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Sump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . 24
Rear engine mounting bracket centre bolts . . . . 220 to 250
Rear engine mounting to flywheel housing bolts . 80 to 110
Rear oil seal housing setscrews . . . . . . . . . . . . . . 9
Timing pin housing ‘Torkscrews’ T–25 . . . . . . . . . 5,4

E9706
0–4–2
0 GENERAL RECOMMENDATIONS
55 Series Torque tightening figures

Torque Tightening Figures Nm

TRANSMISSION
Clutch housing to engine bolts . . . . . . . . . . . . . . . 80 to 110
Clutch housing to gearbox bolts . . . . . . . . . . . . . . 69
Servo slave cylinder mounting bracket nuts/bolts 30
Coupling flange bolts . . . . . . . . . . . . . . . . . . . . . . . 100 to 110
Centre bearing retaining bolts . . . . . . . . . . . . . . . . 100 to 110
Control tube ball joint nut . . . . . . . . . . . . . . . . . . . . 40 to 50
Reaction rod ball joint nut . . . . . . . . . . . . . . . . . . . 58 to 64
Connection plate setscrews . . . . . . . . . . . . . . . . . . 25
Gearbox mounting rubber bolts . . . . . . . . . . . . . . 119 to 131
Chassis mounting bracket bolts . . . . . . . . . . . . . . 119 to 131
Centre mounting bolts . . . . . . . . . . . . . . . . . . . . . .
Propeller shafts:
190 to 210
4
Coupling flange bolts . . . . . . . . . . . . . . . . . . . . 100 to 110
Strap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81
Gear lever/mounting plate ball joint nut . . . . . . . . 80 to 90
Mounting plate/support bracket assembly
nuts/bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 30

S6–36 & S6–36/2 Gearbox

Connection housing bolts . . . . . . . . . . . . . . . . . . . . 50
Connection plate bolts . . . . . . . . . . . . . . . . . . . . . . 25
Coupling flange nut . . . . . . . . . . . . . . . . . . . . . . . . . 360
Intermediate bearing clamp bolts . . . . . . . . . . . . . 25
Pawl limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Pivot bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Reverse gear access plate bolts . . . . . . . . . . . . . . 25
Reversing light switch . . . . . . . . . . . . . . . . . . . . . . . 45
Selector housing bolts . . . . . . . . . . . . . . . . . . . . . . 25
Selector lever pinch bolt . . . . . . . . . . . . . . . . . . . . . 49
Speedometer connection piece . . . . . . . . . . . . . . 100
Stop bolt retaining plug . . . . . . . . . . . . . . . . . . . . . . 50

ZF 9S–75 Gearbox
Refer to publication DW032002

E9706 0–4–3
 GENERAL RECOMMENDATIONS 0
Torque tightening figures 55 Series

Torque Tightening Figures Nm

Eaton 6109 Gearbox

Front casing nuts/bolts . . . . . . . . . . . . . . . . . . . . . . 51 to 58
Rear casing nuts/bolts . . . . . . . . . . . . . . . . . . . . . . 51 to 58
Coupling flange nut:
M39 Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 to 700
M33 Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 to 588
Input shaft cover setscrews . . . . . . . . . . . . . . . . . . 35 to 39
Layshaft front and rear bearing covers . . . . . . . . 69 to 78
Range–change cylinder setscrews . . . . . . . . . . . 20 to 24
Range–change piston nut . . . . . . . . . . . . . . . . . . . 95 to 115
Range–change indicator switch . . . . . . . . . . . . . . 16 to 22
Range–change reaction plate screws . . . . . . . . . 24 to 27
4 Reversing light switch . . . . . . . . . . . . . . . . . . . . . . . 16 to 22
Remote control housing bolts . . . . . . . . . . . . . . . . 35 to 39
Remote control housing detent cover setscrews 20 to 24
Remote control housing end cover setscrews . . 20 to 24
Selector shaft detent cover setscrews . . . . . . . . . 20 to 24
Speedometer/rear oil seal housing bolts . . . . . . . 35 to 39
Speedometer drive pinion adapter . . . . . . . . . . . . 20 to 27
Sun gear retaining setscrew . . . . . . . . . . . . . . . . . 135 to 163
Oil pump setscrews . . . . . . . . . . . . . . . . . . . . . . . . . 35 to 40
Planet gear shaft retaining setscrews . . . . . . . . . 5 to 8
P.T.O./reverse idler gear cover setscrews . . . . . . 35 to 39

CLUTCH
Clutch cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 55
Clutch housing threaded adapter . . . . . . . . . . . . . 95 to 108
Servo slave cylinder mounting bracket nuts/bolts 30
Operating pedal bracket to bulkhead nuts/bolts . 22
Pedal bracket to steering column bolts . . . . . . . . 22
Servo slave cylinder connector housing screws 6 to 10

E9706
0–4–4
0 GENERAL RECOMMENDATIONS
55 Series Torque tightening figures

Torque Tightening Figures Nm

FUEL, INDUCTION AND EXHAUST SYSTEMS

Fuel injection pipes . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel injection pump drive gear nut:
Bosch P–7100 . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Bosch VP 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fuel injection pump mounting nuts:
Bosch P–7100 . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Bosch VP 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Injector locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Lift pump mounting setscrews . . . . . . . . . . . . . . . . 24
Induction manifold bolts . . . . . . . . . . . . . . . . . . . . . 248
Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . 43
Turbocharger:
Clamp band . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4
Diffuser setscrews . . . . . . . . . . . . . . . . . . . . . . . 8,5
Impeller shaft nut . . . . . . . . . . . . . . . . . . . . . . . . 14
Thrust bearing retaining screws . . . . . . . . . . . 4,5
Turbine housing setscrews . . . . . . . . . . . . . . . 14

BRAKES
Perrot Brake Assemblies:
Brake caliper retaining bolts . . . . . . . . . . . . . . 560 to 630
Brake caliper spreader plate socket
headed screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Brake cylinder mounting bracket bolts . . . . . . 74 to 102
Brake shaft lever retaining bolt . . . . . . . . . . . . 35
Guide pin socket headed screw . . . . . . . . . . . 300 to 340
Brake caliper location peg socket headed
screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front hub to brake disc bolts . . . . . . . . . . . . . . 185 to 200
Rear automatic adjuster housing bolts . . . . . . 124 to 146
Rear brake drum retaining bolts . . . . . . . . . . . 40 to 47
Rear brake shoe carrier backplate bolts . . . . 229 to 243
Rear brake shoe steady clip retaining bolt . . 65 to 75
Rear expander location bolts . . . . . . . . . . . . . . 124 to 146
Spring brake wind–off bolt . . . . . . . . . . . . . . . . 30 to 40
Air compressor:
Compressor mounting nuts . . . . . . . . . . . . . . . 77
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . 16
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . 28
Drive gear nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
End–cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power steering pump to compressor bolts . . 43
Unloader valve cap . . . . . . . . . . . . . . . . . . . . . . 63

E9706 0–4–5
 GENERAL RECOMMENDATIONS 0
Torque tightening figures 55 Series

Torque Tightening Figures Nm

Front brake actuators (11 to 15 tonne vehicles):

Actuator mounting nuts . . . . . . . . . . . . . . . . . . . 53
Clamping ring bolt . . . . . . . . . . . . . . . . . . . . . . . 11
Rear spring brake actuators (11 to 15 tonne vehicles):
Actuator release nut . . . . . . . . . . . . . . . . . . . . . 30 to 40
Clamping ring bolt . . . . . . . . . . . . . . . . . . . . . . . 11
Locking ring (using service tool 0484938) . . . 233
Front brake actuators (17/18 tonne vehicles):
Actuator mounting nuts . . . . . . . . . . . . . . . . . . . 122 to 136
Clamping ring bolt . . . . . . . . . . . . . . . . . . . . . . . 11
Rear spring brake actuators (17/18 tonne vehicles):
Actuator release nut . . . . . . . . . . . . . . . . . . . . . 20 to 30
Actuator mounting nuts . . . . . . . . . . . . . . . . . . . 122 to 136
4 Clamping ring bolt . . . . . . . . . . . . . . . . . . . . . . . 11

FRONT AXLE AND STEERING

Front Axle
F56 Axle:
Brake calliper to stub axle bolts . . . . . . . . . . . 560 to 630
Shock absorber nuts . . . . . . . . . . . . . . . . . . . . . 47 to 57
Steering arm/track–rod lever bolts . . . . . . . . . 485 to 665
Swivel pin nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 to 510
Swivel pin top/bottom cover setscrews . . . . . 17 to 23
F71 Axle:
Brake drum setscrews . . . . . . . . . . . . . . . . . . . 14 to 27
Brake carrier bolts . . . . . . . . . . . . . . . . . . . . . . . 179 to 210
Hub cap setscrews . . . . . . . . . . . . . . . . . . . . . . 27 to 41
Hub nut clamp bolt . . . . . . . . . . . . . . . . . . . . . . 27 to 41
Shock absorber nuts . . . . . . . . . . . . . . . . . . . . . 47 to 57
Steering arm/track–rod lever bolts . . . . . . . . . 485 to 665
Swivel pin nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 to 510
Swivel pin bottom cover setscrews . . . . . . . . . 88 to 108
Swivel pin top cover setscrews . . . . . . . . . . . . 24 to 30

Steering Gear
Drop–arm nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 to 550
Steering column universal joint clamping bolts . 24 to 30
Steering box end–cover bolts . . . . . . . . . . . . . . . . 285
Steering box mounting bolts . . . . . . . . . . . . . . . . . 405 to 475
Steering wheel retaining nut . . . . . . . . . . . . . . . . . 58
Power steering pump retaining bolts . . . . . . . . . . 46 to 58

E9706
0–4–6
0 GENERAL RECOMMENDATIONS
55 Series Torque tightening figures

Torque Tightening Figures Nm

Steering Linkage
F56 Axle:
Drag–link ball joint clamp bolt . . . . . . . . . . . . . 80 to 95
Drag–link ball pillar nut . . . . . . . . . . . . . . . . . . . 200 to 240
Track–rod ball clamp bolts . . . . . . . . . . . . . . . . 54 to 81
Track–rod ball pillar nut . . . . . . . . . . . . . . . . . . 220 to 300
F71 Axle:
Drag–link ball joint clamp bolt . . . . . . . . . . . . . 80 to 95
Drag–link ball pillar nut . . . . . . . . . . . . . . . . . . . 200 to 240
Track–rod ball clamp bolts . . . . . . . . . . . . . . . . 61 to 81
Track–rod ball pillar nut . . . . . . . . . . . . . . . . . . 176 to 244

REAR AXLE 4
Driving head retaining nuts/bolts:
8.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 to 101
10.20, 10.26, 10.28 and 11.26 . . . . . . . . . . . . . 202 to 252
Axle shaft setscrews/nuts:
Axle shaft nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 86 to 102
Axle shaft setscrews . . . . . . . . . . . . . . . . . . . . . 208 to 244
Rear hub:
Hub adjusting nut . . . . . . . . . . . . . . . . . . . . . . . . 136
Hub locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 to 149
Brake drum setscrews . . . . . . . . . . . . . . . . . . . . . . 22 to 44
Propeller shaft/coupling flange nuts . . . . . . . . . . . 107 to 119
Shock absorber nuts . . . . . . . . . . . . . . . . . . . . . . . . 47 to 57

Albion Driving Head — 8.20 and 10.20 Axles

Bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 to 160
Bevel pinion bearing housing setscrews . . . . . . . 50 to 58
Coupling flange retaining nut . . . . . . . . . . . . . . . . . 600 to 750
Differential casing/crownwheel bolts . . . . . . . . . . 111 to 129 *
Differential lock cover setscrews . . . . . . . . . . . . . 17 to 32
* Angle torque a further 60°

E9706 0–4–7
 GENERAL RECOMMENDATIONS 0
Torque tightening figures 55 Series

Torque Tightening Figures Nm

Albion Driving Head — 10.26 and 11.26 Axles

Bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 to 244
Bevel pinion bearing housing setscrews . . . . . . . 57 to 79
Coupling flange retaining nut . . . . . . . . . . . . . . . . . 1200 to 1300
Differential casing/crownwheel bolts . . . . . . . . . . 180 to 133 *
Differential lock cover setscrews . . . . . . . . . . . . . 17 to 32
* Angle torque a further 120°

Eaton Driving Head — 10.28 Axles

Bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 475 to 583

4 Bevel pinion bearing cage setscrews . . . . . . . . .

Coupling flange retaining nut . . . . . . . . . . . . . . . . .
240 to 295
735 to 900
Crownwheel nuts/bolts . . . . . . . . . . . . . . . . . . . . . . 352 to 393
Differential casing bolts . . . . . . . . . . . . . . . . . . . . . 210 to 237
Differential lock cylinder setscrews . . . . . . . . . . . 34 to 41
Differential lock switch . . . . . . . . . . . . . . . . . . . . . . 14 to 16
Selector fork clamp bolt . . . . . . . . . . . . . . . . . . . . . 14 to 16
Thrust screw locknut . . . . . . . . . . . . . . . . . . . . . . . . 200 to 245

Road Wheels
Wheel nuts (8–stud) . . . . . . . . . . . . . . . . . . . . . . . . 450 to 520
Wheel nuts (10–stud) . . . . . . . . . . . . . . . . . . . . . . . 570 to 650

E9706
0–4–8
0 GENERAL RECOMMENDATIONS
55 Series Torque tightening figures

Torque Tightening Figures Nm

FRAME and SUSPENSION

Service Information
To obtain the correct pre–tension when nuts and bolts are re–used, clean the nut and bolt threads with
a suitable solvent and dry thoroughly. Apply one drop of clean engine oil to the leading thread of the
bolt and one drop to the bearing face of the bolt or nut. This lubrication instruction also applies to new
bolts obtained from the store.
For standard fastenings, apply the lubricant prior to fitting and tighten to the relevant torque figure
quoted in the tables.

For special fastenings, apply the lubricant prior to fitting and tighten to the torque figure quoted in the
relevant section of the ‘Workshop Manual’.

The figures quoted below apply to flanged or standard hexagon headed nuts, bolts and screws.

Frame
4
Property Class 8.8 Bolt, 8 Nut:
M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3 to 2,7
M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,7 to 5,5
M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,9 to 9,3
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 to 23
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 to 45
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 80
M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 to 125
M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 to 195
M18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 to 270
M20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 to 380
M22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 to 520
M24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 to 650
M27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820 to 960
M30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 to 1300

Property Class 10.9 Bolt, 10 Nut:

M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 60
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 29
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 60
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 105
M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 to 165
M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 to 245
M18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 to 345
M20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 to 475
M22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565 to 665
M24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 to 830
M27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020 to 1200

E9706 0–4–9
 GENERAL RECOMMENDATIONS 0
Torque tightening figures 55 Series

Torque Tightening Figures Nm

Suspension
Shock absorber mounting nuts . . . . . . . . . . . . . . . 47 to 57
Shackle bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 to 245
Shackle pin clamp bolts . . . . . . . . . . . . . . . . . . . . . 85 to 105
U–bolt nuts:
Front axle (16 mm) . . . . . . . . . . . . . . . . . . . . . . 205 to 230
Front axle (20 mm) . . . . . . . . . . . . . . . . . . . . . . 440 to 490
Rear axle (20 mm) . . . . . . . . . . . . . . . . . . . . . . . 440 to 490
Rear axle (22 mm) . . . . . . . . . . . . . . . . . . . . . . . 508 to 560
Front anti–roll assembly:
Link arm ball joint nut . . . . . . . . . . . . . . . . . . . . 75 to 85
Link arm mounting bracket bolt . . . . . . . . . . . . 205 to 245
Location clamp nut . . . . . . . . . . . . . . . . . . . . . . 19 to 23
4 Rear anti–roll bar assembly:
Link arm bracket nuts . . . . . . . . . . . . . . . . . . . . 85 to 105
Flexible bushes to the axle clamp bracket
bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 105

E9706
0–4–10
0 GENERAL RECOMMENDATIONS
55 Series Contents

CONTENTS Page Date

SECTION 5—RECOMMENDED LUBRICANTS, FUEL OILS and FLUIDS

Recommended Lubricants, Fuel Oils and Fluids . . . . . . . . . . . . . . . . . . . . . 0— 5 —1 . . . . . . . . 9706

E9706 1
5

E9706
2
0 GENERAL RECOMMENDATIONS
55 Series Recommended lubricants, fuel oils and fluids

5. RECOMMENDED LUBRICANTS, FUEL OILS AND FLUIDS

WARNING:

— Avoid unnecessary contact with used engine oil. Prolonged and repeated contact with
used engine oil may cause serious skin disorders.

— Extreme care must be taken when draining oil from the engine, gearbox or rear axle; hot oil
can cause severe personal injury.

Specification Operating Viscosity (SAE)

Unit Temperature
T t
CCMC A.P.I. Multigrade Monograde

50

40
40

20W40
30

15W40
30

10W30
20
°C 10
Engine D5 — 0
5
20

-10
10W

-20
-30
000378

Viscosity (SAE)

ZF S6–36
Refer to the ‘‘HYDRAULIC FLUIDS CHART”
Gearbox
ZF 9S
9S–75
5 Above 0°C — 80 W
— GL 4
Gearbox Below 0°C — 80 W
Eaton
ato 66109
09 Above 0°C 80W 90 —
— GL 4
Gearbox Below 0°C 80W 90 —
Above 0°C 85W 140 140 EP
Rear Axle — GL 5
Below 0°C 85W 90 85 EP
All Specified
All Lithium Grease
Grease — —
Temperatures N.L.G.I. Grade 2
Points

CAUTION: DAF Trucks Limited cannot accept any responsibility for trouble experienced by operators
arising from any of the following causes:
— The use of an oil that does not conform to the minimum specification requirements.
— The use of oils of the incorrect viscosity.
— The continued use of oils after the recommended oil change period.
— The use of unauthorised lubricant additives or treatments.

E9706 0–5–1
 GENERAL RECOMMENDATIONS 0
Recommended lubricants, fuel oils and fluids 55 Series

HYDRAULIC FLUIDS CHART

WARNING: Hydraulic fluids are toxic substances which must not be consumed or
allowed to come into eye/skin contact. In the event of slight eye or skin contact
thoroughly rinse the affected area with water. If there is excessive eye/skin contact,
ingestion or inhalation seek medical attention immediately.

Minimum Hydraulic Fluid Specification

System
DOT SAE ISO Other
Clutch DOT 4 J 1703d — —
ZF S6–36 Gearbox,
Dexron IID (AUTRAN DX II)
Power Steering
— — — or
and
ATF Type A Suffix A
Hydraulic Cab Tilt

DIESEL FUEL OIL

5 WARNING: Diesel fuel is an inflammable fluid and must NOT be exposed to a naked
flame, spark or any intense heat source.

The fuel oils which are suitable for use in Diesel engines are generally known as Diesel fuel oil, distillate
Diesel fuel, automotive gas oil or Derv fuel. Users are recommended to obtain their supplies from a
source which can be depended upon to maintain a constant standard of quality and service. Waste or
residual oils of any type must NOT be used.

It is recommended that the Diesel fuel should conform to British Standard EN 590.

Cold Weather Recommendations

When diesel fuel is subjected to low temperatures (below –6°C) paraffin wax particulates will form
within the fuel which will eventually create blockages in the fuel system. To minimise the risk of fuel
‘waxing’, it is recommended that the following precautions are observed:

— The use of ‘winter grade’ diesel fuel will give added protection to the fuel system during cold
weather conditions. Ensure that the vehicle is using winter grade fuel in anticipation of cold weather
conditions.

— In the event of fuel ‘waxing’, it is recommended that a spare fuel filter is carried to enable a blocked
filter to be renewed; wax particulates cannot be dissolved by the application of heat.

— For extreme and prolonged cold weather conditions it is recommended that the vehicle is equipped
with a fuel heater and that all fuel pipes and fuel tank are adequately insulated; refer to your Main
Dealer for further information.

— Authorised cold weather fuel additives are available from your Main Dealer; the addition of any fuel
additives that are not specified or approved by DAF must NOT be mixed in the fuel system.

E9706
0–5–2
0 GENERAL RECOMMENDATIONS
55 Series Recommended lubricants, fuel oils and fluids

COOLANT ANTI–FREEZE

WARNING: Anti–freeze and corrosion inhibitors contain toxic chemicals which must not
be consumed or allowed to come into skin or eye contact. Use suitable eye protection,
impervious protective clothing and gloves when handling anti–freeze or corrosion
inhibitors.

In the event of slight eye or skin contact, thoroughly rinse the affected area with water. If
there is excessive eye/skin contact or ingestion/inhalation seek medical advice
immediately.

COOLANT, ANTI–FREEZE and ANTI–CORROSIVE AGENTS must contain organic acid

(carboxylate) based corrosion inhibitors, but must be free from silicate, nitrate, phosphate,
amine and boron. In all other respects the above must satisfy the specifications in ASTM
D–3306 or SAE J–1034 standards.

CAUTION: The following instructions must be observed; failure to comply with this information may
cause damage to the engine/cooling system and also invalidate the vehicle warranty:

— The engine cooling system MUST be flushed out and the coolant renewed every 2 years.
5
— To maintain the maximum anti–corrosion properties of the coolant do NOT allow the anti–freeze
content to fall below 30% nor exceed 60% (by volume) in the cooling system.

— The cooling system MUST contain the appropriate amount of ethylene glycol anti–freeze or, when
applicable, corrosion inhibitor; the use of 100% water in the cooling system is NOT permitted.

— In tropical regions or conditions (i.e. where atmospheric temperatures do not fall below 5°C) an
approved corrosion inhibitor can be substituted for anti–freeze. The corrosion inhibitor must be
mixed and its concentration level adjusted as instructed by the manufacturer.

The following graph shows the frost protection provided by various concentrations of anti–freeze
solutions. Use the appropriate anti–freeze concentration level to suit all anticipated climatic conditions
that the vehicle may encounter.

0
-10
-20

-30

˚C -40
-50
-60

-70
-80
0 10 20 30 40 50 60 70 80 90 100
% Ethyleneglycol
100 90 80 70 60 50 40 30 20 10 0 H 2O
000379

% Anti–freeze Content

E9706 0–5–3
 GENERAL RECOMMENDATIONS 0
Recommended lubricants, fuel oils and fluids 55 Series

PROPRIETARY PRODUCTS CHART

Application Product
Medium strength threadlocking ‘Loctite 242’ and ‘Loctite 241’
High strength studlock ‘Loctite 270’
High strength locking compound ‘Loctite 290’
Sealing compound ‘Loctite 515’
Multi–gasket sealant ‘Loctite 574’
High strength retainer for close fitting parts ‘Loctite 601’
High strength retainer for interference parts ‘Loctite 620’
High strength retainer—tube weld ‘Loctite 635’
Flexible silicon sealant ‘Loctite RTV Superflex Clear’
Jointing compound ‘Hylomar’
5 General cab panel sealant ‘Kelseal Glasticon 238’
Anti–seize grease Bostik ‘Never Seez’ grease or Rocol MG grease
High temperature anti–seize grease Bostik ‘Never Seez’ grease or Rocol J 166 grease
Salt resistant grease Texaco ‘Thermatex EP1’ or equivalent grease

E9706
0–5–4
 Maintenance Manual
55 SERIES

English
Printed in the Netherlands DW036657
 CONTENTS

INTRODUCTION
1
TECHNICAL DATA
2
SPECIFICATION OF LUBRICANTS
3
MAINTANANCE INTERVALS
4
MAINTENANCE OPERATIONS
5

DAF Trucks N.V., Eindhoven, the Netherlands

In the interest of continuing product
development, DAF reserves the right to change
specification or equipment at any time without
notice.
No part of this publication may be reproduced
and/or published by printing, photocopying,
microfilming or by any other means without the
manufacturer’s prior permission in writing.

 9809
SPECIFICATION

DAF Trucks NV (the Company) reserves the

right to change the procedures, material,
specification, dimensions or design of the
vehicles shown, described or referred to
herein at any time and without prior notice in
accordance with the Company’s policy of
constant product improvement.

Every reasonable effort is made to ensure

that the Company’s publications are accurate
but nothing shown, described or referred to
herein should be regarded as an infallible
guide to the procedures, materials,
specifications, dimensions, design or
availability of any particular vehicle, nor does
this publication constitute an offer for the sale
of any particular vehicle.

Neither the Company nor any Distributor or

Dealer shall in any circumstances be held
liable for any inaccuracy or the consequences
thereof.

Purchasers are advised that the specification

details set out in this publication apply to a
range of vehicles and not to any particular
vehicle. For the specification of any particular
vehicle purchasers should consult their DAF
Main Dealer. Please note that DAF Main
Dealers are not agents of the Company and
have no right or authority whatsoever to bind
the Company in any way or to assume on its
behalf any obligation expressed or implied.

 9809
 INTRODUCTION
55 Series

GENERAL

This Maintenance Manual covers all relevant

maintenance operations and also includes safety
regulations, which must be strictly adhered to. For
operations not dealt with in this publication
(overhaul, fault–tracing etc.) refer to the relevant
Workshop Manual.

In the compilation of this manual it has been

assumed that all personnel are sufficiently
1
experienced and theoretically/practically trained to
carry out the maintenance operations in a sound
and safe manner.

Every effort has been made to ensure that the

technical data and instructions for the maintenance
operations in this manual are correct and only refer
to the 55 vehicle series.

TECHNICAL INFORMATION

The technical information as given in this

maintenance manual, such as explanation of the
maintenance operations and the technical data to
carry out these operations in a safe and sound
manner was up to date at the time of going to
press.
DAF reserves the right to make changes without
prior notice.
Note: Important changes in the technical
information, which could not be included in this
maintenance manual, will be published by means
of Technical Information (T.I.) bulletins.

DISPOSITION OF UNITS

In this publication all references to left–hand or

right–hand sides are, unless otherwise stated, from
the driver’s viewpoint when seated in the driving
position.

 9809 1–1
 INTRODUCTION
55 Series

SAFETY SYMBOL

When this safety symbol is shown, it is

accompanied by information which is essential for
the health and safety of all operating personnel.
Failure to comply with the instructions given may
result in serious damage, injury and death.

1
000278

1–2  9809
 INTRODUCTION
55 Series

SAFETY PRECAUTIONS

The following list of safety

precautions against possible
safety hazards is not exhaustive and,
therefore, all safety related workshop
practices and precautions must be
exercised.
– Observe all the warnings and safety
regulations which are given in this manual.
Always start by reading the instructions and
1
warnings given on labels or stickers attached
to the components concerned and make sure
to observe them! They are given for your
personal safety and health; do not ignore
them.
– Wear clean protective clothing or apparatus
and apply barrier creams when necessary.
– Always wear clean protective clothing,
goggles and face mask when working with
components with friction material. When
renewing clutch or brake linings or any other
friction material related products, always follow
the safety instructions provided by the
manufacturer.
– Do NOT inhale the dust from the clutch or
brake linings or blow the dust from the units.
Remove any dust using a damp cloth or
vacuum cleaner and dispose of used waste,
whilst damp, into a plastic waste disposal bag.
If a cleaning solvent is required, methylated
spirit should be used.
– Do NOT run the engine in a confined space
or unventilated area. If the engine must be run
in a confined space ensure that an exhaust
extractor is used.

 9809 1–3
 INTRODUCTION
55 Series

– Keep clear of any rotating and working

components.
– Do not remove the cooling system filler cap
when the engine is at operating temperature.
– Extreme care must be taken when draining
engine oil; hot engine oil can cause severe
personal injury.

1 – Avoid unnecessary contact with used engine

oil. Prolonged and repeated contact with
used engine oil may cause serious skin
disorders.

– Synthetic rubber seals, O–rings and gaskets

which have been damaged by fire or come
into contact with direct heat, may produce
hazardous fumes and highly corrosive
chemicals. Allow burnt or decomposed
seals etc. to completely cool and use
impervious protective clothing and gloves
and work in a well ventilated area when
handling these components. In the event of
skin contact seek medical attention
immediately.

– Several oils and lubricants are harmful to

your health and the same is true of coolant,
Freon in air–conditioning systems, battery
acid, and diesel fuel. Therefore, avoid any
internal and external contact.

1–4  9809
 INTRODUCTION
55 Series

– When carrying out maintenance operations

under the cab, it must be tilted completely

– To prevent danger of fire risk the engine and

its surrounding area must be free of highly
flammable fluids.

– In the case of engines provided with a sound

insulation make sure to clean thoroughly the
encapsulation after every maintenance
service. This is on account of the risk of fire,
1
which may break out if the inside of the
encapsulation is fouled.

– Always disconnect both battery leads before

commencing work on the vehicle. To
minimise the risk of accidental short circuits
when disconnecting the batteries, ensure
that the negative (–) lead is disconnected
first and the positive (+) lead last; reverse
the procedure when re–connecting the
batteries.

– Always use stands when carrying out

operations under the vehicle.

– When charging batteries make sure that the

room is well ventilated and avoid sparks and
naked fire. Quick–chargers may only be
used in an emergency and only with the
positive and negative leads disconnected.

 9809 1–5
 INTRODUCTION
55 Series

CLEANING OF VEHICLES

It is recommended to clean the vehicle with a

high pressure cleaner before starting
maintenance operations. The advantage is that
the mechanic can better carry out such
operations when the surrounding area is clean
and that any defects will earlier be noticed.

1 When a high–pressure cleaner is used, proceed

with caution and carefully note the hints given
below.

Note: Before starting the cleaning first look for

any leaks on engine, axles, gearbox etc. as this
cannot be done afterwards during the
maintenance operations.

– Make sure that during the cleaning the

doors, windows and roof hatch are securely
closed.

– Do not spray directly on seals. There is a

danger of the seals being forced open by the
high–pressure jet of water so that the
grease packed behind them is flushed away.

– The hydraulic fluid reservoir for the steering

gear is provided with a ventilation opening.
Water may enter the reservoir through this
opening and damage the steering gear.

– When cleaning the radiator/intercooler, take

care not to damage the ribs or fins of the
cores.

– Make sure that no water can enter the

differential or gearbox via the ventilation
openings.

1–6  9809
 INTRODUCTION
55 Series

– Make sure that no water can enter the fluid

reservoirs of the clutch, brakes, load transfer
device, etc. via the ventilation openings.

– The engine and engine compartment can

also be cleaned with the high–pressure
cleaner provided the jet is not specifically
directed at the electric components such as
the starter motor, alternator etc.

– In the case of engines provided with a sound

1
insulation make sure to clean thoroughly the
encapsulation after every maintenance
service. This is on account of the risk of fire,
which may break out if the inside of the
encapsulation is fouled.

– Do not aim the jet of water directly at the

headlight rear covers and electrical
connections such as connectors, cable
feed–throughs for the vehicle lighting, etc.

– When cleaning the vehicle, make sure that

no water enters the air intake system via the
air inlet or its flexible joints.

– After the cleaning has been completed, the

vehicle must be lubricated with a grease gun
or via the automatic lubrication system. This
is very important to prevent penetration of
moisture and dirt at the various pivot points.

– Do not aim the jet of water directly at the air

intake system.

 9809 1–7
 INTRODUCTION
55 Series

DIRECTIVES FOR MAINTENANCE OPERATIONS

– Utmost cleanliness is of major importance

during maintenance operations on the vehicle.
Filler caps, lubricating points, level and drain
plugs must be cleaned before and after
maintenance operations.

– If units require an excessive amount of oil or if

1 leakage from seals is noted, this should be
reported and action taken at the earliest
opportunity.

– The gearbox and rear axle breathers must be

checked at regular intervals. Blocked
breathers may cause leakage due to
overpressure.

– If the vehicle is operating under unfavourable

conditions (very bad roads, on building sites
etc.), main bolt connections such as
semi–trailer couplings, spring assemblies,
U–bolts, trailer couplings, steering box
attachments, superstructure attachments etc.
should be checked more frequently and, if
necessary, be re–torqued.

1–8  9809
 INTRODUCTION
55 Series

– It is essential that all maintenance work is

inspected and tested after completion. When
appropriate, the vehicle should be road tested,
particularly where safety related items are
concerned.

– Do NOT weld or subject the chassis frame to

a severe localized heat source. Failure to
observe this precaution may result in
irreparable damage to the material structure of
the chassis frame with a consequent loss in 1
chassis frame strength.

– Welding or drilling of the chassis frame MUST

NOT be undertaken without the prior written
consent of DAF Trucks NV. Unauthorised,
indiscriminate welding or drilling may
adversely affect the safe load– carrying
characteristics of the chassis frame.

– Before carrying out any welding operation on

the chassis frame, ensure that all electronic
control units (ECU’s) are disconnected from
the chassis/cab negative.

 9809 1–9
 INTRODUCTION
55 Series

ENVIRONMENT

Carrying out the maintenance operations at the

scheduled intervals and with expert knowledge will
contribute to reducing pollution of the environment.
This can be done by detecting and repairing any
leakages in time and keeping the engine in an
optimum condition (adjusting valves, renewing filter
elements etc.) so as to reduce emission of harmful
1 exhaust gasses to a minimum.

It should be noted that lubricants and fluids contain

harmful elements which will pollute the
environment.

Therefore, ensure that not only drained–off oils and

fluids but also old oil and fuel filters are separately
collected in the corresponding waste containers.

Always be environment–conscious when

carrying out maintenance operations.

1–10  9809
 INTRODUCTION
55 Series

PARTS

All DAF parts and components are exactly geared

to each other and that is precisely one of the AF Par
D
determining factors of the original DAF quality.
s AF Part
D

Needless to say, this quality level will best be

served and maintained when genuine DAF parts DA F Parts s AF Part
D

and components are also used for renewing

defective parts and components. This is also true
when it comes to exchanging such parts as
1
windscreen wiper blades, air dryer elements,
gaskets, V–belts and filters.

For instance, non–genuine ‘DAF’ filters will offer 000280

insufficient protection against microscopic dust

particles in the air, metal wear particles in the oil
and contaminants in the fuel, resulting in:

– premature renewal of cylinder liners, pistons,

bearings, valves, fuel injection pumps and
other working parts

– a decrease in the engine performance

– an increase in the fuel consumption

Always use genuine DAF parts and

components.

 9809 1–11
 INTRODUCTION
55 Series

1–12  9809
 TECHNICAL DATA
55 Series

TECHNICAL SPECIFICATIONS

Engine
Valve clearances (cold):
Inlet 0,25 mm
Exhaust 0,50 mm
Engine speeds (under no–load):
Idling speed 740 to 800 rpm
Maximum 2825 to 2925 rpm
Engine drive belt length (overall):
35 and 55 amp alternators 1442 to 1454 mm
80 amp alternator 1226 to 1238 mm

Brakes
2
Minimum brake pad thickness 0,5 mm above the base of the wear indicator
slot
Minimum brake shoe lining thickness:
11 to 15 tonne models 0,5 mm above the base of the wear indicator slot
17/18 tonne models 1,0 mm above the rivet head
Brake shoe lining/brake drum clearance:
11 to 15 tonne models 0,2 to 2,0 mm
17/18 tonne models 0,8 to 1,2 mm
Minimum brake disc thickness 40 mm

Front Axle and Steering

Front wheel alignment Parallel to 1,6 mm toe–in
Front hub end–float:
F56 axle 0,05 to 0,25 mm
F71 axle 0,1 to 0,23 mm
Swivel pin/stub axle clearance:
Minimum 0,05 mm
Maximum 0,3 mm

Rear Axle
Hub end–float 0,05 to 0,20 mm (adjustment by hub nut)

Suspension
ECAS pre–set ride heights (approximate):
Maximum height 466 mm
Normal height 325 mm
Minimum height 235 mm

9809 2–1
 TECHNICAL DATA
55 Series

TORQUE TIGHTENING FIGURES

Engine
Sump drain plug 60 Nm
Valve cover bolt 24 Nm

Gearbox
Filler/level/drain plugs:
ZF S6–36 60 Nm
ZF 9S–75 50 Nm
Eaton 6109 35 Nm
Eaton 6109 oil strainer 40 to 47 Nm
2 Front Axle – F56
Caliper retaining bolts 560 to 630 Nm

Front Axle – F71

Brake drum setscrews 14 to 27 Nm
Hub nut clamp bolt 27 to 41 Nm

Rear Axle
Hub oil filler/drain plug 27 Nm
Hub outer locknut 122 to 149 Nm
Axle shaft setscrews/nuts:
8.20 axle 86 to 102 Nm
10.20, 10.26 and 11.26 axles 208 to 244 Nm
Brake drum setscrews 22 to 44 Nm

2–2  9809
 TECHNICAL DATA
55 Series

Chassis Fastenings
All nuts, bolts and screws used on the 55 Series
range of vehicles are to metric standards.
Medium/high tensile fasteners used in the
manufacture and assembly of the vehicles
generally fall into one of the following categories:
– Property Class 8.8 fixings: Normally plain
hexagon headed with zinc finish and
metric coarse threads.
– Property Class 10.9 fixings: Mainly flange
hexagon headed with zinc finish and
metric fine threads.
Interchangeability requirements for
proprietary equipment dictates that some
2
Property Class 10.9 fixings use zinc finish
with metric coarse threads.
Refer to the ’Chassis Fastenings’ chart, unless Chassis Fastenings
otherwise stated, for all torque tightening figures.
The figures quoted apply to flanged and standard 10.9 Bolt, 10 Nut 8.8 Bolt, 8 Nut
hexagon headed nuts, bolts and screws. Si
Size Torque (Nm)
Important: To obtain the correct pre–tension M4 — 2,3 to 2,7
when nuts and bolts are re–used, clean the nut
and bolt threads with a suitable solvent and dry M5 — 4,7 to 5,5
thoroughly. Apply one drop of clean engine oil to M6 — 7,9 to 9,3
the leading thread of the bolt and one drop to the
bearing face of the bolt or nut. This lubrication M8 25 to 29 19 to 23
instruction also applies to new bolts obtained M10 50 to 60 39 to 45
from the store. For standard fastenings, apply
M12 85 to 105 70 to 80
the lubricant prior to fitting and tighten to the
relevant torque figure. For special fastenings, M14 135 to 165 105 to 125
apply the lubricant prior to fitting and tighten to M16 205 to 245 165 to 195
the torque figure quoted in the ‘Workshop
Manual’. M18 295 to 345 230 to 270
M20 405 to 475 320 to 380
M22 565 to 665 440 to 520
M24 710 to 830 550 to 650
M27 1020 to 1200 820 to 960
M30 — 1100 to 1300

9809 2–3
 TECHNICAL DATA
55 Series

APPROXIMATE REFILL CAPACITIES

Engine
Engine sump (including engine oil filter) 16 litres
Cooling system 26 litres

Transmission
Gearbox:
ZF S6–36 7,5 litres
ZF 9S–75 10,5 litres
Eaton 6109 8,5 litres

2 Power steering
Power steering reservoir 0,75 litre

Rear axle
Differential:
8.20 8,0 litres
10.26 and 11.26 9,0 litres
10.20 9,4 litres
Rear hub (each):
8.20 0,25 litre
10.20, 10.26 and 11.26 0,5 litre

2–4  9809
 TECHNICAL DATA
55 Series

SERVICE TOOLS

D
A
F
2
090110 090112

Timing Pin Extension ABS Test Equipment

0192494 069474

PSI

090111 090220

ISO Test Gauge DAVIE Electronic Test Equipment

0485052

090109 090113

Ball Joint Checking Tool Hub Nut Wrench

0485211 0499805 (8.20 axle)

9809 2–5
 TECHNICAL DATA
55 Series

2 090113 090116

Hub Nut Wrench Driver Handle

0485164 (all axles except 8.20) 0499809

090218 090117

Oil Seal Replacer Oil Seal Replacer

1310453 (8.20 axle) 1240120 (all axles except 8.20)

2–6  9809
 TECHNICAL DATA
55 Series

LOAD SENSING VALVE DATA PLATES – STEEL SUSPENSION MODELS

Data Plate Part Number ACHA964 Data Plate Part Number ACHA965
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 1.5
Rear Axle Weight Output Pressure (bar) Rear Axle Weight Output Pressure (bar)
kg Front Axle Rear Axle kg Front Axle Rear Axle
8240 6,0 6,0 8500 6,0 6,0
5560 6.0 6,0 6030 6,0 6,0
1680 4,6 3,1 1680 4,8 2,3
2000
3000
4,7
5,2
3,3
4,3
3000
4000
5,1
5,6
3,4
4,7
2
4000 5,7 5,4 5000 5,8 5,5
5500 6,0 6000 6,0
5380 6,0 5870 5,9
5260 5,9 5740 5,9
5140 5,9 5610 5,8
5020 5,8 5480 5,8
4900 5,8 5350 5,7
4780 5,8 5220 5,6
4660 5,7 5090 5,5
4540 5,7 4960 5,5
4420 5,6 4830 5,4
4300 5,6 4700 5,3
4180 5,5 4570 5,2
4060 5,4 4440 5,1
3940 5,3 4310 5,0
3820 5,2 4180 4,9
3700 5,0 4050 4,8
3580 4,9 3920 4,6
3460 4,8 3790 4,4
3340 4,7 3660 4,2
3220 4,5 3530 4,0
3100 4,4 3400 3,9
2980 4,3 3270 3,7
2860 4,1 3140 3,5
2740 4,0 3010 3,4
2620 3,9 2880 3,2
2500 3,8 2750 3,1
2380 3,7 2620 3,0
2260 3,6 2490 2,9
2140 3,5 2360 2,8
2020 3,4 2230 2,7
1900 3,3 2100 2,6
1780 3,2 1970 2,5
1660 3,1 1840 2,4
1540 3,0 1710 2,3
1420 2,9 1580 2,2
1300 2,8 1450 2,2
1180 2,8 1320 2,1
1060 2,7 1190 2,0
1000 2,7 1060 2,0
1000 2,0

9809 2–7
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHA966 Data Plate Part Number ACHA967
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 2.7
Rear Axle Weight Output Pressure (bar) Rear Axle Weight Output Pressure (bar)
kg Front Axle Rear Axle kg Front Axle Rear Axle
9800 6,0 6,0 9800 6,0 6,0
6400 6.0 6,0 6400 6,0 6,0
1680 4,1 2,2 1680 3,6 2,2
3000 4,6 3,2 3000 4,2 3,2
4000 5,3 4,5 4000 5,1 4,5
2 5000
6400
5,6 5,2
6,0
5000
6400
5,5 5,2
6,0
6260 6,0 6260 6,0
6120 5,9 6120 5,9
5980 5,8 5980 5,8
5840 5,8 5840 5,8
5700 5,7 5700 5,7
5560 5,6 5560 5,6
5420 5,5 5420 5,5
5280 5,4 5280 5,4
5240 5,3 5140 5,3
5000 5,2 5000 5,2
4860 5,1 4860 5,1
4720 5,0 4720 5,0
4580 4,9 4580 4,9
4440 4,8 4440 4,8
4300 4,7 4300 4,7
4160 4,6 4160 4,6
4020 4,5 4020 4,5
3880 4,3 3880 4,3
3740 4,1 3740 4,1
3600 3,9 3600 3,9
3460 3,7 3460 3,7
3320 3,5 3320 3,5
3180 3,4 3180 3,4
3040 3,2 3040 3,2
2900 3,1 2900 3,1
2760 2,9 2760 2,9
2620 2,8 2620 2,8
2480 2,7 2480 2,7
2340 2,6 2340 2,6
2200 2,5 2200 2,5
2060 2,4 2060 2,4
1920 2,3 1920 2,3
1780 2,3 1780 2,3
1640 2,2 1640 2,2
1500 2,1 1500 2,1
1360 2,0 1360 2,0
1220 2,0 1220 2,0
1080 1,9 1080 1,9
1000 1,9 1000 1,9

2–8  9809
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHA968 Data Plate Part Number ACHA977
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.7 Empty/load valve ratio 2.0
Rear Axle Weight Output Pressure (bar) Rear Axle Weight Output Pressure (bar)
kg Front Axle Rear Axle kg Front Axle Rear Axle
10300 6,0 6,0 8500 6,0 6,0
7240 6.0 6,0 6400 6,0 6,0
1680 3,5 2,0 1680 4,1 2,2
3000 4,0 2,8 3000 4,6 3,2
4000 4,7 3,9 4000 5,3 4,5
5000
7200
5,1 4,6
6,0
5000
6400
5,6 5,2
6,0
2
7040 5,9 6260 6,0
6880 5,9 6120 5,9
6720 5,8 5980 5,8
6560 5,7 5840 5,8
6400 5,6 5700 5,7
6240 5,5 5560 5,6
6080 5,4 5420 5,5
5920 5,3 5280 5,4
5760 5,2 5140 5,3
5600 5,1 5000 5,2
5440 5,0 4860 5,1
5280 4,8 4720 5,0
5120 4,7 4580 4,9
4690 4,6 4440 4,8
4800 4,5 4300 4,7
4640 4,4 4160 4,6
4480 4,3 4020 4,5
4320 4,2 3880 4,3
4160 4,1 3740 4,1
4000 3,9 3600 3,9
3840 3,7 3460 3,7
3680 3,5 3320 3,5
3520 3,3 3180 3,4
3360 3,1 3040 3,2
3200 3,0 2900 3,1
3040 2,8 2760 2,9
2880 2,7 2620 2,8
2720 2,6 2480 2,7
2560 2,5 2340 2,6
2400 2,4 2200 2,5
2240 2,3 2060 2,4
2080 2,2 1920 2,3
1920 2,1 1780 2,3
1760 2,0 1640 2,2
1600 2,0 1500 2,1
1440 1,9 1360 2,0
1280 1,8 1220 2,0
1120 1,8 1080 1,9
1000 1,8 1000 1,9

9809 2–9
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHA286 Data Plate Part Number ACHA288
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.7 Empty/load valve ratio 2.7
Rear Axle Weight Output Pressure (bar) Rear Axle Weight Output Pressure (bar)
kg Front Axle Rear Axle kg Front Axle Rear Axle
11500 6,0 6,0 11500 6,0 6,0
9160 6.0 6,0 8880 6,0 6,0
2280 3,4 1,8 2280 3,3 1,7
4000 3,9 2,7 4000 3,9 2,6
6000 4,6 3,8 6000 4,5 3,8
2 8000
9100
5,4 5,1
5,9
8000
8800
5,4 5,1
5,9
8910 5,8 8620 5,7
8720 5,6 8440 5,5
8530 5,5 8260 5,4
8340 5,3 8080 5,2
8150 5,2 7900 5,0
7960 5,0 7720 4,9
7770 4,9 7540 4,7
7580 4,8 7360 4,6
7390 4,6 7180 4,4
7200 4,5 7000 4,3
7010 4,4 6820 4,2
6820 4,3 6640 4,0
6630 4,1 6460 3,9
6440 4,0 6280 3,8
6250 3,9 6100 3,7
6060 3,8 5920 3,6
5870 3,7 5740 3,5
5680 3,6 5560 3,4
5490 3,5 5380 3,3
5300 3,4 5200 3,2
5110 3,3 5020 3,1
4920 3,3 4840 3,0
4730 3,2 4660 2,9
4540 3,1 4480 2,8
4350 3,0 4300 2,8
4160 2,9 4120 2,7
3970 2,7 3940 2,6
3780 2,6 3760 2,4
3590 2,4 3580 2,3
3400 2,3 3400 2,2
3210 2,2 3220 2,1
3020 2,1 3040 2,0
2830 2,0 2860 1,9
2640 1,9 2680 1,8
2450 1,9 2500 1,8
2260 1,8 2320 1,7
2070 1,7 2140 1,7
2000 1,7 2000 1,6

2–10  9809
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHJ055 Data Plate Part Number ACHJ056
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 1.5
Rear Axle Weight Output Pressure (bar) Rear Axle Weight Output Pressure (bar)
kg Front Axle Rear Axle kg Front Axle Rear Axle
8240 6,0 6,0 8500 6,0 6,0
6130 6.0 6,0 1680 4,8 2,4
1680 4,4 2,8 2500 4,9 2,8
3000 4,9 3,7 4500 5,4 4,1
4000 5,3 4,6 6500 5,6 4,9
5000
6100
5,7 5,4
6,0
7500
8570
5,8 5,4
6,0
2
5960 5,9 8300 5,9
5820 5,8 8100 5,7
5680 5,7 7900 5,6
5540 5,7 7700 5,5
5400 5,6 7300 5,3
5260 5,5 7100 5,2
5120 5,4 6900 5,1
4980 5,3 6700 5,0
4840 5,3 6300 4,8
4700 5,2 6100 4,7
4560 5,1 5900 4,7
4420 5,1 5700 4,6
4280 5,0 5500 4,5
4140 4,8 5300 4,4
3860 4,5 5100 4,3
3720 4,4 4900 4,2
3580 4,2 4700 4,2
3440 4,1 4300 4,0
3300 4,0 4100 3,8
3100 3,8 3900 3,7
3020 3,7 3700 3,5
2880 3,6 3500 3,4
2740 3,5 3300 3,2
2600 3,4 3100 3,1
2460 3,3 2900 3,0
2320 3,2 2700 2,9
2180 3,1 2300 2,7
2040 3,0 2100 2,6
1900 2,9 1900 2,5
1760 2,8 1700 2,4
1620 2,8 1500 2,3
1480 2,7 1300 2,3
1340 2,6 1100 2,2
1200 2,6 1000 2,2
1060 2,5
1000 2,5

9809 2–11
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHJ057 Data Plate Part Number ACHJ058
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 2.7
Rear Axle Weight Output Pressure (bar) Rear Axle Weight Output Pressure (bar)
kg Front Axle Rear Axle kg Front Axle Rear Axle
9800 6,0 6,0 9800 6,0 6,0
8740 6.0 6,0 7350 6.0 6,0
1680 4,1 2,2 1680 3,7 2,3
2500 4,3 2,6 2500 3,9 2,7
4500 5,0 3,9 4500 4,9 4,3
2 6500
8700
5,4 4,7
6,0
6500
7300
5,6 5,4
6,0
8500 5,8 7130 5,8
8300 5,7 6960 5,7
8100 5,6 6790 5,6
7900 5,5 6620 5,5
7700 5,4 6450 5,4
7500 5,3 6280 5,3
7300 5,2 6110 5,2
7100 5,0 5940 5,1
6900 4,9 5770 5,0
6700 4,8 5600 4,9
6300 4,6 5430 4,8
6100 4,5 5260 4,7
5900 4,5 5090 4,6
5700 4,4 4920 4,6
5500 4,3 4750 4,5
5300 4,2 4580 4,4
5100 4,1 4410 4,3
4900 4,0 4240 4,2
4700 3,9 4070 4,0
4300 3,8 3900 3,8
4100 3,6 3730 3,7
3900 3,4 3560 3,5
3700 3,3 3390 3,4
3500 3,2 3220 3,2
3300 3,0 3050 3,1
3100 2,9 2880 3,0
2900 2,8 2710 2,9
2700 2,7 2540 2,8
2300 2,5 2370 2,7
2100 2,4 2200 2,6
1900 2,3 2030 2,5
1700 2,2 1860 2,4
1500 2,1 1690 2,3
1300 2,1 1520 2,2
1100 2,0 1350 2,2
1000 2,0 1180 2,1
1010 2,0
1000 2,0

2–12  9809
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHJ059 Data Plate Part Number ACHJ065
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.7 Empty/load valve ratio 1.5
Rear Axle Weight Output Pressure (bar) Rear Axle Weight Output Pressure (bar)
kg Front Axle Rear Axle kg Front Axle Rear Axle
10300 6,0 6,0 8500 5,9 5,8
7060 6.0 6,0 1680 4,1 2,2
1680 3,4 1,9 2500 4,3 2,6
2500 3,7 2,3 4500 5,0 3,9
4500 4,8 4,1 6500 5,4 4,7
6500
7000
5,7 5,5
5,9
7500
8740
5,7 5,3
6,0
2
6840 5,8 8700 6,0
6680 5,7 8300 5,7
6520 5,5 8100 5,6
6360 5,4 7900 5,5
6200 5,3 7700 5,4
6040 5,1 7300 5,2
5880 5,0 7100 5,0
5720 4,9 6900 4,9
5560 4,8 6700 4,8
5400 4,7 6300 4,6
5240 4,6 6100 4,5
5080 4,4 5900 4,5
4920 4,3 5700 4,4
4760 4,2 5500 4,3
4600 4,1 5300 4,2
4440 4,0 5100 4,1
4280 3,9 4900 4,0
4120 3,7 4700 3,9
3960 3,5 4300 3,8
3800 3,3 4100 3,6
3640 3,2 3900 3,4
3480 3,0 3700 3,3
3320 2,9 3500 3,2
3160 2,7 3300 3,0
3000 2,6 3100 2,9
2840 2,5 2900 2,8
2680 2,4 2700 2,7
2520 2,3 2300 2,5
2360 2,2 2100 2,4
2200 2,1 1900 2,3
2040 2,0 1700 2,2
1880 2,0 1500 2,1
1720 1,9 1300 2,1
1560 1,9 1100 2,0
1400 1,8 1000 2,0
1240 1,8
1080 1,7
1000 1,7

9809 2–13
 TECHNICAL DATA
55 Series

LOAD SENSING VALVE DATA PLATES – AIR SUSPENSION MODELS

Data Plate Part Number ACHA110 Data Plate Part Number ACHE111
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 1.5
Rear Output Rear Output
Axle Bellows Pressure Axle Bellows Pressure
Weight Pressure (bar) Weight Pressure (bar)
Front Rear Front Rear
kg bar Axle Axle kg bar Axle Axle
8240 4,6 6,0 6,0 8500 4,7 6,0 6,0

2 5047
1610
2,6
0,5
6,0
4,6
6,0
3,1
5866
1610
3,1
0,5
6,0
4,8
6,0
2,3
2000 0,7 4,7 3,4 3000 1,3 5,2 3,5
3000 1,3 5,2 4,3 4000 2,0 5,5 4,4
4000 2,0 5,6 5,1 5000 2,6 5,7 5,2
5000 2,6 6,0 5800 3,1 5,9
4860 2,5 5,8 5670 3,0 5,8
4720 2,4 5,7 5540 2,9 5,7
4580 2,3 5,6 5410 2,8 5,6
4440 2,2 5,5 5280 2,7 5,5
4300 2,1 5,4 5150 2,7 5,4
4160 2,1 5,3 5020 2,6 5,3
4020 2,0 5,1 4890 2,5 5,2
3880 1,9 5,0 4760 2,4 5,0
3740 1,8 4,9 4630 2,3 4,9
3600 1,7 4,8 4500 2,3 4,8
3460 1,6 4,7 4370 2,2 4,7
3320 1,5 4,5 4240 2,1 4,6
3180 1,5 4,4 4110 2,0 4,5
3040 1,4 4,3 3980 1,9 4,4
2900 1,3 4,2 3850 1,9 4,2
2760 1,2 4,1 3720 1,8 4,1
2620 1,1 4,0 3590 1,7 4,0
2480 1,0 3,8 3460 1,6 3,9
2340 0,9 3,7 3330 1,6 3,8
2200 0,9 3,6 3200 1,5 3,7
2060 0,8 3,5 3070 1,4 3,6
1920 0,7 3,4 2940 1,3 3,5
1780 0,6 3,2 2810 1,2 3,3
1640 0,5 3,1 2680 1,2 3,2
1500 0,4 3,1 2550 1,1 3,1
1360 0,3 3,1 2420 1,0 3,0
1220 0,3 3,1 2290 0,9 2,9
1080 0,2 3,1 2160 0,8 2,8
2030 0,8 2,7
1900 0,7 2,6
1770 0,6 2,4
1640 0,5 2,3
1510 0,4 2,3
1380 0,4 2,3
1250 0,3 2,3
1120 0,2 2,3
1000 0,1 2,3

2–14  9809
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHA112 Data Plate Part Number ACHA113
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 2.7
Rear Output Rear Output
Axle Bellows Pressure Axle Bellows Pressure
Weight Pressure (bar) Weight Pressure (bar)
Front Rear Front Rear
kg bar Axle Axle kg bar Axle Axle
9800 5,5 6,0 6,0 9800 5,5 6,0 6,0
6029 3,2 6,0 6,0 6029 3,2 6,0 6,0
1610
3000
4000
0,5
1,3
4,1
4,7
2,2
3,4
1610
3000
0,5
1,3
3,6
4,4
2,2
3,4 2
2,0 5,2 4,3 4000 2,0 4,9 4,3
5000 2,6 5,6 5,1 5000 2,6 5,4 5,1
6000 3,2 6,0 3,2 6,0
6000
5880 3,1 5,9 3,1 5,9
5760 5880
3,0 5,8 3,0 5,8
5640 5760
3,0 5,7 3,0 5,7
5520 5640
2,9 5,6 2,9 5,6
5400 2,8 5,5 5520 2,8 5,5
5280 2,7 5,4 5400 2,7 5,4
5160 2,7 5,3 5280 2,7 5,3
5040 2,6 5,1 5160 2,6 5,1
4920 2,5 5,0 5040 2,5 5,0
4800 2,4 4,9 4920 2,4 4,9
4680 2,4 4,8 4800 2,4 4,8
4560 2,3 4,7 4680 2,3 4,7
4440 2,2 4,6 4560 2,2 4,6
4320
2,2 4,5 4440 2,2 4,5
4200
2,1 4,4 4320 2,1 4,4
4080
2,0 4,3 4200 2,0 4,3
3960
1,9 4,2 4080 1,9 4,2
3840
1,9 4,1 3960 1,9 4,1
3720
1,8 4,0 3840 1,8 4,0
3600
3480 1,7 3,9 3720 1,7 3,9
3360 1,6 3,8 3600 1,6 3,8
3240 1,6 3,7 1,6 3,7
3480
3120 1,5 3,6 1,5 3,6
3360
3000 1,4 3,5 1,4 3,5
1,3 3,4 3240 1,3 3,4
2880 3120
2760 1,3 3,3 1,3 3,3
1,2 3,2 3000 1,2 3,2
2640
1,1 3,1 2880 1,1 3,1
2520
1,1 3,0 2760 1,1 3,0
2400
2280 1,0 2,9 2640 1,0 2,9
2160 0,9 2,8 2520 0,9 2,8
2040 0,8 2,7 2400 0,8 2,7
1920 0,8 2,6 2280 0,8 2,6
1800 0,7 2,5 2160 0,7 2,5
1680 0,6 2,4 2040 0,6 2,4
1610 0,5 2,3 1920 0,5 2,3
0,5 2,2 1800 0,5 2,2
1680
1610

9809 2–15
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHA114 Data Plate Part Number ACHE213
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.7 Empty/load valve ratio 2.0
Rear Output Rear Output
Axle Bellows Pressure Axle Bellows Pressure
Weight Pressure (bar) Weight Pressure (bar)
Front Rear Front Rear
kg bar Axle Axle kg bar Axle Axle
10300 5,8 6,0 6,0 8500 5,5 6,0 6,0
6193 3,3 6,0 6,0 6029 3,2 6,0 6,0

2 1610
3000
0,5
1,3
3,5
4,2
2,2
3,4
1610
3000
0,5
1,3
4,1
4,7
2,2
3,4
4000 2,0 4,8 4,3 4000 2,0 5,2 4,3
5000 2,6 5,4 5,1 5000 2,6 5,6 5,1
6100 3,2 6,0 6000 3,2 6,0
5960 3,2 5,9 5880 3,1 5,9
3,1 5,8 3,0 5,8
5820 5760
3,0 5,7 3,0 5,7
5680 5640
2,9 5,6 2,9 5,6
5540 2,8 5,5 5520 2,8 5,5
5400 2,7 5,4 5400 2,7 5,4
5260 2,6 5,3 5280 2,7 5,3
5120 2,6 5,1 5160 2,6 5,1
4980 2,5 5,0 5040 2,5 5,0
4840 2,4 4,9 4920 2,4 4,9
4700 2,3 4,8 4800 2,4 4,8
4560 2,2 4,7 4680 2,3 4,7
4420 2,1 4,6 4560 2,2 4,6
4280 2,0 4,5 4440 2,2 4,5
4140 2,0 4,4 4320 2,1 4,4
4000 1,9 4,3 4200 2,0 4,3
3860 1,8 4,2 4080 1,9 4,2
3720 1,7 4,1 3960 1,9 4,1
3580 1,6 4,0 3840 1,8 4,0
3440 1,5 3,9 3720 1,7 3,9
3300 1,4 3,8 3600 1,6 3,8
1,4 3,7 1,6 3,7
3160 3480
1,3 3,6 1,5 3,6
3020 3360
1,2 3,5 1,4 3,5
2880 1,1 3,4 3240 1,3 3,4
2740 1,0 3,3 3120 1,3 3,3
2600 0,9 3,2 3000 1,2 3,2
2460 0,8 3,1 2880 1,1 3,1
2320 0,8 3,0 2760 1,1 3,0
2180 0,7 2,9 2640 1,0 2,9
2040 0,6 2,8 2520 0,9 2,8
1900 0,5 2,7 2400 0,8 2,7
1760 0,4 2,6 2280 0,8 2,6
1620 0,3 2,5 2160 0,7 2,5
1480 0,2 2,4 2040 0,6 2,4
1340 0,2 2,3 1920 0,5 2,3
1200 0,1 2,2 1800 0,5 2,2
1060 1680
1000 1610

2–16  9809
 TECHNICAL DATA
55 Series

Data Plate Part Number ACHA292

Input Pressure = 6 bar
Empty/load valve ratio 2.7
Rear Output
Axle Bellows Pressure
Weight Pressure (bar)
Front Rear
kg bar Axle Axle
11500 6,2 6,0 6,0
6988 3,6 6,0 6,0
2280
4000
0,8
1,9
3,5
4,4
2,0
3,5 2
5000 2,4 4,9 4,3
6000 3,0 5,5 5,2
6900 3,5 5,9
6760 3,5 5,8
3,4 5,7
6620
3,3 5,6
6480
3,2 5,5
6340 3,1 5,4
6200 3,1 5,3
6060 3,0 5,1
5920 2,9 5,0
5780 2,8 4,9
5640 2,7 4,7
5500 2,6 4,6
5360 2,6 4,5
5220 2,5 4,4
5080 2,4 4,3
4940 2,3 4,1
4800 2,2 4,0
4660 2,2 3,9
4520 2,1 3,8
4380 2,0 3,7
4240 1,9 3,6
4100 1,8 3,4
1,7 3,3
3960
1,7 3,2
3820
1,6 3,1
3680 1,5 3,0
3540 1,4 2,8
3400 1,3 2,7
3260 1,3 2,6
3120 1,2 2,5
2980 1,1 2,4
2840 1,0 2,3
2700 0,9 2,1
2560 0,8 2,0
2420 0,8 1,9
2280 0,7 1,8
2140
2000

9809 2–17
 TECHNICAL DATA
55 Series

2–18  9809
 SPECIFICATION OF LUBRICANTS
55 Series

INTRODUCTION

DAF Trucks N.V. cannot accept any responsibility for trouble experienced by operators arising from any
of the following causes:

1. The use of an oil that does not conform to the minimum specification requirements.

2. The use of oils of the incorrect viscosity other than the recommended grades.

3. The continued use of oils after the recommended oil change period.

4. The use of unauthorised lubricant additives or treatments.

Ask your lubricant and fuel supplier(s) if their products comply with DAF’s specifications.

ENGINE OIL SPECIFICATIONS 3

Avoid unnecessary contact with used engine oil. Prolonged and repeated contact
with used engine oil may cause serious skin disorders.

Extreme care must be taken when draining oil from the engine, gearbox or rear axle;
hot oil can cause severe personal injury.

Type Specification Viscosity Chart

All engines CCMC–D5 °C

50
SAE-40

40
30
20
SAE-20W40
SAE-30

10
SAE-15W40
SAE-20

0
SAE-10W30

- 10
SAE-10W**

- 20
- 30
001415

Note: The temperature limits should be regarded as approximate.

** Avoid continuously operating the engine at high speed or under a heavy load when SAE–10W is
used and the ambient temperature is higher than the specified value.

 9809 3–1
 SPECIFICATION OF LUBRICANTS
55 Series

GEARBOX OIL SPECIFICATIONS

Viscosity
Type Multi–grade oil Monograde oil Specification
<0°C >0°C <0°C >0°C
Eaton 6109 SAE–80W/90 — — API GL4
ZF 9S–75 — — SAE–80W SAE–80W API GL4
ZF S6–36 Refer to the ‘HYDRAULIC FLUID SPECIFICATIONS’

REAR AXLE OIL SPECIFICATIONS

Viscosity
3 Type Multi–grade oil Monograde oil Specification
<0°C >0°C <0°C >0°C
All axles SAE–85W90 SAE–85W140 SAE–85 EP SAE–140 EP API GL5

HYDRAULIC FLUID SPECIFICATIONS

System Specification
Power steering ATF type A suffix A or ATF Dexron II D or E (AUTRAN DX II) type with valid
Cab tilt approval number
ZF S6–36 gearbox ATF type A suffix A or ATF Dexron II D
Clutch DOT 4

GREASE SPECIFICATIONS
Application Specification
Lithium Hydroxystearate grease, containing Molybdenum
General lubrication Disulphide–specification NLGI class 2

AUTOMATIC CHASSIS LUBRICATION

Lubrication System Specification
Oil based Engine oil CCMC –D4, SAE 30
Grease based Lithium–based NLGI class 00 or 2 grease (depending on the installation)

3–2  9809
 SPECIFICATION OF LUBRICANTS
55 Series

DIESEL FUEL SPECIFICATIONS

Diesel fuel is an inflammable fluid which must not be exposed to a naked flame, spark
or any intense heat source

Diesel fuel should conform to British Standard EN 590 (1995). Waste oils or residual oils of any type must
not be used.

Cold weather recommendations

When diesel fuel is subjected to low temperatures (below –6°C), paraffin wax particulates will form within
the fuel which will eventually create blockages in the fuel system. To minimise the risk of fuel ‘waxing’, it is
recommended that the following precautions are observed:

– The use of winter grade fuel will give added protection to the fuel system during cold weather
conditions. Ensure that the vehicle is using winter grade fuel in anticipation of cold conditions.

– In the event of fuel waxing, it is recommended that a replacement fuel filter is carried to enable a
blocked filter to be renewed; wax particulates cannot be dissolved by application of heat. 3
– For extreme and prolonged cold weather conditions, it is recommended that the vehicle is equipped
with a heated fuel sedimenter and that all fuel pipes and fuel tank are adequately insulated; refer to
your DAF Dealer for further information.

– Authorised cold weather fuel additives are available from your DAF Dealer. The addition of any fuel
additives that are not specified or approved by DAF must not be mixed in the fuel system.

 9809 3–3
 SPECIFICATION OF LUBRICANTS
55 Series

COOLING SYSTEM SPECIFICATIONS

Anti–freeze and corrosion inhibitors contain toxic chemicals which must not be
consumed or allowed to come into skin or eye contact. Use suitable eye protection,
impervious protective clothing and gloves when handling anti–freeze or corrosion
inhibitors.

In the event of slight eye or skin contact, thoroughly rinse the affected area with water.
If there is excessive eye/skin contact or ingestion/inhalation seek medical advice
immediately.

The cooling system must preferably be filled with a ready mixed coolant containing anti–freeze and
anti–corrosion agents in the solution.
If tap water is used, an ethylene glycol based anti–freeze with an anti–corrosion additive must be added in
case the temperature drops below + 5°C.
– For temperatures down to –12°C a solution containing 33% anti–freeze is necessary.
3 – For temperatures –18°C and below, a solution containing 50% anti–freeze is necessary.
In climates where the temperature never falls below +5°C, it is sufficient to add a corrosion–inhibiting
agent to the coolant. Mix in accordance with manufacturer’s instructions.
COOLANT, ANTI–FREEZE and ANTI–CORROSIVE AGENTS must contain organic acid
(carboxylate) based corrosion inhibitors, but must be free from silicate, nitrate, phosphate,
amine and boron. In all other respects the above must satisfy the specifications in ASTM
D–3306 or SAE J–1034 standards.

Coolants containing anti–freeze may remain in the cooling system during the summer months.

EVERY TWO YEARS THE COOLING SYSTEM MUST BE FLUSHED OUT AND THE COOLANT
CHANGED

The above data refers to vehicles operating under normal conditions. As the specified substances are
marketed under various brand names, consult the corresponding supplier for the correct interpretation of
these specifications.

3–4  9809
 MAINTENANCE INTERVALS
55 Series

MAINTENANCE SCHEDULE

The maintenance intervals stated in the

Maintenance Schedule are based on the oil
specifications stipulated by DAF.

001414

(1) One year (40 000 km max) for automatic

gearboxes.
(2) 65 CF 40 000 km with special oil filter.
45/55 Series is limited to 30 000 km max.
(3) One year (100 000 km max) except 1347
axle.
(4) Applicable with the 100 000 km interval, see
the ‘Explanatory Notes on the Maintenance
Schedule’ in this Section.
(5) ZF gearboxes only.
(6) Two year (200 000 km max) except 1347
axle.

 9809 4–1
 MAINTENANCE INTERVALS
55 Series

EXPLANATORY NOTES ON THE

MAINTENANCE SCHEDULE

Y–service
This symbol indicates a Y–service.
A Y–service is an annual maintenance service
which consists of changing the oil in the gearbox
and rear axle, plus a number of maintenance
operations.

001412

X–service
4 This symbol indicates an X–service.
An X – service is a kilometerage related
maintenance check which consists of changing the
engine oil plus a number of lubrication and visual
check operations.
The kilometre service interval is dependent upon
the specific transport role and operating conditions
of the vehicle.

Note: An X–service must be carried out once 001409

every six months (minimum).

Intermediate inspection
This symbol indicates an intermediate inspection
which consists of several visual checks.
When carrying out an X–service with 100 000 km
interval, an intermediate inspection must be carried
001411
out at 50 000 km.
100 000 km interval
A service interval of 100 000 km for the 55 Series
is not permitted.

4–2  9809
 MAINTENANCE INTERVALS
55 Series

Mineral oil
This symbol indicates the use of mineral oil.

001410

Synthetic oil
This symbol indicates the use of synthetic oil.

001409

4
Vehicle deployment
Depending upon the specific transport role and
operating conditions, the vehicle is assigned to the
following maintenance categories.

Maintenance category I
Operation on building sites, in quarries etc.
– Operation on unsurfaced roads.
– Operation in dusty environments.
– Refuse disposal.
– Distribution transport with annual
kilometerage up to 30 000 km.

Maintenance category II
Urban and regional transport.
– Distribution work in urban areas.
– Transport between adjacent
towns/cities.

Maintenance category III

National/international transport.
– Long distance transport.

 9809 4–3
 MAINTENANCE INTERVALS
55 Series

INFLUENCE OF DIESEL FUEL AND P.T.O.

HOURS ON MAINTENANCE INTERVALS

Diesel fuel
Sulphur content Oil change
> 1.0 % Half interval

P.T.O. hours
P.T.O. operating hours have to be converted to
the equivalent number of kilometres according to
the following method:

1 P.T.O. hour = 20 km

MAINTENANCE IN SPECIAL AND

EXCEPTIONAL OPERATING CONDITIONS

4 When the vehicle is operated under exceptional

conditions, it is important to consult your local
dealer as it may be necessary to change the
service intervals to suit the operating conditions.
The service intervals can be adapted, as
necessary, in consultation with the local dealer to
suit the appropriate operating conditions.

FIRST SERVICE INTERVAL

The first service inspection should be carried out

between the first 7 500 and 10 000 km and no
later than eight weeks after the vehicle delivery
date, whichever comes first.

4–4  9809
 MAINTENANCE INTERVALS
55 Series

FIRST SERVICE MAINTENANCE ACTIVITIES

f Change gearbox oil

f Change oil in differential
f Check components and hose connections for leaks
f Check condition of engine drive belt
f Check/adjust load sensing valve
f Check security of propeller shaft bolts
f Check security of ‘U’ bolts
f Grease lubricate the swivel pins
f Grease lubricate the propeller shaft

 9809 4–5
 MAINTENANCE INTERVALS
55 Series

ANNUAL MAINTENANCE ACTIVITIES

ANNUAL MAINTENANCE ACTIVITIES = Y SERVICE INTERVAL

‘Correct if necessary after inspection’

Cab and Electrical System

f Check pedal rubbers for wear or damage
f Check/adjust headlamp alignment
f Check cab lock–down suspension
f Check/top–up cab tilting pump
f Check cab tilt mechanism

Engine, Cooling System and Fuel System

f Renew air filter element
f Check/adjust valve clearances
f Check coolant anti–freeze concentration

4 f Renew engine coolant – see note 1

f Renew fuel filter
Changed f Yes f No

f Check engine idle and maximum running speed

Steering and Brake System

f Renew filter element of hydraulic power steering – see note 1 Changed f Yes f No
f Check all pivot points of steering system for wear
f Renew filter element of air dryer
f Check operation of brake slack adjusters – cam operated brakes only
f Check/adjust load sensing valve
f Check ABS/ASR modulator valves

Transmission and Chassis

f Renew differential oil – see note 2 Changed f Yes f No
f Renew rear axle hub oil (oil lubricated hubs) – see note 2 Changed f Yes f No
f Clean/re–pack hub bearings (grease lubricated hubs) – see note 1 Changed f Yes f No
f Check operation of differential lock
f Check propeller shafts, universal and sliding joints for play
f Renew gearbox oil – see note 3 Changed f Yes f No
f Check security of propeller shaft bolts
f Check operation of ECAS and vehicle ride height
f Check trailer couplings

Note 1: Every two years

Note 2: For renewal interval refer to the ‘Maintenance Schedule’ in this Section.
Note 3: For renewal interval refer to the ‘Maintenance Schedule’ in this Section.
When renewing the oil on a gearbox with a retarder or on an automatic gearbox, the oil filter
must also be replaced.

4–6  9809
 MAINTENANCE INTERVALS
55 Series

KILOMETERAGE–DEPENDENT MAINTENANCE ACTIVITIES

KILOMETERAGE–DEPENDENT MAINTENANCE ACTIVITIES = X SERVICE INTERVAL

‘Correct if necessary after inspection’

Cab and Electrical System

f Clean battery terminals/chassis earth connections

Engine, Cooling System and Fuel System

f Renew engine oil
f Renew engine oil filter
f Check fuel system for leakages
f Drain/clean fuel sedimenter
f Check coolant level
f Check engine drive belt Changed f Yes f No
f Check cooling system components and hoses for leakage
f Check the radiator and intercooler for fouling
f Check the air intake system hoses and seals 4
f Check engine vibration damper

Steering and Brake System

f Check condition of ball joint gaiters
f Check power steering reservoir fluid level
f Check hoses and connections of steering system
f Check brake components and pipes for leakage
f Check brake lining thickness
f Check brake pad thickness and brake disc condition
f Drain air reservoirs

Transmission and Chassis

f Check clutch hydraulic fluid level
f Check rear axle for leaks – see note 1
f Check gearbox for leaks – see note 2
f Check security/ condition of shock absorbers
f Check security/ condition of spring leaves, spring clamps and U–bolts
f Check security/ condition of suspension pivot points, air suspension
f Check security/ condition of air suspension bellows
f Check grease level of automatic lubrication reservoir
f Check operation of automatic lubrication system
f Lubricate all grease/oil points, see ‘Lubrication Schedule’

Note 1: For renewal interval refer to the ‘Maintenance Schedule’ in this Section.
Note 2: For renewal interval, refer to the‘ Maintenance Schedule’ in this Section.
When renewing the oil on a gearbox with a retarder or on an automatic gearbox, the oil filter
must also be replaced.

 9809 4–7
 MAINTENANCE INTERVALS
55 Series

4–8  9809
 MAINTENANCE OPERATIONS
55 Series Cab

CHECKING THE CAB TILT PUMP FLUID LEVEL

Hydraulic fluid is a toxic substance

which must not be consumed or
allowed to come into skin contact.
In the event of slight skin contact,
thoroughly rinse the affected area
with water. If there is excessive skin
contact, ingestion or inhalation
seek medical attention immediately.

1. Ensure that the cab is in the down position

and that the spool valve pin (3) is in the up
position before attempting to check the fluid 1
level.

2. Thoroughly clean the filler/level plug (1) and 2

its surrounding area to prevent the ingress
of dirt or foreign matter.

3. Slacken, but do not remove, the filler/level

plug and wait 2 to 3 seconds to allow the
hydraulic fluid to stabilise and then remove
the filler/level plug. Check that the fluid level
is just visible below the filler/level aperture; if 5
necessary, top–up with clean hydraulic fluid
of the approved specification.
3 060286

4. Examine the filler/level plug sealing ring (2)

for damage or deterioration; renew as
necessary. Refit the filler/level plug into the
cab tilt pump.

Important: Should the cab tilt pump require an

excessive amount of hydraulic fluid, the
complete system must be inspected for leaks
and rectified as necessary.

Data

Hydraulic fluid . . . . . . . . . . . . . . . . . . see Section 3

 9809 5–1
 MAINTENANCE OPERATIONS
Cab 55 Series

CHECKING THE CAB TILT MECHANISM

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– To maintain vehicle stability, do NOT
remove the rear axle whilst the cab is
tilted nor attempt to tilt the cab whilst the
rear axle is removed; failure to observe
these precautions may result in the
vehicle up–turning.

– Ensure that all workshop personnel are

standing clear of the area immediately in
front of the vehicle.

– Ensure that there is adequate clearance

in front and above the cab, refer to Data.

– Ensure that there are no loose articles in

the cab and that the vehicle tool kit and
hydraulic jack are secured in their

5 stowed positions.

– The engine MUST be switched off, the

handbrake in the park position and the
gear lever in neutral.

– Ensure that the cab is fully tilted and the

hydraulic ram is fully extended before
attempting to work under the cab.

To Raise
1. Remove the pump handle from the vehicle
tool kit. Remove all loose items from the cab
interior. Ensure that the cab doors and front
access panel are closed and locked in
position.

2. Ensure that the spool valve pin (1) is in the

up position and then insert the pump handle
in the pump. Operate the pump handle until
the cab is fully tilted.

1
060287

5–2  9809
 MAINTENANCE OPERATIONS
55 Series Cab

To Lower High roof sleeper cab:

1. Ensure that all personnel are standing clear 11 to 15 tonne models:
and that there are no obstructions to impede Dimension ‘A’ . . . . . . . . . . . . . 1352 mm
the lowering of the cab.
Dimension ‘B’ . . . . . . . . . . . . . 3605 mm
2. Using the pump handle, turn the spool valve
pin (1) to the down position. 17/18 tonne models:
Dimension ‘A’ . . . . . . . . . . . . . 1352 mm
3. Insert the pump handle into the pump.
Operate the pump until the cab lock–down Dimension ‘B’ . . . . . . . . . . . . . 3754 mm
brackets are just above the cab lock–down
mechanisms. * Maximum design dimension (unladen)
4. With the aid of an assistant, energise the
contact circuits and check that the cab
lock–down warning light illuminates.
Continue to lower the cab until the cab
brackets are fully engaged with the
lock–down mechanisms and, that the cab
lock–down warning light has extinguished.
Switch off the contact circuits.

Note: There should be an audible ‘click’

from each locking mechanism as the cab
automatically locks in position. 5
5. Store the pump handle in the vehicle tool kit.

Data

* Cab clearances:
Day cab:
11 to 15 tonne models:
Dimension ‘A’ . . . . . . . . . . . . . 1205 mm

Dimension ‘B’ . . . . . . . . . . . . . 3108 mm

17/18 tonne models:

Dimension ‘A’ . . . . . . . . . . . . . 1205 mm

Dimension ‘B’ . . . . . . . . . . . . . 3257 mm

Sleeper cab:
11 to 15 tonne models:
Dimension ‘A’ . . . . . . . . . . . . . 1205 mm

Dimension ‘B’ . . . . . . . . . . . . . 3470 mm

17/18 tonne models:

Dimension ‘A’ . . . . . . . . . . . . . 1205 mm

Dimension ‘B’ . . . . . . . . . . . . . 3619 mm

 9809 5–3
MAINTENANCE OPERATIONS
Cab 55 Series

1 060288

A
060289

5–4  9809
 MAINTENANCE OPERATIONS
55 Series Cab

 9809 5–5
 MAINTENANCE OPERATIONS
Engine 55 Series

RENEWING THE ENGINE OIL

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Avoid unnecessary contact with used
engine oil. Prolonged and repeated
contact with used engine oil can cause
serious skin disorders.

– Extreme care must be taken when

draining engine oil; hot engine oil can
cause serious personal injury.

1. When applicable, rotate the four quick

release fasteners anti–clockwise and
withdraw the front half of the noise
suppression panel.

2. Position a suitable container beneath the

engine sump. Remove the sump drain plug
(1) complete with washer and allow the

5 engine oil to drain into the container.

3. Renew the engine oil filter as instructed on

page 5–7.

4. Clean the sump drain plug and discard the

copper washer.

5. When the drainage is complete, fit the sump

drain plug, complete with a new copper
washer; tighten the sump drain plug to the 1
torque figure quoted in Data. 040565

5–6  9809
 MAINTENANCE OPERATIONS
55 Series Engine

6. Remove the oil filler cap (2) and refill the

engine with clean oil of the approved
specification (see Chapter 3) until the oil level
registers on the ‘H’ (maximum) mark on the
dipstick (3); do NOT overfill.

7. Start the engine but do NOT exceed the

engine idling speed, and check that the oil
pressure warning light extinguishes within 15
seconds. Check that the sump drain plug and
oil filter are free from leakages. Stop the
2
engine and, after allowing sufficient time for 3
the oil to flow into the sump, re–check the oil 040929

level; top–up as necessary.

8. When applicable, refit the front half of the

noise suppression panel.

Data

Oil specification . . . . . . . . . . . . . . . . . see Section 3

Oil capacity (including filter) . . . . . . . . . . . . 16 litres 5

Tightening torque:

Sump drain plug . . . . . . . . . . . . . . . . . . 60 Nm

 9809 5–7
 MAINTENANCE OPERATIONS
Engine 55 Series

RENEWING THE ENGINE OIL FILTER

1. Remove the noise suppression panels

before carrying out maintenance work on the
engine.

2. Using a suitable filter wrench, unscrew and

discard the oil filter cartridge (2). Thoroughly
clean the contact surfaces of the oil filter
head.

3. Ensure that the integral seal (1) in the new

filter cartridge is correctly seated and clean.
1
4. Fill the new oil filter cartridge and smear its
integral seal with clean engine oil of the
approved specification. Screw the filter
cartridge on by hand until it contacts the
filter head and then tighten an additional 1/2 2
turn; do NOT overtighten.

040944

5–8  9809
 MAINTENANCE OPERATIONS
55 Series Engine

RENEWING THE AIR CLEANER ELEMENT

Note: The air induction system is equipped with a

vacuum operated restriction indicator (7). The air
filter element must be renewed whenever the 2
restriction indicator has been activated; this is 1
indicated by the appearance of a coloured plunger
within the indicator body.

1. Tilt the cab.

2. Release the retaining clamps (2) and detach 4 3

the end cover (3).

3. Withdraw the element (5) from the filter

canister (6).
5
4. Empty any accumulated dust from the end
cover and then thoroughly clean the interior of
the end cover with a damp cloth.
6 040921

5. Thoroughly clean the interior of the filter

canister using a damp cloth or suction
cleaner; do NOT allow any dust or debris to
pass into the inlet side of the air intake
system.
5
6. Refitment is a reversal of the removal
procedure, noting:

– When fitting the end cover ensure that

the unloader valve (4) faces downwards.

– Ensure that all air ducting, hoses and

connections are secure and in good
condition.
7
– If necessary, depress the button on the
end of the restriction indicator (7) to reset 040922
the plunger.

 9809 5–9
 MAINTENANCE OPERATIONS
Engine 55 Series

CHECKING THE VALVE CLEARANCES

Note: The valve clearances must only be

checked/adjusted with the engine in a ‘cold’
condition.

1. Remove the retaining bolts and detach the

valve covers complete with rubber seals.

2. Locate Top Dead Centre (T.D.C.) for No.1

cylinder using the following method:

– Use an open ended spanner on the flats of

the fan hub to rotate the engine; do NOT
use the fan blades.

– Slowly rotate the engine whilst 1 2 040570

simultaneously pressing on the timing pin (1)
(located at the rear of the timing gearcase) Rotary Pump Application
until it engages in the camshaft gear. To
prevent accidental damage to the timing pin
ensure that it is disengaged after locating
T.D.C.

5 – A timing pin extension tool (2) is available to

aid the engagement and disengagement of
the timing pin.

040591

In–line Pump Application

3. Using feeler gauges of the correct value,
check the clearance between the valve
rocker arms and the valve stems; the feeler
gauge should be a sliding fit. Check/adjust
the clearance of the valves in the following
sequence:

Cylinder Inlet valve Exhaust valve

No.1 1 2
No.2 3 –
No.3 – 6
No.4 7 –
No.5 – 10
No.6 – –

6 5 4 3 2 1 040571

5–10  9809
 MAINTENANCE OPERATIONS
55 Series Engine

4. To adjust valve clearance slacken the locknut

(1) and turn the adjusting screw (2) in the 2
appropriate direction until the correct 1
clearance is obtained. Hold adjusting screw
against rotation, tighten locknut then re–check
the valve clearance.

040572

5. Suitably mark the crankshaft drive pulley and

gearcase cover, then rotate the crankshaft
through 360° and check/adjust the remaining
valves in the following sequence:

Cylinder Inlet valve Exhaust valve

No.1 – –
No.2 – 4 5
No.3 5 –
No.4 – 8
No.5 9 –
No.6 11 12
6 5 4 3 2 1
6. Refit the valve covers, ensuring that the 040573

rubber seals are serviceable. Tighten the

valve cover retaining bolts to the specified
torque.

Data

Valve clearances:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm

Exhaust . . . . . . . . . . . . . . . . . . . . . . . 0,50 mm

Tightening torques:

Valve cover bolt . . . . . . . . . . . . . . . . . . 24 Nm

Special tool:

Timing pin extension . . . . . . . . . . . . 0192494

 9809 5–11
 MAINTENANCE OPERATIONS
Engine 55 Series

CHECKING THE ENGINE DRIVE BELT

Note: All engines are fitted with an automatic drive

belt tensioner and, therefore, cannot be manually
adjusted. Incorrect drive belt tension can be
caused by either an elongated drive belt or a
defective automatic tensioner. Should the drive belt
or automatic tensioner fail the following checks
then the appropriate remedial action must be taken
as instructed in the ‘Workshop Manual’.

1. Isolate the vehicle electrical supply. Insert a

3/8 in square drive knuckle bar (1) into the
automatic tensioner (2). Push the knuckle bar
in the direction shown to release the tension
and then detach the drive belt (4).

2. Examine the drive belt for cracks, damage,

excessive wear or contamination with oil, fuel
or hydraulic fluids; renew the drive belt as
necessary.

3. Check that the tensioner pulley (3) spins freely

under normal hand pressure without any
5 detectable binding or sticking; the tensioner
pulley must be overhauled or renewed if it is
found to be defective.

4. Raise the automatic drive belt tensioner to

allow the new belt to be fitted; when the belt is
correctly positioned, release the tensioner.

5–12  9809
 MAINTENANCE OPERATIONS
55 Series Engine

1 2 4
2
3 1

4 3

041211

35 and 55 amp Alternators

041213

80 amp Alternators

 9809 5–13
 MAINTENANCE OPERATIONS
Engine 55 Series

CHECKING THE COOLANT ANTI–FREEZE CONCENTRATION/SPECIFIC GRAVITY

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Do NOT attempt to remove the header
tank filler cap whilst the engine is running
or still hot.

– Do NOT attempt to fill/top–up a hot engine

with cold coolant.

– Anti–freeze solutions contain toxic

chemicals which must not be consumed
or allowed to come into skin contact. Use
impervious protective clothing and gloves
when handling anti–freeze. In the event of
slight skin contact, thoroughly rinse the
affected area with water. If there is
excessive skin contact, ingestion or
inhalation seek medical advice
immediately.

5 Important:
– Excessive or insufficient amounts of
anti–freeze in the engine coolant will have a
detrimental effect upon the components,
efficiency and frost protection capabilities of
the cooling system.

– For accurate and consistent specific gravity

readings it is recommended that the engine
coolant is at room temperature
(approximately 20°C).

5–14  9809
 MAINTENANCE OPERATIONS
55 Series Engine

1. Determine the coolant specific gravity

1.13
(anti–freeze/water mixing ratio) as follows:
1.12
– Obtain a coolant sample from the
1.11
vehicle and, using a hydrometer,

Coolant Specification Gravity

record the coolant specific gravity. 1.10

1.09
– Using the specific gravity graph
shown, determine the percentage of 1.08
anti–freeze in the cooling system; this
1.07
should be within the indicated optimum
range. 1.06

– If necessary, drain the appropriate 1.05

amount of coolant from the cooling 1.04

system and refill with the required
1.03
amount of either anti–freeze or pure
water. 1.02
Optimum
1.01 Range

1.00
0 10 20 30 40 50 60 70 80 90 100
Data % Anti-Freeze Content 041207

Coolant . . . . . . . . . . . . . . . . . . . . . . . see Section 3

5

 9809 5–15
 MAINTENANCE OPERATIONS
Engine 55 Series

CHECKING THE COOLANT LEVEL

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Do NOT attempt to remove the header
tank filler cap whilst the engine is running
or still hot.

– Do NOT attempt to fill/top–up a hot engine

with cold coolant.

– Do NOT fill/top–up the cooling system

through the pressure cap aperture.

– Anti–freeze solutions contain toxic

chemicals which must not be consumed
or allowed to come into skin contact. Use
impervious protective clothing and gloves
when handling anti–freeze. In the event of
slight skin contact, thoroughly rinse the
affected area with water. If there is

5 excessive skin contact, ingestion or

inhalation seek medical advice
immediately.

1. Remove filler cap (1) and check that the

engine coolant is level with the lower lip of the
filler neck. If necessary, top–up the header
tank with a clean water/anti–freeze or
water/corrosion inhibitor solution.

2. If the coolant level is extremely low, check the

system for leakage.

Data

Coolant . . . . . . . . . . . . . . . . . . . . . . . see Section 3

5–16  9809
 MAINTENANCE OPERATIONS
55 Series Engine

040928

 9809 5–17
 MAINTENANCE OPERATIONS
Engine 55 Series

RENEWING THE COOLANT

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Do NOT attempt to remove the header
tank filler cap whilst the engine is running
or still hot.

– Do NOT attempt to fill/top–up a hot engine

with cold coolant.

– Do NOT fill/top–up the cooling system

through the pressure cap aperture.

– Anti–freeze solutions contain toxic

chemicals which must not be consumed
or allowed to come into skin contact. Use
impervious protective clothing and gloves
when handling anti–freeze. In the event of
slight skin contact, thoroughly rinse the
affected area with water. If there is

5 excessive skin contact, ingestion or

inhalation seek medical advice
immediately.

Important: To maintain the maximum

anti–corrosion properties and frost protection of the
anti–freeze the engine coolant MUST be renewed
every 2 years.

1. Remove the header tank filler cap (1) to

release any pressure within the cooling
system.

2. Move the cab heater temperature control to

the fully open (hot) position.

5–18  9809
 MAINTENANCE OPERATIONS
55 Series Engine

040927

 9809 5–19
 MAINTENANCE OPERATIONS
Engine 55 Series

3. Position a suitable container beneath the

radiator drain plug (2). Remove the drain plug
and allow the coolant to drain; clear the drain
aperture of any accumulated sediment whilst
the coolant is draining.

4. Reverse flush the cooling system with clean

water; refit the drain plug when the cooling
system has been flushed.
2
5. Using the coolant graph shown, determine
the appropriate anti–freeze/water mixing
ratio for optimum frost and anti–corrosion
protection.
040585

6. Fill the cooling system through the header

tank with the pre–mixed coolant until the
coolant is level with the lower lip of the filler
neck.

7. Run the engine for approximately 3 minutes

to de–aerate the cooling system and
re–check the coolant level; top–up as
necessary.
5
Data
Coolant . . . . . . . . . . . . . . . . . . . see Section 3
Cooling system capacity . . . . . . . . . 26 litres

5–20  9809
 MAINTENANCE OPERATIONS
55 Series Engine

-10

-20

-30

-40

-50

-60
Optimum
-70 Range

-80
0 10 20 30 40 50 60 70 80 90 100

041218

 9809 5–21
 MAINTENANCE OPERATIONS
Engine 55 Series

CLEANING THE RADIATOR AND INTERCOOLER ELEMENTS

1. Using a low pressure air line (3 bar

maximum), carefully blow any loose
deposits from the matrix.

2. Remove any dried dirt or mud deposits

using a soft bristle brush with a soap and
water solution; do NOT damage the matrix
fins or tubes.

3. Ingrained or stubborn deposits should be

removed by carefully hosing/steam cleaning
the affected areas; ensure any vulnerable
areas (electrical connections, mechanical
linkages etc.) are protected against
corrosion or damage.

5–22  9809
 MAINTENANCE OPERATIONS
55 Series Engine

CHECKING THE AIR INLET SYSTEM

Important: The ingress of unfiltered air into the air

induction system will have a detrimental effect
upon the components and performance of the
engine.

1. Examine the air intake (1) for cleanliness and

obstructions; clean as necessary.

2. Examine the rubber unloaded valve (2) for

damage or obstruction; it must be renewed if
it is split, abraded or its lips adhere together.

3. The air inlet system is equipped with a

5
vacuum operated restriction indicator (3). The
air filter must be renewed whenever the
restriction indicator has been activated; this is
indicated by the appearance of a coloured
plunger within the indicator body. Ensure that
the restriction indicator is secure and clean.

4. Ensure that all air ducting, hoses and

connections are secure, in good condition and
free from any apparent damage; suspected
leakages in the air induction system should be
subjected to an air pressure test as instructed
in the ‘Workshop Manual’.

 9809 5–23
MAINTENANCE OPERATIONS
Engine 55 Series

2
3
041212

040925

5–24  9809
 MAINTENANCE OPERATIONS
55 Series Engine

CHECKING THE ENGINE VIBRATION DAMPER

1. Apply the handbrake to the park position

and isolate the vehicle electrical supply.

2. Should the engine vibration damper fail any

of the following examinations then the
complete vibration damper unit must be
renewed as instructed in the ‘Workshop
Manual’:

– Check that the reference lines (1)

scribed on the inertia member (2) and
damper hub (3) are aligned; the
maximum misalignment must not
exceed 1,6 mm.
– Examine the rubber member (4) for
damage or deterioration. The vibration
damper must be renewed if pieces of
the rubber member are missing or if the
member has receded more than 3,2
mm below the surface of the inertia
member and damper hub.

 9809 5–25
MAINTENANCE OPERATIONS
Engine 55 Series

2 1

3 4

040920

5–26  9809
 MAINTENANCE OPERATIONS
55 Series Engine

 9809 5–27
 MAINTENANCE OPERATIONS
Transmission 55 Series

CHECKING THE CLUTCH FLUID LEVEL

Hydraulic fluid is a toxic substance

which must not be consumed or
allowed to come into skin contact. In
the event of slight skin contact,
thoroughly rinse the affected area with
water. If there is excessive skin
contact, ingestion or inhalation seek
medical attention immediately.

1. Open the cab front panel to gain access to

the clutch reservoir.

2. Remove the reservoir cap (1) and extract the

rubber diaphragm (3) from the reservoir (4).
The clutch hydraulic fluid level should register
on the fluid level mark (5); if necessary,
top–up with clean hydraulic fluid of the
approved specification.
Important: Do NOT allow the clutch hydraulic
fluid to contact paint finished surfaces as the
paintwork could be damaged.

5 3. Insert the rubber diaphragm into the reservoir

and, to prevent fluid leakage from the
reservoir, ensure that the seal (2) in the cap is
in good condition and that the reservoir cap is
correctly fitted and secure.
Important: Should the clutch fluid reservoir
require an excessive amount of hydraulic fluid,
the complete system must be inspected for
leaks and rectified as necessary.

Data

Hydraulic fluid . . . . . . . . . . . . . . . . . . see Section 3

5–28  9809
 MAINTENANCE OPERATIONS
55 Series Transmission

1
2
3
4

5 050435

 9809 5–29
 MAINTENANCE OPERATIONS
Transmission 55 Series

RENEWING THE GEARBOX OIL

Avoid unnecessary contact with

drained oil. Prolonged and repeated
contact with used oil can cause 1
serious skin disorders.

1. ZF S6–36 and ZF 9S–75: Position a suitable

container beneath the gearbox, remove the
drain plug (2) and allow the oil to drain. Clean
and refit the drain plug when drainage is
complete; tighten the drain plug to the
specified torque, see Data. 2
Eaton 6109: Remove the oil strainer (3) and
allow the oil to drain. Clean the oil strainer in a
suitable solvent and dry thoroughly; renew the 050810

washer (5) and O–ring (4). Refit the strainer ZF S6–36

and tighten to the specified torque, see Data.

2. Remove the filler/level plug (1) and fill the

gearbox with clean oil of the approved
specification until oil just begins to emerge
from the filler/level aperture. Clean and refit
5 the filler/level plug; tighten the plug to the
specified torque, see Data.

5–30  9809
 MAINTENANCE OPERATIONS
55 Series Transmission

1
1

5
4
3

050811

2 Eaton 6109
050812

ZF 9S–75

 9809 5–31
 MAINTENANCE OPERATIONS
Transmission 55 Series

Data

Oil specification . . . . . . . . . . . . . . . . see Section 3

Gearbox oil capacity:

ZF S6–36 . . . . . . . . . . . . . . . . . . 7,5 litres
ZF 9S–75 . . . . . . . . . . . . . . . . . 10,5 litres
Eaton 6109 . . . . . . . . . . . . . . . . . 8,5 litres
Tightening torques:
Filler/level and drain plug:
ZF S6–36 . . . . . . . . . . . . . . . . . . . 60 Nm
ZF 9S–75 . . . . . . . . . . . . . . . . . . . 50 Nm
Eaton 6109 . . . . . . . . . . . . . . . . . . 35 Nm
Oil strainer:
Eaton 6109 . . . . . . . . . . . . . 40 to 47 Nm

5–32  9809
 MAINTENANCE OPERATIONS
55 Series Transmission

CHECKING THE PROPELLER SHAFTS

Do NOT attempt to examine the

propeller shafts nor work beneath
the vehicle whilst the engine is
running.

1. Check the propeller shafts as follows:

– Check security of gearbox and axle
flange/yoke coupling flange retaining
bolts.
– Check all universal joints and the centre
bearing for distortion, damage or
overheating (discolouration).
– Check security of centre bearing
assembly mounting bolts. 050438

– Examine the propeller shaft tubes for

damage, twisting/distortion or missing
balance weights.
– Examine the propeller shafts for
cleanliness or attachment of any foreign
material that may affect the dynamic
balance of the propeller shaft; clean as
necessary.
5
– Check the radial movement of the
propeller shaft sliding joint splines does
not exceed the figure quoted in Data.
– Check all universal joints for play (radial
movement), see Data.
Note: There must NOT be any perceptible
movement at the universal joints, centre bearing
or sliding joints. Any worn or damaged
component must be renewed as instructed in
the ‘Workshop Manual’.

Data

Radial movement:
Universal joint . . . . . . . . . . . . . . 0,152 mm (max)
Sliding spline . . . . . . . . . . . . . . 0,178 mm (max)

 9809 5–33
MAINTENANCE OPERATIONS
Transmission 55 Series

050440

050439

5–34  9809
 MAINTENANCE OPERATIONS
55 Series Fuel System

CLEANING THE FUEL SEDIMENTER

Fuel spillages are highly

inflammable and must not be
exposed to a naked flame, spark
or any intense heat source.

1. Position a suitable container beneath the

fuel sedimenter to collect all fuel spillages.
Remove the drain plug (8) and allow the
accumulated water/sediment to drain into
the container.

2. When drainage is complete remove the

retaining bolt (1) and detach the
sedimenter bowl (6) and sealing ring (5).
Clean all components in a suitable solvent
and dry thoroughly. Check/clean the filter
(4) within the sedimenter head (3).

3. Examine the retaining bolt sealing ring (2),

sedimenter bowl sealing ring (5) and drain
plug sealing ring (7) for damage or
deterioration; renew as necessary. Ensure
that the drain plug aperture in the base of
the sedimenter bowl is clean and
5
unobstructed.

4. Lightly smear the sedimenter bowl sealing

ring with grease and locate in position
within the sedimenter filter head (3).

5. Refit the drain plug and then fill the

sedimenter bowl with clean, filtered diesel
fuel. Locate the sedimenter bowl and
secure in position with the retaining bolt.

Note: Small amounts of air introduced into the

fuel system when refitting the sedimenter bowl
will be vented automatically providing the
sedimenter bowl is filled with diesel fuel prior to
refitment. However, in isolated instances the
fuel system may require manually bleeding as
instructed on page 5–27.

 9809 5–35
MAINTENANCE OPERATIONS
Fuel System 55 Series

1
2

4
5
6

7
8 040578

5–36  9809
 MAINTENANCE OPERATIONS
55 Series Fuel System

RENEWING THE FUEL FILTER

Fuel spillages are highly

inflammable and must not be
exposed to a naked flame, spark
or any intense heat source.

1. Remove the noise suppression panels,

prior to working on the fuel filter and fuel
injection pump.

2. Position a suitable container beneath the

fuel filter cartridge (1) to collect all fuel
spillages.

3. Using a suitable filter wrench, remove

and discard the filter cartridge. Clean the
filter head in a suitable solvent and dry
thoroughly.

4. Examine the new filter cartridge and

ensure that the integral sealing ring (2) in
the new filter cartridge is correctly
located and its contact surfaces are
clean. 5
5. Lightly smear the filter cartridge sealing
ring with clean engine oil and fill the filter
cartridge with clean, filtered diesel fuel.

6. Screw the filter cartridge on by hand until

it contacts the filter head and then tighten
an additional 1/2 to 3/4 of a turn; do NOT
overtighten.

Note: Small amounts of air introduced into

the fuel system when refitting the filter
cartridge will be vented automatically
providing the filter cartridge is filled with diesel
fuel prior to refitment. However, in isolated
instances the fuel system may require
manually bleeding as instructed on page
5–27.

 9809 5–37
MAINTENANCE OPERATIONS
Fuel System 55 Series

1 1
2 2

040939
040940

Rotary Pump Application In–line Pump Application

5–38  9809
 MAINTENANCE OPERATIONS
55 Series Fuel System

BLEEDING THE FUEL SYSTEM

Do not attempt to bleed a hot

engine; fuel spillages are highly
inflammable and must not be
exposed to a naked flame, spark
or any intense heat source.

1. Small amounts of air introduced into the

fuel system during routine maintenance
will be vented automatically. However, in
isolated instances the fuel system may
require manually bleeding as follows:

– Ensure that there is an adequate

supply of fuel in the fuel tank.
Position a container beneath the fuel
filter head to collect expelled diesel
fuel.
– Attach a bleed pipe to the bleed
screw connection, open the filter
head bleed screw (1) and operate
the fuel lift pump hand lever/primer
(2) until air–free fuel flows from the
bleed tube; tighten the bleed screw 5
whilst operating the hand
lever/primer. Remove the bleed tube.

 9809 5–39
 MAINTENANCE OPERATIONS
Fuel System 55 Series

1
1

2 040941

Rotary Pump Application

2 040926

In–line Pump Application

5–40  9809
 MAINTENANCE OPERATIONS
55 Series Fuel System

CHECKING THE ENGINE SPEEDS

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Do not attempt to start or run the
engine in a confined space or
unventilated area; exhaust fumes
contain toxic gases which, if inhaled,
may be fatal.
– Only authorised personnel are
permitted to adjust the engine running
speeds. All unauthorised fuel pump
adjustments will invalidate the vehicle
warranty.
1. Before checking the engine speeds ensure
that the accelerator pedal and linkage is
free and that it travels smoothly and fully
between the idle (1) and maximum (2) fuel
stop positions.

2. With the vehicle connected to an exhaust

extractor, start and run the engine until it
attains normal running temperature.
5

 9809 5–41
MAINTENANCE OPERATIONS
Fuel System 55 Series

1 2
2

041210
041171

Rotary Pump Application

In–line Pump Application

5–42  9809
 MAINTENANCE OPERATIONS
55 Series Fuel System

3. Using a strobe type tachometer (4) on the

engine vibration damper (3), check that the 4
engine idling and maximum governed
speeds are within the tolerances quoted in
Data. If either of the engine speeds are
incorrect then the fuel pump will require
adjustment by authorised personnel as
instructed in the ‘Workshop Manual’.
3

Data
040582
Engine speeds (no–load):
Idling . . . . . . . . . . . . . . . . . 740 to 800 rpm
Maximum governed . . . 2825 to 2925 rpm

 9809 5–43
 MAINTENANCE OPERATIONS
Fuel System 55 Series

5–44  9809
 MAINTENANCE OPERATIONS
55 Series Electrical

CHECKING THE HEADLIGHT BEAM ALIGNMENT

Note: For the necessary accuracy required it is

recommended that proprietary optical or
electronic beam alignment equipment is used
and that in all cases the manufacturer’s
instructions and recommendations are followed.

1. Before checking the headlight beam

alignment ensure the following:

– Ensure that all tyres are inflated to the

correct pressure and that the vehicle is
standing on level ground.
– Ensure that the vehicle is in an unladen
condition.
– Ensure that the headlight load levelling
control (1), if fitted, is in the ‘O’ position.

 9809 5–45
MAINTENANCE OPERATIONS
Electrical 55 Series

081212

5–46  9809
 MAINTENANCE OPERATIONS
55 Series Electrical

2. Using suitable optical or electronic equipment,

determine the headlight beam alignment; the
beam alignment must conform to the current
statutory legal requirements.

– The initial headlight beam alignment for

EEC countries is shown on a label
attached to the cab door pillar.
– In the absence of suitable test
equipment, check the headlight (dipped)
beam alignment by parking the vehicle 10
m away from a suitable wall or vertical
surface. Mark a horizontal line at the
same height as the centre of the
headlight lens; 150 mm below the line
represents a 1,5% down setting. Ensure
that the headlight (main) beam is parallel
with the horizontal axis of the vehicle.
3. If the beam alignment is incorrect, adjust the
headlight unit(s) as follows:

– Rotate the headlight vertical (upper)

and/or horizontal (lower) adjustment
screws in the appropriate direction until
the required setting is attained.
5

 9809 5–47
MAINTENANCE OPERATIONS
Electrical 55 Series

080654

5–48  9809
 MAINTENANCE OPERATIONS
55 Series Electrical

CHECKING THE BATTERY CONNECTIONS AND CHASSIS EARTH TERMINALS

Batteries contain electrolyte

(sulphuric acid) which is a highly
corrosive and toxic substance.
Accidental skin/eye contact with
battery electrolyte can cause
serious personal injury. In the
event of accidental contact
thoroughly rinse the affected area
with clean cold water and seek
medical attention immediately.

Important:
– Ensure that the correct battery polarity is
maintained at all times; reversed battery or
charger connections will damage the
alternator.
081594
– Do NOT disconnect the batteries whilst the
engine is running.

– All vehicles are equipped with sealed

‘Maintenance–Free’ batteries as standard
factory fitted equipment. Do NOT attempt to
check or top–up the battery electrolyte level.
5
1. Check that all battery terminals and
connections are secure and free from
corrosion. If corrosion is evident proceed as
follows:

– Disconnect the battery leads and

thoroughly clean the connections and
terminals. Re–connect the battery leads
and ensure that they are secure.
– Lightly smear the battery
connections/terminals with petroleum jelly
to prevent subsequent corrosion; do NOT
use excessive amounts of petroleum jelly
as this can contribute to further corrosion.

 9809 5–49
MAINTENANCE OPERATIONS
Electrical 55 Series

081592

5–50  9809
 MAINTENANCE OPERATIONS
55 Series Electrical

2. Examine the battery cases and covers for

cracks, damage or leakage; renew the battery
as necessary.

3. Check the chassis earth terminals for signs

of corrosion or deterioration of grease at the
following locations:

– Front LH and RH side of the chassis

frame adjacent to the engine.
– Frame side at the rear of the batteries.
– Rear of chassis adjacent to the rear
cross–member.
4. If corrosion or deterioration of grease is
evident proceed as follows:

– Clean all grease from the terminal, then

disconnect the terminal from the
chassis frame. Thoroughly clean the
terminal area of the frame until bare
metal is exposed.
– Reconnect the earth terminal and
liberally apply ‘Rocol J166’ grease to
the terminal fixing at both sides of the
frame to correctly seal the terminal.
5

 9809 5–51
 MAINTENANCE OPERATIONS
Brakes 55 Series

DRAINING THE AIR RESERVOIRS

Fully charged air reservoirs

contain air at an approximate
pressure of 8,4 bar. It is essential
that suitable eye protection and
protective gloves are worn whilst
releasing the air pressure from the
reservoirs.

1. Chock the road wheels and fully charge the

air system.

2. Completely drain each air reservoir as follows:

– Pull each reservoir drain valve ring pull in

a sideways direction: the expelled air
must be free of any condensate
(water/oil/particles). Should any
condensate be observed from any air
reservoir then the air dryer filter cartridge
MUST be renewed as instructed on page
5–36.

5–52  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

070389

 9809 5–53
 MAINTENANCE OPERATIONS
Brakes 55 Series

RENEWING THE AIR DRYER FILTER

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– The air dryer and filter cartridge
contains pressurised air at the brake
system operating pressure. Do NOT
puncture nor attempt to remove the
filter cartridge until the complete
vehicle air system has been depleted.
– Ensure that suitable eye protection is
worn when removing the air dryer
cartridge.

To Remove
1. Position chocks beneath the road wheels and
then deplete the vehicle air system by
repeated applications of the hand and foot
brakes or by draining the reservoirs; when the
air system is fully depleted ensure that the
handbrake is applied to the park position.
5 2. Using a suitable filter wrench, remove and
discard the filter cartridge (1).

3. Thoroughly clean the filter cartridge contact

surface on the air dryer (3).

To Refit
1. Ensure that the sealing ring (2) in the
replacement filter cartridge is correctly seated
and clean. Lightly smear the sealing ring with
clean engine oil.

2. Screw the filter cartridge into position until the

sealing ring just contacts the air dryer and
then tighten a further one complete revolution;
do NOT overtighten.

3. Fully charge the vehicle air system and check

the air dryer filter cartridge for any air
leakages; rectify as necessary.

5–54  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

1
3
2

070390

 9809 5–55
 MAINTENANCE OPERATIONS
Brakes 55 Series

CHECKING THE BRAKE LINING THICKNESS

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Ensure that suitable protective clothing
and a face mask are worn to prevent the
inhalation of brake lining dust or particles.
– Do NOT inhale dust from the brake
linings or blow dust from the brake
assemblies; remove dust using a damp
cloth or vacuum cleaner, deposit used
cloths, whilst damp, in a plastic waste
disposal bag. If a cleaning solvent is
required, methylated spirit should be
used.

1. Chock the road wheels, fully charge the air

system and move the handbrake to the off
position.

5 2. Should any of the brake shoe linings fail

either of the following checks, the
appropriate remedial action must be taken
as instructed in the ‘Workshop Manual’:

– Remove the rubber grommets (1 and, if

applicable, 2) from the inspection
apertures in each backplate.
– Using an adjustable inspection mirror,
examine the thickness of each brake
shoe lining; brake shoes MUST be
renewed if the lining material is worn
below the level of the brake wear
indicator.
Important: Worn brake shoes MUST
be renewed as complete axle sets as
instructed in the ‘Workshop Manual’.

5–56  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

2
1
2

070677

11 to 15 tonne models

1
070670

17 and 18 tonne models

 9809 5–57
 MAINTENANCE OPERATIONS
Brakes 55 Series

– Check that the brake shoe lining to brake

drum clearance is within the limits
specified; an unacceptable clearance
indicates a defective automatic
adjuster/slack adjuster which must be
tested and, if necessary, renewed or
overhauled.

Data

Lining/drum clearance:

11 to 15 tonne models . . . . . . 0,2 to 2,0 mm

17/18 tonne models . . . . . . . . 0,8 to 1,2 mm

5–58  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

CHECKING THE BRAKE PADS AND DISCS

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Ensure that suitable protective
clothing and a face mask are worn to
prevent the inhalation of brake lining
dust or particles.
– Do NOT inhale dust from the brake
linings or blow dust from the brake
assemblies; remove dust using a
damp cloth or vacuum cleaner,
deposit used cloths, whilst damp, in a
plastic waste disposal bag. If a
cleaning solvent is required,
methylated spirit should be used.

Note: Electrical wear indicators are fitted to the

brake pads.

1. Isolate the batteries.

2. Apply the handbrake to the park position

5
and chock the rear road wheels.

3. Jack the front axle sufficiently to enable the

the front road wheels to be freely rotated;
position suitable supports beneath the front
axle.

4. Using an adjustable inspection mirror,

examine the lining material thickness of
each brake pad; brake pads MUST be
renewed if the lining material is worn below
the level of the brake wear indicator slot.

Important: Worn brake pads MUST be

renewed as complete axle sets as instructed
in the ‘Workshop Manual’.

 9809 5–59
MAINTENANCE OPERATIONS
Brakes 55 Series

070679

5–60  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

5. Whilst rotating the road wheel, carefully

examine the inboard and outboard brake
disc surfaces for excessive wear, distortion
or damage as follows:

– Crazing (1). Light surface crazing or a

network of light surface cracks on the
friction surface of the disc are
permissible.
– Full Radial Cracks (2). Radial cracks
over the complete friction surface of the
disc are NOT permissible.
– Partial Cracks (3). The maximum width
or depth of any partial crack on the disc
friction surface must NOT exceed 0,5
mm.
– Scoring (4). The width or depth of any
score (groove) in the disc friction
surface must NOT exceed 0,5 mm.
– Disc Thickness (5). The minimum disc
thickness must not be less than the
specified minimum figure.
– Disc Penetration (6). Using an 5
adjustable inspection mirror, examine
each brake disc for cracks or splits;
penetration of the brake disc is NOT
permissible.
Important: Any unacceptable worn or
damaged disc MUST be renewed as
instructed in the ‘Workshop Manual’.

6. Remove the axle supports and lower the

vehicle to the ground.

Data

Disc thickness . . . . . . . . . . . . . . . 40 mm (minimum)

 9809 5–61
MAINTENANCE OPERATIONS
Brakes 55 Series

1 2

4 3
070393

070678

5–62  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

CHECKING THE LOAD SENSING VALVE – STEEL SUSPENSION MODELS

Important:
– The vehicle should be preferably tested in an
unladen condition, but the following
procedures can be used for a partially or fully
laden vehicle if required.

– Obtain the part number of the load sensing

data plate (attached to the cab door aperture).
The part number will enable the operator to
select the relevant load sensing valve setting
chart, see Data. Ensure that the relevant
setting chart is available before commencing
work on the vehicle.

 9809 5–63
MAINTENANCE OPERATIONS
Brakes 55 Series

P4

F mm
P2
Lm
m

L = 130 F = 68
P4 = 6 bar
P2
ASLAST UITGESTUURDE DRUK
AXLE LOAD DELIVERY PRESSURE
ACHSLAST AUSGESTEUERTER
CHARGE SOIS DRUCK
ESSIEU PRESSION DELIVREE
CARICO ASSE PRESSIONE USCITA
CARGA EJE PRESION DE SALIDA
Kg bar
1680 3.1
2000 3.3
3000 4.3
4000 5.4
5560 6.0
8240 6.0

ACHA964
070398

5–64  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

Valve Function Test

1. Chock the road wheels and, using a workshop
air line fitted to the vehicle full flow I.S.O. 1
connection (1), fully charge the vehicle air
system.

2. Using three air pressure gauges 0485052,

connect them to the load sensing valve (2),
rear spring brake actuator (3) and the front
brake chamber (4) I.S.O. test connections.

070668

 9809 5–65
 MAINTENANCE OPERATIONS
Brakes 55 Series

3. Should the load sensing valve fail any of the

following tests, it must be renewed as
instructed in the ‘Workshop Manual’.

– Detach the flexible connection link (6)

from the adjustment screw (7) and pull
the operating lever (5) upwards to its 5
maximum lift position.
– With the aid of an assistant, lightly
depress and then hold the footbrake
pedal stationary when a constant air
pressure of 6 bar registers on the inlet air
gauge; the outlet gauge should register
the same pressure.
– Release the footbrake and then push the
operating lever downwards to its
maximum position. 6
– Re–apply and then hold the footbrake
stationary when a constant air pressure
of 6 bar registers on the inlet air gauge; 7
the outlet gauge should register the
unladen output pressure of 1,3 ± 0,25
070508
bar. Release the footbrake pedal.
5 4. If the load sensing valve has successfully
completed the above test re–connect the
flexible connection link to the adjustment
screw and continue testing the valve as
instructed in ‘Output Pressure Test’.

5–66  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

Output Pressure Test

1. Weigh the vehicle to obtain the actual rear
axle ground weight.

2. Using the appropriate setting chart, see

Data, select the nearest rear axle ground
weight figure above the actual recorded rear
axle ground weight and note the
corresponding output pressure.

3. Check and, if necessary, adjust the

operating lever setting dimension ‘L’ to the
figure quoted on the load sensing data plate.

 9809 5–67
MAINTENANCE OPERATIONS
Brakes 55 Series

P4

F mm
P2
Lm
m

L = 130 F = 68
P4 = 6 bar
P2
ASLAST UITGESTUURDE DRUK
AXLE LOAD DELIVERY PRESSURE
ACHSLAST AUSGESTEUERTER
CHARGE SOIS DRUCK
ESSIEU PRESSION DELIVREE
CARICO ASSE PRESSIONE USCITA
CARGA EJE PRESION DE SALIDA
Kg bar
1680 3.1
2000 3.3
3000 4.3
4000 5.4
5560 6.0
8240 6.0

ACHA964
070398

5–68  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

4. Lightly depress and hold the footbrake pedal

stationary when a constant air pressure of 6
bar registers on the inlet pressure gauge; L
note the outlet pressure reading. If the
output air pressure is not within ± 0,25 bar of
the required output pressure, adjust the
valve setting as follows:

– Release the footbrake pedal; all

adjustments MUST be made whilst the
load sensing valve is unpressurised.
– Adjust the length of the adjustment
screw, dimension ‘C’, to modify the
outlet pressure; an increase in length
will increase the pressure and,
conversely, a decrease in length will
decrease the pressure.
C
– Repeat the output pressure test
070404
procedure until the required pressure is
achieved.
Important: In certain circumstances, it may
be necessary to adjust the ‘L’ dimension to
achieve the required output pressures in both
the unladen and laden conditions. 5

 9809 5–69
 MAINTENANCE OPERATIONS
Brakes 55 Series

5. When the load sensing valve has been set

correctly, check the front brake output
pressure as follows:

– Lightly depress and hold the footbrake

pedal stationary when a constant air
pressure of 6 bar registers on the inlet
pressure gauge; check the gauge
reading is within ± 0,25 bar of the
required output pressure. An incorrect
reading indicates a faulty empty/load
valve; renew the valve as instructed in
the ‘Workshop Manual’.

Data

Special tool:

Air pressure gauge . . 0485052 (3 required)

Input test pressure . . . . . . . . . . . . . . . . . . . . . 6 bar

5 Data plate information . . . . . . . . . . see Section 2

5–70  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

CHECKING LOAD SENSING VALVE – AIR SUSPENSION MODELS

Important:
– The vehicle should be preferably tested in an
unladen condition, but the following
procedures can be used for a partially or fully
laden vehicle if required.

– Obtain the part number of the load sensing

data plate (attached to the cab door aperture).
The part number will enable the operator to
select the relevant load sensing valve setting
chart, see Data. Ensure that the relevant
setting chart is available before commencing
work on the vehicle.

Output Pressure Test

1. Weigh the vehicle to obtain the actual rear
axle ground weight.

2. Chock the road wheels and, using a

workshop air line connected to the vehicle
full flow ISO connection, fully charge the
vehicle air system.
5
3. Connect three air pressure gauges 0485052
to the following locations.

– The load sensing valve ISO test

connection (1).
– The rear brake actuator ISO test
connection.
– The front brake chamber ISO test
connection.

 9809 5–71
MAINTENANCE OPERATIONS
Brakes 55 Series

070509

5–72  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

4. Using the appropriate setting chart, see Data,

select the nearest rear axle ground weight
figure above the actual recorded rear axle
ground weight and note the corresponding P1
P1 = 6 bar
output pressure ‘P2’. P2

5. Depress and hold the footbrake pedal

stationary when an input pressure of 6 bar
P3
registers on the gauge connected to port ‘1’
and check that the output pressure at the P2 = UITGESTUURDE DRUK
DELIVERY PRESSURE
gauge connected to the rear brake actuator is
AUSGESTEUERTER DRUCK
within ± 0,25 bar of the required output PRESSION DELIVREE
pressure. PRESSIONE USCITA
PRESION DE SALIDA
If the output pressure reading is not within the
P3 = BALG DRUK
required limits, the load sensing valve MUST PRESSURE BELLOWS
be re–calibrated as instructed in the BALG DRUCK
‘Workshop Manual’. PRESSION COUSSIN
PRESS. CUSCINI ARIA
PRESION FUELLES
6. If the load sensing valve has successfully
completed the above test, check the front ASLAST
AXLE LOAD
brake output pressure as follows: ACHSLAST
P3 P2
CHARGE SOUS ESSIEU bar bar
CARICO ASSE
– Lightly depress and hold the footbrake CARGA EJE Kg

pedal stationary when a constant air

pressure of 6 bar registers on the inlet
1610
3000
0.5
1.3
2.3
3.5
5
pressure gauge; check the gauge reading 4000 2.0 4.4
is within ± 0,25 bar of the required output 5000 2.6 5.2
pressure. An incorrect reading indicates a 5866 3.1 6.0
faulty empty/load valve; renew the valve 8500 4.7 6.0
as instructed in the ‘Workshop Manual’.
ACHA111
070506

Data

Special tool:

Air pressure gauge . . 0485052 (3 required)

Input test pressure . . . . . . . . . . . . . . . . . . . . . 6 bar

Data plate information . . . . . . . . . . see Section 2

 9809 5–73
 MAINTENANCE OPERATIONS
Brakes 55 Series

TESTING THE ABS BRAKING SYSTEM

The function and operation of the

electro–pneumatic controls of the
ABS braking system are NOT
monitored by the ABS warning
system; these controls must be
manually tested.

Important:
– The ABS system is equipped with 4
electro–pneumatic modulator valves which
must be individually tested. Any modulator
valve that fails the following leakage or
operating tests MUST be renewed as
instructed in the ‘Workshop Manual’.

– Dependent upon equipment available, the

ABS operating tests can be preformed using
DAVIE or, alternatively, electronic test kit
0694974. Ensure that appropriate test
procedure is followed.

5 Leakage Test
1. Fully charge the vehicle air system and
apply the handbrake.

2. Turn the ignition key to the on position; do

not start the engine.

3. With the aid of an assistant, fully depress

and hold the brake pedal and check each
modulator valve and air line connection for
leaks; leakages are NOT permissible.

5–74  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

Operating Test

Method 1: Using test equipment 0694974

1. Fully charge the vehicle air system and
apply the handbrake.

2. Detach the cover from the electronic control

unit (ECU), situated at the L.H. side of the 1 2 3 4 5

cab rear panel. 6 7 8 9

11 12 13 14 15

3. Using diagnostic test equipment (1) 16 17 18 19 20

0694974, prepare the vehicle as follows: 21 22 23 24 25

26 27

– Disconnect the 35–pin connector (4) 31 32 33 34 35

1
from the ECU (2). 3 2
– Couple the test equipment connector
(3) to the ECU 35–pin connector.
– Using the master/start key, energise the
vehicle auxiliary circuits.

5
4
070399

4. Each modulator valve contains two solenoid

valves that have been designated ‘X’ (inlet )
and ‘Y’ (outlet). Refer to the conversion
table in Data to identify the test equipment
pin numbers that activate the appropriate
solenoid valves.

 9809 5–75
MAINTENANCE OPERATIONS
Brakes 55 Series

070400

5–76  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

5. Connect air pressure gauge, 0485052, to

the relevant air actuator ISO test
connection; ensure that the air actuator
corresponds to the modulator valve to be
tested.

6. Fully apply the footbrake and then, using the

diagnostic test equipment, connect pin No. 9
to the appropriate ‘X’ pin number. Connect
pin No.9 with the appropriate ‘Y’ pin number
for approximately 5 seconds and ensure that
the air pressure reading on the air pressure
gauge rapidly drops and remains at 0 bar.
Should the air pressure fail to drop or if it
initially drops and then commences to rise
then the modulator valve is defective.

7. Interrupt the connection between pin No. 9

and the ‘X’ pin number and check that the
air pressure at the air pressure gauge rises
to its original value; if the air pressure fails to
rise then the modulator valve is defective.

8. When the vehicle is taken for its road test

check the functions of the ABS warning
system as follows:
5
– Check that the relevant ABS warning
light(s) illuminate when the auxiliary
circuits are energised.
– Ensure that the relevant ABS warning
lights(s) extinguish when the vehicle
attains a speed of 15 km/h.

 9809 5–77
 MAINTENANCE OPERATIONS
Brakes 55 Series

Operating Test

Method 2: Using DAVIE

1. Fully charge the vehicle air system and
apply the handbrake.

2. Detach the protective cover (3) from the

diagnostic test socket (1). Connect the
DAVIE test plug (2) to the diagnostic test
socket.

3. With the aid of an assistant, fully apply the

footbrake and then, using DAVIE (4), select
the ABS and, if applicable, ASR test
procedure and test the operation and
function of:

– each modulator valve,

– all ABS/ASR warning lights.
4. After successfully testing the ABS system,
disconnect the air pressure gauge and
DAVIE electronic test equipment from the
vehicle.
5

5–78  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

070671

 9809 5–79
 MAINTENANCE OPERATIONS
Brakes 55 Series

Data

Special tools:

Test equipment . . . . . . . . . . DAVIE or 0694974

Air pressure gauges . . . . . . . . . . . . . 0485052

Conversion table (for use with 0694974):

Modulator Solenoid Activated by

Valve Valve Pin Number
‘X’ 23
LH front brakes
‘Y’ 24
‘X’ 6
RH front brakes
‘Y’ 7
‘X’ 21
LH rear brakes
‘Y’ 22
‘X’ 4
RH rear brakes
‘Y’ 5

5–80  9809
 MAINTENANCE OPERATIONS
55 Series Brakes

 9809 5–81
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

RENEWING THE POWER STEERING FILTER ELEMENT

Hydraulic fluid is a toxic

substance which must not be
consumed or allowed to come into
skin/eye contact. In the event of
slight skin/eye contact, thoroughly
rinse the affected area with water.
If there is excessive skin/eye
contact, ingestion or inhalation
seek medical attention immediately.

1. Thoroughly clean the top of the dipstick,

reservoir cap and their surrounding areas;
the ingress of dirt or foreign particles into the
reservoir will have a severe detrimental
effect upon the components of the power
steering system.

2. Remove the reservoir cap (1). Rotate and

then extract the retaining handle (3),
complete with the filter element (4), from the
reservoir (5).

5 3. Detach the retaining handle and spring (3)

from the old filter element and attach them
to the new filter element.

4. Check condition of sealing ring (2).

5. Insert and lock the new filter element

assembly into the reservoir. Check and, if
necessary, top–up the hydraulic fluid level
as instructed on page 5–56.

5–82  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

1
5 2
3

020117

 9809 5–83
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

CHECKING THE POWER STEERING FLUID LEVEL

Before attempting any

maintenance operations is
essential that the following safety
precautions are strictly observed:
– Hydraulic fluid is a toxic substance which
must not be consumed or allowed to
come into skin/eye contact. In the event of
slight skin/eye contact, thoroughly rinse
the affected area with water. If there is
excessive skin/eye contact, ingestion or
inhalation seek medical attention
immediately.

– Do not attempt to start or run an engine in

a confined space or unventilated area;
exhaust fumes contain toxic gases which,
if inhaled, may prove fatal.

1. Thoroughly clean the top of the dipstick (1),

reservoir cap (2) and their surrounding areas;
the ingress of dirt or foreign particles into the

5 reservoir will have a severe detrimental effect

upon the components of the power steering
system.

2. With the engine running at idling speed,

remove the dipstick and check that the
hydraulic fluid level registers on the maximum
mark on the dipstick. If necessary, remove the
reservoir cap and top–up the hydraulic fluid
until the correct level is attained; do NOT
exceed the recommended fluid level.

Important: Should the power steering

reservoir require an excessive amount of
hydraulic fluid, the complete system must be
inspected for leaks and rectified as necessary.

Data

Hydraulic fluid . . . . . . . . . . . . . . . . . see Section 3

Reservoir capacity . . . . . . . . . . . . . . . . . . . 0,75 litre

5–84  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

020124

 9809 5–85
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

CHECKING THE STEERING PIVOT POINTS

Note: Check all ball joints, hub end–float and

swivel pin/stub axle clearance using the
appropriate procedure:

Ball joints
1. Disconnect the batteries, apply the
handbrake and chock the rear road wheels.
Jack the front axle until the road wheels are
clear of the ground and position suitable
supports beneath the axle beam.

2. Clean and then examine the rubber gaiter

on each ball joint for damage, deterioration
or cracks; if any damage, deterioration or
cracks are evident then the affected ball joint
MUST be renewed as instructed in the
‘Workshop Manual’.

3. Check that all ball pillar nuts are secure and

locked in position with a split pin.

5–86  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

4. Using service tool 0485211, check all ball

joints as follows:

‘Concave Head’ type

– Assemble service tool 0485211,

ensuring that the correct thrust pad (6)
and thrust cap (8) are selected, see
Data. Screw the thrust cap onto the
adjusting screw (9) and insert the collet
(3), spring (4) and thrust pad into the
tool body (1); ensure the slot in the
thrust pad aligns with the hole in the
tool body.
– Secure the thrust pad in position with
the setscrew (5) and ensure the thrust
pad moves freely; slacken the setscrew
accordingly. Rotate the thrust screw (2)
anti–clockwise until the thrust pad abuts
the face of the tool body.
– Locate the service tool on the ball joint
(7), ensuring the ball joint nut split pin is
clear of the top face of the ball joint.
Tighten the adjusting screw (9), using
5
hand pressure only, until the thrust pad
firmly engages the face of the ball joint.
– Fully tighten the thrust screw and then,
using feeler gauges, measure the
clearance ‘A’ between the thrust pad
and tool body. If the clearance exceeds
2,0 mm then the ball joint MUST be
renewed as instructed in the ‘Workshop
Manual’.

 9809 5–87
MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

2
1 3
4
5
A

6
7
8

9
020121

5–88  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

‘Convex Head’ type

– Assemble service tool 0485211, 1
ensuring that the correct thrust pad (4)
and thrust cap (2) are selected, see
Data. Screw the thrust cap into the tool
body (1) and then insert the collet (7),
spring (6) and thrust pad into position 2
within the tool body; ensure the slot in
the thrust pad aligns with the hole in the
tool body.
– Secure the thrust pad in position with
3
the setscrew (5) and ensure the thrust
pad moves freely; slacken the setscrew 4
accordingly. Rotate the thrust screw (8)
anti–clockwise until the thrust pad abuts
the face of the tool body. A
– Locate the service tool on the ball joint 5
(3), ensuring the ball joint nut split pin is
clear of the top face of the ball joint. 6
Tighten the thrust pad, using hand
pressure only, until it engages the face
of the ball joint.
7
– Fully tighten the thrust screw and then, 8 020174 5
using feeler gauges, measure the
clearance (‘A’) between the thrust pad
and tool body. If the clearance exceeds
2,0 mm then the ball joint MUST be
renewed as instructed in the ‘Workshop
Manual’.

 9809 5–89
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

Hub end–float
Note: At the specified service interval, the front
hub bearings must be re–packed with grease
and the hub end–float checked/adjusted as
instructed on page 5–62.

1. Remove the hub end cap and thoroughly

clean the end of the stub axle.

2. Attach a dial test indicator on the hub and

locate the indicator stylus on the end of the
stub axle. Check that the hub end–float is
within the tolerances quoted in Data. If
necessary, adjust the hub nut until the
020126
required end–float is obtained. Secure the
hub nut in position and refit the hub end cap. F56 axle
Important: Excessive hub end–float and/or
noisy bearings MUST be investigated and
rectified as instructed in the ‘Workshop Manual’.

5–90  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

020172

F71 axle

 9809 5–91
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

Swivel pin/stub axle clearance

1. Using feeler gauges, check the clearance ‘X’ X
between the stub axle and axle beam. X
Any swivel pin that exceeds the maximum
worn limit quoted in Data MUST be
re–shimmed or overhauled as instructed in
the ‘Workshop Manual’.

020244

F56 axle F71 axle

Data

Ball joints

5 Ball joint clearance . . . . . . . . 2,0 mm (maximum)

Special tools:

Checking tool . . . . . . . . . . . . . . . . . . . 0485211

Thrust pad . . . . . . . . . . . 0485211–(Detail 6)

Thrust pad * . . . . . . . . . . 0485211–(Detail 7)

Thrust cap . . . . . . . . . . . 0485211–(Detail 10)

Thrust cap * . . . . . . . . . . 0485211–(Detail 5)

* Used with ‘Convex Head’ ball joints

Swivel pins

Swivel pin/stub axle clearance:

Minimum . . . . . . . . . . . . . . . . . . . . . . 0,05 mm

Maximum worn limit . . . . . . . . . . . . . . 0,3 mm

Front hubs

Hub end–float . . . . . . . . . . . . . . . . 0,05 to 0,25 mm

5–92  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

RE–PACKING THE FRONT HUB BEARINGS

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Ensure that suitable protective clothing
and a face mask are worn to prevent
the inhalation or penetration of brake
pad dust and particles.
– Do NOT inhale the dust from the brake
pads/shoes or blow dust from the
brake assemblies; remove any dust
using a damp cloth or vacuum cleaner
and dispose of all used cloths, whilst
damp, into a plastic waste disposal
bag. If a cleaning solvent is required,
methylated spirit should be used.

Important: Axles fitted with ABS: Any

maintenance operation that exposes the ABS
exciter ring, the following precautions MUST
be observed:
– Do NOT use the exciter ring as a lever 5
(fulcrum) point.
– Do NOT strike or dent the exciter ring;
protect the ring from damage.
– Do NOT stand the hub on the exciter
ring.

F56 Front Axle

Dismantling
1. Isolate the batteries, apply the handbrake to
the park position and deplete the air system.

2. Remove the front road wheels.

3. Disconnect the air pipe from the brake

chamber and separate the brake pad indicator
cable plug connection; position the air
pipe/cable clear of the caliper.

 9809 5–93
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

4. Suitably support the caliper, remove the

retaining bolts (1) securing the caliper (2) to
the stub axle and carefully withdraw the 2
caliper assembly. 1

1 020125

5. Prise the hub cap (3) from the hub. Release

the split pin, remove the hub nut (4) and
detach the keyed washer (5).

6. Remove the outer bearing (6) from its bearing

race and withdraw the complete hub
5 assembly (7) from the stub axle (11).

7. Extract the hub oil seal (9) and inner bearing

(8) from the hub, leaving the bearing race in
position within the hub.

8. Thoroughly clean all components in a suitable

solvent and dry thoroughly.

Inspection
1. Inspect the following items for excessive wear,
damage or distortion:

– Bearings
– Hub assembly
– Hub abutment ring (10)
– Wheel bolts
– Exciter ring (ABS models)
– Brake pads
If any of these items are found to be
defective, they must be overhauled or
renewed as instructed in the ‘Workshop
Manual’.

5–94  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

11

10
9

6
5
4
3
020245

 9809 5–95
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

Reassembly
1. Thoroughly pack or inject the outer and inner
bearings with the correct specification grease.

2. Apply a uniform layer of grease within the hub

cavity to achieve an approximate thickness of
6 mm.

Important: Do NOT pack the hub cavity with

grease. An excessive amount of grease can
create an adverse pressure build–up within in
the hub causing hub oil seal failure.

3. Locate the inner bearing (8) into the hub

(7).

4. Press the new oil seal (9) into position until it

is flush with the face of the hub. Lightly
lubricate the sealing lip of the new oil seal and
then carefully locate the hub assembly in
position on the stub axle.

5. Locate the outer bearing (6) in the hub, fit the

keyed washer (5) and then secure the hub
5 assembly with the hub nut (4).

6. Whilst rotating the hub assembly, tighten the

hub nut to seat the hub bearings. Slacken the
hub nut 1/2 turn and then re–tighten.

7. Attach a dial test indicator on the hub and

locate the indicator stylus on the end of the
stub axle. Measure the amount of hub
end–float; if necessary, tighten or slacken the
hub nut until the required end–float is
obtained. Secure the hub nut in position with a
new split pin.

5–96  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

6 mm

020126

020243

 9809 5–97
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

8. Apply a layer of grease between the keyed

washer (5) and the hub cap bore and then
refit the hub cap (3).

Important: Do NOT pack the hub cap with

grease. An excessive amount of grease can
create an adverse pressure build–up within in
the hub causing hub oil seal failure.

9. Refit the caliper to the stub axle and tighten

the retaining bolts to the specified torque
figure.

10. Reconnect the wear indicator cable plug and

reconnect the air pipe to the brake chamber.
3 5 020247

11. ABS models only: Push the sensor inwards

until it just contacts the exciter ring and then
rotate the hub several times to set a minimum
running clearance between the sensor and
exciter ring.

12. Refit the front road wheels and torque tighten

the wheel nuts as instructed in the ‘Driver’s
5 Handbook’.

5–98  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

070401

 9809 5–99
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

F71 Front Axle

Dismantling 1
1. Isolate the batteries, apply the handbrake to
the park position and chock the rear road 2
wheels.

2. Remove the front road wheels.

3
3. Remove the two setscrews (13) and detach
4
the brake drum (12), if necessary, use two
extractor bolts in the holes provided to remove
the brake drum.
5
4. Remove the setscrews and detach the hub
cap (11) complete with hub cap joint (10).

5. Release the lockwasher and remove the nut 6

and clamp bolt from the split hub nut (9).
Remove the split hub nut noting that the L.H.
split hub nut has L.H. threads and the R.H.
split hub nut has R.H. threads. Detach the 7
thrust washer (8).
8
5 6. Withdraw the hub assembly (6), complete with
its inner and outer bearings and oil seal, from 9
the stub axle (1).

7. Remove the outer bearing (7), leaving the

10
bearing race in position within the hub.
11
8. Remove the oil seal (3) and inner bearing (4),
leaving the inner bearing race in position
within the hub. 12
9. Thoroughly clean all components in a suitable
solvent and dry thoroughly.

13
020173

5–100  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

Inspection
1. Inspect the following items for excessive wear,
damage or distortion:

– Bearings
– Hub assembly
– Abutment ring (2)
– Exciter ring (5) – ABS Models
– Wheel bolts
– Brake shoe linings.
– Brake drums.
If any of these items are found to be
defective, they must be overhauled or
renewed as instructed in the ‘Workshop
Manual’.

 9809 5–101
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

Reassembly
1. Thoroughly pack or inject the inner and outer
bearings with the correct specification grease,
see Data.

2. Apply a uniform layer of grease within the hub

cavity to achieve an approximate thickness of
6 mm.

Important: Do NOT pack the hub cavity with

grease. An excessive amount of grease can
create an adverse pressure build–up within in
the hub causing hub oil seal failure.

3. Locate the inner bearing and the new oil seal

in the hub.

4. Lightly lubricate the sealing lip of the oil seal

and then carefully locate the hub assembly in
position on the stub axle.

5. Fit the outer bearing into position in the hub,

fit the thrust washer and then secure the hub
assembly with the split hub nut. Fit and
5 partially tighten the clamp bolt.

6. Whilst rotating the hub assembly, tighten the

split hub nut to seat the hub bearings.
Slacken the split hub nut 1/2 turn and then
re–tighten.

7. Attach a dial test indicator on the hub and

locate the indicator stylus on the end of the
stub axle. Measure the amount of hub
end–float; if necessary, tighten or slacken the
split hub nut until the specified end–float is
obtained. Tighten the clamp bolt to the
specified torque and secure in position with
the lock washer.

5–102  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

6 mm

020243

020172

 9809 5–103
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

8. Apply a layer of grease between the keyed Brake drum setscrews . . . . 14 to 27 Nm

washer (5) and the hub cap bore. Using a
new joint, refit the hub cap (3). Hub nut clamp bolt . . . . . . . 27 to 41 Nm

Important: Do NOT pack the hub cap with

grease. An excessive amount of grease can
create an adverse pressure build–up within in
the hub causing hub oil seal failure.

9. Fit the brake drum and tighten the setscrews

to the quoted torque figure.

10. ABS models only: Push the sensor inwards

until it just contacts the exciter ring and then
rotate the hub several times to set a
5 minimum running clearance between the
sensor and exciter ring.

11. Refit the front road wheels and torque

tighten the wheel nuts as instructed in the
‘Driver’s Handbook’.

Data

Grease specification . . . . . . . . . . . . . see Section 3

Hub end–float:

F56 axle . . . . . . . . . . . . . . . . . 0,05 to 0,25 mm

F71 axle . . . . . . . . . . . . . . . . . . 0,1 to 0,23 mm

Tightening torques:

F56 axle:

Caliper retaining bolts . . . 560 to 630 Nm

F71 axle:

5–104  9809
 MAINTENANCE OPERATIONS
55 Series Steering and Front Axle

070401

3 5 020247

 9809 5–105
 MAINTENANCE OPERATIONS
Steering and Front Axle 55 Series

5–106  9809
 MAINTENANCE OPERATIONS
55 Series Rear Axle

RENEWING THE DIFFERENTIAL OIL

1. Position a suitable container beneath the rear

axle differential. Remove the drain plug (1)
and allow the oil to drain. Thoroughly clean
and then apply PTFE tape to the threads of
the drain plug. When drainage is complete,
refit the drain plug.

2. Remove the filler/level plug (2) and fill the rear

axle with clean oil of the approved
specification until oil just begins to emerge
from the filler/level aperture. Thoroughly clean
and then apply PTFE tape to the threads of
2
the filler/level plug; refit the filler/level plug.
1 030168
Note: It is recommended that the oil level is
re–checked after the vehicle has completed its
test drive.

3. Clean the rear axle breather as follows:

– Remove the cap (3) and vent disc (4)

from the breather body (5). Thoroughly
clean all components, ensuring that the
breather body and vent disc are
5
unobstructed. Reassemble the breather
and ensure that the breather cap is
securely fitted.

Data

Oil specification . . . . . . . . . . . . . . . . see Section 3

Differential oil capacity:

8.20 axle . . . . . . . . . . . . . . . . . . . . . . . . 8,0 litres

10.26 and 11.26 axles . . . . . . . . . . . . . 9,0 litres

10.20 axle . . . . . . . . . . . . . . . . . . . . . . . 9,4 litres

 9809 5–107
MAINTENANCE OPERATIONS
Rear Axle 55 Series

3
4

5
030271

5–108  9809
 MAINTENANCE OPERATIONS
55 Series Rear Axle

RENEWING THE REAR HUB OIL – OIL LUBRICATED HUBS

Avoid unnecessary contact with

drained oil. Prolonged and repeated
contact with used oil can cause
serious skin disorders.

1. Position the vehicle on a level surface,

rotate the road wheels until the hub
filler/drain plug (1) is at its lowermost
position.

2. Position a suitable tray and container

beneath the hub. Remove the plug and
allow the oil to drain.

3. When drainage is complete, rotate the road

wheels until the filler/drain aperture is in its
uppermost position. Fill the hub with the
correct amount and specification of oil, see
Data.

4. Thoroughly clean the filler/drain plug and then

apply ‘Loctite 572’ to the plug threads; fit and
tighten the filler/drain plug to the specified
torque.
5
5. Repeat the oil renewal procedure for the
opposite hub.

Data

Oil specification . . . . . . . . . . . . . . . . see Section 3

Hub oil capacity (each):

8.20 axle . . . . . . . . . . . . . . . . . . . . . . . . 0,25 litre

10.20, 10.26 and 11.26 axles . . . . . . . 0,5 litre

Tightening torque:

Oil filler/drain plug . . . . . . . . . . . . . . . . 27 Nm

 9809 5–109
MAINTENANCE OPERATIONS
Rear Axle 55 Series

030276

5–110  9809
 MAINTENANCE OPERATIONS
55 Series Rear Axle

RE–PACKING THE REAR HUB BEARINGS – GREASE LUBRICATED HUBS

Before attempting any maintenance

operations is essential that the
following safety precautions are
strictly observed:
– Ensure that suitable protective clothing
and a face mask are worn to prevent the
inhalation or penetration of brake lining
dust and particles.

– Do NOT inhale the dust from the brake

linings or blow dust from the brake
assemblies; remove any dust using a
damp cloth or vacuum cleaner and
dispose of all used cloths, whilst damp,
into a plastic waste disposal bag. If a
cleaning solvent is required, methylated
spirit should be used.

Important: Axles fitted with ABS: Any

maintenance operation that exposes the ABS
exciter ring, the following precautions MUST be
observed:
– Do NOT use the exciter ring as a lever 5
(fulcrum) point.

– Do NOT strike or dent the exciter ring;

protect the ring from damage.

– Do NOT stand the hub on the exciter ring.

 9809 5–111
 MAINTENANCE OPERATIONS
Rear Axle 55 Series

Dismantling
1. Isolate the batteries and chock the front road
wheels. 11
2. Remove the rear road wheels.

3. Manually release the spring brake actuators.

10
4. Axles fitted with a differential lock:

– Engage the differential lock.

– Disconnect the cable from the differential
lock switch.
9
– Remove the differential lock switch, then
screw a suitable 16 mm bolt into the
switch bore to retain the differential lock 8
in the engaged position.

5
7
6
5
4
3
2

1 030274

8.20 Axle

5–112  9809
 MAINTENANCE OPERATIONS
55 Series Rear Axle

5. Remove the axle shaft setscrews/nuts (1) and

lever the axle shaft (2) from the hub.
Withdraw the axle shaft and clean all joint
faces.
11
6. Remove the two setscrews and detach the
brake drum, noting, if necessary:
10
– Manually retract the brake shoes as
detailed in the ‘Workshop Manual’.
– Use two extractor bolts in the holes
provided to remove the brake drum.
9
7. Release the lockwasher (4). Using the
appropriate hub nut wrench tool, see Data,
remove the outer locknut (3) and detach the
lockwasher. Using the hub nut wrench, 8
remove the adjusting nut (5) and detach the
keyed thrust washer (6).

8. Remove the outer bearing (7) from its race

and withdraw the hub assembly (8) from the
axle.

9. Extract and discard the oil seal (10) and then

withdraw the inner bearing (9) from the hub
5
assembly leaving the bearing race in position
within the hub. 7
10. Thoroughly clean all components in a suitable
solvent and dry thoroughly.
6
5
Inspection
1. Inspect the following items for wear, damage 4
or distortion:

– Bearings. 3
– Hub.
– Exciter ring (ABS models). 2
– Hub abutment ring (11).
– Wheel bolts.
– Brake shoe linings. 1 030273
– Brake drums.
If any of these items are found to be 10.20, 10.26 and 11.26 Axles
defective, they must be overhauled or
renewed as instructed in the ‘Workshop
Manual’.

 9809 5–113
 MAINTENANCE OPERATIONS
Rear Axle 55 Series

Reassembly

1. Thoroughly pack or inject the outer and inner

bearings with the correct specification grease.
Apply a light film of grease to the internal
surfaces of the hub; do NOT pack the hub
cavity with grease.

2. Fit the new hub oil seal using the appropriate

procedure:

8.20 Axles
– Apply a light film of lithium grease
(N.L.G.I. Grade 2) to the oil seal bore
within the hub.
– Locate the inner bearing in the hub.
– Using the appropriate oil seal replacer
tool (3), see Data, locate the new oil seal
(2) on the replacer tool ensuring that the
lip of the oil seal is inserted into the tool
recess and that the face marked ‘OIL
SIDE’ faces outwards.
– Insert the replacer tool, complete with oil
5 seal, into the inner bearing and then
locate the driver handle tool (1), see
Data, in the oil seal replacer; press the
new oil seal into the hub.
Note: The oil seal replacer tool positions
the oil seal at the correct depth within in
the hub.
– Apply a light film of silicon grease to the
outside diameter of the abutment ring.
– Position the hub assembly on the axle
case and then fit the outer bearing cone,
keyed thrust washer and adjusting nut.
– Using the hub nut wrench tool, see Data,
slowly tighten the adjusting nut to draw
the hub assembly into position.

5–114  9809
 MAINTENANCE OPERATIONS
55 Series Rear Axle

3
2

1
3 2
030272

 9809 5–115
 MAINTENANCE OPERATIONS
Rear Axle 55 Series

10.20, 10.26 and 11.26 Axles

– Locate the inner bearing in the hub.
– Locate the new oil seal (2) within the hub,
ensuring that the oil seal face marked
‘OIL SIDE’ faces the hub bearing.
– Using driver handle (1) and oil seal
replacer tool (3), see Data, carefully
press the oil seal into position within the
hub.
Note: The oil seal replacer tool positions
the oil seal at the correct depth within in
the hub.
– Position the hub assembly on the axle
case and then fit the outer bearing cone,
keyed thrust washer and adjusting nut.
– Using the appropriate hub nut wrench
tool, see Data, slowly tighten the
adjusting nut to draw the hub assembly
into position.

5–116  9809
 MAINTENANCE OPERATIONS
55 Series Rear Axle

3
2 030277

 9809 5–117
 MAINTENANCE OPERATIONS
Rear Axle 55 Series

3. Adjust the hub end–float using the following

procedure:

– Using the appropriate hub nut wrench

and a suitable torque wrench, tighten the
adjusting nut to the torque figure quoted
in Data.
– Rotate the hub assembly two complete
revolutions to ‘bed’ the hub bearings and
then re–torque the adjusting nut to the
specified torque. Rotate the hub
assembly two complete revolutions.
– Suitably reference mark the hub nut
wrench in relationship with an axle shaft
setscrew fixing hole, then slacken the
adjusting nut two setscrew fixing hole
positions.
– Using a dial test indicator, measure the
hub end–float; if necessary, tighten or
slacken the adjusting nut until the 030171
required end–float is obtained.
– Fit a new lockwasher and then fit the hub
locknut; tighten the locknut to the
5 specified torque Secure the hub nuts in
position with the tabs of the lockwasher.
4. Axles equipped with ABS: Push the sensor
inwards until it just contacts the exciter ring
and then rotate the hub several times to set a
minimum running clearance between the
sensor and exciter ring.

5. Fit the brake drum and tighten the brake drum

setscrews to the torque figure quoted in Data.

6. Apply ‘Loctite 515’ jointing compound to the

joint faces of the hub and axle shaft. Refit the
axle shaft and tighten the axle shaft
setscrews/nuts to the torque figure quoted in
Data.

5–118  9809
 MAINTENANCE OPERATIONS
55 Series Rear Axle

030172

 9809 5–119
 MAINTENANCE OPERATIONS
Rear Axle 55 Series

7. Axles fitted with a differential lock:

– Remove the bolt from the differential lock

cylinder, refit the differential lock switch
and reconnect the cable.
8. If necessary, reset the brake adjusters as
detailed in the ‘Workshop Manual’.

9. Manually apply the spring brake actuators and

tighten the actuator release bolt to the torque
figure quoted in Data.

10. Refit the rear road wheels and torque tighten

the wheel nuts as instructed in the ‘Driver’s
Handbook’.

11. Fully charge the vehicle air system and

repeatedly apply the footbrake until the brake
shoes have been automatically adjusted to
their optimum running clearance, see Data.

Data
5 Grease specification . . . . . . . . . . . . . see Section 3

Hub end–float . . . . . . . . . . . . . . . . . 0,05 to 0,2 mm

Tightening torques:

Hub locknut . . . . . . . . . . . . . . . 122 to 149 Nm

Hub adjustment nut . . . . . . . . . . . . . . 136 Nm
Axle shaft nuts/setscrews:

8.20 axle . . . . . . . . . . . . . . 86 to 102 Nm

All axles except 8.20 . . . 208 to 244 Nm
Brake drum setscrews . . . . . . . . 22 to 44 Nm
Actuator release bolt . . . . . . . . . 15 to 20 Nm
Special tools:

Hub nut wrench:

8.20 axle . . . . . . . . . . . . . . . . . . . 0499805
All axles except 8.20 . . . . . . . . . 0485164
Oil seal replacer:

8.20 axle . . . . . . . . . . . . . . . . . . . 1310453

All axles except 8.20 . . . . . . . . . 1240120
Driver handle . . . . . . . . . . . . . . . . . . . . 0499809
Brake shoe/drum clearance:

11 to 15 tonne models . . . . . . . 0,2 to 2,0 mm

17/18 tonne models . . . . . . . . . 0,8 to 1,2 mm

5–120  9809
 MAINTENANCE OPERATIONS
55 Series Rear Axle

 9809 5–121
 MAINTENANCE OPERATIONS
Suspension 55 Series

CHECKING THE AIR SUSPENSION BELLOWS

Important:
– Do NOT use paraffin (kerosene) or
petroleum based cleaners to clean the air
suspension bellows; failure to observe this
precaution will result in an adverse chemical
reaction (degradation) in the bellows.

– Remove any grease or oil from the air

suspension bellows using methylated spirits
or any other suitable cleaning solvent.

1. Fully charge the vehicle air system and,

using the remote control (1) raise the air
suspension to its maximum ride height.

2. Using a soap and water solution, thoroughly

clean the air suspension bellows (4) and
then check each air suspension bellow as
follows:

– Examine the air suspension bellows for

cracks, damage or deterioration;
5 cracks, splits or cuts are permissible
providing that their depths do NOT
expose the fabric of the bellows. If
necessary, renew the air bellows as
instructed in the ‘Workshop Manual’.
– Check the air suspension bellows,
seating surfaces (3) and air pipe
connections (2) for leakages; rectify as
necessary.
3. After completion of all checks return the
vehicle to its normal ride height.

5–122  9809
 MAINTENANCE OPERATIONS
55 Series Suspension

2
1

4 3
030217

 9809 5–123
 MAINTENANCE OPERATIONS
Suspension 55 Series

CHECKING THE ECAS AIR SUSPENSION SYSTEM

1. Fully charge the vehicle air system and apply

the handbrake.

2. Turn the ignition key to the on position and

check that both ECAS warning lights
momentarily illuminate and then extinguish.

3. Using the ECAS remote control (1) check the

air suspension at each of its pre–set ride
heights, noting:

– Ensure that the red warning light remains

extinguished throughout the tests.
– Ensure that the amber warning light (2)
and the ride height dimensions (‘A’)
attained conform to the following criteria:

Pre–set Warning Dimension

Ride light (‘A’)
Height Condition
Maximum on 466 mm
5 Normal off 325 mm
Minimum on 235 mm

If any possible faults are detected then

the air suspension system MUST be
electronically tested using the ‘DAVIE’
test equipment as instructed in the
‘Workshop Manual’.
4. After completion of all checks return the
vehicle air suspension to its normal ride
height.

5–124  9809
 MAINTENANCE OPERATIONS
55 Series Suspension

1
2

030218 030219

 9809 5–125
 MAINTENANCE OPERATIONS
Lubrication Schedule 55 Series

LUBRICATION DIAGRAMS

General Information
Inject all chassis grease points in accordance
with the relevant lubrication diagram, noting the
following:
– To prevent the ingress of dirt or foreign
particles ensure that all grease nipples and
their surrounding areas are cleaned before
each lubrication service.

– Clean all areas of excess grease after each

lubrication service.

– A hand operated grease gun must be used

to lubricate the propeller shaft universal
joints; the use of high pressure equipment
may result in partial lubrication and possible
damage to the trunnion seals.

– The lubrication diagrams do not identify

ancillary items that require lubrication.
These items include locks, hinges, catches,

5 moving parts/slides, pivots/linkages.

– If the vehicle is steam cleaned it is

recommended that all moving
parts/pivots/linkages and in particular the
alternator pivots and the fuel pump control
linkages are lubricated after the cleaning
operation.

5–126  9809
 MAINTENANCE OPERATIONS
55 Series Lubrication Schedule

2 2

11/15 tonne models 3

1. Steering box universal joint

2. Swivel pins
4
3. Road speed limiter pivot levers

4. Propeller shaft universal joints

5. Spare wheel carrier 5 5

6. Propeller shaft sliding joint 4
6
4

010562

 9809 5–127
 MAINTENANCE OPERATIONS
Lubrication Schedule 55 Series

2 1
2

3 3

4 4
17/18 tonne models 5
1. Steering box universal joint

2. Front brake camshaft

6
3. Swivel pin

4. Track rod ball joint

5 5. Road speed limiter pivot levers 7

6. Propeller shaft universal joint 6
7. Spare wheel carrier 8
8. Propeller shaft sliding joint
6
9. Rear brake camshaft 9 9

010563

5–128  9809
 MAINTENANCE OPERATIONS
55 Series Lubrication Schedule

LUBRICATION PROCEDURES

Steering box universal joint

Inject the grease nipple until clean grease is
seen to exude from the joint.

Swivel pins
To ensure maximum grease penetration when
lubricating the swivel pins, it is recommended
that they are lubricated in a ‘no–load’ condition
5
(i.e. the front axle is jacked until the road wheels
are clear of the ground and suitable supports are
positioned beneath the axle beam).

Inject grease into the upper and lower grease

nipple until clean grease is seen to exude from
the bearings.

 9809 5–129
MAINTENANCE OPERATIONS
Lubrication Schedule 55 Series

020252

020250

5–130  9809
 MAINTENANCE OPERATIONS
55 Series Lubrication Schedule

Propeller shaft universal joints

Using a hand operated grease gun, inject each
grease nipple and ensure that clean grease
exudes from all the trunnion seals on each
universal joint.

050813

If grease does not exude from any of the seals,

proceed as follows:

– Circlip design: Dismantle the universal joint

and investigate the blockage as detailed in
the ‘Workshop Manual’.
5
– Bearing plate design: Slacken the relevant
bearing setscrews (1) and release the
bearing assembly (2) approximately 1,6 mm
to allow the grease to penetrate the
bearing/seal. Torque tighten the bearing
setscrews to 38 to 65 Nm. If releasing the
bearing does not relieve the problem,
dismantle the universal joint and investigate
the blockage as detailed in the ‘Workshop
Manual’.

 9809 5–131
MAINTENANCE OPERATIONS
Lubrication Schedule 55 Series

1 1.6 mm
2

050817

5–132  9809
 MAINTENANCE OPERATIONS
55 Series Lubrication Schedule

Track rod ball joints (if fitted)

To ensure maximum grease penetration when
lubricating the track rod ball joints, it is
recommended that they are lubricated in a
‘no–load’ condition (i.e. the front axle is jacked
until the road wheels are clear of the ground and
suitable supports are positioned beneath the axle
beam).

Inject grease into the nipple until clean grease is

seen to exude from the joint.

020251

Propeller shaft sliding joint

Inject the grease nipple until clean grease is
seen to exude from the sliding joint seal. If a vent
plug is fitted to the yoke end of the sliding joint,
inject the grease nipple until grease is seen to 5
exude from the vent hole. Cover the vent hole
and continue to inject the grease nipple until
grease exudes from the sliding joint seal.
Caution: In cold temperatures drive the vehicle
immediately after lubricating the propeller shafts;
this will force excessive grease from the sliding
joint splines. Failure to carry out this procedure
in cold temperatures could cause the excess
lubricant to harden and force the plug out of the
sliding joint.

 9809 5–133
MAINTENANCE OPERATIONS
Lubrication Schedule 55 Series

050814

5–134  9809
 MAINTENANCE OPERATIONS
55 Series Lubrication Schedule

Road speed limiter

Inject grease into each grease nipple and check
the pivot levers for freedom of movement.

041217

Brake camshafts
Inject each brake camshaft grease nipple with 2
5
to 3 applications of grease.

Data
Grease specification . . . . . . . . . . . . see Section 3

 9809 5–135
MAINTENANCE OPERATIONS
Lubrication Schedule 55 Series

070673

5–136  9809
 Maintenance Manual
55 SERIES

English
Printed in the Netherlands DW036657
1 SUB DIVISION
55 Series

CAB STRUCTURE AND COMPONENTS

1
CAB HYDRAULIC TILT EQUIPMENT
2
CAB MIRROR SETTINGS AND ADJUSTMENTS
3

E9710
1 CAB
55 Series Contents

CONTENTS Page Date

SECTION 1—CAB STRUCTURE AND COMPONENTS

Adjustment:
External Handle Latch Release Mechanism . . . . . . . . . . . . . . . . . . . . . 1— 1 — 35 . . . . . . 9710
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 1 . . . . . . . 9710
Paintwork and Refinishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 37 . . . . . . 9710 1
Removal and Refitment:
Cab Door and Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 28 . . . . . . 9710
Cab Front Mounting Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 7 . . . . . . . 9710
Cab Lock–down Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 2 . . . . . . . 9710
Cab Mounting Lock Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 6 . . . . . . . 9710
Cab Rear Mounting Damper – Coil Spring Type . . . . . . . . . . . . . . . . . 1— 1 — 5 . . . . . . . 9710
Cab Rear Mounting Damper – Shock Absorber Type . . . . . . . . . . . . . 1— 1 — 4 . . . . . . . 9710
Drop Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 20 . . . . . . 9710
Drop Glass Regulator Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 18 . . . . . . 9710
Exterior Door Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 23 . . . . . . 9710
Front Centre Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 32 . . . . . . 9710
Headlamp Grille Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 33 . . . . . . 9710
Headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 30 . . . . . . 9710
Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 25 . . . . . . 9710
Quarter Ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 16 . . . . . . 9710
Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 10 . . . . . . 9710
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 1 — 1 . . . . . . . 9710

E9710 1
1

E9710
2
1 CAB
55 Series Cab structure and components

1. CAB STRUCTURE AND COMPONENTS

DATA

Cab rear mounting damper (shocker absorber type):

Length–closed . . . . . . . . . . . . . . . . . . . . . . . . . 186 " 4 mm
Length–open . . . . . . . . . . . . . . . . . . . . . . . . . . 246 " 4 mm

Torque Tightening Figures Nm 1

Cab lock bracket bolts . . . . . . . . . . . . . . . . . . . . . . 50 to 60
Cab mounting upper bracket bolts . . . . . . . . . . . . 85 to 105
Cab lock–down mechanism mounting
setscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 to 58
Cab front mounting bush/bracket (M14) nuts . . . 135 to 165
Cab mounting centre bolt . . . . . . . . . . . . . . . . . . . . 205 to 245
Cab front mounting bush/bracket to
steering box bracket (M12) setscrews . . . . . . . . 85 to 105
Ram pivot nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 105

CAUTION: Care must be taken when tightening small screws as overtightening may result in damage
to the screw or panel surround.

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE VEHICLE, BOTH BATTERY LEADS MUST BE
DISCONNECTED TO PREVENT ACCIDENTAL OR INADVERTENT STARTING OF THE
ENGINE.

2. DO NOT ATTEMPT TO WORK ON THE VEHICLE WITH THE CAB PARTIALLY TILTED, OR
WITHOUT THE CAB BEING SUITABLY SUPPORTED.

3. TO MAINTAIN VEHICLE STABILITY, DO NOT REMOVE THE REAR AXLE WHILST THE CAB
IS TILTED, NOR ATTEMPT TO TILT THE CAB WITH THE REAR AXLE REMOVED.

E9710 1–1–1
 CAB 1
Cab structure and components 55 Series

REMOVAL AND REFITMENT

Cab Lock–Down Mechanism

To Remove
1. Apply the handbrake to the park position and
chock the road wheels.
1 1
2. Before disconnecting the vehicle battery
supply, ensure that: 5
2
— If applicable, the radio security code is
available to enable the radio to be
re–activated upon completion of all work.
3
— If applicable, disarm the vehicle
immobiliser/alarm.

3. Isolate batteries.

4. Tilt the cab, see “Driver’s Handbook”. 4

5. Disconnect the cab warning light switch cable

at the electrical plug and socket.

6. Position a suitable container under the

hydraulic actuator pipe connection and then
disconnect hydraulic pipe; fit a protective plug
in the hydraulic pipe to prevent ingress of
foreign matter.

7. Remove the nuts and bolts and detach the

lock–down mechanism from the mounting
bracket top plate. A

8. Examine the mounting plate reaction pad for

excessive wear or damage; renew as 8
necessary.
7
To Refit
1. Lightly lubricate all moving parts within the 6
lock–down mechanism with lithium grease 060798

(N.L.G.I. No.2).
FIG.1. CAB LOCKDOWN MECHANISM
2. Remove the protective plug and then connect
the hydraulic pipe the the hydraulic actuator. 1. Lock–down mechanism
2. Hydraulic actuator
3. Hydraulic hose connection
4. Electrical connector
5. Warning light micro–switch
6. Chassis mounted bracket
7. Reaction pad
8. Mounting bracket top plate

Dimension ‘A’ = 3 mm

E9710
1–1–2
1 CAB
55 Series Cab structure and components

3. It is essential that the cab lock–down

mechanism and mounting bracket top plate
are correctly aligned using the following
procedure:

– Locate the cab lock–down mechanism in 1

position on the mounting bracket top
plate and refit the nuts and bolts; do not
tighten at this stage. Ensure that the
mounting bracket top plate is centrally
located within the flanges of the chassis
mounted bracket.
– A clearance of 3 mm must exist
between the reaction pad and chassis
mounted bracket, see Fig.1. To achieve
the required clearance, insert a 3 mm
flat metal spacer between the reaction
pad and chassis mounted bracket.
NOTE: The 3 mm metal spacer must
contact the full length of the reaction
pad.
– Carefully lower the cab fully into position
to align the lock–down mechanism and
then tighten the front nuts and bolts.
Raise the cab and tighten all nuts and
bolts to the torque figure quoted in
DATA.
– Extract the 3 mm spacer and then
lubricate the reaction pad/chassis
mounting bracket contact surfaces with
grease.
4. Connect the warning light switch plug and
socket and ensure that the warning light
switch is in contact with the mechanism;
adjust the switch as necessary.

5. If applicable, re–activate the radio security

code and re–arm the vehicle
immobiliser/alarm.

E9710 1–1–3
 CAB 1
Cab structure and components 55 Series

Cab Rear Mounting Damper –

2
Shock Absorber Type

To Remove
1 1. Apply the handbrake to the park position
and chock the road wheels.
3 4

2. Before disconnecting the vehicle battery

supply, ensure that:
3
— If applicable, the radio security code is
available to enable the radio to be
re–activated upon completion of all
work.
— If applicable, disarm the vehicle
immobiliser/alarm.

3. Isolate the batteries.

4. Tilt cab, see ”Driver’s Handbook”.

1
5. Remove the upper and lower locknuts
securing the shocker absorber to mounting
bracket; retain rubber mountings and plates.

6. Compress the shocker absorber and then

remove it from the mounting bracket; retain
060708
rubber mountings and plates.

To Refit FIG.2. CAB REAR MOUNTING DAMPER –

Reverse removal procedure, noting: SHOCK ABSORBER TYPE

1. If applicable, re–activate the radio security 1. Cab mounting shock absorber

code and re–arm the vehicle 2. Locknut
immobiliser/alarm. 3. Mounting plate
4. Mounting rubber

E9710
1–1–4
1 CAB
55 Series Cab structure and components

Cab Rear Mounting Damper –

Spring Coil Type
1
To Remove
1. Apply the handbrake to the park position and
chock the road wheels. 1
2. Before disconnecting the vehicle battery
supply, ensure that:

— If applicable, the radio security code is

available to enable the radio to be
re–activated upon completion of all work.
— If applicable, disarm the vehicle 5
immobiliser/alarm. 2
3

3. Isolate the batteries.

4. Tilt cab, see “Driver’s Handbook”.

3
6
5. Remove the nuts and bolts and detach the
cab lock–down mechanism from the spring 5 4
coil unit; position the mechanism aside taking
care not to strain the hydraulic pipe. 060709

6. Remove the retaining nut and detach the

FIG.3. CAB REAR MOUNTING DAMPER –
washer, bottom mounting rubber and spacer
SPRING COIL TYPE
washer (if fitted) and detach the mounting
damper assembly; retain the upper mounting 1. Lock–down mechanism
rubber, washer and ferrule. 2. Coil spring unit
3. Mounting washer
7. Remove the reaction pad from the mounting
4. Locknut
bracket top plate.
5. Washer
6. Spacer washer (if fitted)
To Refit
Reverse removal procedure, noting:

1. Examine the reaction pad for wear or

damage; renew as necessary.

2. Refit the lock–down mechanism as instructed

in this Section; ensure that the alignment
procedures are strictly observed.

3. If applicable, re–activate the radio security

code and re–arm the vehicle
immobiliser/alarm.

E9710 1–1–5
 CAB 1
Cab structure and components 55 Series

Cab Mounting Lock Bracket

To Remove
1. Apply the handbrake to the park position
and chock the road wheels.
1
2. Before disconnecting the vehicle battery
supply, ensure that:

— If applicable, the radio security code is

available to enable the radio to be
re–activated upon completion of all
work.
— If applicable, disarm the vehicle
immobiliser/alarm.

3. Isolate the batteries.

4. Tilt cab, see “Driver’s Handbook”.

5. Remove the four bolts securing the bracket

to the underside of the cab frame; withdraw
bracket.

To Refit
Reverse removal procedure, noting:

1. Tighten the cab mounting lock bracket bolts

to the torque figure quoted in DATA.

2. If applicable, re–activate the radio security

code and re–arm the vehicle
immobiliser/alarm.

060344

FIG.4. CAB MOUNTING LOCK BRACKET

E9710
1–1–6
1 CAB
55 Series Cab structure and components

Cab Front Mounting Bushes

To Remove

WARNING: Do NOT attempt to remove both

cab mounting bushes at the same time. One 1
side only MUST be removed and refitted
before removing opposite side. Failure to
observe these precautions may result in
SERIOUS PERSONAL INJURY.

1. Apply the handbrake to the park position

and chock the road wheels.

2. Before disconnecting the vehicle battery

supply, ensure that:

— If applicable, the radio security code is

available to enable the radio to be
re–activated upon completion of all
work.
— If applicable, disarm the vehicle
immobiliser/alarm.

3. Isolate the batteries.

4. Open front panel and secure with stay.

5. Remove front grille panel.

6. Remove headlamp grille panel as instructed

in this Section.

7. Using suitable overhead lifting equipment

support weight of cab to relieve tension
from the cab bush centre bolt; remove
centre bolt.

E9710 1–1–7
 CAB 1
Cab structure and components 55 Series

1 1

7
11

10
3

9
4

8 12 060345

FIG.5. FRONT CAB MOUNTING BUSHES

1. Front grille panel 7. Setscrew (12 mm)

2. Headlamp grille panel 8. Nuts/bolts (14 mm)
3. Pipe support bracket 9. Centre bolt
4. Mounting bracket 10. Bracket and bush assembly
5. Centre bolt 11. Mounting bracket cab mounted
6. Bracket and bush assembly 12. Tilt protection pad

E9710
1–1–8
1 CAB
55 Series Cab structure and components

8. Remove the 14 mm nuts and bolts securing

the RH mounting bracket/bush assembly to
the chassis frame; withdraw bracket and
bush assembly.

9. Remove pipe support bracket from the LH 1

mounting upper bracket and remove upper
mounting bracket from cab frame.

10. Remove the 12 mm setscrews securing the

mounting bracket/bush assembly to the
steering box mounting bracket; withdraw
the mounting bracket/bush assembly.

11. Push out ferrules and remove bushes.

Inspection
1. Examine bushes and ferrules for wear;
renew as necessary.

2. Examine the tilt protection pad for wear; if

worn prise out of bracket and renew.

To Refit
Reverse removal procedure, noting:

1. Tighten the cab front mounting

bush/bracket nuts/setscrews to the torque
figures quoted in DATA.

2. If applicable, re–activate the radio security

code and re–arm the vehicle
immobiliser/alarm.

E9710 1–1–9
 CAB 1
Cab structure and components 55 Series

Windscreen

To Remove
A bonding kit (Part No. BBU 6525) and a
removal kit (Part No. BBU 6581) will be required
1 when replacing windscreens, these can be
obtained from DAF Main Dealers.

WARNING: Removal and refitment of the

windscreen must be carried out using safety
glasses and protective gloves.

1. Apply the handbrake to the park position

and chock the road wheels.

2. Before disconnecting the vehicle battery

supply, ensure that:

— If applicable, the radio security code is

available to enable the radio to be
re–activated upon completion of all
work.
— If applicable, disarm the vehicle
immobiliser/alarm.

3. Isolate the batteries.

4. Raise the front panel and secure in position

with the support stay.

5. Disconnect windscreen washer piping from

the wiper arms, then remove wiper arms.

6. Remove the cab front panel as instructed in

this Section, then remove front grille panel,
lower panel and both corner panels.

7. Prise out the plugs from the grab handles

and remove the retaining screws; detach
the grab handles. Remove the setscrews
on corner panels and remove the
windscreen finisher rail noting clips on the
cab front, see Fig.6.

8. Remove rubber finisher from exterior of

windscreen.

E9710
1–1–10
 1 CAB
55 Series Cab structure and components

4
1
1
3

13

12 7
5
11 6

10

9
8 060713

FIG.6. WINDSCREEN REMOVAL DETAILS

1. Wiper blade and arm assembly 8. Release lever

2. Plugs 9. Lower panel
3. Screws 10. Front centre panel
4. Grab handles 11. Corner panel
5. Retaining screws 12. Finisher rail
6. Hinge screws 13. Front centre panel
7. Nuts

E9710 1–1–11
 CAB 1
Cab structure and components 55 Series

9. Remove air dam rubber from windscreen

interior.
2
10. Cut a length of wire approximately 610 mm
from roll provided in the removal kit. 3
1
11. Guide the cutting wire into clamp opening at
the grip end of guide tool until 13 mm
remains protruding from the clamp opening,
then fully tighten the clamp, see Fig.7.
1
12. Using pliers, push the opposite end of the
cutting wire through the sealant to the
outside of the cab, guide the end of the wire
through the finger guard tube into the clamp
bore hole of the puller tool, then clamp end
2
of wire in tool, see Fig.7. 1
13. Position suction pads on the outside of the
windscreen. Position guide tool in cutting
direction, then insert point of guide tool into
sealant as near as possible to windscreen 060347
flange.

FIG.7. ASSEMBLING CUTTING WIRE IN

TOOLS

1. Guide tool
2. Cutting wire
3. Pulling tool

E9710
1–1–12
1 CAB
55 Series Cab structure and components

14. Pull cutting wire using an even pulling

action, in cutting direction close to the
opening between windscreen and cab.
When end of cutting length is reached,
re–position guide tool as instructed in
operation 12, until sealant is cut completely
2
1
around windscreen aperture, see Fig.8.

15. Withdraw windscreen from cab.

16. Trim sealant remaining on windscreen

aperture to give a flat base for re–glazing.

060346

FIG.8. CUTTING WINDSCREEN SEALANT

1. Guide tool in position

2. Pulling tool in position

E9710 1–1–13
 CAB 1
Cab structure and components 55 Series

To Refit
NOTE: Re–activate the sealant, using the wipe
and primer supplied with the kit. If necessary
apply new sealant to the windscreen aperture.

1 1. Fit internal air dam rubber around

windscreen aperture ensuring it is correctly
positioned.

2. Clean new windscreen, then position

suction pads on outside of screen, invert
screen so that the inside of windscreen is
uppermost.

3. Using solvent supplied with kit, wipe inner

edge of screen, then using primer supplied
with kit, prime inner edge of windscreen and
allow to dry thoroughly.

4. Using applicator gun, apply sealant around

edge of windscreen.

E9710
1–1–14
1 CAB
55 Series Cab structure and components

5. Position windscreen in cab, then position

rubber support blocks under lower edge of
windscreen, see Fig.9. Ensuring
windscreen is correctly positioned, press
screen firmly and evenly around its
periphery to form a good contact. 1
NOTE: Allow sealant to cure for four hours,
then remove rubber support blocks.

6. Fit external rubber finisher, pressing rubber

into windscreen aperture. Trim rubber
finisher at lower corners, then fit
windscreen finisher rail noting clips,
retaining screws, grab handles and plugs.

7. Fit cab corner panels, lower panel and front

grille panel.

8. Connect windscreen washer piping then fit 060348

wiper arms.

9. Fit front panel as instructed in this Section. FIG.9. POSITION OF RUBBER SUPPORT
BLOCKS
10. Allow six to eight hours for the sealant to
fully cure before driving the vehicle.

11. If applicable, re–activate the radio security

code and re–arm the vehicle
immobiliser/alarm.

E9710 1–1–15
 CAB 1
Cab structure and components 55 Series

Quarter Ventilator
3
To Remove 2
1. Remove screw and withdraw drop glass
regulator handle from spline.
1
2. Unscrew the sill button from the link rod.

3. Remove the screws and detach the pull

handle from the door trim panel.
1
4. Remove screws and withdraw interior door
handle.

5. Withdraw door trim panel by carefully

releasing the panel from the door panel
4
retaining clips.

6. Remove the weather sheet from door

060350
panel.

7. Slacken lower pivot retainer screw on inside FIG.10. QUARTER VENTILATOR PIVOT
of door. POINTS

8. Remove screws securing upper pivot 1. Quarter ventilator

retainer to door. 2. Glazing rubber
3. Upper pivot ventilator
9. Ease back glazing rubber and manoeuvre 4. Lower pivot retainer
ventilator, upper pivot retainer and rubber
from aperture.

E9710
1–1–16
1 CAB
55 Series Cab structure and components

To Refit
1. Refit glazing rubber to ventilator.

2. Refit upper pivot retainer over peg on top of

ventilator.
1
3. Locate assembly in door aperture ensuring
glazing rubber is correctly seated.

4. Refit upper pivot screws, tighten screws

securely.

5. Refit lower pivot retainer over peg and

tighten screw securely, close ventilator and
clean glass.

6. Secure the weather sheet to the door panel.

7. Position the door trim panel on the door and

then press the trim panel onto the retaining
clips.

8. Fit the interior door handle and assemble

the pull handle to the trim panel.

9. Screw the sill button onto the link rod.

10. Refit drop glass regulator handle on spline,

ensuring that handle is slightly forward of
vertical when drop glass is fully closed.
Secure the regulator handle in position with
the retaining screw.

E9710 1–1–17
 CAB 1
Cab structure and components 55 Series

Drop Glass Regulator Mechanism 1

To Remove
1. Fully lower the drop glass.

1 2. Remove screw and withdraw drop glass

8
regulator handle from spline.

3. Unscrew the sill button from the link rod.

4. Remove the screws and detach the pull

handle from the door trim panel.

5. Remove screws and withdraw interior door

handle.

6. Withdraw door trim panel by carefully 2

releasing the panel from the door panel
retaining clips.

7 3
7. Remove the weather sheet from door
panel.

8. Remove screws and withdraw regulator

mounting plate with mechanism.
4
6
9. Remove setscrews and detach mechanism 5
from mounting plate. 060351

FIG.11. DROP GLASS CHANNEL

ARRANGEMENT

1. Drop glass channel screws

2. Drop glass
3. Rear channel securing screw
4. Regulator channel
5. Drop glass buffer stop
6. Front channel securing screw
7. Regulator mechanism
8. Glass channel guide

E9710
1–1–18
1 CAB
55 Series Cab structure and components

To Refit
1. Lubricate regulator mechanism and arm
with Lithium grease (N.L.G.I. No.2), then
secure on mounting plate.

2. Locate assembly in door, ensuring 1

mechanism arm engages in regulator
channel, secure mounting plate.

3. Temporarily fit regulator handle and check

operation of drop glass; rectify as
necessary, then remove handle.

4. Secure the weather sheet to the door panel.

5. Position the door trim panel on the door and

then press the trim panel onto the retaining
clips.

6. Fit the interior door handle and assemble

the pull handle to the trim panel.

7. Screw the sill button onto the link rod.

8. Refit drop glass regulator handle on spline,

ensuring that handle is slightly forward of
vertical when drop glass is fully closed.
Secure the regulator handle in position with
the retaining screw.

E9710 1–1–19
 CAB 1
Cab structure and components 55 Series

Drop Glass

To Remove
1. Fully lower drop glass.

1 2. Remove screw and withdraw drop glass

regulator handle from spline.

3. Unscrew the sill button from the link rod.

4. Remove the screws and detach the pull

handle from the door trim panel.

5. Remove screws and withdraw interior door

handle.

6. Withdraw door trim panel by carefully

releasing the panel from the door panel
retaining clips.

7. Remove the weather sheet from door

panel.

8. Remove screws and withdraw regulator

mounting plate with mechanism.

9. Remove lower screw securing front glass

channel to bottom of door, release plug to
gain access to rear channel screw, Fig.11,
release screw.

10. Ease back glass channel guides around

door aperture and remove screws from
channels; manoeuvre channels from door;
check condition of rubbers and renew as
necessary.

11. Withdraw drop glass from door; the inner

waist seal and clips may be dislodged in
process. Renew inner waist seal if worn or
damaged.

E9710
1–1–20
1 CAB
55 Series Cab structure and components

12. Examine glazing rubber in regulator

channel; renew as necessary.

13. Check condition of outer waist seal; renew

1
as necessary.

8 2
1
14. Examine drop glass buffer stop; renew if
worn.

To Refit
1. If removed, refit drop glass buffer stop.

2. Refit glazing rubber in regulator channel, 7

lightly soap rubber and fit assembly to drop
6 3
glass using a rubber mallet or suitable
clamp.

3. Refit inner waist seal and secure with spring

clips.

4. Locate drop glass in door, ensuring inner

waist seal and clips are not disturbed, 5 4 060352

Fig.12.
FIG.12. DROP GLASS SEALING
5. Refit rear glass channel guide, tighten lower ARRANGEMENT
screw securely, then fit plug over rear
channel screw. 1. Drop glass
2. Outer waist seal
6. Manoeuvre glass to one side and locate 3. Door
front glass channel in door, push glass to 4. Regulator channel
engage in rear channel guide. 5. Regulator mechanism arm
6. Regulator channel rubber
7. Refit lower screw in front glass channel and 7. Inner waist seal clip
tighten securely. 8. Inner waist seal

E9710 1–1–21
 CAB 1
Cab structure and components 55 Series

8. Ease back glass channel guides at top of

door aperture, fit and secure screws, push
glass guides into position.

9. Ensure drop glass locates correctly in both

1 front and rear channel guides.

10. Refit outer waist seal.

11. Locate regulator mechanism assembly into

door, ensure arm engages in regulator
channel; secure mounting plate.

12. Temporarily fit regulator handle, check drop

glass operation, rectify as necessary,
remove handle.

13. Secure the weather sheet to the door panel.

14. Position the door trim panel on the door and

then press the trim panel onto the retaining
clips.

15. Fit the interior door handle and assemble

the pull handle to the trim panel.

16. Screw the sill button onto the link rod.

17. Refit drop glass regulator handle on spline,

ensuring that handle is slightly forward of
vertical when drop glass is fully closed.
Secure the regulator handle in position with
the retaining screw.

18. Close and clean drop glass.

E9710
1–1–22
1 CAB
55 Series Cab structure and components

Exterior Door Handle

To Remove
1. Fully lower drop glass.

2. Remove screw and withdraw drop glass 1

regulator handle from spline.

3. Unscrew the sill button from the link rod.

4. Remove the screws and detach the pull

handle from the door trim panel.

5. Remove screws and withdraw interior door

handle.

6. Withdraw door trim panel by carefully

releasing the panel from the door panel
retaining clips.

7. Remove the weather sheet from door

panel.

8. Remove grommet, release nut and back–off

latch adjusting screw.

9. Remove screws from exterior door handle.

10. Release retaining clip and disconnect

exterior release link lock from handle,
private lock will be dislodged in process.

11. Remove nuts and setscrew securing latch

assembly, move latch assembly clear.

12. Manoeuvre exterior door handle and rubber

seal from door.

E9710 1–1–23
 CAB 1
Cab structure and components 55 Series

To Refit
1. Refit exterior door handle and seal, tighten
screws securely.

2. Lubricate latch and private lock barrel with

1 Lithium grease (N.L.G.I. No.2).

3. Locate latch assembly mounting studs

through holes in door, ensuring latch
assembly adjusting screw is positioned on
top of door handle operating lever face. Fit
setscrew and nuts, tighten securely.

4. Refit private lock in exterior handle,

reconnect exterior release link lock and
secure with retaining clip.

5. Set exterior handle latch release

mechanism, see ‘ADJUSTMENT’.

6. Secure the weather sheet to the door panel.

7. Position the door trim panel on the door and

then press the trim panel onto the retaining
clips.

8. Fit the interior door handle and assemble

the pull handle to the trim panel.

9. Screw the sill button onto the link rod.

10. Refit drop glass regulator handle on spline,

ensuring that handle is slightly forward of
vertical when drop glass is fully closed.
Secure the regulator handle in position with
the retaining screw.

11. Raise drop glass ensuring it is correctly

located in channel guides.

E9710
1–1–24
1 CAB
55 Series Cab structure and components

Latch Assembly

To Remove
1. Fully lower drop glass.

2. Remove screw and withdraw drop glass 1

regulator handle from spline.

3. Unscrew the sill button from the link rod.

4. Remove the screws and detach the pull

handle from the door trim panel.

5. Remove screws and withdraw interior door

handle.

6. Withdraw door trim panel by carefully

releasing the panel from the door panel
retaining clips.

7. Remove the weather sheet from door

panel.

8. Disconnect interior release link from interior

door handle assembly.
NOTE: It is not necessary to remove
interior handle assembly unless worn or
damaged; should this be the case, release
the three setscrews and withdraw door
handle assembly.

9. Release plug and gain access to rear glass

channel screw at bottom of door, remove
screw.

10. Ease back glass channel guide around door

aperture and remove screws from rear
glass channel, manoeuvre channel from
door.

11. Release retaining clip and disconnect

exterior release link lock from handle,
private lock will be dislodged in process.

12. Remove setscrews, nuts and washers, then

withdraw latch assembly complete.

E9710 1–1–25
 CAB 1
Cab structure and components 55 Series

To Refit
1. Lubricate latch and interior door handle
assemblies with Lithium grease (N.L.G.I.
No.2).

1 2. Locate latch and interior release handle in

door, pass interior door handle fixing points
through slots in centre of door and sill
button link through top of door, fit setscrews
in interior release handle assembly, do not
tighten at this stage.

3. Refit private lock in exterior handle,

reconnect exterior release link lock and
secure with retaining clip.

4. Refit setscrew and nut to latch assembly,

tighten setscrew and then nuts finger–tight.
Secure setscrew and then nuts, this
procedure will ensure correct positioning of
latch and minimize any installation stresses
to door.

5. Locate rear glass channel into door, fit and

secure lower screw, refit plug over lower
screw.

6. Ease back glass channel guide at top of

door aperture, fit and secure screws, push
glass guide back into position.

7. Reconnect interior release link to handle

assembly, ensure it is secured into
anti–rattle bush.

8. Temporarily fit interior door handle, with no

force applied to handle, set interior release
link lock to dimension shown in Fig.15, inset
C; tighten setscrew securely.

E9710
1–1–26
1 CAB
55 Series Cab structure and components

9. Check operation of handle and latch

assembly, rectify as necessary, see
‘ADJUSTMENT’, remove interior handle.

10. Secure the weather sheet to the door panel.

1
11. Position the door trim panel on the door and
then press the trim panel onto the retaining
clips.

12. Fit the interior door handle and assemble

the pull handle to the trim panel.

13. Screw the sill button onto the link rod.

14. Refit drop glass regulator handle on spline,

ensuring that handle is slightly forward of
vertical when drop glass is fully closed.
Secure the regulator handle in position with
the retaining screw.

15. Raise drop glass ensuring it is correctly

located in channel guides.

E9710 1–1–27
 CAB 1
Cab structure and components 55 Series

Cab Door and Hinges

To Remove
1. Remove screw and withdraw drop glass
regulator handle from spline.
1
2. Unscrew the sill button from the link rod.

3. Remove the screws and detach the pull

handle from the door trim panel.

4. Remove screws and withdraw interior door

handle.

5. Withdraw door trim panel by carefully

releasing the panel from the door panel
retaining clips.

6. Remove the weather sheet from door

panel.

7. Remove screws and withdraw the drop

glass regulator plate/mechanism.

8. Unplug the heated mirror and courtesy light

connectors; remove clips, sleeves and
striker plate, then withdraw the cable from
the door.

9. With the aid of an assistant, support weight

of door.

10. Remove upper and lower setscrews,

withdraw door leaving hinges secured to
cab.

11. If necessary, reference mark the position of

the door hinges, then remove setscrews
securing hinges to cab.

E9710
1–1–28
1 CAB
55 Series Cab structure and components

To Refit
1. If removed, align reference marks made
previously, then refit hinges to cab.

2. With the aid of an assistant, mount the door

onto hinges and secure with setscrews. 1
3. Insert electrical cables into the door, refit
sleeves, clips and striker plate, then
connect electrical cables.

4. Assemble drop glass regulator mounting

plate/mechanism to the door panel.

5. Check that door closes correctly and

locking mechanism is functioning, adjust as
necessary.

6. Secure the weather sheet to the door panel.

7. Position the door trim panel on the door and

then press the trim panel onto the retaining
clips.

8. Fit the interior door handle and assemble

the pull handle to the trim panel.

9. Screw the sill button onto the link rod.

10. Refit drop glass regulator handle on spline,

ensuring that handle is slightly forward of
vertical when drop glass is fully closed.
Secure the regulator handle in position with
the retaining screw.

E9710 1–1–29
 CAB 1
Cab structure and components 55 Series

Headlining

To Remove
1. Before disconnecting the vehicle battery
supply, ensure that:
1
— If applicable, the radio security code is
available to enable the radio to be
re–activated upon completion of all
work.
— If applicable, disarm the vehicle
immobiliser/alarm.

2. Isolate the batteries

3. Extract both courtesy lights from their

apertures and, noting the positions,
disconnect the electrical connections from
the courtesy lights.

4. Vehicles up to Chassis No. L148340:

— If fitted, remove radio.
— Remove screws and spacers securing
sun visors to cab roof and radio
console; detach the sun visors.
— Remove the two screws and detach the
radio console.
Vehicles from Chassis No. L148341:
— Remove the screws retaining the
central sun visor to the centre roof
console and the detach the sun visor.
— Noting their positions, disconnect all
electrical connections from the centre
roof console components.
— Remove the screws securing the
driver’s and passengers sun visors to
the cab roof; detach the sun visors.

5. Remove the plastic retainers securing the

headlining to the cab roof, then manoeuvre
the headlining clear of the cab.

E9710
1–1–30
1 CAB
55 Series Cab structure and components

1
2

3
3

4
6

060786

FIG.13 HEADLINING PANEL TRIM

* 1. Radio console 4. Console retaining screw

** 2. Centre roof console 5. Courtesy light
3. Sun visor retaining screws 6. Headlining plastic retainer

* Up to Chassis No. L148340

** From Chassis No. L148341

E9710 1–1–31
 CAB 1
Cab structure and components 55 Series

To Refit
Reverse the removal procedure, noting:

1. If applicable, re–activate the radio security

code.
1
2. Check the operation of all electrical
components disconnected during the
removal procedure.

3. If applicable, re–arm the vehicle

immobiliser/alarm.

Front Centre Panel

To Remove, Fig.14
1. Push the panel release lever in a sideways
direction to release the internal fasteners.
Raise the front centre panel and secure in
position with the support stay.

2. With the aid of an assistant, support the

front centre panel and then remove the
setscrews securing the front centre panel
hinges to the windscreen finisher rail;
detach the front centre panel.

3. Remove the screws securing the hinges to

the front centre panel; detach the hinges.

To Refit
Reverse removal procedure.

E9710
1–1–32
1 CAB
55 Series Cab structure and components

Headlamp Grille Panel

To Remove
1. Push the panel release lever in a sideways
direction to release the internal fasteners.
Raise the front centre panel and secure in 1
position with the support stay.

2. Release the retaining clip and extract

shunting pin.

3. Remove the screws and partially withdraw

the direction indicator units. Disconnect the
electrical connections and then detach the
direction indicator units.

4. Remove the screws and nuts, noting the

four inner screws on the tread plate, and
then remove headlight grille panel.

To Refit
Reverse removal procedure, noting:

1. Check operation of the direction indicators.

E9710 1–1–33
 CAB 1
Cab structure and components 55 Series

2
2
1

4
4

6
16

15 14 13 12 11 8
10 9 060712

FIG.14. FRONT CENTRE AND HEADLAMP GRILLE PANEL

1. Front centre panel 9. Tread plate

2. Centre panel latch plate 10. Shunting pin
3. Hinge securing setscrews 11. Direction indicator securing screw
4. Centre panel locking peg 12. Direction indicator
5. Release lever 13. Headlamp grille panel setscrews
6. Electrical connector 14. Cable plug
7. Direction indicator 15. Headlamp grille panel
8. Countersunk setscrews 16. Bracket

E9710
1–1–34
1 CAB
55 Series Cab structure and components

ADJUSTMENT

External Handle Latch Release Mechanism

To Adjust, Fig.15
1. Remove latch adjuster grommet (5).

2. Ensure adjusting screw (4) contacts middle 1

of operating lever face (2).

3. Slacken locknut (3) and back–off adjusting

screw (4) to end of its thread.

4. Place fork bolt (6) in engaged position, see

inset ‘A’.

5. Partially open external release handle (12).

6. With handle (12) held open, screw in

adjusting screw (4) until latch hook lever (1)
is lifted clear of fork bolt (6), see ‘X’ insert
‘A’ for tolerance, tighten locknut (3)
securely.

7. Operate interior door handle (15) and check

latch hook lever (1) lifts 1,5 to 2,00 mm
clear of fork bolt (6) before interior door
handle (15) reaches dimension ‘Y’ shown in
insert ‘B’; this dimension plus clearance
dimension ‘Z’ shown in inset ‘C’ is obtained
by slackening setscrews (7) and moving
interior door handle assembly (16) as
necessary. Tighten setscrews (7) after
adjustment is complete.
NOTE: After adjustment, check functions of
sill button link (8) and key lock/unlock
linkage, ensure intermittent lever (19) falls
under hook bolt (18), see inset ‘D’, when
unlock mode is selected.

8. Refit latch adjuster grommet (5).

E9710 1–1–35
 CAB 1
Cab structure and components 55 Series

16
1

1 X Y

14
6
2
5 15 17
16
4 3 A 7 B
8
9
9
10 10
8 15
14 11 14
Z
11 18

13
19 12
11
13
C
D
060360

FIG.15. EXTERIOR HANDLE LATCH RELEASE MECHANISM

X = 1,5 to 2,00 mm Y = 10 mm Z = 1,0 mm

1. Latch hook lever 11. Latch assembly

2. Operating lever face 12. Exterior door handle
3. Locknut 13. Exterior release link lock
4. Adjusting screw 14. Interior release link lock
5. Latch adjuster grommet 15. Interior door handle
6. Fork bolt 16. Interior door handle assembly
7. Setscrew 17. Anti–rattle bush
8. Sill button link 18. Hook bolt
9. Snubbing block 19. Intermittent lever
10. Snubbing tube

E9710
1–1–36
1 CAB
55 Series Cab structure and components

PAINTWORK AND REFINISHING

—Cab and Chassis
Vehicles are available in a wide range of
colours. Details of the three most common
colours can be found at the end of this Section.
Details of the original cab colours can be
obtained from your DAF Main Dealer. In some
instances a temporary wax preservative coat is 1
sprayed over the colour coat. This preservative
protects the vehicle from contamination during
storage and transit, it will stand natural
weathering for a minimum period of three
months.

The following procedures give necessary

information for wax removal, vehicle repair and
respray. A list of proprietary materials available
is included in this Section.

CAUTION: DO NOT use cellulose based paints

and finishing materials as they are incompatible
with the manufacturer’s paint finish.

Removal of Wax Preservative

It is essential that all traces of wax preservative
are removed prior to respraying of vehicle and
transfer application; incomplete removal of wax
results in inadequate adhesion of subsequent
paint coats.

E9710 1–1–37
 CAB 1
Cab structure and components 55 Series

Procedure
1. Wash off any accumulated dirt.

2. Using a soft cloth, apply white spirit to wax.

1 3. Allow film to soften for approximately 30

minutes.

4. Remove wax using wet steam from a steam

generator charged with a suitable
detergent.
Particular care should be taken to ensure
that all wax is removed from surfaces
requiring subsequent refinishing, including
crevices, recesses and underside of frame.

Respraying Complete Vehicle

When cab and/or chassis is required in colours
other than standard range supplied, employ
following procedure:

1. Using white spirit or thinners of subsequent

paint coat; remove wax preservative as
necessary, or thoroughly clean and
degrease complete cab and/or chassis to
be resprayed.

2. Thoroughly wet–flat, with no coarser than

P320 wet–and–dry paper, to provide a key
for new paint. Any damage to underlying
paint coats must be repaired at this stage
using information detailed in ‘Repair
Procedure’; rinse thoroughly and dry.

3. Tack rag to remove all traces of dust.

4. Coat cab with undercoat as necessary.

5. Apply colour coat.

E9710
1–1–38
1 CAB
55 Series Cab structure and components

Repair Procedure
1. Using white spirit or appropriate repair paint
thinners, thoroughly degrease area to be
repaired.

2. Remove all rust, flaking and loose paint; 1

wet–flat affected area with no coarser grade
than P320 wet–and–dry paper, feather
edges to ensure a smooth finish, rinse
thoroughly and dry.

3. Apply a proprietary chemical conversion

coat, as listed in this Section for details
under list of materials available, remove
remaining rust and treat bare metal areas.
CAUTION: DO NOT apply glass reinforced
plastic (GRP) laminate or aluminium.

4. Build up any imperfections (shallow

indentations), gradually using thin layers of
stopper, sand smooth and feather edges.

5. Apply a self–etching primer/filler.

6. Using no coarser than P400 wet–and–dry

paper, de–nib affected area.

7. Tack rag to remove all traces of dust.

8. Apply colour coat, misting–in at edges.

9. After paint has had sufficient time to

harden, apply a smoothing
compound/cutting paste.

10. Finish polish using a soft cloth.

E9710 1–1–39
 CAB 1
Cab structure and components 55 Series

Complete Cab Panel and Chassis Repair

Repeat operations 1 to 7 detailed in ‘Repair
Procedure’ above, ensuring complete panel is
flatted down.

1 8. Apply colour coat, using undercoat as

necessary.

9. Polish cab if required.

E9710
1–1–40
1 CAB
55 Series Cab structure and components

Proprietary List of Materials

NOTE: The following list of materials is included
for guidance only; further information concerning
application, health and safety precautions can
be obtained from the manufacturer.
1
CAUTION: Cellulose based materials must NOT
be used.

Wax removal detergent 10% solution of Ardrox 600

Degreasant White spirit to B.S.245.

Paint thinners, use thinners corresponding to
subsequent paint coat.

Rust removers and metal conditioners Duckhams Jenolite RRPL.

Herberts metal pre–treatment and rust remover
301–2595.
Dupont metal conditioner 5717S.
ICI Deoxidine 125.

Primers and Surfacers Herberts Fastfill Primer 802–0570.

Dupont Self–etch Primer 820R.
Dupont 2 pack High Build Surfacer 1220R.

Finish Paint Herberts CV2K 2 pack Acrylic Enamel.

Herberts Superfleet Polyurethane modified
Alkyd Enamel.
Dupont Centari 700 Transport 2K Polyurethane.
Dupont Centari 500 Vehicle 2K Acrylic.
Standard cab colours and reference
numbers
Colour DAF Ref Herberts Ref Dupont Ref
Brilliant White WE5 13283 47635
Sunset Red RD2 15417 8494
Golden Yellow YW2 14275 47697

Textured Grey Finish paint, used on bumpers etc, is available from DAF Parts, Colour reference
0393761.

DAF Part No:

Paint 0513805
Hardener 0513816
Thinner 0513817

E9710 1–1–41
 CAB 1
Cab structure and components 55 Series

E9710
1–1–42
1 CAB
55 Series Contents

CONTENTS Page Date

SECTION 2—CAB HYDRAULIC TILT EQUIPMENT

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 2 —1 . . . . . . . . 9710
Filling and Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 2 —3 . . . . . . . . 9710
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 2 —2 . . . . . . . . 9710
Overhaul:
Hydraulic Tilt Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 2 —6 . . . . . . . . 9710
Removal and Refitment:
Hydraulic Tilt Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Tilt Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1— 2 —4 . . . . . . . . 9710
1— 2 —5 . . . . . . . . 9710
2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 2 —1 . . . . . . . . 9710

E9710 1
2

E9710
2
1 CAB
55 Series Cab hydraulic tilt equipment

2. CAB HYDRAULIC TILT EQUIPMENT

DATA

Cab Tilt Pump

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weber
Nominal pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 250 bar
Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . 350 to 380 bar

Cab Tilt Ram

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closed length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weber
683 to 689 mm
2
Open length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1133 to 1145 mm
Nominal pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 250 bar

Torque Tightening Figures Nm

Ram pivot nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 105

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE VEHICLE, BOTH BATTERY LEADS MUST BE
DISCONNECTED TO PREVENT ACCIDENTAL OR INADVERTENT STARTING OF THE
ENGINE.

2. DO NOT ATTEMPT TO WORK ON THE VEHICLE WITH THE CAB PARTIALLY TILTED, OR
WITHOUT THE CAB BEING SUITABLY SUPPORTED.

3. TO MAINTAIN VEHICLE STABILITY, DO NOT REMOVE THE REAR AXLE WHILST THE CAB
IS TILTED, NOR ATTEMPT TO TILT THE CAB WITH THE REAR AXLE REMOVED.

4. HYDRAULIC FLUID IS A TOXIC SUBSTANCE WHICH MUST NOT BE CONSUMED OR

ALLOWED TO COME INTO SKIN CONTACT. IN THE EVENT OF SLIGHT SKIN CONTACT OR
INGESTION/INHALATION SEEK MEDICAL ATTENTION IMMEDIATELY.

E9710 1–2–1
 CAB 1
Cab hydraulic tilt equipment 55 Series

GENERAL INFORMATION

The cab is tilted and lowered using a manually 3 2 1 2 3

operated hydraulic tilt pump controlling a
hydraulic ram attached to underside of the cab.
The cab is automatically locked in the down
position by two hydraulically operated locking
mechanisms. When tilting the cab, the locking
mechanisms are automatically disengaged.

2 Each hydraulic lock mechanism incorporates a

micro–switch which activates the cab tilt warning
light (instrument panel mounted) and an audible
warning buzzer whenever a lock–down
mechanism is disengaged.
5

060707

FIG.1. DIAGRAMMATIC VIEW OF THE CAB

HYDRAULIC TILT SYSTEM

1. Cab lock warning light

2. Hydraulic lock mechanism
3. Cab lock warning light switch
4. Hydraulic tilt pump
5. Hydraulic ram

E9710
1–2–2
1 CAB
55 Series Cab hydraulic tilt equipment

FILLING AND BLEEDING PROCEDURE

Cab Tilt Hydraulic System

NOTE: The cab tilt pump and ram are of a
‘self–bleed’ type and come ready filled with
hydraulic fluid. It is recommended that all
hydraulic pipes are ready for connection before
any sealing plugs are removed from the ram or
pump assemblies; this procedure will minimise
hydraulic fluid loss and also reduce time
required to bleed the hydraulic tilt system.
2
1. Operate the hydraulic tilt pump to fully
extend and then fully retract the hydraulic
ram. Repeat this operation three times to
evacuate the air from the cab tilt hydraulic
system.

2. Remove the filler/level plug and check the

hydraulic fluid level. If necessary, top–up
the tilt pump with clean hydraulic fluid of the
correct specification, see Group 0. Refit the
filler/filler plug.

E9710 1–2–3
 CAB 1
Cab hydraulic tilt equipment 55 Series

REMOVAL AND REFITMENT

Hydraulic Tilt Pump

1
To Remove
2
WARNING: DO NOT attempt to work on the
vehicle with the cab tilted.

1. Before disconnecting the vehicle battery

2 supply, ensure that:

— If applicable, the radio security code is

available to enable the radio to be
re–activated upon completion of all
work.
— If applicable, disarm the vehicle
immobiliser/alarm.
3 060710
2. Isolate the batteries.

3. Clean all dirt and grease from pump unit.

FIG.2. HYDRAULIC TILT PUMP
4. Place a suitable container beneath pump
unit. 1. Hydraulic pump
2. Filler/level plug
5. Suitably identify, then disconnect hydraulic 3. Hydraulic pipe
pipes from base of pump and plug pipe
ends to prevent ingress of foreign matter.

6. Remove nuts and bolts securing pump to

chassis frame mounting bracket,
manoeuvre pump from vehicle.

To Refit
Reverse removal procedure, noting:

1. Fill and bleed the cab hydraulic system as

instructed in this Section.

2. If applicable, re–activate the radio security

code and re–arm the vehicle
immobiliser/alarm.

E9710
1–2–4
1 CAB
55 Series Cab hydraulic tilt equipment

Hydraulic Tilt Ram 1

To Remove
1. Before disconnecting the vehicle battery
2
supply, ensure that:

— If applicable, the radio security code is

available to enable the radio to be
re–activated upon completion of all
work. 2
— If applicable, disarm the vehicle 3
immobiliser/alarm.

2. Isolate batteries.

3. Clean all dirt and grease from ram.

4. Place a suitable container beneath ram,

then disconnect hydraulic pipes, plug pipe
ends to prevent ingress of foreign matter.

5. Remove nut and bolt securing ram to upper

bracket.
7
6. Remove nut from lower pivot pin, withdraw
ram from vehicle, noting washer.
4
To Refit 5
Reverse removal procedure, noting:

1. Grease pivot pin before refitment.

060356
6
2. Tighten pivot bolt to torque figure quoted in
DATA.
FIG.3. HYDRAULIC TILT RAM
3. Fill and bleed the cab hydraulic system as
detailed in this Section. 1. Upper mounting bracket
2. Upper pivot nut and bolt
4. If applicable, re–activate the radio security 3. Ram
code and re–arm the vehicle 4. Washer
immobiliser/alarm. 5. Lower pivot nut
6. Hydraulic pipes
7. Lower mounting bracket

E9710 1–2–5
 CAB 1
Cab hydraulic tilt equipment 55 Series

OVERHAUL

Hydraulic Tilt Pump

To Dismantle
1. Remove pump from vehicle.

2. Noting that the reservoir is under spring

pressure, reference mark for reassembly,
then carefully remove the retaining screws
2 and separate from housing body.

3. Remove gasket.

4. Withdraw plunger and grooved ring, spring

retaining washer and spring from plunger
housing.

5. Unscrew plunger housing from housing

body and remove seal and copper washer;
noting seal chamfer faces towards plunger
housing.

6. Withdraw valve block from housing body,

noting ball. Remove copper washer.
NOTE: The valve block is a sealed unit,
housing a pressure relief valve which is
pre–set by the manufacturer, and must
NOT be dismantled.

7. Knock out roll pin securing direction bolt

cross–shaft, carefully withdraw cross–shaft
from housing noting O–rings and seals.

8. Remove circlip and fitted washer securing

handle block assembly. Withdraw handle
block assembly and lifting cam from
reservoir, noting O–rings.

E9710
1–2–6
1 CAB
55 Series Cab hydraulic tilt equipment

7
8

1
2
10
2

11
4

12
27 13
3 14
6 5
15
24 16 19
25 18
26 17

23
22

20
21
060680

FIG.4. EXPLODED VIEW OF PUMP

1. Reservoir 15. Ball

2. Filler/level plug 16. Valve block
3. Handle block 17. Copper washer
4. O–ring 18. O–ring
5. O–ring 19. Seal
6. Lifting cam 20. Direction bolt
7. Split ring 21. Roll pin
8. Spring retaining washer 22. Split ring
9. Spring 23. O–ring
10. Plunger 24. Pump housing
11. Grooved ring 25. Fitted washer
12. Plunger housing 26. Circlip
13. Seal 27. Gasket
14. Copper washer

E9710 1–2–7
 CAB 1
Cab hydraulic tilt equipment 55 Series

Inspection
1. Clean all parts in a suitable solvent and dry
thoroughly.

2. Examine all parts for excessive wear or

damage and renew if necessary.

2 To Reassemble
Reverse dismantling procedure, noting:

1. Renew all items supplied in repair kit.

2. To ease assembly, lightly lubricate parts

with clean hydraulic fluid, noting absolute
cleanliness is essential when assembling
pump.

3. Ensure large hole in valve block aligns with

filter.

E9710
1–2–8
1 CAB
55 Series Contents

CONTENTS Page Date

SECTION 3—CAB MIRROR SETTINGS AND ADJUSTMENTS

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 3 — 4 ........ 9710
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 3 — 1 ........ 9710
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 3 — 2 ........ 9710
Mirror Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1— 3 — 2 ........ 9710

E9710 1
3

E9710
2
1 CAB
55 Series Cab mirror settings and adjustments

3. CAB MIRROR SETTINGS AND ADJUSTMENTS

DATA

Torque Tightening Figures Nm

Detent plate retaining setscrews . . . . . . . . . . . . . . 7,5 to 8,5
Mirror head retaining bolt:
Class 2 and 4 mirrors . . . . . . . . . . . . . . . . . . . 15 to 16
Class 5 mirror . . . . . . . . . . . . . . . . . . . . . . . . . . 7 to 8
Spring clutch locknut . . . . . . . . . . . . . . . . . . . . . . . . 10

E9710 1–3–1
 CAB 1
Cab mirror settings and adjustments 55 Series

INTRODUCTION

All mirrors and mirror arm assemblies fitted to

the 55 Series model range have been adjusted
in the factory to a temporary transit condition. It
is a legal requirement that after the fitment of a
body to the vehicle all mirrors and mirror arm
assemblies are adjusted incompliance with EEC
Directive 88/321. These critical adjustments are
wholly dependent upon the body width of the
vehicle.

To ensure correct settings of the mirror arm

assemblies and to conform to the field of view
3 requirements, see Fig.1, it is essential that all
adjustment procedures are strictly observed.

NOTE: All illustrations shown in this Section

depict a left–hand drive (LHD) vehicle.

MIRROR CLASSIFICATIONS
Throughout this Section the differing types of
vehicle mirrors are identified using the standard
EEC mirror classifications. The following
categories of vehicle mirrors are applicable for
all trucks over 7,5 tonnes:

‘Class 2’ — Main exterior mirror.

‘Class 4’ — Wide angle mirror.
‘Class 5’ — Close proximity mirror.

NOTE: Class 1 (interior) and Class 3 (exterior)

mirror types are for automobile applications only.

E9710
1–3–2
1 CAB
55 Series Cab mirror settings and adjustments

FIG.1. MIRROR FIELD OF VIEW DIAGRAM

A. Class 5 (close proximity) mirror field of view

B. Class 4 (wide angle) mirror field of view
C. Class 2 (main exterior) mirror field of view—passengers side
D. Class 2 (main exterior) mirror field of view—driver’s side

E9710 1–3–3
 CAB 1
Cab mirror settings and adjustments 55 Series

ADJUSTMENT

Initial Setting Requirements A

Before attempting to check or adjust any mirror
assembly, ensure that the following criteria are
established:

1. Obtain an accurate dimension of the

maximum width of the vehicle body.

2. Using the mirror setting charts shown at the

end of this Section, check the following
initial requirements:

3 — Mirror arms are available in varying

lengths to suit a wide range of body
widths. It is essential that the correct
mirror arm combinations are used.
— Class 2 and Class 4 mirror heads are
attached to the mirror arms by an offset
B
fixing enabling a maximum (‘outboard’)
or minimum (‘inboard’) horizontal
protrusion from the mirror arm. When
required, the mirror head(s) must be
removed from the mirror arm, rotated
through 180° and refitted in the
appropriate inboard/outboard position,
see Fig.2; tighten the mirror head
retaining bolt to the torque figure
quoted in DATA.
CAUTION: When changing the inboard
or outboard position of the mirror head,
it will be necessary to remove the
mirror glass and disconnect the
electrical connection from the heating 060787
element. When refitting the mirror
head in its revised position, ensure that
the heating element electrical cable is FIG.2. MIRROR HEAD SETTINGS
NOT pulled taut or put under tension. A —‘Outboard’ position
B —‘Inboard’ position

E9710
1–3–4
1 CAB
55 Series Cab mirror settings and adjustments

3. After completing the initial setting

procedures, it is recommended that the
mirror adjustment procedures are carried
out in the following sequence:

Class 2 and Class 4 Mirrors. Check/

adjust the following:
— Mirror arm angular setting.
— Mirror arm pre–load.
— Mirror head vertical height

—
setting.
Mirror head angular setting.
3
Class 5 Mirrors. Check/adjust the
mirror head setting dimension.

E9710 1–3–5
 CAB 1
Cab mirror settings and adjustments 55 Series

Mirror Arm Angular Settings

Check that the driver’s and passengers mirror
arm angular settings conform to the required
angles prescribed in the mirror setting charts. If
necessary, adjust the angular settings as
follows:

1. Remove the setscrews from the lower

mirror arm shroud cover and then withdraw
the shroud cover to gain access to the
adjustment mechanism, see Fig.3. 1 2 1 060152

3 2. Release the setscrews securing the mirror

arm detent plate, see Fig.4, and then move
FIG.3. LOWER MIRROR ARM SHROUD
COVER
the mirror arm to the prescribed angular
setting. 1. Retaining screws
2. Shroud cover
3. Torque tighten the detent plate retaining
setscrews to the torque figure quoted in
DATA.

4. Check and, if necessary, adjust the mirror

arm pre–load as instructed in ‘Mirror Arm
Pre–Load’.

5. Refit the lower mirror arm shroud cover.

E9710
1–3–6
1 CAB
55 Series Cab mirror settings and adjustments

Mirror Arm Pre–Load

The mirror arms are held in position by a detent
located under the lower mirror shroud. The
detent is fitted with a spring–loaded clutch to
enable the mirror arms to remain in position
during normal driving conditions but enable the
mirror arms to folded forwards or rearwards 1
when manoeuvring the vehicle in a confined
space. 2

Check/adjust the pre–load of each mirror arm

using the following procedure:

1. Remove the setscrews from the lower

3
mirror arm shroud cover and then withdraw
the shroud cover to gain access to the
adjustment mechanism, see Fig.3.
4 3
3 060153
2. Using a spring balance attached centrally to
the mirror vertical arm, check that the force
required to pull the mirror arm off its detent
plate conforms to the figure quoted in the FIG.4. MIRROR ARM DETENT ASSEMBLY
relevant setting chart. 1. Adjusting bolt
2. Spring clutch assembly
3. When required, the mirror arm pre–load can
3. Detent retaining setscrews
be adjusted by releasing the spring clutch
4. Locknut
locknut and rotating the adjusting bolt (see
Fig.4) in the appropriate direction until the
required force (spring balance reading) is
achieved. After adjustment, torque tighten
the spring clutch locknut to the torque figure
quoted in DATA.

E9710 1–3–7
 CAB 1
Cab mirror settings and adjustments 55 Series

Class 2 and Class 4 Mirror Head Settings

Check that all Class 2 (exterior) and Class 4
(wide angle) mirror heads conform to the
following requirements:

1. Check that the vertical height setting of B

each mirror head conforms to the
dimensions shown in Fig.5; adjust as
necessary.
CAUTION: When adjusting the mirror head
ensure that the heating element electrical
cable is NOT pulled taut or put under
3 tension. A C
060788

FIG.5. MIRROR HEAD VERTICAL HEIGHT

SETTINGS

Dimension ‘A’
This setting dimension is applicable to all body
widths:
Dimension ‘A’ = 288 mm (ex–factory
setting). If required, this setting can be
adjusted within the allowable setting range
of 273 mm (minimum) to 488 mm
(maximum).

Dimension ‘B’
All vehicles with a 2,338 to 2,42 m body width
and fitted with a 324 mm mirror arm length:
Dimension ‘B’ = 320 mm

All other body widths and mirror arm lengths:

Dimension ‘B’ = 289 mm

Dimension ‘C’
All vehicles with a 2,338 to 2,42 m body width
and fitted with a 324 mm mirror arm length:
Dimension ‘C’ = 288 mm

All other body widths and mirror arm lengths:

Dimension ‘C’ = 273 mm

E9710
1–3–8
1 CAB
55 Series Cab mirror settings and adjustments

2. Check that each mirror head conforms to

the prescribed angular position as shown in
the mirror setting charts. If required, the
mirror head to mirror arm attachment can
be slackened (to aid adjustment) or
tightened (to secure in position) using the
following procedure, see Fig.6:
— Using a small screwdriver or equivalent
inserted into the slot provided, release
the trim cover (1) and then extract it
from its slotted location in the mirror
head.
— As applicable, release/tighten the
3
mirror head retaining bolt (2); tighten
the retaining bolt to the torque figure
quoted in DATA.
— Ensure that, after completion of all
adjustments, the mirror head(s) is
secured in position on the mirror arm.
— When refitting the mirror head trim
cover ensure that it is correctly located
within its slotted location and that it is
firmly pushed into its engaged position;
no gaps must exist between the trim FIG.6. MIRROR HEAD ATTACHMENT
cover (slotted end) and mirror head.
1. Trim cover
2. Attachment bolt

E9710 1–3–9
 CAB 1
Cab mirror settings and adjustments 55 Series

Class 5 Mirror Head Setting

Check that the Class 5 (close proximity) mirror
head has been adjusted to the required setting
A
dimension shown in Fig.7. Adjust the mirror
head as necessary and then tighten the mirror
head retaining bolt to the torque figure quoted in
DATA.

3
060706

FIG.7. CLASS 5 MIRROR HEAD

ADJUSTMENT DIAGRAM

A = 110 mm

E9710
1–3–10
1 CAB
55 Series Cab mirror settings and adjustments

Mirror Setting Chart — Driver’s Side,

see Fig.8

Mirror Arm Angular Settings Spring Balance

y Width
Body Mirror Head
Length Reading
(metres) ‘A’ ‘B’ Setting
(mm) (kgf)
2,338 to 2,4 * 270 14.50° 26° Inboard 6,4 to 7,3
2,4 to 2,5 * 270 10.63° 28.5° Outboard 7,7 to 8,6
2,5 to 2,55 382 21.49° 24° Inboard 9,1 to 10
2,55 to 2,6 382 24.43° 26° Outboard 9,1 to 10 3
* Standard factory fitment (unless otherwise specified)

060789

FIG.8. MIRROR SETTING DIAGRAM — DRIVER’S SIDE

A. Mirror arm angular setting B. Mirror head angular setting

E9710 1–3–11
 CAB 1
Cab mirror settings and adjustments 55 Series

Mirror Setting Chart — Passengers Side,

see Fig.9

Mirror Arm Angular Settings Spring Balance

y Width
Body ** Mirror Head
Length Reading
(metres) ‘C’ ‘D’ ‘E’ Setting
(mm) (kgf)
2,338 to 2,36 * 324 +30.5° 35.5° 30° Inboard 6,4 to 7,3
2,36 to 2,42 * 324 +32° 36.3° 31° Outboard 7,7 to 8,6
2,42 to 2,45 * 324 –7° 39.5° 31° Inboard 7,7 to 8,6
3 2,45 to 2,50 * 324 –17.5° 40.5° 31.5° Outboard 7,7 to 8,6
2,50 to 2,55 * 324 –8° 40° 35° Outboard 7,7 to 8,6
2,50 to 2,52 * 324 –15° 41.5° 33° Inboard 9,1 to 10
2,52 to 2,55 * 382 –8° 40° 32° Inboard 9,1 to 10
2,55 to 2,58 * 382 –7° 41° 34° Inboard 9,1 to 10
2,58 to 2,60 * 382 –12° 41° 34° Outboard 9,1 to 10
* Standard factory fitment (unless otherwise specified).
** This position is applicable to both Class 2 and Class 4 mirrors.

E9710
1–3–12
1 CAB
55 Series Cab mirror settings and adjustments

C+

E
D

3
2

C-
E
D

060790

FIG.9. MIRROR SETTING DIAGRAM — PASSENGERS SIDE

Inset 1 = 2,338 to 2,420 metre body widths C. Mirror arm angular setting
Inset 2 = 2,420 to 2,600 metre body widths D. Class 2 mirror head angular setting
E. Class 4 mirror head angular setting

E9710 1–3–13
 CAB 1
Cab mirror settings and adjustments 55 Series

E9710
1–3–14
9 SUB DIVISION
55 Series

FRAME
1
SUSPENSION
2
AIR SUSPENSION (ECAS)
3

E9611
9 FRAME & SUSPENSION
55 Series Contents

CONTENTS Page Date

SECTION 1—FRAME
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 1 — 1 . . . . . . . . 9611
Torque Tightening Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 1 — 3 . . . . . . . . 9611

E9611 1
1

E9611
2
9 FRAME & SUSPENSION
55 Series Frame

1. FRAME
INTRODUCTION

General Information
The frame is a ladder–type rivetted and bolted
construction consisting of deep section
side–members and pressed steel
cross–members.
1
Frame Fastenings
All nuts and bolts used on the frame assembly
are to metric standards and, therefore, ensure
that any frame fastenings are not interchanged
with those from other components during
maintenance operations.

Where specified high grade flanged nuts and

bolts are incorporated in the frame assembly.
When using high grade flanged nuts and bolts
the following instructions must be strictly
adhered to:

— High grade flanged bolts MUST be used

with high grade flanged nuts; under no
circumstances must a lower grade nut or
bolt be substituted where a high grade
flanged fastening is specified.

— High grade flanged nuts and bolts must be

kept clean, dry and free from oil or grease
prior to assembly.

— The security of all frame fastenings must be

checked at each service interval using the
appropriate torque tightening chart.

Chassis Frame
Do NOT weld or subject the chassis frame to a
severe localised heat source. Failure to observe
this precaution may result in irreparable damage
to the material structure of the chassis frame
with a consequent loss in chassis frame
strength.

Welding or drilling of the chassis frame must

NOT be undertaken without the prior written
consent of DAF Limited. Unauthorised,
indiscriminate welding or drilling may adversely
affect the safe load–carrying characteristics of
the chassis frame.

E9611 9–1–1
 FRAME & SUSPENSION 9
Frame 55 Series

TORQUE TIGHTENING FIGURES

All nuts, bolts and screws used on the 55 Series

range of vehicles are to metric standards.
Medium/high tensile fasteners used in the
manufacture and assembly of the vehicles

1 generally fall into one of the following three

categories:

— Property Class 8.8 fixings: Normally plain

hexagon, zinc finish, metric coarse threads,
dry condition.

— Property Class 10.9 fixings: Mainly flange

hexagon, zinc finish, metric fine threads,
lubricated condition.

— Interchangeability requirements for

proprietary equipment dictates that some
Property Class 10.9 fixings use zinc finish,
metric coarse threads, dry condition.

Service Information
To obtain the correct pre–tension when nuts and
bolts are re–used, clean the nut and bolt threads
with a suitable solvent and dry thoroughly. Apply
one drop of clean engine oil to the leading
thread of the bolt and one drop to the bearing
face of the bolt or nut. This lubrication
instruction also applies to new bolts obtained
from the store.

Refer to the following tables, unless otherwise

stated, for all torque tightening figures. The
figures quoted apply to flanged or standard
hexagon headed nuts, bolts and screws.

For standard fastenings, apply the lubricant prior

to fitting and tighten to the relevant torque figure
quoted in the tables.

For special fastenings, apply the lubricant prior

to fitting and tighten to the torque figure quoted
in the relevant section of the ‘Workshop
Manual’.

E9611
9–1–2
9 FRAME & SUSPENSION
55 Series Frame

Property Class: 10.9 Bolt, 10 Nut

Torque Tightening
Size Figure
Nm 1
M8 25 to 29
M10 50 to 60
M12 85 to 105
M14 135 to 165
M16 205 to 245
M18 295 to 345
M20 405 to 475
M22 565 to 665
M24 710 to 830
M27 1020 to 1200

Property Class: 8.8 Bolt, 8 Nut

Torque Tightening
Size Figure
Nm
M4 2,3 to 2,7
M5 4,7 to 5,5
M6 7,9 to 9,3
M8 19 to 23
M10 39 to 45
M12 70 to 80
M14 105 to 125
M16 165 to 195
M18 230 to 270
M20 320 to 380
M22 440 to 520
M24 550 to 650
M27 820 to 960
M30 1100 to 1300

E9611 9–1–3
1

E9611
9–1–4
9 FRAME & SUSPENSION
55 Series Contents

CONTENTS Page Date

SECTION 2—SUSPENSION
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 1 . . . . . . . . 9611
Removal and Refitment:
Front Anti–Roll Bar/Link Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 11 . . . . . . . 9611
Front Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 2 . . . . . . . . 9611
Front Spring Eye Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 7 . . . . . . . . 9611
Front Spring Eye Bush/Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 8 . . . . . . . . 9611
Front Spring Hanger Bracket Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 9 . . . . . . . . 9611
Rear Anti–Roll Bar Bearing Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Anti–Roll Bar/Link Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
9— 2 — 26 . . . . . . .
9— 2 — 23 . . . . . . .
9611
9611
2
Rear Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 14 . . . . . . . 9611
Rear Spring Eye Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 19 . . . . . . . 9611
Rear Spring Eye Bush/Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 20 . . . . . . . 9611
Rear Spring Hanger Bracket Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 21 . . . . . . . 9611
Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 2 — 27 . . . . . . . 9611

E9611 1
2

E9611
2
9 FRAME & SUSPENSION
55 Series Suspension

2. SUSPENSION
DATA

Front spring assembly:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taperleaf (parabolic)
Number of leaves:
11 and 12 tonne GVW vehicles . . . . . . . One
13 to 15 tonne GVW vehicles . . . . . . . . Two
16 to 18 tonne GVW vehicles . . . . . . . . Three

Rear spring assembly:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of leaves (all models) . . . . . . . . . . .
Taperleaf (parabolic)
Two with underslung parabolic helper spring 2
Shock absorbers:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double acting, telescopic
Open length . . . . . . . . . . . . . . . . . . . . . . . . . . 714 to 722 mm
Closed length . . . . . . . . . . . . . . . . . . . . . . . . . . 438 to 446 mm

Torque Tightening Figures Nm

Shock absorber mounting nuts . . . . . . . . . . . . . . . 47 to 57 Nm
Shackle bolt nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 to 245
Shackle bush/pin clamp bolts . . . . . . . . . . . . . . . . 85 to 105
U–bolt nuts:
Front axle (16 mm) ..................... 205 to 230
Front axle (20 mm) ..................... 440 to 490
Rear axle (20 mm) ..................... 440 to 490
Rear axle (22 mm) ..................... 508 to 560

Front anti–roll assembly:

Link arm ball joint nut . . . . . . . . . . . . . . . . . . . 75 to 85
Link arm mounting bracket bolt . . . . . . . . . . . 205 to 245
Location clamp nut . . . . . . . . . . . . . . . . . . . . . 19 to 23

Rear anti–roll bar assembly:

Link arm bracket nuts . . . . . . . . . . . . . . . . . . . 85 to 105
Flexible bush pin flanged bolts . . . . . . . . . . . 85 to 105

E9611 9–2–1
 FRAME & SUSPENSION 9
Suspension 55 Series

REMOVAL AND REFITMENT

Front Spring Assembly

To Remove
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.
2 2. Disconnect the batteries.

3. Tilt the cab as instructed in the ‘‘Driver’s

Handbook”.

4. Chock the rear road wheels.

5. Remove the retaining nut and bolt and

disconnect the anti–roll bar link arm from
the chassis mounting bracket; pull the link
arm clear of the spring assembly.

6. Disconnect the shock absorber from the

shock absorber mounting bracket/spring
seat and fully compress the shock
absorber.

7. Slacken the spring shackle bolt nuts and

the clamp bolts securing the spring eye pin.

8. Position suitable supports beneath the

anti–roll bar and then remove the U–bolt
nuts. Detach the U–bolts and spring
saddle/bump stop.
NOTE: The U–bolts are of differing lengths;
the front U–bolt is a longer length to
accommodate the anti–roll bar mounting
bracket.

E9611
9–2–2
9 FRAME & SUSPENSION
55 Series Suspension

9. Temporarily secure the anti–roll bar to the

axle bracket with a suitable nut and bolt.
Remove the support from the anti–roll bar.

10. Jack up the axle and position suitable

supports under the chassis frame. Lower
the axle until the chassis frame is resting on
the supports.

11. Remove the bolts from the spring eye 2

bush/pin clamps.

12. Remove the retaining nut and then extract

the lowermost spring shackle bolt. Position
the spring shackle clear of the spring
assembly.
NOTE: To enable the shackle bolt to be
withdrawn, it may be necessary to further
lower the axle to relieve the tension from
the bolts.

13. Lower the spring assembly to enable the

spring eye bush/pin clamps to be released
from their dowelled location on the spring
hanger bracket; remove the clamps from
the spring eye bush/pin.

14. With the weight of the front spring assembly

suitably supported, lower the axle assembly
sufficiently to enable the spring assembly to
be withdrawn.

15. Detach the shock absorber mounting

bracket/spring seat from the axle.

E9611 9–2–3
 FRAME & SUSPENSION 9
Suspension 55 Series

3 4 7
8
1 2

9
10

11 14
6 12
5 15
17
13 16
010248

FIG.1. EXPLODED VIEW OF THE FRONT SPRING ASSEMBLY

(Twin Leaf Suspension illustrated)

1. Spring shackle 10. Spring saddle/bump stop

2. Spring hanger shackle bush 11. Centre bolt
3. Spring shackle 12. Spring assembly
4. Spring shackle bolt 13. Shock absorber mounting
5. Spring eye shackle bush bracket/spring seat
6. Spring shackle nut 14. Dowel pin
7. U–bolt 15. Spring eye clamp
8. U–bolt (long) 16. Spring eye clamp bolt
9. Flange nut 17. Spring eye bush/pin

E9611
9–2–4
9 FRAME & SUSPENSION
55 Series Suspension

To Refit
1. Position the shock absorber mounting
bracket/spring seat on the axle.

2. Locate the clamps on each side of the

spring eye bush/pin, ensuring that the slots
in the clamps face rearwards.

3. Locate the front spring assembly into

position on the axle; ensure that the spring
centre bolt head is correctly located in the
2
spring seat.

4. With the anti–roll bar suitably supported,

remove the temporary nut and bolt securing
the anti–roll bar to the axle.

5. Fit the spring saddle/bump stop to the

spring assembly.

6. Locate the U–bolts, ensuring that the longer

length U–bolt is fitted in the forward
position (through the anti–roll bar bracket).
Fit the U–bolt nuts; do not torque tighten at
this stage.

7. Jack the front axle until the until the spring

eye bush/pin clamps locate in the hanger
bracket dowel pins. Fit the clamp bolts; do
NOT tighten at this stage.

8. Align the shackle and fit the lowermost the

shackle bolt; fit the nut to the shackle bolt,
but do NOT tighten at this stage.

E9611 9–2–5
 FRAME & SUSPENSION 9
Suspension 55 Series

9. Deflect the front spring assembly by jacking 1

the front axle until a dimension of 170 mm
can be measured between the bottom of
the bump stop reaction plate and the top of
the bump stop/U–bolt bracket, see Fig.2.
When the required spring deflection
dimension is attained, tighten the shackle
bolt nuts and spring eye pin clamp bolts to
2 the torque figures quoted in DATA.
NOTE: The quoted deflection setting
dimension is applicable to both single and
twin leaf suspension systems.

10. Tighten the U–bolt nuts to the torque figure 2 A

quoted in DATA.

11. Connect the anti–roll bar link arm to the 3

chassis mounting bracket and tighten the
retaining nut to the torque figure quoted in
DATA.

12. Reconnect shock absorber to the mounting

bracket/spring seat; tighten the retaining nut
to the torque figure quoted in DATA.

13. Reconnect the batteries.

010249

14. If applicable, re–activate the radio security

code. FIG.2. FRONT SPRING DEFLECTION
SETTING

A = 170 mm
1. Chassis frame
2. Reaction plate
3. Bump stop

E9611
9–2–6
9 FRAME & SUSPENSION
55 Series Suspension

Front Spring Eye Bush

To Remove
1. Remove spring as instructed in this Section.

2. Press the bush from the spring eye.

To Refit
1. Press a new bush into the spring eye. 2
2. Refit spring to vehicle as instructed in this
Section.

E9611 9–2–7
 FRAME & SUSPENSION 9
Suspension 55 Series

Front Spring Eye Bush/Pin

To Remove
1. Remove spring as instructed in this Section.

2. Press the spring eye bush/pin from the

spring eye.

2 To Refit
1. Press a new spring eye bush/pin into the
spring eye.

2. Refit spring to vehicle as instructed in this

Section.

E9611
9–2–8
9 FRAME & SUSPENSION
55 Series Suspension

Front Spring Hanger Bracket Bush

To Remove
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries. 2

3. Chock the rear road wheels.

4. Disconnect the shock absorber from the

shock absorber mounting bracket/spring
seat and fully compress the shock
absorber.

5. Slacken the spring shackle bolt nuts and

spring eye pin clamp bolts .

6. Jack up axle and place suitable supports

beneath the chassis frame. Lower the axle
until the chassis frame is resting on the
supports.

7. Remove the spring hanger shackle bolt and

position the shackle clear of the spring
hanger bracket.
NOTE: To enable the shackle bolt to be
withdrawn, it may be necessary to further
lower the axle to relieve the tension from
both shackle bolts.

8. Press the bush from the spring hanger

bracket.

E9611 9–2–9
 FRAME & SUSPENSION 9
Suspension 55 Series

To Refit
1. Press a new bush into the spring hanger
bracket.

2. Align the shackle and fit the spring hanger

the shackle bolt; fit the nut to the shackle
bolt, but do NOT tighten at this stage.

2 3. Deflect the front spring assembly by jacking

the front axle until a dimension of 170 mm
can be measured between the bottom of
the bump stop reaction plate and the top of
the bump stop/U–bolt bracket, see Fig.2.
When the required spring deflection
dimension is attained, tighten the shackle
bolt nuts and spring eye pin clamp bolts to
the torque figures quoted in DATA.
NOTE: The quoted deflection setting
dimension is applicable to both single and
twin leaf suspension systems.

4. Reconnect shock absorber to the mounting

bracket/spring seat; tighten the retaining nut
to the torque figure quoted in DATA.

5. Reconnect the batteries.

6. If applicable, re–activate the radio security

code.

E9611
9–2–10
9 FRAME & SUSPENSION
55 Series Suspension

Front Anti–Roll Bar/Link Arm Assembly

Service tool: 0485122

To Remove (Fig.4)
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.
2
2. Disconnect the batteries.

3. Tilt the cab as instructed in the ‘‘Driver’s

Handbook”.

4. Chock the rear road wheels.

5. Remove the retaining nut and bolt and

disconnect the anti–roll bar link arms from
each chassis mounting bracket; pull the link
arms clear of the spring assembly.

6. Position suitable supports beneath the

anti–roll bar.

7. Remove the front U–bolt nuts securing the

anti–roll bar mounting bracket to the axle
and then manoeuvre the anti–roll bar and
link arm assembly from the vehicle.

8. Remove the retaining nut from each link

arm ball joint and, using ball joint separator
0485122, remove each ball joint from the
anti–roll bar. Extract the bushes and metal
ferrule from the link arm.

9. Remove the location clamps from the

anti–roll bar and extract the bearings from
the anti–roll bar brackets; detach the
bearing brackets from anti–roll bar.

E9611 9–2–11
 FRAME & SUSPENSION 9
Suspension 55 Series

To Refit
Reverse removal procedure, noting:

1. Check and, if necessary, adjust the length

of the link arm/ball joint assembly to the
setting dimension ‘‘A”, see Fig.3, and then
tighten the ball joint locknut.

2 2. Tighten the U–bolt nuts and the link arm

ball joint nut and mounting bracket nut to
the torque figures quoted in DATA.

010251

FIG.3. LINK ARM/BALL JOINT SETTING

DIMENSION

A = 295 to 299 mm

E9611
9–2–12
9 FRAME & SUSPENSION
55 Series Suspension

8 9
10
1

11
2
2

3 5
6

12
13 7
14
15

16

17
18

010250

FIG.4. EXPLODED VIEW OF THE FRONT ANTI–ROLL BAR/LINK ARM ASSEMBLY

1. Link arm mounting bracket — RH 10. Mounting bracket

2. Link arm assembly — RH 11. Nut
3. Mounting bracket — RH 12. Bush
4. Anti–roll bar 13. Metal ferrule
5. Link arm mounting bracket — LH 14. Bush
6. Mounting bracket assembly — LH 15. Link arm
7. Link arm assembly — LH 16. Locknut
8. Location clamp 17. Ball joint
9. Bearing 18. Nut

E9611 9–2–13
 FRAME & SUSPENSION 9
Suspension 55 Series

Rear Spring Assembly

To Remove
WARNING: To maintain vehicle stability it is
imperative that the following precautions are
strictly adhered to:

— Do NOT attempt to remove the rear

2 springs whilst the cab is tilted.

— Do NOT attempt to tilt the cab whilst the

rear springs are removed.

Failure to observe these precautions may

cause the vehicle to become unstable.

1. Before disconnecting the vehicle battery

supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries.

3. Chock the front road wheels.

4. Remove the retaining bolt and release the

load sensing valve linkage attachment
bracket from the rear axle; reference mark
the applicable bolt hole in the bracket to aid
refitment.

5. Disconnect the shock absorber from the

axle clamp bracket and then fully compress
the shock absorber.

6. Remove the anti–roll bar as instructed in

this Section.

7. Slacken the spring shackle bolt nuts and

the spring eye pin clamp bolts.

E9611
9–2–14
9 FRAME & SUSPENSION
55 Series Suspension

8
2 7
1 3

11
6 9
1
12
13
4
5

14
10 15

010252

FIG.5. EXPLODED VIEW OF THE REAR SPRING ASSEMBLY

1. Spring shackle 6. Centre bolt 11. Spring eye bush/pin

2. Spring hanger bracket bush 7. Spring saddle 12. Dowel pin
3. Shackle bolt 8. U–bolt 13. Wear pad
4. Spring eye bush 9. Flanged nut 14. Spring bush/pin clamp
5. Flanged nut 10. Spring seat 15. Flanged bolt

E9611 9–2–15
 FRAME & SUSPENSION 9
Suspension 55 Series

8. Remove U–bolt nuts and detach the

U–bolts, spring saddle and axle clamp
bracket.

9. Jack up the rear axle and position suitable

supports beneath the chassis frame. Lower
the rear axle until the chassis frame is
resting on the supports.
2 10. Remove the bolts from each spring eye pin
clamp.

11. Remove the retaining nut and then extract

the spring hanger shackle bolt through the
access hole in the chassis frame.
NOTE: To enable the shackle bolt to be
withdrawn, it may be necessary to further
lower the axle to relieve the tension from
the bolts.

12. With the weight of the spring assembly

suitably supported, lower the rear axle
sufficiently to enable the spring assembly to
be withdrawn.

13. Lower the spring assembly to enable the

spring eye bush/pin clamps to be released
from their dowelled location on the spring
hanger bracket; remove the clamps from
the spring eye bush/pin.

14. Remove the retaining nut and extract the

spring eye shackle bolt, complete with
spring shackle; manoeuvre the spring
assembly from the vehicle. Retain the
spring seat.

E9611
9–2–16
9 FRAME & SUSPENSION
55 Series Suspension

To Refit
1. Position the spring seat on the axle casing.

2. Attach the shackle and spring eye shackle

bolt to the spring assembly; align the
shackle in a vertical position. Fit the
retaining nut to the shackle bolt but do NOT
tighten at this stage.

3. Position the clamps on the spring eye 2

bush/pin, ensuring that the slot in each
clamp faces rearwards.

4. Locate the rear spring assembly into

position on the rear axle; ensure that the
spring centre bolt head is correctly located
in the spring seat.

5. Fit the spring saddle, U–bolts, axle clamp

bracket and U–bolt nuts; do not torque
tighten at this stage.

6. Jack the rear axle until the spring bush/pin

clamps locate in the hanger bracket dowel
pins. Fit the clamp bolts but do NOT tighten
at this stage.

7. Align the shackle with spring hanger

bracket. Insert the shackle bolt through the
access hole in the chassis frame and into
the spring hanger bracket. Fit the retaining
nut to the shackle bolt but do NOT tighten
at this stage.

E9611 9–2–17
 FRAME & SUSPENSION 9
Suspension 55 Series

8. Deflect the rear spring assembly by jacking 1

the rear axle until a dimension of 410 mm
can be measured between the top of the
chassis frame and the bottom edge of the
helper spring, see Fig.6. When the required
spring deflection dimension is attained,
tighten the shackle bolt nuts and spring eye
bush/pin clamp bolts to the torque figures
A
2 quoted in DATA.
2
9. Tighten the U–bolt nuts to the torque figure
quoted in DATA.

10. Refit the anti–roll bar as instructed in this

Section.

11. Fit the shock absorber to the axle clamp

bracket and tighten the retaining nut to the
torque figure quoted in DATA. 3

12. Refit the load sensing valve linkage

attachment bracket to the axle, ensuring
that the correct bolt hole in the bracket is
utilised.

13. Reconnect the batteries. 010253

14. If applicable, re–activate the radio security FIG.6. REAR SPRING ASSEMBLY
code. DEFLECTION SETTING

A = 410 mm
1. Chassis frame
2. Spring saddle
3. Spring seat

E9611
9–2–18
9 FRAME & SUSPENSION
55 Series Suspension

Rear Spring Eye Bush

To Remove
1. Remove the rear spring assembly as
instructed in this Section.

2. Press the bushes from the spring.

To Refit 2
Reverse the removal procedure.

E9611 9–2–19
 FRAME & SUSPENSION 9
Suspension 55 Series

Rear Spring Eye Bush/Pin

To Remove
1. Remove the rear spring assembly as
instructed in this Section.

2. Press the spring bush/pin from the spring.

2 To Refit
Reverse the removal procedure.

E9611
9–2–20
9 FRAME & SUSPENSION
55 Series Suspension

Rear Spring Hanger Bracket Bush

To Remove
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries. 2

3. Chock the front road wheels.

4. Disconnect the shock absorber from the

axle clamp bracket and then fully compress
the shock absorber.

5. Slacken the spring shackle bolt nuts and

the spring eye bush/pin clamp bolts.

6. Jack up the rear axle and position suitable

supports beneath the chassis frame. Lower
the rear axle until the chassis frame is
resting on the supports.

7. Remove the retaining nut and then extract

the spring hanger shackle bolt through the
access hole in the chassis frame; position
the shackle clear of the spring hanger
bracket.
NOTE: To enable the shackle bolt to be
withdrawn, it may be necessary to further
lower the axle to relieve the tension from
the bolts.

8. Press the bush from the spring hanger

bracket.

E9611 9–2–21
 FRAME & SUSPENSION 9
Suspension 55 Series

To Refit
1. Press the new bush into the spring hanger
bracket.

2. Align the shackle with spring hanger

bracket. Insert the shackle bolt through the
access hole in the chassis frame and into
the spring hanger bracket. Fit the retaining
2 nut to the shackle bolt but do NOT tighten
at this stage.

3. Deflect the rear spring assembly by jacking

the rear axle until a dimension of 410 mm
can be measured between the top of the
chassis frame and the bottom edge of the
helper spring, see Fig.6. When the required
spring deflection dimension is attained,
tighten the shackle bolt nuts and spring eye
bush/pin clamp bolts to the torque figures
quoted in DATA.

4. Fit the shock absorber to the axle clamp

bracket and tighten the retaining nut to the
torque figure quoted in DATA.

5. Reconnect the batteries.

6. If applicable, re–activate the radio security

code.

E9611
9–2–22
9 FRAME & SUSPENSION
55 Series Suspension

Rear Anti–Roll Bar/Link Arm Assembly

To Remove (Fig.8)
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries. 2

3. Chock the road wheels.

4. Position suitable supports beneath the

anti–roll bar.

5. Remove the flanged bolts securing the

anti–roll bar flexible bush pins to the axle
clamp bracket.

6 Remove the nuts and bolts and separate

the link arm brackets.

7. Remove the flexible bearings from the link

arm brackets.

8. Manoeuvre the anti–roll bar assembly from

the vehicle.

9. Press the flexible bush pins out of the

anti–roll bar.

E9611 9–2–23
 FRAME & SUSPENSION 9
Suspension 55 Series

To Refit
Reverse removal procedure, noting:

1. Press the flexible bush pins into the anti–roll 3. Reconnect the batteries.
bar bores to the angular and dimensional
settings shown in Fig.7. 4. If applicable, re–activate the radio security
code.
2. Tighten the anti–roll bar flexible bush pin
2 flanged bolts and the link arm bracket nuts
to the torque figures quoted in DATA.

C
B B 010255

FIG.7. ANTI–ROLL BAR FLEXIBLE BUSH PIN SETTINGS

A = 856 to 862 mm
B = Both dimensions must be equal within 2 mm
C = 10° " 1.0°

E9611
9–2–24
9 FRAME & SUSPENSION
55 Series Suspension

4
3
2

5 2

7
9

10
8

10
13

12 11
010254

FIG.8. REAR ANTI–ROLL BAR ASSEMBLY

1. Circlip — outer 8. Link arm plate assembly — LH

2. Bearing pin 9. Axle clamp bracket assembly — LH
3. Thrust washer 10. Flexible bearing
4. Circlip — inner 11. Link arm bracket
5. Axle clamp bracket assembly — RH 12. Flange bolt
6. Link arm plate assembly — RH 13. Flexible bush pin
7. Anti–roll bar

E9611 9–2–25
 FRAME & SUSPENSION 9
Suspension 55 Series

Rear Anti–Roll Bar Bearing Pin

To Remove
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.
2 2. Isolate the batteries.

3. Chock the road wheels.

4. Position suitable supports beneath the

anti–roll bar.

5 Remove the nuts and bolts and separate

the link arm brackets, complete with the
flexible bearings.

6. Remove the inner circlip and detach the

thrust washer from bearing pin.

7. Remove the outer circlip and extract the

bearing pin from its chassis mounting
bracket.

To Refit
Reverse removal procedure, noting:

1. Tighten the link arm bracket nuts to the

torque figures quoted in DATA.

2. Reconnect the batteries.

3. If applicable, re–activate the radio security

code.

E9611
9–2–26
9 FRAME & SUSPENSION
55 Series Suspension

Shock Absorbers

To Remove
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries. 2

3. Chock the road wheels.

4. Front shock absorbers: Tilt cab as

instructed in the ‘‘Driver’s Handbook”.

5. Remove the lower mounting nut, compress

shock absorber to release the mounting
stud from the mounting bracket; retain
mounting rubbers and washers.

6. Remove the upper mounting nut and

withdraw the shock absorber from the
vehicle; retain mounting rubbers and
washers.

To Refit
Reverse removal procedure, noting:

1. Tighten the shock absorber mounting nuts

to torque figure quoted in DATA

2. Reconnect the batteries.

3. If applicable, re–activate the radio security

code.

E9611 9–2–27
 E9611
9–2–28
9 FRAME & SUSPENSION
55 Series Contents

CONTENTS Page Date

SECTION 3—AIR SUSPENSION

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 16 . . . . . . . 9611
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 1 . . . . . . . . 9611
Removal and Refitment:
Air Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 7 . . . . . . . . 9611
Electro–Pneumatic Regulating Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 14 . . . . . . . 9611
Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 12 . . . . . . . 9611
Lower Torque Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 9 . . . . . . . . 9611
Lower Torque Rod Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 11 . . . . . . . 9611
Rear Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 2 . . . . . . . . 9611
Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9— 3 — 15 . . . . . . . 9611
3

E9611 1
3

E9611
2
9 FRAME & SUSPENSION
55 Series Air Suspension

3. AIR SUSPENSION
DATA

Spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taperleaf

Number of leaves . . . . . . . . . . . . . . . . . . . . . . . . . . One
Shock absorbers:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Telescopic

Torque Tightening Figures Nm

Shock absorber mounting bolt . . . . . . . . . . . . . . . 125 to 160
Spring to air spring cross–member retaining bolt . . 405 to 475
U–bolt nuts (dry thread condition) . . . . . . . . . . . . 508 to 560
Air spring attachment:
Air spring cross–member retaining nut . . . . 27 to 40 3
Air spring mounting bracket to chassis
retaining nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 405 to 475
Load sensor mounting bracket locknuts . . . . . . . 440 to 520
Lower torque rod retaining bolts . . . . . . . . . . . . . . 205 to 245

E9611 9–3–1
 FRAME & SUSPENSION 9
Air Suspension 55 Series

REMOVAL AND REFITMENT

IMPORTANT: Before attempting any work on

the components of the air suspension system, it
is essential that electronic test equipment
‘DAVIE 2.0’ and the ”System Manual ECAS–2”
(Part Number DW032071) are available to
enable the adjustment of the vehicle ride height
and to test/re–program the ECAS system.

Rear Spring Assembly

To Remove

3 WARNING: Do NOT attempt to remove the

rear spring assemblies whilst the cab is
tilted nor attempt to tilt the cab whilst the
spring assemblies are removed. Failure to
observe these precautions may cause the
vehicle to become unstable.

1. Apply the handbrake and chock the front

road wheels.

2. Using the ECAS remote control unit, fully

deplete (lower) the air springs.

3. Before disconnecting the vehicle battery

supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

4. Disconnect the batteries.

5. Slacken, but do not remove, the road wheel

nuts.

6. Jack the rear of the vehicle and support the

chassis frame using suitable chassis
stands.

E9611
9–3–2
9 FRAME & SUSPENSION
55 Series Air Suspension

1 2 1 3

3
5

7
13
9
10

12
11 010463

FIG.1. REAR SPRING ASSEMBLY

1. Spacer 8. Spring seat

2. Rebound roller 9. Lower torque rod
3. Thrust washer 10. Axle clamp
4. U–bolt 11. Height sensor bracket
5. Spring saddle 12. Air spring cross–member
6. Shim 13. Shock absorber
7. Spring leaf

E9611 9–3–3
 FRAME & SUSPENSION 9
Air Suspension 55 Series

7. Remove the road wheel nuts and detach

the road wheels.

8. Jack the rear axle sufficiently to relieve the

weight of the rear axle from the spring
assembly.

9. Remove the lower shocker absorber

mounting bolt and then compress the shock
absorber clear of the spring assembly.

10. Remove the nut, bolt and washers securing

3 the rebound roller assembly within the
spring front mounting:
NOTE: The rebound roller assembly
comprises of the rebound roller, spacers
and offset thrust washer.

11. Remove the bolts securing the spring to the

air spring cross–member.

12. Remove the locknuts securing the height

sensor bracket to the spring U–bolt; detach
the bracket and move aside.

13. Remove the retaining nuts and bolts

securing the lower torque rod to the axle
clamps and spring front mounting bracket;
detach the lower torque rod.
NOTE: The lower torque rod bush fitted to
the front spring mounting is offset.

14. Remove the spring U–bolt nuts and detach

the axle clamps. Withdraw the U–bolts and
detach the spring saddle and shim.

15. Lower the rear axle sufficiently to allow the

spring assembly to be removed and then
manoeuvre the spring from the vehicle.

E9611
9–3–4
9 FRAME & SUSPENSION
55 Series Air Suspension

To Refit
1. Ensure that the spring seat is correctly
engaged with the locating lugs on the axle
casing.

2. Jack the rear axle as necessary to enable

the spring assembly to be manoeuvred into
position on the rear axle seat. Ensure that
the front and rear ends of the spring are
correctly located in their respective
positions within the front mounting bracket
and the air spring cross–member.

3. Position the shim and spring saddle on the

3
spring assembly. Fit the U–bolts and axle
clamp and then torque tighten the U–bolt
nuts to the torque figure quoted in DATA.

4. Fit the lower torque rod to the axle clamps

and spring front mounting bracket; ensure
that the offset bush is fitted to the front
mounting bracket. Tighten the torque rod
retaining nuts to the torque figure quoted in
DATA.

5. Attach the height sensor bracket to the

spring U–bolt; tighten the bracket locknuts
to the torque figure quoted in DATA.

6. Fit the spring to air spring cross–member

retaining nut and tighten to the torque figure
quoted in DATA.

E9611 9–3–5
 FRAME & SUSPENSION 9
Air Suspension 55 Series

7. Locate the spacer, rebound roller, spacer

and thrust washer within the spring front
mounting, ensuring that the thrust washer is
fitted to the outside edge of the mounting
bracket with it flat edge uppermost. Secure
the rebound assembly in position with the
retaining bolt, nut and washers; tighten the
retaining nut to the torque figure quoted in
DATA.

8. Position the shock absorber lower mounting

in position on the air spring cross–member
3 and then fit the shocker absorber mounting
bolt; tighten the mounting bolt to the torque
figure quoted in DATA.

9. Fit the road wheels. Tighten the road wheel

nuts to the required torque and in the
required sequence as instructed in the
‘Maintenance Manual’.

10. Jack the vehicle and remove the supports

and chassis stands; lower the vehicle to the
ground.

11. Connect the batteries.

12. Fully inflate (raise) the air suspension using

the ECAS remote control unit.

13. Check and, if necessary, adjust the initial

vehicle ride height as instructed in
‘ADJUSTMENT’.
IMPORTANT: The vehicle ride height must
also be programmed using DAVIE 2.0 as
instructed in the ”System Manual ECAS–2”.

14. If applicable, re–activate the radio security

code.

E9611
9–3–6
9 FRAME & SUSPENSION
55 Series Air Suspension

Air Spring
1
To Remove
NOTE: Replacement air springs are only 5
available as an assembly consisting of the air
spring, piston piece and chassis frame mounting
bracket.
2
1. Apply the handbrake and chock the front
road wheels.
3
2. Fully deplete the vehicle air system.

3. Using the ECAS remote control unit,

4 3
exhaust all the air from the air springs.

4. Before disconnecting the vehicle battery

supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

5. Disconnect the batteries.

010464

6. Disconnect the air supply pipe from the air

spring. FIG. 2. AIR SPRING ASSEMBLY

7. Remove the flanged nuts securing the air 1. Mounting bracket.

spring mounting bracket to the chassis 2. Air spring
frame. 3. Piston piece
8. Remove the retaining bolt securing the air 4. Air spring retaining nut
spring to air spring cross–member. 5. Retaining bolt and nut

9. Jack the rear of the vehicle sufficiently to

enable the air spring assembly to be
removed and support the chassis frame
using suitable chassis stands. Remove the
air spring.

E9611 9–3–7
 FRAME & SUSPENSION 9
Air Suspension 55 Series

To Refit
Reverse the removal procedure, noting:

1. Tighten the air spring mounting bracket to

chassis frame flanged nuts and bolts to the
torque figure quoted in DATA.

2. Tighten the air spring to air spring

cross–member retaining bolt to the torque
figure quoted in DATA.

3. Check and, if necessary, adjust the initial

3 vehicle ride height as instructed in
‘ADJUSTMENT’.
IMPORTANT: The vehicle ride height must
also be programmed using DAVIE 2.0 as
instructed in the ”System Manual ECAS–2”.

4. If applicable, re–activate the radio security

code.

E9611
9–3–8
9 FRAME & SUSPENSION
55 Series Air Suspension

Lower Torque Rod

To Remove
1. Apply the handbrake and chock the front
road wheels.

2. Before disconnecting the vehicle battery

supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

3. Disconnect the batteries. 3

4. Remove the retaining nuts and bolts
securing the lower torque rod to the axle
clamps and spring front mounting bracket;
detach the lower torque rod.
NOTE: The lower torque rod bush fitted to
the front spring mounting is offset.

010469

FIG.3. LOWER TORQUE ROD REMOVAL

E9611 9–3–9
 FRAME & SUSPENSION 9
Air Suspension 55 Series

To Refit
Reverse the removal procedure, noting:

1. Fit the lower torque rod to the axle clamps

and spring front mounting bracket; ensure
that the offset bush is fitted to the front
mounting bracket, see Fig.4. Tighten the
torque rod retaining nuts to the torque
figure quoted in DATA.

2. If applicable, re–activate the radio security

code.
3 A

010468

FIG.4. LOWER TORQUE ROD BUSH

ALIGNMENT

A = 10°

E9611
9–3–10
9 FRAME & SUSPENSION
55 Series Air Suspension

Lower Torque Rod Bushes

To Remove

1. Remove the lower torque rod as instructed

in this Section.

2. Press out the lower torque rod bushes.

To Refit
Reverse the removal procedure, noting:

1. Before pressing in new bushes ensure that

3
they are correctly aligned as follows:

— The torque rod bush that will be fitted

to the spring front mounting bracket
must have its axis offset by 10°
(anti–clockwise) to the axis of the
torque rod, see Fig.4.

— The torque rod bush that will be fitted

to the axle clamps must have its axis
perpendicular to the axis of the torque
rod, see Fig.4.

E9611 9–3–11
 FRAME & SUSPENSION 9
Air Suspension 55 Series

Height Sensor
2
To Remove
1. Before disconnecting the vehicle battery 3
supply, ensure that, if applicable, the radio 1 4
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries.

3. Disconnect the electrical connection from

3 the height sensor.

4. Remove the setscrew retaining the

operating lever to the height sensor
moveable core; detach the operating lever.

5. Remove the bolts securing the height

sensor to the chassis frame; detach the
height sensor.
010465

FIG.5. HEIGHT SENSOR

1. Electrical connection
2. Height sensor
3. Moveable core
4. Operating lever

E9611
9–3–12
9 FRAME & SUSPENSION
55 Series Air Suspension

To Refit 1
Reverse the removal procedure, noting:

1. The height sensor moveable core is fitted

with an alignment spline. The horizontal
position of the alignment spline will vary
dependent upon the location of the height
sensor on the chassis frame (LH or RH
side). It is essential that the height sensor
moveable core is rotated until the alignment
spline is in the correct position before fitting
the operating lever. Align the moveable core
as follows: 3
— LH chassis side: If necessary, rotate
the moveable core until the alignment
spline is in the 3 o’clock position (i.e.
facing the rear of the vehicle), see
Fig.6.
— RH chassis side: If necessary, rotate
the moveable core until the alignment
2
spline is in the 9 o’clock position (i.e.
facing the front of the vehicle), see
Fig.6.

NOTE: When the alignment spline is in the

required horizontal position, the sensor core
can be locked in position by inserting a
010466
4mm bar through the holes provided in the
sensor core.
FIG.6. HEIGHT SENSOR CORE ALIGNMENT
2. Check and, if necessary, adjust the initial
vehicle ride height as instructed in 1. Height sensor – LH chassis side
‘ADJUSTMENT’. 2. Height sensor – RH chassis side
IMPORTANT: The vehicle ride height must
be programmed using DAVIE 2.0 as
instructed in the ”System Manual ECAS–2”.

3. If applicable, re–activate the radio security

code.

E9611 9–3–13
 FRAME & SUSPENSION 9
Air Suspension 55 Series

Electro–Pneumatic Regulating Unit

To Remove
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries.

3. Fully deplete the vehicle air system.

3 4. Noting their positions, disconnect the
electrical connections from the unit.

5. Noting their positions, disconnect the air

supply pipes from the unit.

6. Remove the bolts securing the unit to the 010472

chassis frame; detach the unit.

FIG.7. ELECTRO–PNEUMATIC REGULATING
UNIT
To Refit
Reverse the removal procedure, noting:

1. Ensure that all air pipes and electrical

connections are refitted to their original
positions

2. Connect the batteries and fully charge the

air system.

3. Check and, if necessary, adjust the initial

vehicle ride height as instructed in
‘ADJUSTMENT’.
IMPORTANT: The vehicle ride height must
be programmed using DAVIE 2.0 as
instructed in the ”System Manual ECAS–2”.

4. If applicable, re–activate the radio security

code.

E9611
9–3–14
9 FRAME & SUSPENSION
55 Series Air Suspension

Shock Absorbers

To Remove
1. Apply the handbrake and chock the front
road wheels.

2. Using the ECAS remote control unit,

position the chassis to the normal ride
height position.

3. Remove the lower shocker absorber

mounting nut and extract the mounting bolt.
Compress the shock absorber clear of the
spring assembly.
3
4. Remove the upper shocker absorber
mounting bolt and detach the shock
absorber.

To Refit
Reverse the removal procedure, noting:

1. Tighten the shock absorber mounting bolts

to the torque figure quoted in DATA. 010470

FIG.8. SHOCKER ABSORBER

E9611 9–3–15
 FRAME & SUSPENSION 9
Air Suspension 55 Series

ADJUSTMENT

Initial Vehicle Ride Height

Service tools: 03905301 (2 required)

1. Park the vehicle on level ground and ensure

that the tyre pressures are correct.

2. Using the ECAS remote control unit, raise

the chassis to maximum height.

3 3. Attach the height setting tools 03905301 to

either side of the chassis frame as follows:

— Insert the two tubes of each height

setting tool 03905301 into the axle
bump stop bracket, see Fig.9.

— Using the ECAS remote control, lower 1

the chassis until the chamfered tube on
each setting tool abuts the rear axle 2
casing and holds the weight of the 010467
chassis.

4. Detach the setting linkage from the height

FIG.9. HEIGHT SETTING TOOL 03905301
sensor lever.
1. Bump stop
5. Insert a 4mm pin through the hole in the
sensor core to prevent the sensor lever 2. Tool 03905301
from moving out of the zero (horizontal)
position.

6. Adjust the setting linkage sufficiently to

allow it to be re–connected to the height
sensor lever. Extract the pin from the
sensor core.

7. With the setting tools still in position,

program the vehicle ride height as
instructed in ”System Manual ECAS–2”.

E9611
9–3–16
8 SUB DIVISION
55 Series

DRIVING HEAD AND REAR AXLE ASSEMBLY

1
HUB ASSEMBLY
2
DRIVING HEAD – 10.28
3
DRIVING HEAD – 8.20, 10.20, 10.26 and 11.26
4

E9611
8 REAR AXLE
55 Series Contents

CONTENTS Page Date

SECTION 1—DRIVING HEAD AND REAR AXLE ASSEMBLY

Removal and Refitment:
Driving Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8—1—1 . . . . . . . . . 9611
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8—1—5 . . . . . . . . . 9611
Rear Axle (Air suspension vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8—1—9 . . . . . . . . . 9611
1

E9611 1
1

E9611
2
8 REAR AXLE
55 Series Driving head and rear axle assembly

1. DRIVING HEAD AND REAR AXLE ASSEMBLY

REMOVAL AND REFITMENT

Driving Head

To Remove
1. Isolate the batteries and chock the front
road wheels.
1
2. Drain oil from the axle casing, refer to the
‘Maintenance Manual’.

3. Jack the rear of the vehicle until the road

wheels are clear of the ground; position
suitable supports beneath the axle.

4. 8.20, 10.26 and 11.26 Axles Fitted With A

Differential Lock:
Engage the differential lock.
Disconnect the cable from the differential
lock switch.
Remove the differential lock switch, then
screw a suitable 16 mm bolt into the switch
bore to retain the differential lock in the
engaged position.
Deplete the air system, depress the quick
release sleeve and disconnect the air pipe
from the differential lock cylinder.

5. 10.28 Axles Fitted With A Differential Lock:

Deplete the air system, depress the quick
release sleeve and disconnect the air pipe
from the differential lock cylinder.
Remove the pipe adapter, then screw a
suitable 12 mm bolt into the adapter bore to
engage the differential lock.
DO NOT force the bolt if resistance is felt;
this indicates that the sliding clutch is not
correctly aligned with the fixed clutch on the
differential cage. Slowly rotate the hub (lock
side) and continue tightening the bolt to fully
engage the differential lock.

E9611 8–1–1
 REAR AXLE 8
Driving head and rear axle assembly 55 Series

6. Remove the axle shaft retaining

setscrews/nuts and lever the shaft flange
from the hub to break the joint seal.
Withdraw the shafts and clean the joint

1 faces.

7. Disconnect the propeller shaft from the axle

coupling flange and suspend the shaft from
a convenient point on the chassis.

8. 8.20, 10.20, 10.26 and 10.28 Axles only:

Disconnect the brake pipes (metal) from the
spring brake actuators and Tee piece.

9. Detach the Tee piece/air supply pipe

bracket assembly from the driving head and
position clear.

10. Attach a suitable lifting cradle to the driving

head and support the weight of the
assembly.

11. Remove retaining nuts and bolts and then

manoeuvre the driving head from the axle
casing and clear of the vehicle.

12. Clean the joint faces of the axle casing and

driving head.

E9611
8–1–2
8 REAR AXLE
55 Series Driving head and rear axle assembly

2 1
1

030234

FIG.1. DRIVING HEAD REMOVAL DETAILS

(8.20 Axle illustrated)
1. Air pipes (metal) 4. Propeller shaft
2. Tee piece/air supply pipe bracket 5. Differential lock switch
3. Driving head 6. Differential lock air pipe

E9611 8–1–3
 REAR AXLE 8
Driving head and rear axle assembly 55 Series

To Refit
Refitment is a reversal of the removal
procedure, noting:

1. Apply ‘Loctite 515’ jointing compound to the

1 joint faces of the axle casing, driving head
casing, hubs and axle shafts.

2. Tighten the driving head retaining nuts and

bolts to the following torque figures:
8.20 Axle . . . . . . . . . . . . . . . . . . 81 to 101 Nm
(60 to 74 lbf ft).
10.20, 10.26 , 10.28 and
11.26 Axles . . . . . . . . . . . . . . . 202 to 252 Nm
(149 to 186 lbf ft).

3. Tighten the axle shaft setscrews/nuts to the

following torque figures:
Axle shaft nuts . . . . . . . . . . . . . 86 to 102 Nm
(63 to 75 lbf ft).
Axle shaft setscrews . . . . . . . 208 to 244 Nm
(153 to 180 lbf ft).

4. Tighten the propeller shaft/coupling flange

bolts to 107 to 119 Nm (79 to 88 lbf ft).

5. Refill axle with correct grade of oil, see the

‘Maintenance Manual’.

E9611
8–1–4
8 REAR AXLE
55 Series Driving head and rear axle assembly

Rear Axle Assembly

To Remove
1. Isolate the batteries, chock the front road
wheels and deplete the air system.
1
2. If necessary, drain the axle, refer to the
‘Maintenance Manual’.

3. Slacken the road wheel nuts, jack the axle

until the wheels are clear of the ground,
position suitable supports beneath the
chassis frame and remove the wheels.

4. Manually release the spring brake

actuators.

5. Disconnect the propeller shaft from the axle

coupling flange and suspend the shaft from
a convenient point on the chassis frame.

6. Remove nuts securing the shock absorbers

to the axle brackets, fully compress the
shock absorbers and retain the mounting
rubbers and washers.

7. Remove the ant–roll bar as detailed in

Group 9.

8. Axles Fitted With A Differential Lock:

Depress the quick release sleeve and
disconnect the air pipe from the differential
lock cylinder.
Unscrew the cap and disconnect the cable
from the differential lock switch.

9. Disconnect the air supply pipes from the

Tee pieces.

10. Detach the load sensing valve bracket from

the axle casing, note position of the fixing
bolt hole.

E9611 8–1–5
 REAR AXLE 8
Driving head and rear axle assembly 55 Series

3
6
4

1 2

030186

FIG.2. REAR AXLE REMOVAL/REFITMENT DETAILS

1. Axle clamp/shock absorber bracket 6. Air supply pipes

2. Shock absorber 7. Spring seat
3. U–bolts 8. Locating lug
4. Spring saddle 9. Load sensing valve bracket
5. Anti–roll bar assembly

E9611
8–1–6
8 REAR AXLE
55 Series Driving head and rear axle assembly

11. Using suitable trolley jacks or cradle,

support the weight of the axle assembly.

12. Remove the U–bolt nuts, axle clamp/shock

absorber brackets, U–bolts and spring
saddles. Lower and withdraw the axle from 1
the rear of the vehicle; retain the spring
seats.

To Refit
1. Place the spring seats on the axle, ensure
the slots in the spring seats are correctly
engaged with the locating lugs on the axle
casing. Manoeuvre the axle into position, fit
the spring saddles, U–bolts, axle
clamp/shock absorber brackets and U–bolt
nuts. Tighten the U–bolt nuts to the
following torque figures:

11 to 15 tonne Vehicles:
440 to 490 Nm (325 to 362 lbf ft)
16 to 18 tonne Vehicles:
508 to 560 Nm (374 to 413 lbf ft)
NOTE: The above torque figures apply to
U–bolts in an oiled thread condition.

2. Assemble the load sensing valve bracket to

the axle casing.

3. Reconnect the air supply pipes to the Tee

pieces.

4. Fit the shock absorbers to the axle brackets

and tighten the retaining nuts to 47 to 57 Nm
(35 to 42 lbf ft).

5. Axles Fitted With A Differential Lock:

Connect the cable to the differential lock
switch and the air pipe to the cylinder.

6. Connect the propeller shaft to the axle

coupling flange; tighten the coupling flange
bolts to 107 to 119 Nm (79 to 88 lbf ft).

E9611 8–1–7
 REAR AXLE 8
Driving head and rear axle assembly 55 Series

7. Manually re–apply the spring brake

actuators.

8. Refit the anti–roll bar as detailed in

Group 9.
1
9. Fit road wheels ensuring the tyre valves are
opposed 180° to each other; tighten the
wheel nuts evenly but do not torque at this
stage.

10. Jack up axle and remove the supports from

beneath the chassis frame; lower the
vehicle to the ground and tighten the wheel
nuts to the correct torque and in the correct
sequence as detailed in the ‘Maintenance
Manual’.

11. If necessary, refill the axle with the correct

grade of oil, refer to the ‘Maintenance
Manual’.

12. Reconnect the batteries and recharge the

air system.

13. If necessary, adjust the load sensing valve

as detailed in Group 6, ‘Brakes’.

E9611
8–1–8
8 REAR AXLE
55 Series Driving head and rear axle assembly

Rear Axle Assembly

Air Suspension Vehicles

To Remove
1. Isolate the batteries, chock the front road
wheels and deplete the air system. 1
2. If necessary, drain the axle, refer to the
‘Maintenance Manual’.

3. Using the ECAS remote control unit,

exhaust all air from the suspension bellows.

4. Slacken the road wheel nuts, jack the axle

until the wheels are clear of the ground,
position suitable supports beneath the
chassis frame and remove the wheels.

5. Manually release the spring brake actuators.

6. Disconnect the propeller shaft from the axle

coupling flange and suspend the shaft from
a convenient point on the chassis frame.

7. Axles Fitted With A Differential Lock:

Depress the quick release sleeve and
disconnect the air pipe from the differential
lock cylinder.
Unscrew the cap and disconnect the cable
from the differential lock switch.

8. Disconnect the air supply pipes from the Tee

piece and elbows at the driving head bracket.

E9611 8–1–9
 REAR AXLE 8
Driving head and rear axle assembly 55 Series

1 2

1 1

7
6

4
5

030235

FIG.3. REAR AXLE REMOVAL/REFITMENT DETAILS

(Air suspension vehicles)

1. Lower torque rod 5. U–bolts

2. Propeller shaft 6. Air supply pipes
3. Height sensor link–arm bracket 7. Upper torque rod
4. Axle clamp

E9611
8–1–10
8 REAR AXLE
55 Series Driving head and rear axle assembly

9. Using suitable trolley jacks or cradle,

support the weight of the axle assembly;
position suitable packing beneath the air
suspension support crossmember.

10. Remove nuts and bolts and detach the

lower torque rods from the front hanger
1
bracket and axle clamps.
NOTE: The lower torque rod bush secured
to the front hanger bracket is offset.

11. Detach the upper torque rod from the axle

pivot and chassis bracket.

12. Remove locknuts and release the height

sensor link–arm brackets from the U–bolts.

13. Remove the U–bolt nuts, axle clamps,

U–bolts and spring saddles. Lower and
withdraw the axle from the rear of the
vehicle; retain the spring seats.

E9611 8–1–11
 REAR AXLE 8
Driving head and rear axle assembly 55 Series

To Refit
NOTE: Unless otherwise stated, refer to the
torque figure charts in Section 1, Group 9.
1. Place the spring seats on the axle, ensure
1 the slots in the spring seats are correctly
engaged with the locating lugs on the axle
casing. Manoeuvre the axle into position, fit
the spring saddles, U–bolts, axle clamps and
U–bolt nuts. Tighten the nuts to 508 to
560 Nm (374 to 413 lbf ft), oiled thread
condition.
2. Locate the height sensor link–arm brackets
on the U–bolts and secure with locknuts.
3. Refit the upper torque rod to the axle pivot
and chassis frame.
4. Assemble the lower torque rods to the front
hanger brackets and axle clamps, ensuring
the offset bush is connected to the front
hanger bracket.
5. Reconnect the air supply pipes to the Tee
piece and elbows at the driving head bracket.
6 Axles Fitted With A Differential Lock:
Connect the cable to the differential lock
switch and the air pipe to the cylinder.
7. Connect the propeller shaft to the axle
coupling flange; tighten the coupling flange
bolts to 107 to 119 Nm (79 to 88 lbf ft).

E9611
8–1–12
8 REAR AXLE
55 Series Driving head and rear axle assembly

8. Manually re–apply the spring brake actuators.

9. Fit road wheels ensuring the tyre valves are
opposed 180° to each other; tighten the
wheel nuts evenly but do not torque tighten
at this stage. 1
10. Jack up axle and remove the supports from
beneath the chassis frame and the air
suspension support crossmember; lower
the vehicle to the ground and tighten the
wheel nuts to the correct torque and in the
correct sequence as detailed in the
‘Maintenance Manual’.
11. If necessary, refill the axle with the correct
grade of oil, refer to the ‘Maintenance
Manual’.
12. Reconnect the batteries and recharge the
air system.
13. Using the ECAS remote control unit, inflate
the air suspension bellows.

E9611 8–1–13
 REAR AXLE 8
Driving head and rear axle assembly 55 Series

E9611
8–1–14
8 REAR AXLE
55 Series Contents

CONTENTS Page Date

SECTION 2—HUB ASSEMBLY

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8—2—1 . . . . . . . . . 9611

E9611 1
2

E9611
2
8 REAR AXLE
55 Series Hub assembly

2. HUB ASSEMBLY
OVERHAUL

WARNING:
Ensure that suitable protective clothing and
a face mask are worn to prevent the
inhalation or penetration of brake lining dust
and particles.

Do NOT inhale the dust from the brake

linings or blow dust from the brake
assemblies; remove any dust using a damp
cloth or vacuum cleaner and dispose of all 2
used cloths, whilst damp, into a plastic
waste disposal bag. If a cleaning solvent is
required, methylated spirit should be used.

CAUTION:
Axles fitted with ABS: Before carrying out the
Overhaul procedure the following precautions
MUST be observed:

— Do NOT use the exciter ring as a lever

(fulcrum) point.

— Do NOT strike or dent the exciter ring;

protect the ring from damage.

— Do NOT stand the hub on the exciter ring.

E9611 8–2–1
 REAR AXLE 8
Hub assembly 55 Series

To Dismantle
Service tools:
8.20 Axle: 0484910, 0499805, 0499809*,
1310453* and 1240119
10.20, 10.26, 10.28 and 11.26 Axles: 0485164,
0499809, 1310449* and 1240120
* ‘Bruss’ oil seal application

2 1. Isolate the batteries and chock the front

road wheels.

2. Slacken the rear road wheel nuts.

3. Jack and suitably support the rear axle,

remove the wheel nuts and withdraw the
road wheels.

4. Manually release the spring brake

actuators, see Group 6, ‘Brakes’.

5. 8.20, 10.26 and 11.26 Axles Fitted With A

Differential Lock:
Engage the differential lock.
Disconnect the cable from the differential
lock switch.
Remove the differential lock switch, then
screw a suitable 16 mm bolt into the switch
bore to retain the differential lock in the
engaged position.

6. 10.28 Axles Fitted With A Differential Lock:

Deplete the air system, depress the quick
release sleeve and disconnect the air pipe
from the differential lock cylinder.
Remove the pipe adapter, then screw a
suitable 12 mm bolt into the adapter bore to
engage the differential lock.
DO NOT force the bolt if resistance is felt;
this indicates that the sliding clutch is not
correctly aligned with the fixed clutch on the
differential cage. Slowly rotate the hub (lock
side) and continue tightening the bolt to fully
engage the differential lock.

E9611
8–2–2
8 REAR AXLE
55 Series Hub assembly

7. Remove the axle shaft setscrews/nuts and

lever the axle shaft from the hub. Withdraw
the axle shaft and clean all joint faces.

8. Remove the two setscrews and detach the

brake drum, noting, if necessary:
— Manually retract the brake shoes as
detailed in Group 6, ‘Brakes’.
— Use two extractor bolts in the holes 2
provided to remove the brake drum.

9. Release the lockwasher. Using hub nut

wrench 0499805 (8.20 axle) or 0485164
(10.20, 10.26, 10.28 and 11.26 axles),
remove the outer locknut and detach the
lockwasher. Using the hub nut wrench,
remove the adjusting nut and detach the
keyed thrust washer.

10. Withdraw the hub assembly from the axle;

retain the outer bearing.

11. 8.20 Axle — ‘Stemco’ oil seal: Extract the

inner bearing from the hub.
— Using a suitable puller, remove and
discard the oil seal from the abutment
ring.

12. Remove the oil seal and withdraw the inner

bearing from the hub assembly.

13. If necessary, press or drift the bearing races

from the hub.

E9611 8–2–3
 REAR AXLE 8
Hub assembly 55 Series

To Inspect
1. Thoroughly clean all components in a
suitable solvent, inspect for wear or
damage; renew as necessary.

2. Replace any damaged wheel bolts.

3. ABS Axles: Check the exciter ring teeth for

2 burrs or dents, if evident, lever the ring from
the hub.
Inspect the hub exciter ring spigot/bore for
damage; rectify as necessary.

4. The ‘Stemco’ and ‘Forsheda’ oil seals have

been replaced with a ‘Bruss’ oil seal. The
‘Bruss’ seal can be used as a replacement
seal on axles previously fitted with a
‘Stemco’ or ‘Forsheda’ oil seal.

E9611
8–2–4
8 REAR AXLE
55 Series Hub assembly

11

2
12

6
10
5
4 9
3
1 2

030187

FIG.1. EXPLODED VIEW OF HUB ASSEMBLY (8.20 Axle)

1. Axle shaft 5. Keyed washer 9. Inner taper roller bearing

2. Locknut 6. Outer taper roller bearing 10. Oil seal
3. Lockwasher 7. Hub 11. Exciter ring (ABS Axles)
4. Adjusting nut 8. Wheel bolt 12. Abutment ring

E9611 8–2–5
 REAR AXLE 8
Hub assembly 55 Series

11

12 13

2
7

6
10
5
4 9
3
1 2

030188

FIG.2. EXPLODED VIEW OF HUB ASSEMBLY (10.20, 10.26, 10.28 and 11.26 Axles)

1. Axle shaft 6. Outer taper roller bearing 10. Oil seal

2. Locknut 7. Hub * 11. Exciter ring (ABS Axles)
3. Lockwasher 8. Wheel bolt 12. Oil catcher
4. Adjusting nut 9. Inner taper roller bearing 13. Abutment ring
5. Keyed washer

NOTE: On axles fitted with ABS item 11 replaces item 12.

* 10 Wheel bolt fixing on 11.26 axle.

E9611
8–2–6
8 REAR AXLE
55 Series Hub assembly

To Reassemble
NOTE: ABS Axles: Exciter rings which have been
removed from the hub MUST NOT be re–used.
1. If the abutment ring has been removed,
ensure the axle journal is clean; apply
‘Permabond’ surface conditioner to bore of
abutment ring and axle journal. Wipe bore
of abutment ring and axle journal clean,
then apply ‘Permabond’ adhesive to axle
journal and refit abutment ring. 2
2. 8.20 ABS Axles: Using a suitable diameter
tube or flat plate press the new exciter ring
onto the hub. Check the condition of the
new exciter ring prior to fitting.
10.20, 10.26, 10.28 and 11.26 ABS Axles:
Using a suitable diameter tube or flat plate
press the new exciter ring flush into the hub
bore. Check the condition of the new exciter
ring prior to fitting.
NOTE: Ensure the thickness of the tube is
sufficient to cover the ring teeth to prevent
damage when pressing the ring into position.

3. If removed, press the bearing races into the

hub.

4. Thoroughly pack or inject the inner and

outer inner bearings with lithium grease
(N.L.G.I. Grade 2). Apply a light film of
grease to the internal surfaces of the hub;
do NOT pack the hub cavity with grease.

E9611 8–2–7
 REAR AXLE 8
Hub assembly 55 Series

5. ‘Stemco’ oil seal — 8.20 Axle: Fit the new

hub oil seal and hub using the following
procedure:
— Apply ‘Hylomar’ sealant to the leading 1
edge of the abutment ring.
2
— Position the oil seal on the abutment
ring with its embossed marking ‘DRY 3
2 SIDE’ facing the brake back plate.
— Using oil seal drift 0484910 and oil seal
4
replacer 1240119, drive the oil seal
squarely onto the abutment ring; check
that the oil seal is flush with the outer
edge of the abutment ring.
— Position the inner bearing on the axle
case, locate the hub on the bearing and
oil seal then fit the outer bearing cone,
keyed thrust washer and adjustment nut. 030206

— Using hub nut wrench 0499805 slowly

tighten the adjusting nut to draw the FIG.3. FITTING THE HUB OIL SEAL
hub over the oil seal. (8.20 Axle — ‘Stemco’ oil seal)

1. Abutment ring
2. Hub seal
3. Tool 1240119
4. Tool 0484910

E9611
8–2–8
8 REAR AXLE
55 Series Hub assembly

6. ‘Forsheda’ oil seal — 10.20, 10.26, 10.28

and 11.26 Axles:
— Place the inner bearing in the hub.
— Locate the oil seal in the hub with the
face marked ‘OIL SIDE’ to the bearing.
Using driver handle 0499809 with oil
seal replacer 1240120, press the new
oil seal into the hub, with the seal ring
flush to the hub face. DO NOT bottom
2
the seal in the bore.
— Fit the hub on the axle case and then
fit the outer bearing, keyed thrust
washer and adjusting nut.

E9611 8–2–9
 REAR AXLE 8
Hub assembly 55 Series

7. ‘Bruss’ Oil Seal — All axles: Apply a light 1

film of lithium grease (N.L.G.I. Grade 2) to
the oil seal bore in the hub.

— Place the inner bearing cone in the

hub.
— Locate the oil seal on the relevant tool,
with the seal lip to the recess and the
2 face marked ‘OIL SIDE’ facing outward
(Fig. 4).
8.20 axle: Use oil seal replacer
1310453
10.20, 10.26, 10,28 and 11.26 axles:
Use oil seal replacer 1310449
— Insert the tool into the inner bearing
and locate the driver handle 0499809 in
the oil seal replacer; press the new oil
3
seal into the hub.
NOTE: The tool positions the oil seal at
the correct depth in the hub. 2 3
— Apply a light film of silicon grease to
the O/D of the abutment ring.
4
— Fit the hub on the axle case and fit the
outer bearing cone, keyed thrust
washer and adjusting nut.
— Using hub nut wrench 0499805 slowly
tighten the adjusting nut to draw the
hub into position.

030221

FIG.4. HUB OIL SEAL SERVICE TOOL

(‘Bruss’ Oil Seal)

1. Driver handle
2. Hub seal
3. Oil seal replacer
4. ‘OIL SIDE’ face of seal

E9611
8–2–10
8 REAR AXLE
55 Series Hub assembly

8. Adjust the hub end–float using the following

procedure:
— Using hub nut wrench 0499805 or
0485164 and a suitable torque wrench, 1
tighten the adjusting nut to 136 Nm 2
(100 lbf ft).
— Rotate the hub assembly two complete
revolutions to seat the hub bearings
and then re–torque the adjusting nut to
2
136 Nm (100 lbf ft). Rotate the hub
assembly two complete revolutions.
— Suitably reference mark the hub nut 1
wrench in relationship with an axle
shaft stud/setscrew fixing hole, then
slacken the adjusting nut two
stud/setscrew fixing hole positions.
— Using a dial test indicator, measure the
hub end–float; if necessary, tighten or 030204

slacken the adjusting nut until an

end–float of 0,05 to 0,2 mm (0.002 to
FIG.5. HUB END–FLOAT ADJUSTMENT
0.008 in) is obtained.
— Fit a new lockwasher and then fit the 1. Reference marks
hub locknut; tighten the locknut to 122 2. Tool 0499805
to 149 Nm (90 to 110 lbf ft). Secure the (8.20 axle)
hub nuts in position with the tabs of the Tool 0485164
lockwasher. (10.20, 10.26, 10.28 and 11.26 axles)

9. ABS Axles only: Push the sensor inwards

until it just contacts the exciter ring and then 1
rotate the hub several times to set a
minimum running clearance between the
sensor and exciter ring.

030205

FIG.6. ABS SENSOR

1. Exciter ring
2. Sensor

E9611 8–2–11
 REAR AXLE 8
Hub assembly 55 Series

10. Fit the brake drum and tighten the brake

drum setscrews to 22 to 44 Nm
(16 to 32 lbf ft).

11. Apply ‘Loctite 515’ jointing compound to the

joint faces of the hub and axle shaft. Refit
the axle shaft and tighten the axle shaft
setscrews/nuts to the following torque
2 figures:
Axle shaft nuts . . . . . . . . . . . . . 86 to 102 Nm
(63 to 75 lbf ft)
Axle shaft setscrews . . . . . . . 208 to 244 Nm
(153 to 180 lbf ft)

12. 8.20, 10.26 and 11.26 Axles Fitted With A

Differential Lock:
Remove the bolt from the differential switch
bore, refit the differential lock switch and
reconnect the cable.

10.28 Axles Fitted With A Differential Lock:

Remove the bolt from the differential lock
cylinder, refit the pipe adapter and
reconnect the air pipe.

13. If necessary, reset the brake adjusters as

detailed in Group 6, ‘Brakes’.

14. Manually apply the spring brake actuators.

15. Refit the rear road wheels and nuts, lower

the vehicle to ground and tighten the wheel
nuts to the correct torque and in the correct
sequence as detailed in the ‘Maintenance
Manual’.

16. Fully charge the vehicle air system and

repeatedly apply the footbrake until the
brake shoes have been automatically
adjusted to their optimum running
clearance.

E9611
8–2–12
8 REAR AXLE
55 Series Contents

CONTENTS Page Date

SECTION 3—DRIVING HEAD – 10.28

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8—3—1 . . . . . . . . . 9611
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8—3—2 . . . . . . . . . 9611

E9611 1
3

E9611
2
8 REAR AXLE
55 Series Driving head – 10.28

3. DRIVING HEAD – 10.28

DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton single speed differential unit available

with differential lock

Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36:1, 3.70:1, 4.11:1, 4.63:1 and 5.29:1

Crownwheel and pinion backlash . . . . . . . . . . . . . 0,20 to 0,46 mm (0.008 to 0.018 in)

Pinion bearing cage shims available . . . . . . . . . . 0,08 mm (0.003 in)
0,127 mm (0.005 in)
0,25 mm (0.010 in)
0,508 mm (0.020 in)
0,76 mm (0.030 in)
Pinion bearing pre–load . . . . . . . . . . . . . . . . . . . . . 1,7 to 4 Nm (15 to 35 lbf in)

Pinion bearing spacers available . . . . . . . . . . . . .

Spring balance reading: 23 to 49 N (5 to 11 lbf)
18,16 to 18,39 mm (0.715 to 0.724 in) in steps
3
of approximately 0,025 mm (0.001 in)

Torque Tightening Figures Nm lbf ft

Bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 475 to 583 350 to 430
Bevel pinion bearing cage setscrews . . . . . . . . . 240 to 295 177 to 217
Coupling flange retaining nut . . . . . . . . . . . . . . . . . 735 to 900 542 to 664
Crownwheel nuts/bolts . . . . . . . . . . . . . . . . . . . . . . 352 to 393 259 to 290
Differential casing bolts . . . . . . . . . . . . . . . . . . . . . 210 to 237 155 to 175
Differential lock cylinder setscrews . . . . . . . . . . . 34 to 41 25 to 30
Differential lock switch . . . . . . . . . . . . . . . . . . . . . . 14 to 16 10 to 12
Selector fork clamp bolt . . . . . . . . . . . . . . . . . . . . . 14 to 16 10 to 12
Thrust screw locknut . . . . . . . . . . . . . . . . . . . . . . . . 200 to 245 148 to 181

E9611 8–3–1
 REAR AXLE 8
Driving head – 10.28 55 Series

OVERHAUL

To Dismantle
1. Remove the differential lock switch from the
driving head casing.

2. Remove the 12 mm bolt from the differential

lock cylinder to release the differential lock
mechanism.

NOTE: If the crownwheel and pinion is to be

reused, check the crownwheel/pinion backlash
and tooth contact pattern prior to dismantling the
driving head assembly.
3 3. Detach the differential lock cylinder and
withdraw the piston from the cylinder.

4. Remove the blanking plug from the driving

head casing to gain access to the selector
fork clamp bolt. Remove the clamp bolt and
withdraw the selector rod, selector fork,
sliding clutch, spring and switch actuator.
Remove the spring pin and separate the
sliding clutch from the selector fork.

5. Remove snap ring and withdraw the fixed

clutch from the differential unit.

6. If fitted, release the locknut and remove the

thrust screw.

7. Reference mark the bearing caps in relation

to the casing. If reusing the crownwheel
and pinion, reference mark the adjuster
rings in relation to the bearing caps.

E9611
8–3–2
8 REAR AXLE
55 Series Driving head – 10.28

8. Remove the adjuster ring lock pins, bearing

cap bolts, washers and bearing caps. Using
suitable lifting equipment, withdraw the
crownwheel/differential unit from the casing;
retain the adjuster rings and bearing outer
races.

9. Remove the pinion bearing cage setscrews;

lift the pinion assembly from the driving
head casing and retain the shims for
reassembly purposes. If the shims cannot
be reused, note the number and size of
shims in the pack. 3
1
2
3 4

5 6
7 8
9 10
13
12
11

030192

FIG.1. DIFFERENTIAL LOCK ASSEMBLY

1. Fixed clutch 6. O–ring 10. Cylinder bracket

2. Snap ring 7. Piston 11. Selector fork
3. Spring pin 8. Seal 12. Switch actuator
4. Sliding clutch 9. Differential lock cylinder 13. Spring
5. Selector rod

E9611 8–3–3
 REAR AXLE 8
Driving head – 10.28 55 Series

Bevel Pinion Assembly

Service tool: 0484977

1. Assemble tool 0484977 to the coupling

flange and secure the assembly in a vice;
remove the flange nut and washer. 9

2. Remove the assembly from the vice and 8

detach the service tool. Using a suitable
puller withdraw the coupling flange. 7

3. Press the pinion from the bearing cage; 6

3 retain the bearing spacer. 5
4. Press the oil seal and the outer bearing 4
race and cone from the bearing cage.
Discard the oil seal. 3
1 2
5. Using a suitable bearing separator and
puller, withdraw the inner bearing cone from 14
the pinion. Repeat the operation for removal
of the pilot bearing.

6. Press the inner and outer bearing races

from the bearing cage.
13

12

11
10 030189

FIG.2. BEVEL PINION ASSEMBLY

1. Coupling flange nut cage

2. Washer
3. Coupling flange
4. Mud flinger
5. Oil seal
6. Bearing cone
7. Bearing race
8. Bearing
9. Shim(s)
10. Spacer
11. Bearing race
12. Bearing cone
13. Bevel pinion
14. Pilot bearing

E9611
8–3–4
8 REAR AXLE
55 Series Driving head – 10.28

Crownwheel/differential Unit
1. If the crownwheel is being reused,
reference mark the crownwheel in relation
to the differential casings. Remove nuts and
bolts and separate the crownwheel from the
differential casings.

2. Reference mark the differential casings.

Remove retaining bolts, separate the
casings and withdraw the side gears,
pinions, trunnion and thrust washers.

3. Using a suitable bearing separator and

puller, remove the bearing cones from the
3
differential casings.

To Inspect
1. Clean all components in a suitable solvent
and dry thoroughly.

2. Examine all components for wear, damage

or distortion; renew as necessary.
NOTE: The crownwheel and pinion MUST
be replaced as a matched pair.

3. Renew all sealing rings and oil seal.

4. Lubricate all relevant parts during assembly

procedure to prevent initial oil starvation.

E9611 8–3–5
 REAR AXLE 8
Driving head – 10.28 55 Series

3 4 8
7 9

1 10
2

6
3 5

17
13

11
12

14 15

16 030191

FIG.3. CROWNWHEEL/DIFFERENTIAL UNIT

1. Bearing 10. Bearing

2. Differential casing (plain) 11. Adjuster ring (R.H.)
3. Thrust washer 12. Bearing cap (R.H.)
4. Side gear 13. Bearing cap bolt
5. Thrust washer 14. Bearing cap (L.H.)
6. Pinion 15. Adjuster ring (L.H.)
7. Trunnion 16. Thrust screw and locknut
8. Crownwheel 17. Driving head casing
9. Differential casing (flanged)

E9611
8–3–6
8 REAR AXLE
55 Series Driving head – 10.28

To Reassemble

Crownwheel/differential Unit 3 1
1. Press the bearing cones onto the 12 10
differential casings.

2. Assemble the thrust washers, side gears, 5 8

bevel pinions and trunnion into the flanged
differential casing.
7 6
3. Locate the plain casing, aligning reference
marks, on the flanged casing; refit retaining
bolts.
NOTE: The differential casings are retained
9 11 3
with self locking ‘thread patch’ bolts. If the 2 4
bolts are to be reused, apply ‘Loctite 242’ to
the threaded holes in the casing prior to
fitting the bolts.

4. Tighten the differential casing bolts as

follows:
Stage 1: Tighten the bolts in the sequence
shown in Fig.4. to a torque of 105 to 118 Nm
(77 to 87 lbf ft).

Stage 2: Further tighten the bolts to a final

torque of 210 to 237 Nm (155 to 175 lbf ft).

Stage 3: Re–check all bolts are tightened to

210 to 237 Nm (155 to 175 lbf ft).

030193

FIG.4. TORQUE TIGHTENING SEQUENCE

E9611 8–3–7
 REAR AXLE 8
Driving head – 10.28 55 Series

5. Check the differential for free rotation by A

turning the side gear. A torque of up to
68 Nm (50 lbf ft) may be required to rotate
the differential.
NOTE: To check the rotating resistance of
the differential unit, manufacture a tool from
a used axle shaft as shown in Fig.5.
1
030190

6. Assemble the crownwheel to the flanged

half of the differential casing and tighten the FIG.5. DIFFERENTIAL TOOL
nuts and bolts to the torque figure quoted in
DATA. A = 305 mm (12 in) approximately
3 1. Welded nut

E9611
8–3–8
8 REAR AXLE
55 Series Driving head – 10.28

Bevel Pinion Assembly

1. Press the pilot bearing onto the pinion and
stake into position.

2. Press the pinion inner and outer bearing

races into the bearing cage.

3. Place the bearing cones and original spacer

in the bearing cage. Lubricate the bearings
and position the assembly on a press.

4. Position a suitable spacer on the bearing

cone and apply a press force of 14 to 15
tonne to the assembly.
3
5. Wrap a length of cord several times around
the bearing cage, attach a spring balance
and pull steadily noting the reading. Check
the recorded figure is within a tolerance of
1,1 to 2,3 Nm (10 to 20 lbf in); this will give
a spring balance reading of 13 to 30 N (3 to
7 lbf). If necessary, replace the spacer to
obtain the correct pre–load.

6. When correct pre–load is obtained, select a

spacer 0,025 mm (0.001 in) larger for use in
the final bearing cage assembly.

E9611 8–3–9
 REAR AXLE 8
Driving head – 10.28 55 Series

7. Pinion oil seals used on the 10.28 driving

head create a small amount of drag which
can affect the final pre–load measurement.
Check the oil seal drag as follows:
— Press the inner bearing cone onto the
pinion.
— Place the selected bearing spacer on
the pinion.
— Place the outer bearing cone in the
bearing cage and, using a suitable
sleeve press the oil seal into the
bearing cage. Apply suitable sealing
3 compound to the outer diameter of the
seal prior to fitting.
— Lubricate the oil seal lip, then place the
bearing cage assembly on the pinion.
— Locate the coupling flange on the
pinion splines. Using a suitable sleeve,
press the coupling flange onto the
pinion until a bearing end play of
approximately 1,5 mm (0.062 in) exists.
— Using a spring balance and cord check
the oil seal drag and note the reading.

8. When the oil seal drag has been

determined, carry out the final bearing
pre–load check as follows:
— Press the coupling flange and bearing
cage fully into position.
— Assemble tool 0484877 to the coupling
flange and secure the assembly in a
vice. Fit and tighten the flange nut to
the torque figure quoted in DATA.
— Using a spring balance and cord check
the bearing pre–load. Subtract the oil
seal drag reading from the spring
balance reading to obtain the correct
pre–load figure, see DATA.
— If the final reading is not within the
tolerances quoted in DATA, dismantle
the pinion assembly and replace the
pre–load spacer with one of
appropriate size to obtain the correct
pre–load.

E9611
8–3–10
8 REAR AXLE
55 Series Driving head – 10.28

Driving Head
1. If the bevel pinion is being reused, place the
original shim pack on the driving head
casing. Apply a thin bead of sealant to the
shims.
NOTE: If a new crownwheel and pinion is
being fitted, use a nominal shim pack of
0,61 mm (0.024 in)

2. Fit the bevel pinion assembly into the

driving head casing; tighten the bearing
cage setscrews to the torque figure quoted
in DATA.
NOTE: The bearing cage setscrews are self
3
locking ‘thread patch’ setscrews. If the
setscrews are to be reused, apply
‘Loctite 270’ to the threads prior to fitting.

3. Using suitable lifting equipment, fit the

crownwheel/differential unit into the driving
head casing. Refit the bearing outer races
and adjuster rings.

4. Refit the bearing caps, aligning the

reference marks previously scribed; fit but
do not tighten the bearing cap bolts at this
stage.

E9611 8–3–11
 REAR AXLE 8
Driving head – 10.28 55 Series

5. Set the differential bearing pre–load as

follows:
— Unscrew the R.H. adjuster ring until its
first thread is visible.
— Tighten the L.H. adjuster ring until all
backlash is eliminated. Rotate the
crownwheel and check for any point
where the crownwheel may bind, if
such a point exists, unscrew and then
tighten the L.H. adjuster ring; repeat
the operation until the crownwheel
rotates freely without binding.
3 — Tighten the R.H. adjuster ring until it
contacts the bearing race, then further
tighten the adjuster ring two to three
notches to pre–load the bearings and
give a backlash setting.
— Tighten the bearing cap bolts to the
torque figure quoted in DATA.
FIG.6. CHECKING CROWNWHEEL/PINION
6. Mount a dial test indicator (D.T.I) on the BACKLASH
driving head casing, with the indicator
button locating against the crownwheel
teeth (Fig.6). Check the backlash setting.
NOTE: If the original crownwheel and
pinion is fitted, set the backlash to the
original figure. For a new crownwheel and
pinion set the backlash to the dimension
quoted in DATA.

E9611
8–3–12
8 REAR AXLE
55 Series Driving head – 10.28

7. To remove backlash, slacken but do not

remove the bearing cap bolts. Unscrew the
R.H. adjuster ring, then tighten the L.H.
adjuster ring by an equal amount. Torque
24
tighten the bearing cap bolts and re–check 075 K

1
the backlash.

6.37
8. To increase backlash, slacken but do not
remove the bearing cap bolts. Unscrew the EATON
L.H. adjuster ring, then tighten the R.H.
adjuster ring by an equal amount. Torque
tighten the bearing cap bolts and re–check
the backlash. 3
9. Most 10.28 crownwheel/pinion assemblies
have the same distinctive tooth contact
pattern, which will be referred to as the
‘Standard’ tooth contact pattern.
030197

Some crownwheel/pinion assemblies

require a tooth contact pattern different to FIG.7. PINION PART NUMBER
the standard pattern. This is due to the
manufacturing process used to cut the gear
teeth. These crownwheel/pinion sets are
B
identified with a suffix ‘K’ on the pinion part C
number (Fig.7). The tooth contact pattern
required will be referred to as the ‘K’ tooth
contact pattern.

E
A

F
030196

FIG.8. CROWNWHEEL TERMINOLOGY

A. Face width
B. Tooth contact
C. Heel end
D. Root
E. Top land
F. Toe end

E9611 8–3–13
 REAR AXLE 8
Driving head – 10.28 55 Series

10. ‘Standard’ tooth contact pattern, Fig.9.

— Paint several teeth of the crownwheel A
with marking compound, then rotate
the crownwheel several times in both
directions to obtain a tooth contact
impression.
— Refer to Fig.8. for the correct
crownwheel terminology.
— Compare the impressions obtained with
those shown in Fig.9 and adjust as
necessary.
3 View A. Correct tooth contact: The
length of the pattern is approximately
1/2 to 2/3 of the tooth, evenly centred
and approximately 9,5 mm (3/8 in) off B C
the toe end of the tooth.
View B. Insufficient backlash: Move the
crownwheel away from the pinion and
move the pinion towards the
crownwheel, by removing shims from
between the input bearing cage and
driving head casing.
View C. Excessive backlash: Move the
crownwheel towards the pinion, then
move the pinion away from the D E
crownwheel by adding shims.
View D. Pinion too far into mesh: Move
the pinion away from the crownwheel
by adding shims; move the crownwheel
towards the pinion to retain the
backlash.
View E. Pinion too far out of mesh:
Move the pinion towards the 030195
crownwheel by removing shims; move
the crownwheel away from the pinion
to retain the backlash. FIG.9. ADJUSTMENT OF CROWNWHEEL
AND PINION
11. Adjust original crownwheel/pinion to display ‘Standard’ Contact Tooth Pattern
the same contact pattern observed prior to
dismantling the driving head.

E9611
8–3–14
8 REAR AXLE
55 Series Driving head – 10.28

12. ‘K’ tooth contact pattern, Fig.10.

— Paint several teeth of the crownwheel
A
with marking compound, then rotate
the crownwheel several times in both
directions to obtain a tooth contact
impression.
— Refer to Fig.8. for the correct
crownwheel terminology.
— Compare the impressions obtained with
those shown in Fig.10. and adjust as
necessary.
View A. Correct tooth contact: The 3
length of the pattern is approximately
1/2 to 2/3 of the tooth, evenly centred
and up off the toe end of the tooth. B C
View B. Insufficient backlash: Move the
crownwheel away from the pinion and
move the pinion towards the
crownwheel, by removing shims from
between the input bearing cage and
driving head casing.
View C. Excessive backlash: Move the
crownwheel towards the pinion, then
move the pinion away from the
crownwheel by adding shims. D E
View D. Pinion too far into mesh: Move
the pinion away from the crownwheel
by adding shims; move the crownwheel
towards the pinion to retain the
backlash.
View E. Pinion too far out of mesh:
Move the pinion towards the
crownwheel by removing shims; move 030194
the crownwheel away from the pinion
to retain the backlash.
FIG.10. ADJUSTMENT OF CROWNWHEEL
13. Adjust original crownwheel/pinion to display AND PINION
the same contact pattern observed prior to ‘K’ Contact Tooth Pattern
dismantling the driving head.

E9611 8–3–15
 REAR AXLE 8
Driving head – 10.28 55 Series

14. When all adjustments have been completed

fit the adjuster ring lock pins.

15. When applicable, fit and adjust the thrust

screw until a clearance of 1,0 mm (0.039 in)
exists between the crownwheel and thrust
screw. Tighten the locknut to the torque
figure quoted in DATA.

16. Locate the differential lock fixed clutch on

the splined differential casing and retain
with snap ring.
3 17. Locate the sliding clutch in the selector fork
and retain with the spring pin.

18. Position the spring, switch actuator and

selector fork assembly in the driving head
casing, engage the sliding clutch with the
fixed clutch.

19. Slide the selector rod into the casing and

selector fork.

20. Locate the piston, complete with new

O–ring, on the selector rod; ensure the
recess face of the piston is to the selector
rod.

21. Refit the differential lock cylinder and seal;

tighten the cylinder setscrews to the torque
figure quoted in DATA.

E9611
8–3–16
8 REAR AXLE
55 Series Driving head – 10.28

22. Set the position of the selector fork as

follows:
— Insert a dummy shaft or axle shaft
through the sliding clutch into the
differential side gear.
— Position two 3,0 mm (0.120 in) feeler
gauges, diametrically opposed,
between the tips of the sliding clutch
and fixed clutch teeth.
— Slide the selector fork along the
selector rod to retain the clutch teeth
setting and centralise the fork in the
sliding clutch groove. Tighten the
selector fork clamp bolt to the torque
3
figure quoted in DATA.
— Connect an air supply to the cylinder
and check the operation of the
differential lock.
— When the fork is adjusted correctly, the
sliding clutch teeth should be fully
engaged with the fork in free load
condition. The unit should disengage
freely when the air supply is
disconnected.

23. Screw a 12 mm bolt into the cylinder to

manually apply the differential lock.

24. Refit the blanking plug and differential

switch into the driving head casing.

E9611 8–3–17
 REAR AXLE 8
Driving head – 10.28 55 Series

E9611
8–3–18
8 REAR AXLE
55 Series Contents

CONTENTS Page Date

SECTION 4—DRIVING HEAD – 8.20, 10.20, 10.26 and 11.26

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8—4—1 . . . . . . . . . 9611
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8—4—3 . . . . . . . . . 9611

E9611 1
4

E9611
2
8 REAR AXLE
55 Series Driving head – 8.20, 10.20, 10.26 and 11.26

4. DRIVING HEAD – 8.20, 10.20, 10.26 and 11.26

DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Albion single speed differential unit

Differential lock available on 8.20, 10.26 and
11.26 driving heads

Ratios:
8.20/10.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31:1, 3.73:1, 4.10:1, 4.56:1 and 5.13:1
10.26/11.26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31:1, 3.73:1, 4.10:1, 4.56:1, 5.13:1, 5.71:1
and 6.33:1

Crownwheel and pinion backlash

8.20/10.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 to 0,30 mm (0.008 to 0.012 in)
10.26/11.26 0,25 to 0,33 mm (0.010 to 0.013 in)

Pinion bearing housing shims available . . . . . . . 0,127 mm (0.005 in)

0,25 mm (0.010 in)
0,51 mm (0.020 in)
0,75 mm (0.030 in)
1,00 mm (0.039 in)
4
Pinion bearing pre–load . . . . . . . . . . . . . . . . . . . . . 1,13 to 3 Nm (10 to 27 lbf in)
Spring balance reading: 13 to 40 N (3 to 9 lbf)
Pinion bearing spacers available
8.20/10.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,70 to 6,20 mm (0.224 to 0.244 in) in steps of
approximately 0,05 mm (0.002 in) plus
14,60 mm (0.575 in), 14,625 mm (0.576 in),
15,175 mm (0.597 in) and 15,20 mm (0.598 in)

10.26/11.26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,70 to 6,20 mm (0.224 to 0.244 in) in steps of

approximately 0,05 mm (0.002 in)
12,200 to 12,2375 mm (0.4803 to 0.4818 in)
and 12,7625 to 12,800 mm (0.5025 to
0.5039 in) in steps of approximately 0,0125 mm
(0.0005 in)

E9608 8–4–1
 REAR AXLE 8
Driving head – 8.20, 10,20, 10.26 and 11.26 55 Series

Torque Tightening Figures Nm lbf ft

8.20/10.20 Driving head:

Bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 to 160 100 to 118
Bevel pinion bearing housing bolts . . . . . . . . . . . 50 to 58 37 to 43
Coupling flange retaining nut . . . . . . . . . . . . . . . . . 600 to 750 442 to 553
Crownwheel/differential casing bolts . . . . . . . . . . 111 to 129 82 to 95
Angle torque a further 60°
Differential lock cover setscrews . . . . . . . . . . . . . 17 to 32 13 to 24

10.26/11.26 Driving head:

Bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 to 244 153 to 180
Bevel pinion bearing housing bolts . . . . . . . . . . . 57 to 79 42 to 58
Coupling flange retaining nut . . . . . . . . . . . . . . . . . 1200 to 1300 884 to 958
Crownwheel/differential casing bolts . . . . . . . . . . 180 133
Angle torque a further 120°
4 Differential lock cover setscrews . . . . . . . . . . . . . 17 to 23 13 to 17

E9611
8–4–2
8 REAR AXLE
55 Series Driving head – 8.20, 10,20, 10.26 and 11.26

OVERHAUL

To Dismantle
Service tools:
All Driving Heads: 0484977, 0499809
8.20 and 10.20 Driving Head: 1310405,
1310406, 1310407, 1310408, 1310409,
1310410, 1310411, 1310412, 1310413,
1310414, 1310415, 1310416
10.26 and 11.26 Driving Head: 1310438,
1310439, 1310440, 1310441, 1310442,
1310443, 1310444, 1310445, 1310446,
1310447, 1310448

NOTE: Service tool numbers quoted in brackets

refer to the 10.26 and 11.26 Driving Head.
1. Remove the bolt from the differential lock
switch bore to release the differential lock. 4
NOTE: If the original crownwheel and pinion is
to be reused, check the crownwheel/pinion
backlash prior to dismantling the driving head
assembly.

2. Remove the split pins from the adjuster

rings and bearing caps.

3. Remove the bearing cap bolts and withdraw

the bearing caps.

4. Driving Head Fitted With A Differential

Lock: Slacken and remove the L.H. adjuster
ring, slide the differential/crownwheel
assembly out of mesh with the pinion to
enable the sliding dog to be withdrawn.

5. Using suitable lifting equipment, withdraw

the crownwheel/differential assembly from
the casing; retain the adjuster rings and
bearing outer races.

E9611 8–4–3
 REAR AXLE 8
Driving head – 8.20, 10,20, 10.26 and 11.26 55 Series

Bevel Pinion Assembly

1. Assemble tool 0484977 to the coupling
flange and then remove the flange nut using
socket 1310405. Dismantle the service tool
from the coupling flange.

2. Using a suitable puller, withdraw the 8

coupling flange.
7
3. Remove the pinion bearing housing bolts.
Using two extractor bolts, withdraw the 6
housing assembly from the driving head
casing; retain the adjustment shims for 5
reassembly purposes. If the shims cannot 4
be reused, note the number and size of
shims in the pack. 3
4 4. Remove and discard the oil seal.
2
5. Press the bevel pinion from the bearing 1 14
housing; retain the bearing pre–load
spacers.

6. Withdraw the outer bearing cone from the

bearing housing.
13
7. Using tool 1310410 (1310439) withdraw the
inner bearing cone from the pinion.
12
8. Using a suitable bearing separator and
puller remove the nose bearing inner race. 11

9. Press the inner and outer bearing races 10

030200
from the bearing housing. 9

10. Remove the pinion nose bearing outer race FIG.1. BEVEL PINION ASSEMBLY
from the driving head casing using a 1. Coupling flange nut
suitable bearing puller.
2. Coupling flange
3. Mud flinger
4. Oil seal
5. Bearing cone
6. Bearing race
7. Bearing housing
8. Shim(s)
9. Pre–load spacer (outer)
10. Pre–load spacer (inner)
11. Bearing race
12. Bearing cone
13. Bevel pinion
14. Pinion nose bearing

E9611
8–4–4
8 REAR AXLE
55 Series Driving head – 8.20, 10,20, 10.26 and 11.26

Crownwheel/differential Assembly
1. Using tool 1310410 (1310439) with end cap
1310411 (1310440), remove the bearing
cones from the differential casings.

2. Remove the differential casing/crownwheel

retaining bolts and separate the L.H.
differential casing and crownwheel from the
R.H. casing.
NOTE: The differential casings are
reference stamped to facilitate correct
refitment.

3. Withdraw the side gears, pinions, trunnion

and thrust washers from the R.H. casing.

E9611 8–4–5
 REAR AXLE 8
Driving head – 8.20, 10,20, 10.26 and 11.26 55 Series

Differential Lock Assembly

1. Remove the differential lock cover plate and
discard the O–ring.

2. Withdraw the spindle and discard the

O–ring.

3. Carefully withdraw the return spring and

shift fork from the driving head casing.

4. Remove the spindle bush from the

differential lock bore.

4
8
6

3
2

030202
1

FIG.2. DIFFERENTIAL LOCK

1. Cover plate 5. Shift fork

2. Cover plate O–ring 6. Sliding dog
3. Spindle O–ring 7. Spring
4. Spindle 8. Spindle bush

E9611
8–4–6
8 REAR AXLE
55 Series Driving head – 8.20, 10,20, 10.26 and 11.26

To Inspect
1. Clean all components in a suitable solvent
and dry thoroughly.

2. Examine all components for wear, damage

or distortion; renew as necessary.
NOTE: The crownwheel and pinion MUST
be replaced as a matched pair.

3. Renew all sealing rings and oil seal.

4. Thoroughly clean all old Loctite sealant

from the threads of the pinion and the
coupling flange nut.

5. Lubricate all relevant parts during assembly

procedure to prevent initial oil starvation. 4

E9611 8–4–7
 REAR AXLE 8
Driving head – 8.20, 10,20, 10.26 and 11.26 55 Series

7
4 5
6
3
2
10

1 9

8
11
4
17

16
12
15
14

13

030201

FIG.3. CROWNWHEEL/DIFFERENTIAL ASSEMBLY

1. Bearing 10. Bearing

2. Differential casing (R.H.) 11. Adjuster ring (L.H.)
3. Thrust washer 12. Driving head casing
4. Thrust washer 13. Dowel
5. Bevel pinion 14. Adjuster ring (R.H.)
6. Trunnion 15. Bearing cap (R.H.)
7. Side gear 16. Bearing cap bolt
8. Crownwheel 17. Bearing cap (L.H.)
9. Differential casing (L.H.)

E9611
8–4–8
8 REAR AXLE
55 Series Driving head – 8.20, 10,20, 10.26 and 11.26

To Reassemble

Crownwheel/differential Assembly
1. Assemble the thrust washers, side gears,
bevel pinions and trunnion into the R.H.
differential casing.

NOTE: When the crownwheel is assembled to

the R.H. casing the position of the reference
number will be restricted. To ensure correct
alignment of the differential casings, highlight
the position of the reference number on the R.H.
casing.

2. Locate the crownwheel and L.H. differential

casing, aligning reference numbers, on the
R.H. casing. 4
3. Fit and tighten the crownwheel/differential
casing bolts to the torque figure quoted in
DATA. Apply ‘Loctite 572’ to the bolt
threads prior to fitting.

4. Locate tool 1310406 (1310438) into one of

the differential side gears and, using a
torque wrench check the rolling resistance
of the differential assembly.
NOTE: A torque of up to 68 Nm (50 lbf ft)
may be required to rotate the differential.

5. If an excessive torque is required to rotate

the differential, dismantle the assembly and
inspect the components to identify the
cause of the problem.

6. Using tool 1310412 (1310441) press the

bearing cones onto the differential casings.

E9611 8–4–9
 REAR AXLE 8
Driving head – 8.20, 10,20, 10.26 and 11.26 55 Series

Bevel Pinion Assembly

1. Using tool 0499809 and adapters 1310414
(1310443) and 1310415 (1310444) press
the pinion inner and outer bearing races
into the bearing housing.

2. Press the inner bearing cone onto the

pinion, using tool 1310408 (1310447).

3. Place the original pre–load spacers on the

pinion.

4. Locate the bearing housing on the pinion.

Using a suitable sleeve press the outer
bearing cone onto the shaft. Do not fit the
oil seal at this stage.
4 5. Locate the coupling flange on the pinion
splines and, using a suitable sleeve press
the coupling flange onto the pinion.

6. Assemble tool 0484977 to the coupling

flange and secure the assembly in a vice.
Fit the flange nut and, using socket
1310405, tighten to the torque figure quoted
in DATA.

E9611
8–4–10
8 REAR AXLE
55 Series Driving head – 8.20, 10,20, 10.26 and 11.26

7. Wrap a length of cord several times around

the 155 mm (6.1 in) diameter of the bearing
housing (Fig.4.), attach a spring balance
and pull steadily noting the reading. Check
the recorded figure is within the tolerance
quoted in DATA. If necessary, replace the
spacer(s) to obtain the correct pre–load.

8. When correct pre–load is obtained remove

the coupling flange.

9. Using tool 1310407 (1310446), press a new

oil seal into the bearing housing, ensuring
that the face marked ‘AIR SIDE’ is facing
outward. Refit the coupling flange.

10. Apply ‘Loctite 262’ to the pinion shaft

threads, fit and tighten the coupling flange
4
nut to the torque figure quoted in DATA.

11. Press the nose bearing inner race onto the

pinion shaft using tools 0499809 and
1310409 (1310448).

030198

FIG.4. CHECKING THE PINION PRE–LOAD

E9611 8–4–11
 REAR AXLE 8
Driving head – 8.20, 10,20, 10.26 and 11.26 55 Series

Differential Lock Assembly

1. Using tools 0499809 and 1310416
(1310445), press a new spindle bush into
the differential lock bore.

2. Position the return spring in a vice,

gradually tighten the vice to fully compress
the spring. Wire lock the spring at two
diametrical points to retain in a compressed
condition.

3. Position the shift fork and return spring in

the driving head casing. Slide the spindle,
complete with new O–ring, through the
casing bore, shift fork, return spring and
into the spindle bush.
4 4. Remove the lock wire and check the spring
is correctly seated between the casing and
shift fork.

5. Refit the differential lock cover plate,

complete with new O–ring, and tighten the
setscrews to the torque figure quoted in
DATA.

E9611
8–4–12
8 REAR AXLE
55 Series Driving head – 8.20, 10,20, 10.26 and 11.26

Driving Head
1. Using tools 0499809 and 1310413
(1310442), press the pinion nose bearing
outer race into the driving head casing.

2. Reference mark the oil feed channels on

the pinion bearing housing and driving head
casing.

3. Place the original shims on the driving head

casing.

4. Fit the bevel pinion assembly, aligning

reference marks, into the driving head
casing; tighten the bearing housing bolts to
the torque figure quoted in DATA.

5. Using suitable lifting equipment, fit the

4
crownwheel/differential assembly into the
driving head casing. Refit the bearing outer
races and adjuster rings.

6. Locate the sliding dog in the shift fork.

7. Refit the bearing caps, aligning the

reference marks previously scribed; fit and
tighten the bearing cap bolts to the torque
figure quoted in DATA.
NOTE: Apply ‘Loctite 262’ to the bolt
threads prior to fitting.

8. Mount a dial test indicator (D.T.I) on the

driving head casing, with the indicator
button locating against the crownwheel
face.

E9611 8–4–13
 REAR AXLE 8
Driving head – 8.20, 10,20, 10.26 and 11.26 55 Series

9. Tighten the adjuster rings until all bearing

end–float is eliminated. Reposition the
D.T.I. so the indicator button locates against
the crownwheel teeth. Check the
crownwheel/pinion backlash is within the
tolerance quoted in DATA.
NOTE: If the original crownwheel and
pinion is fitted, set the backlash to the
original figure. For a new crownwheel and
pinion set the backlash to the dimension
quoted in DATA.

10. Adjust the crownwheel/pinion backlash as

necessary, by rotating both adjuster rings
by an equal amount. i.e. If the R.H. adjuster 030199

ring is screwed inwards the distance of one

4 slot, the L.H. adjuster ring must be screwed
FIG.5. CHECKING CROWNWHEEL/PINION
outwards the same amount.
BACKLASH
11. When the crownwheel/pinion backlash has
been set, further tighten the L.H. adjuster
ring two notches to pre–load the bearings.
Check the diametrical dimension across the
bearing caps ‘A’ Fig.6. is within the
tolerances quoted below:
8.20 . . . . . . . . . . . . . . . 336,5 to 336,63 mm
(13.248 to 13.253 in).
10.20, 10.26 and
11.26 . . . . . . . . . . . . . 365,38 to 365,51 mm
(14.385 to 14.390 in).

If necessary, further tighten the adjuster

ring to obtain the correct dimension.

030203

FIG.6. CHECKING THE BEARING CAP

DIMENSION

E9611
8–4–14
8 REAR AXLE
55 Series Driving head – 8.20, 10,20, 10.26 and 11.26

12. Paint several teeth of the crownwheel,

adjacent to the serial number, with marking
compound, then rotate the crownwheel
several times in both directions to obtain a
tooth contact impression.

13. Compare the impressions obtained with

those shown in Fig.7. and adjust as
necessary.
— View B. Pinion too far into mesh. Move
the pinion away from the crownwheel
by adding shims between the pinion A
housing and driving head casing; move
the crownwheel towards the pinion to
retain the backlash.
— View C. Pinion too far out of mesh.
Move the pinion towards the
4
crownwheel by removing shims from
between the pinion housing and driving
head casing; move the crownwheel
away from the pinion to retain the
backlash.

B C 030166

FIG.7. ADJUSTMENT OF CROWNWHEEL

AND PINION

A—Correct tooth contact impression

E9611 8–4–15
 REAR AXLE 8
Driving head – 8.20, 10,20, 10.26 and 11.26 55 Series

14. When the correct tooth contact impression

is achieved (View A), re–check the
crownwheel/pinion backlash.

15. When all adjustments have been completed

carry out the following instructions:
— Retain the adjuster rings in position
with new split pins.
— Remove the pinion assembly and apply
‘Loctite 572’ to the joint faces of the
driving head casing, pinion bearing
housing and shims. Refit the pinion
assembly into the casing.
— Apply ‘Loctite 515’ to the pinion bearing
4 housing bolts; refit and tighten the bolts
to the torque figure quoted in DATA.

16. Engage the differential lock, then screw a

suitable 16 mm bolt into the differential
switch bore to retain the lock in the
engaged position.

E9611
8–4–16
6 SUB DIVISION
55 Series

GENERAL INFORMATION
0
BRAKE SYSTEM DESCRIPTIONS AND DIAGRAMS
1
BRAKE ASSEMBLIES
2
BRAKE COMPONENTS
3
ANTI–LOCK BRAKING SYSTEM (ABS)
4

E9612
6 BRAKES
55 Series Contents

CONTENTS Page Date

SECTION 0—GENERAL INFORMATION

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—0—1 . . . . . . . . . 9612 0

E9612 1
0

E9612
2
6 BRAKES
55 Series General information

0. GENERAL INFORMATION
TECHNICAL DATA

Braking System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual circuit, full air system 0
Operation:
Footbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air pressure operating front and rear brakes
Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring brake actuators operating rear brakes

Brake Assemblies – 11 to 15 tonne vehicles

Type:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perrot sliding caliper disc brakes
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perrot single air wedge (SAW) drum brakes
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic

Front brake disc:

Maximum run–out . . . . . . . . . . . . . . . . . . . . . . 0,2 mm per side
Minimum thickness . . . . . . . . . . . . . . . . . . . . . 40 mm

Front brake pad minimum thickness . . . . . . . . . . 0,5 mm above the base of the wear indicator
slot

Rear brake lining:

Minimum thickness . . . . . . . . . . . . . . . . . . . . . 0,5 mm above the wear indicator slots where
visible, or 5,5 mm of total lining thickness
Brake lining to drum clearance . . . . . . . . . . . 0,2 to 2,0 mm

Rear brake drum:

Maximum run–out . . . . . . . . . . . . . . . . . . . . . . 0,2 mm
Maximum machining tolerance . . . . . . . . . . . 3 mm on diameter (maximum diameter
363,23 mm)

Brake Assemblies – 17/18 tonne vehicles

Type (front and rear) . . . . . . . . . . . . . . . . . . . . . . . . DAF ‘S’ cam drum brakes

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic slack adjusters

Rear brake lining:

Minimum lining thickness . . . . . . . . . . . . . . . . 1,0 mm above the rivet head
Brake lining to drum clearance . . . . . . . . . . . 0,8 to 1,2 mm

Rear brake drum machining tolerance . . . . . . . . 3 mm on diameter

E9612 6–0–1
 BRAKES 6
General information 55 Series

Compressor
0 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 cm3 air cooled or
250 cm3 water cooled

Air Dryer
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knorr Bremse AD6

Pressure relief valve opening pressure . . . . . . . . 14 bar

Working pressure:
Cut–out pressure . . . . . . . . . . . . . . . . . . . . . . . 8,4 bar
Cut–in pressure . . . . . . . . . . . . . . . . . . . . . . . . 7,2 bar

E9612
6–0–2
6 BRAKES
55 Series General information

Brake Actuators – 11 to 15 tonne vehicles

Type:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single diaphragm (push–rod actuation)
0
Type 16, 14 or 12 dependent on vehicle
specification
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring brake actuator (tube mounted)
Type 12/20, 10.5/20, 9/20 or 7/20 dependent on
vehicle specification

Brake Actuators – 17/18 tonne vehicles

Type:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single diaphragm (lever actuation)
Type 27
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring brake actuator (lever actuation)
Type 24

Air Pressure Switch

Air pressure switch setting . . . . . . . . . . . . . . . . . . . 5,5 bar

Stop–Light Micro–Switch
Stop–light micro–switch setting . . . . . . . . . . . . . . . 2,5 to 3 mm

E9612 6–0–3
 BRAKES 6
General information 55 Series

E9612
6–0–4
6 BRAKES
55 Series Contents

CONTENTS Page Date

SECTION 1—BRAKE SYSTEM DESCRIPTIONS AND DIAGRAMS

Air Pressure System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 26 . . . . . . . 9612
Brake System Description:
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 1 ........ 9612
Anti–Lock Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Controlled Air Suspension (ECAS) . . . . . . . . . . . . . . . . . . .
6— 1 — 3
6— 1 — 4
........
........
9612
9612
1
Park Braking System – 11 to 15 Tonne Vehicles . . . . . . . . . . . . . . . . . 6— 1 — 3 ........ 9612
Park Braking System – 17/18 Tonne Vehicles . . . . . . . . . . . . . . . . . . . 6— 1 — 3 ........ 9612
Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 1 ........ 9612
Secondary Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 2 ........ 9612
Service Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 2 ........ 9612
Traction Control (ASR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 3 ........ 9612
Warning Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 3 ........ 9612
Description of Anti–lock Brakes (ABS) Components:
ABS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 23 ....... 9612
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 24 ....... 9612
Modulator Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 24 ....... 9612
Wheel Sensors and Pole Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 24 ....... 9612
Description of Brake System Components:
Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 14 ....... 9612
Air Piping and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 22 ....... 9612
Air Piping Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 22 ....... 9612
Air Pressure Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 21 ....... 9612
Brake Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 21 ....... 9612
Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 21 ....... 9612
Brake Valve Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 22 ....... 9612
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 14 ....... 9612
Dual Concentric Footbrake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 16 ....... 9612
Expansion Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 14 ....... 9612
Handbrake Valve – Rigid Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 18 ....... 9612
Handbrake Valve – Drawbar Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 19 ....... 9612
Inverting Relay Valve – Drawbar Models . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 20 ....... 9612
Load Sensing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 16 ....... 9612
Multi–Circuit Protection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 15 ....... 9612
Rear Axle Service Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 16 ....... 9612
Relayed Empty/Load Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 18 ....... 9612
Spring Brake Relay Valve – 11 to 15 Tonne Vehicles . . . . . . . . . . . . . 6— 1 — 16 ....... 9612
Spring Brake (Overload Protection) Relay Valve – 17/18 Tonne
Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 17 . . . . . . . 9612
Trailer control Valve – Drawbar Vehicles . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 20 . . . . . . . 9612
Description of Traction Control (ASR) Components:
ASR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 25 . . . . . . . 9612
Double Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 25 . . . . . . . 9612
3/2 Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 1 — 25 . . . . . . . 9612

E9612 1
1

E9612
2
6 BRAKES
55 Series Brake system descriptions and diagrams

1. BRAKE SYSTEM DESCRIPTIONS AND DIAGRAMS

BRAKE SYSTEM DESCRIPTION

Air supply
The engine driven air compressor supplies
compressed air through an expansion tank to an
air dryer with integral unloader valve. The air
dryer supplies air to a multi–circuit protection
valve. The vehicle air supply can be charged 1
from an external source using the air dryer
mounted ISO (full flow) test connection.

Pressure Protection
The multi–circuit protection valve supplies air to
the front service, rear service and park
reservoirs and also supplies the vehicle
auxiliaries.

E9612 6–1–1
 BRAKES 6
Brake system descriptions and diagrams 55 Series

Service Braking System

The service braking system comprises of two
independent air pressure circuits. The front
service reservoir supplies air to the secondary

1 circuit of a dual concentric footvalve and the

supply port of a relayed empty/load valve.
The rear service reservoir supplies air to the
primary circuit of a dual concentric footvalve and
the supply port of a relay valve. The secondary
port of the footvalve supplies graduated air
pressure to the control port of the relayed
empty/load valve to operate the front brake
actuators. The primary port of the footvalve
supplies graduated air pressure to a load
sensing valve connected to the rear axle. The
load sensing valve supplies a signal to the
control port of the relay valve to operate the rear
brake actuators, and also to the LSV signal port
of the relayed empty/load valve.
NOTE: Drawbar Vehicles: A trailer control valve,
which incorporates an integral supply dump
valve, monitors the pressure difference between
the footvalve output lines and the control/service
line connection to the trailer. In the event of a
loss of pressure in the control/service line during
a service brake application, the imbalance of
pressure created across the supply dump valve
causes the supply/emergency line pressure to
be exhausted to atmosphere. This pressure
dump activates the emergency function of the
trailer emergency relay valve and applies the
trailer brakes.

Secondary Braking System

The secondary braking system comprises of the
front brakes only and the rear brakes only. This
system is controlled by the dual concentric
footvalve of the service braking system.

E9612
6–1–2
6 BRAKES
55 Series Brake system descriptions and diagrams

Park Braking System – 11 to 15 Tonne

Vehicles
The park reservoir supplies the handbrake valve
and the supply port of a relay valve. The hand
control valve supplies graduated air pressure to
the control port of the relay valve operating the 1
spring brake actuators on the rear axle.
NOTE: Drawbar Vehicles: Application of the
handbrake supplies air to port 4.3 of the trailer
control valve to operate the trailer brakes.

Park Braking System – 17/18 Tonne Vehicles

The park/trailer reservoir supplies air to the
supply port of the spring brake relay valve. The
relay valve supplies air to the handbrake valve.
The hand control valve supplies graduated air
pressure to the control port of the relay valve
operating the spring brake actuators on the rear
axle. The relay valve is also signalled with air
from the rear service brake system to enable
anti–compounding of the spring brake actuators.
NOTE: Drawbar Vehicles: Application of the
handbrake supplies air to port 4.3 of the trailer
control valve to operate the trailer brakes.

Warning Indicators
All the reservoirs are connected to an audible
buzzer and warning light to indicate when the air
pressure in part of the brake system has fallen
below a pre–determined value. The operation of
the spring brake illuminates a warning light by
either a micro–switch in the hand control valve
or a separate low pressure switch. The rear
brake lights are operated by a micro–switch on
the foot brake pedal.

Anti–Lock Brakes (ABS) – Option

ABS modulator valves, one for each wheel, are
supplied with air by the delivery ports of the
relayed empty/load valve on the front axle and
the relay valve on the rear axle. The modulators
are operated by the ABS electronic control unit
(ECU). The ECU receives signals from the
outputs of each wheel mounted sensor.

E9612 6–1–3
 BRAKES 6
Brake system descriptions and diagrams 55 Series

Traction Control (ASR) – Option

The traction control (ASR) system is an
additional inclusion within the vehicle ABS
system. The ASR system comprises of two

1 double check valves and two additional 3/2

solenoid valves. The double check valves are
supplied by the rear service relay valve and the
3/2 solenoid valves. The 3/2 solenoid valves are
supplied by the auxiliary port of the multi–circuit
protection valve. The double check valves are
able to receive system air pressure when the
ABS ECU operates the 3/2 solenoid valves; thus
allowing the rear brakes to be operated by the
ABS system when the ASR function is required.

Electronic Air Suspension (ECAS) – Option

The air suspension system air is fed
independently from the brake system via the
auxiliary port on the multi–circuit protection
valve and stored in a separate reservoir which is
equipped with a manual ‘tilt’ drain valve.
Electronic height sensors monitor the pre–set
ride height and transmit this information to an
electronic control unit (ECU) in the cab. In the
event of deviations from the pre–set ride height
the ECU activates a solenoid valve, which
depending on the existing level, pressurises or
exhausts the air bellows until the correct ride
height is attained.
Air is taken from each of the air bellows to the
load sensing valve which modulates the rear
axle brake forces in proportion to the axle load.
The system is interfaced with the tachograph so
that the bellows are neither filled or vented
during dynamic axle load fluctuations during
travel, whilst accelerating, braking, or
negotiating bends.
A remote control unit located on the drivers side
of the cab can be used to alter the loading ramp
height from either inside or outside the drivers
cab.

E9612
6–1–4
 6 BRAKES
55 Series Brake system descriptions and diagrams

10
9 11
11
12 17
7
1 5
15
18
3 4 13 1
2 16 15 19
6
8
14

30 15
20

29 22 21

24

25
23
31 32
27 26

28 070550

FIG. 1. STANDARD BRAKE SYSTEM DIAGRAMMATIC LAYOUT – 11 TO 15 TONNE VEHICLES

1. Air filter 12. Front service reservoir 23. Load sensing valve
2. Compressor 13. Park reservoir 24. ISO test connection
3. Expansion tank 14. Rear service reservoir 25. Empty/load valve
4. Air dryer with integral unloader 15. Manual drain valve 26. Single relay valve
5. Pressure relief (safety) valve 16. ISO test connection 27. Spring brake actuator
6. ISO test connection (full flow) 17. Park brake warning light 28. ISO test connection
7. Purge tank 18. Park brake warning light switch 29. Spring brake actuator
8. Multi–circuit protection valve 19. Hand control valve 30. Front brake actuator
9. Low pressure switch 20. Single relay valve 31. Front brake actuator
10. Warning light and buzzer 21. Micro–switch 32. ISO test connection
11. Air gauges 22. Dual footbrake valve

PIPING CODE
Air pressure supply/storage
Service/delivery circuit
Secondary/parking circuit
Auxiliary
Exhaust
Electrical cable

E9612 6–1–5
 BRAKES 6
Brake system descriptions and diagrams 55 Series

10 17
9 11
11
12 12
7
1 5
15 15
18
1 3 4 13

2 16 15 19
6
8
14

15

14
30 20
15

29 22 21

24

25
23
31 32
27 26

28 070551

FIG.2. STANDARD BRAKE SYSTEM DIAGRAMMATIC LAYOUT – 17/18 TONNE VEHICLES

1. Air filter 12. Front service reservoir 22. Dual footbrake valve
2. Compressor 13. Park reservoir 23. Load sensing valve
3. Expansion tank 14. Rear service reservoir 24. ISO test connection
4. Air dryer with integral unloader 15. Manual drain valve 25. Empty/load valve
5. Pressure relief valve 16. ISO test connection 26. Single relay valve
6. ISO test connection (full flow) 17. Park brake warning light 27. Spring brake actuator
7. Purge tank 18. Park brake warning light switch 28. ISO test connection
8. Multi–circuit protection valve 19. Hand control valve 29. Spring brake actuator
9. Low pressure switch 20. Spring brake (overload 30. Front brake actuator
10. Warning light and buzzer protection) relay valve 31. Front brake actuator
11. Air gauges 21. Micro–switch 32. ISO test connection

PIPING CODE
Air pressure supply/storage
Service/delivery circuit
Secondary/parking circuit
Auxiliary
Exhaust
Electrical cable

E9612
6–1–6
6 BRAKES
55 Series Brake system descriptions and diagrams

1 1
2
2

4 4 6

5
5 1
7

9 8
16

10
12
5 11
14 13
5 14

15

2 2
1 1
070555

FIG.3. ANTI–LOCK BRAKES (ABS) DIAGRAMMATIC LAYOUT

1. Sensor ring 9. ISO test connection

2. Wheel sensor 10. Load sensing valve
3. Front brake actuator 11. Single relay valve
4. ISO test connection (full flow) 12. Empty/load valve
5. Modulator valve 13. Spring brake actuator
6. Spring brake actuator 14. ISO test connection
7. Dual footbrake valve 15. Front brake actuator
8. Micro–switch 16. ABS electronic control unit (ECU)

PIPING CODE
Air pressure supply/storage
Service/delivery circuit
Secondary/parking circuit
Electrical cable

E9612 6–1–7
 BRAKES 6
Brake system descriptions and diagrams 55 Series

1 1
2 2

1 3 7
4 4 6
5
5

9
8
19 8 11 10

12
14
17 5 16
17
5 15 15
13
18

2 2
1 1
070556

FIG.4. ANTI–LOCK BRAKES (ABS) AND TRACTION CONTROL (ASR) DIAGRAMMATIC LAYOUT

1. Sensor ring 11. ISO test connection

2. Wheel sensor 12. Load sensing valve
3. Front brake actuator 13. Single relay valve
4. ISO test connection (full flow) 14. Empty/load valve
5. Modulator valve 15. Double check valve
6. Spring brake actuator 16. Spring brake actuator
7. Multi–circuit protection valve 17. ISO test connection
8. 3/2 Solenoid valve 18. Front brake actuator
9. Dual footbrake valve 19. ABS electronic control unit (ECU)
10. Micro–switch

PIPING CODE
Air pressure supply/storage
Service/delivery circuit
Secondary/parking circuit
Auxiliary
Electrical cable

E9612
6–1–8
6 BRAKES
55 Series Brake system descriptions and diagrams

2
1

1
6
10
5 7 11
3
4
8
12
7 9

13
18 17

15
14

16
070553

FIG.5. 2–LINE DRAWBAR CIRCUIT DIAGRAM — 11 TO 15 TONNE MODELS

1. Warning light and buzzer 10. Handbrake warning light

2. Low pressure switch 11. Handbrake micro–switch
3. Shunt coupling (option) 12. Handbrake valve
4. Multi–circuit protection valve 13. Single relay valve
5. ISO test connection 14. Trailer coupling (service)
6. Park/trailer reservoir 15. Trailer coupling (emergency)
7. Manual drain valve 16. Trailer control valve
8. Front service reservoir 17. Micro–switch
9. Single check valve 18. Dual footbrake valve

PIPING CODE
Air pressure supply/storage
Service/delivery circuit
Secondary/parking circuit
Auxiliary
Exhaust
Electrical cable

E9612 6–1–9
 BRAKES 6
Brake system descriptions and diagrams 55 Series

2
1 3
1
6
8
7 9
4
5

10

11
15
16

13 12

14

070557

FIG.6. 2–LINE DRAWBAR CIRCUIT DIAGRAM — 17/18 TONNE MODELS

1. Warning light and buzzer 9. Handbrake micro–switch

2. Low pressure switch 10. Handbrake valve
3. ISO test connection 11. Spring brake (overload protection) relay valve
4. Shunt coupling (option) 12. Trailer coupling (service)
5. Multi–circuit protection valve 13. Trailer coupling (emergency)
6. Park/trailer reservoir 14. Trailer control valve
7. Manual drain valve 15. Micro–switch
8. Handbrake warning light 16. Dual footbrake valve

PIPING CODE
Air pressure supply/storage
Service/delivery circuit
Secondary/parking circuit
Auxiliary
Exhaust
Electrical cable

E9612
6–1–10
6 BRAKES
55 Series Brake system descriptions and diagrams

2
1

1
6
10
5 7 11
3
4
8
12
7 9

19 13
20

14

15
17
16

18
070554

FIG.7. 3–LINE DRAWBAR CIRCUIT DIAGRAM — 11 TO 15 TONNE MODELS

1. Warning light and buzzer 11. Handbrake micro–switch

2. Low pressure switch 12. Handbrake valve
3. Shunt coupling (option) 13. Single relay valve
4. Multi–circuit protection valve 14. Trailer coupling (auxiliary)
5. ISO test connection 15. Inverting relay valve
6. Park/trailer reservoir 16. Trailer coupling (emergency)
7. Manual drain valve 17. Trailer coupling (service)
8. Front service reservoir 18. Trailer control valve
9. Single check valve 19. Micro–switch
10. Handbrake warning light 20. Dual footbrake valve

PIPING CODE
Air pressure supply/storage
Service/delivery circuit
Secondary/parking circuit
Auxiliary
Exhaust
Electrical cable

E9612 6–1–11
 BRAKES 6
Brake system descriptions and diagrams 55 Series

2
1

1
6
8
5 7
3 9
4

10

17 11
18

12

13
15
14

16
070567

FIG.8. 3–LINE DRAWBAR CIRCUIT DIAGRAM — 17/18 TONNE MODELS

1. Warning light and buzzer 10. Handbrake valve

2. Low pressure switch 11. Spring brake (overload protection) relay valve
3. Shunt coupling (option) 12. Trailer coupling (auxiliary)
4. Multi–circuit protection valve 13. Inverting relay valve
5. ISO test connection 14. Trailer coupling (service)
6. Park/trailer reservoir 15. Trailer coupling (emergency)
7. Manual drain valve 16. Trailer control valve
8. Handbrake warning light 17. Footbrake micro–switch
9. Handbrake micro–switch 18. Footbrake valve

PIPING CODE
Air pressure supply/storage
Service/delivery circuit
Secondary/parking circuit
Auxiliary
Exhaust
Electrical cable

E9612
6–1–12
6 BRAKES
55 Series Brake system descriptions and diagrams

5
3
4
7
1 1
6
2

15
9 9

11

10

12

13
14
070552

FIG.9. ELECTRONIC AIR SUSPENSION (ECAS) CIRCUIT DIAGRAM

1. Air suspension reservoir 9. Air bellows

2. Manual drain valve 10. Footbrake valve
3. Warning light and buzzer 11. Footbrake micro–switch
4. Low pressure switch 12. ISO test connection
5. Multi–circuit protection valve 13. Load sensing valve
6. ECAS electronic control unit (ECU) 14. Single relay valve
7. Height sensor 15. Empty/load valve
8. ECAS solenoid valve

E9612 6–1–13
 BRAKES 6
Brake system descriptions and diagrams 55 Series

DESCRIPTION OF BRAKE SYSTEM COMPONENTS

Compressor
The engine driven single cylinder air compressor
supplies the brake system with compressed air.

1 Air Dryer
The air dryer is of the cartridge type and serves
the following functions:

— The desiccant and internal filters dry and

clean the air entering the brake system. A
separate purge tank of 3,5 litres capacity is
connected to the air dryer and is used to
create a back flow expelling the
accumulated dirt and condensate. The
purging of the air dryer is activated by a
purge valve when the maximum normal
system operating pressure is reached.

— The integral unloader valve controls the

compressor duty cycle, maintaining the
system pressure between upper and lower
limits during normal operation.

— The pressure relief (safety) valve fitted to

the air dryer limits the brake system
pressure in the event of a failure of the
pressure governing system.

Expansion Reservoir
The expansion reservoir damps the pressure
pulses from the compressor on the feed pipe to
the air dryer to prevent excessive noise.

E9612
6–1–14
6 BRAKES
55 Series Brake system descriptions and diagrams

Multi–Circuit Protection Valve

The multi–circuit protection valve is of the all
parallel full feedback type and has the following
functions:

— The valve prioritises the charging of the 1

front and rear service reservoirs over the
charging of the park reservoir. This priority
ensures that the service reservoirs are
charged to a pre–determined pressure
before the spring brakes can be released.

— The valve ensures that the front, rear and

park reservoirs are charged independently
and that a pressure failure in one reservoir
does not cause a pressure failure in any
other.

— The valve allows full feedback between all

the circuits above the closing pressure of
the valve elements.

— A feature within the valve allows for a slow

bleedback between the park reservoir and
the front reservoir. This feature operates
when the compressor is stationary and there
is an air leak in the front reservoir system. It
ensures that the vehicle spring brakes will
eventually be applied if the front reservoir is
allowed to drain whilst the vehicle is
stationary. The front reservoir will therefore
have to be replenished before the spring
brakes can be released and the vehicle
moved.

E9612 6–1–15
 BRAKES 6
Brake system descriptions and diagrams 55 Series

Dual Concentric Footbrake Valve

The dual concentric footvalve provides a
graduated upright air pressure supply to apply
the brake assemblies in proportion to the travel

1 of the footbrake pedal. The air from the two

service reservoirs is controlled through
independent circuits in the valve and produces
near equal output pressures under normal
operating conditions.

Load Sensing Valve

The load sensing valve in the rear service brake
circuit modulates the rear brake operating
pressure in proportion to the rear axle load.
When the rear axle is in an unladen condition
the valve reduces the rear brake pressure to
prevent premature wheel lock–up. When the
rear axle is laden the valve supplies an
unmodulated pressure to utilise the full
performance of the rear brakes. A signal is also
provided to the relayed empty/load valve in the
front brake circuit.

Rear Axle Service Relay Valve

The relay valve in the rear service brake circuit
is fitted to minimise the delay in the application
of the rear brakes. The air volume required for
the delivery port of the valve is supplied directly
from the rear reservoir. The pressure at the
delivery port of the valve is controlled by a
signal from the footvalve and is proportional to
the signal pressure. The signal is supplied
through the load sensing valve from the upright
primary port of the footvalve.

Spring Brake Relay Valve – 11 to 15 Tonne

Vehicles
The relay valve in the spring brake circuit is
fitted to minimise the delay in the release of the
pressurised air from the spring brake actuators.
The air volume required for the delivery port is
supplied from the park reservoir. The pressure
at the delivery port of the valve is controlled by a
signal from the hand control valve and is
proportional to the signal pressure.

E9612
6–1–16
6 BRAKES
55 Series Brake system descriptions and diagrams

Spring Brake (Overload Protection) Relay

Valve – 17/18 Tonne Vehicles
The relay valve in the spring brake circuit is
fitted to minimise the delay in the release of the
pressurised air from the spring brake actuators.
The air volume required for the delivery port is 1
supplied from the park/trailer reservoir, via a
single check valve incorporated in the supply
port. The single check valve protects the spring
brake circuit in the event of failure of the trailer
circuit, thus preventing an involuntary
application of the spring brakes. The relay valve
also supplies the supply port of the handbrake
valve with air protected by a single check valve.

The design of the relay valve includes the

anti–compounding function required for the rear
axle spring brake actuators. This achieved by
sensing the pressure in the rear service brake
system through a control port on the valve,
enabling the relay valve to increase the pressure
supplied to the spring brake actuators when the
footbrake is applied. The output force of the
spring brake actuators is limited to a value
which will not damage the rear brake
assemblies when both the service and park
brake are applied simultaneously. The pressure
at the delivery port of the relay valve is
controlled by a signal from the handbrake valve
and is proportional to the signal pressure.

E9612 6–1–17
 BRAKES 6
Brake system descriptions and diagrams 55 Series

Relayed Empty/Load Valve

The relayed empty/load valve (RELV) has two
functions in the front brake circuit. The relay
portion of the valve is used to minimise the

1 delay in the application of the front brakes. The

air volume required for the delivery port of the
valve is supplied directly from the front reservoir.
The pressure at the delivery port of the valve is
controlled by a signal from the footvalve and a
signal from the rear axle load sensing valve.
The signal from the load sensing valve provides
the second function of the valve. When the
vehicle is in a partially laden condition the load
sensing valve reduces the pressure at the LSV
signal port of the RELV. The empty/load function
senses the ratio between the LSV signal and the
footvalve pressure being fed directly from the
footvalve. When the ratio is non 1:1 the
empty/load function reduces the valve output
pressure to the front brakes. This feature
provides a similar footbrake pedal feel under all
vehicle load conditions.
If the load sensing valve signal remains at zero
pressure due to a failure in the rear brake circuit
the valve responds to the failure by returning the
valve ratio to 1:1 and therefore utilising the full
performance of the front brakes.

Hand Control Valve – Rigid Vehicles

A single element hand control valve is fitted to
rigid vehicles and provides a graduated inverse
pressure supply for the spring brake actuators
on the rear axle. The valve has three operating
positions:

Off Position: With the valve in the off

position the spring brake actuators are
pressurised and the rear brakes are
released.

Spring Loaded Graduated Brake

Position: The first part of the control lever
travel from the off position provides a
graduated inverse output pressure to the
spring brake relay, which can progressively
apply and release the rear brakes. In this
intermediate position the travel is spring
loaded to return to the off position when the
lever is released. This feature of the valve
provides a graduated brake separate to the
footbrake service air circuits.

E9612
6–1–18
6 BRAKES
55 Series Brake system descriptions and diagrams

On/Park Position: The on/park position is

used to lock the control lever in a position
with the air exhausted from the spring brake
relay valve signal line. This applies the rear
axle brakes using the spring brake
actuators, giving an effective park brake. 1
Hand Control Valve – Drawbar Vehicles
A dual element hand control valve is fitted to
drawbar vehicles and provides a graduated
inverse pressure supply for the spring brake
actuators on the tractive unit rear axle and the
trailer brakes. The valve has four operating
positions:

Off Position: With the handbrake valve in

the off position, the spring brake actuators
on the tractive unit are pressurised and the
brakes are released.

Spring Loaded Graduated Brake

Position: The first part of the control lever
travel from the off position provides a
graduated inverse output pressure to the
spring brake relay and trailer control valve,
which can progressively apply and release
the tractive unit rear brakes and trailer
brakes. In this intermediate position the
travel is spring loaded to return to the off
position when the lever is released. This
feature of the valve provides a graduated
brake separate to the footbrake service air
circuits.

On/Park Position: With the handbrake

valve applied to the on/park position, the air
is exhausted from the spring brake relay
valve signal line to apply the tractive unit
rear brakes and, via the trailer control valve,
the trailer brakes.

E9612 6–1–19
 BRAKES 6
Brake system descriptions and diagrams 55 Series

Test Position: The test position enables

the vehicle brakes to remain applied whilst
the brakes on the trailer are released. This
test facility enables the driver to ascertain

1 that the tractive unit is capable of holding

the vehicle combination in the event of a
failure in the trailer braking system.

To select the test position, apply the

handbrake control to the on/park position
and then depress the control lever and then
move it fully rearwards.

Trailer Control Valve – Drawbar Vehicles

The trailer control valve, which incorporates a
bolt–on choke type supply dump valve, monitors
the pressures between the footvalve and the
trailer service control line. In the event of a
pressure loss in the trailer service line which
results in an imbalance of pressures, the next
service brake application will cause the supply
control (dump) valve to choke or cut–off air to
the trailer emergency supply line. This signals
the trailer emergency relay valve to apply the
trailer brakes from the air stored in the trailer
reservoirs.

Inverting Relay Valve – 3–Line Drawbar

Vehicles
This valve is a trailer control valve which is used
to upright the inverse trailer control valve signal
from the handbrake valve to the auxiliary trailer
coupling.

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6 BRAKES
55 Series Brake system descriptions and diagrams

Brake Actuators

Front Brake Actuators: The front axle

brakes are fitted with diaphragm brake
chambers which admit service brake air
pressure to apply the brake assemblies. 1
The output force of the chambers is
proportional to the air pressure admitted.

Rear Brake Actuators: The rear axle

brakes are fitted with spring brake actuators
which combine the functions of normal
service braking and park braking. The
service brake portion of the actuator
operates as a brake chamber. The parking
brake is applied by exhausting the air in the
spring brake portion of the actuator allowing
a powerful brake spring in the chamber to
expand and apply the brake. The brakes
are released by admitting air pressure into
the spring brake portion of the actuator to
re–compress the brake spring. In the event
of a breakdown the brake spring can also
be compressed by rotating a wind–off bolt
on the rear of the actuator.

Brakes Assemblies
Front Brakes – 11 to 15 Tonne Vehicles:
The front axle is fitted with self–adjusting
sliding caliper disc brakes operated by
diaphragm brake actuators.

Front Brakes – 17/18 Tonne Vehicles:

The front axle is fitted with self–adjusting
DAF ‘S’ cam drum brakes operated by
diaphragm brake actuators.

Rear Brakes – 11 to 15 Tonne Vehicles:

The rear axle is fitted with self–adjusting
single wedge drum brakes operated by
spring brake actuators.

Rear Brakes – 17/18 Tonne Vehicles: The

rear axle is fitted with self–adjusting DAF ‘S’
cam drum brakes operated by spring brake
actuators.

Air Pressure Test Points

ISO test points are located at various points in
the air system, and are identified in the air
piping diagrams.

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Brake system descriptions and diagrams 55 Series

Air Piping and Fittings

Metric piping and fittings to DIN 3852 standard,
are used throughout. Rubber O–ring seals also
replace Loctite sealant. Metric quick release

1 push–in fittings, can be identified by the size,

which is stamped on the collet. The green
letterings on the plastic pipes also indicate
metric sizes. Imperial sizes are coded white.

Air Piping Identification

All air pipes, with the exception of some exhaust
pipes, are fitted with coloured/numbered coded
identification sleeves which are fitted to each
end of the air pipe. The identification sleeves
are coded as follows:
0—Orange
1—Pink
2—Green
3—Red
4—Blue
5—Brown
6—Grey
7—Yellow
8—Purple
9—White

Brake Valve Port Identification

The valve ports and connections in all brake
system components are identified in accordance
with ISO standards. The ISO reference
numbers, which are cast in each valve body
adjacent to the relevant port, identify each port
connection as follows:
1—Supply (inlet) port
2—Delivery (outlet) port
3—Exhaust port (to atmosphere)
4—Signal port

NOTE: A second digit is used to identify

additional and similar port connections (eg.
2.1—delivery port number one and 2.2—delivery
port number two).

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6 BRAKES
55 Series Brake system descriptions and diagrams

DESCRIPTION OF ANTI–LOCK BRAKES (ABS) COMPONENTS

ABS System
The ABS system is a WABCO four channel, four
sensor system using the principles of individual
wheel control on the rear axle (IR) and modified
individual wheel control on the front axle (MIR).
The system meets all the legislative 1
requirements of a category 1 ABS system and
operates in the following manner.
A toothed pole wheel rotating with the wheel hub
is in the proximity of a fixed sensor which
generates electrical impulses. These signals,
one for each wheel, are transmitted to an
electronic control unit (ECU). The ECU
computes the speed, acceleration and
deceleration of each wheel from the sensor
impulses; these values are compared to a
calculated vehicle reference speed to establish
the level of slip for each wheel. As soon as a
wheel exceeds a threshold value for
deceleration or slip, the ECU signals a solenoid
valve for the particular wheel which modulates
the air pressure in the brake actuator thus
controlling the brake force at the tyre. The ABS
system can therefore control the amount of
braking to a level below that demanded by the
driver.
The IR control logic of the rear axle provides the
basis for optimum control of the braking forces
and distinguishes itself when braking on laterally
different coefficients of friction (eg. ice/asphalt)
or on bends. This gives shorter stopping
distances when stopping on split adhesion
surfaces or braking on a bend.
The MIR control of the front axle attempts to
provide the optimum braking forces while not
creating an adverse steering force across the
front axle. This feature maintains the steerability
of the vehicle while creating an acceptable level
of brake force.
A failure of any part of the ABS system will
result in partial or total shutdown of the ABS
function, dependent upon the type and location
of the failure. A failure in the ABS system is
indicated to the driver by means of a warning
light located in the main instrument panel.

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Brake system descriptions and diagrams 55 Series

Electronic Control Unit

The electronic control unit (ECU) is located
inside the cab and contains microprocessors
which process the signals from the sensors. The

1 calculated values for each wheel are updated

every few milliseconds and the ECU controls
solenoid modulator valves to ensure that the
wheels are braked at the slip point for optimum
braking.
The circuit in the ECU checks the integrity of the
electronic system when the vehicle electrics are
switched on and monitors the system during
braked and unbraked running.

Modulator Valves
A modulator valve is fitted in the supply line to
each of the brake actuators enabling the
pressure in each actuator to be individually
controlled. The valves have the facility to
release, hold and re–apply air to a brake
actuator in response to the electrical signals
from the ECU.

Wheel Sensors and Pole Wheels

The pole wheel is a ring of equi–spaced teeth
attached to the wheel hub. The inductive sensor
consists of a permanent magnet with a round
pole pin and a coil. The rotation of the toothed
wheel alters the magnetic flux picked up by the
coil and thereby produces an alternating
voltage. The frequency of this voltage is
proportional to the wheel speed and the rate of
change of frequency is proportional to the wheel
deceleration.

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6 BRAKES
55 Series Brake system descriptions and diagrams

DESCRIPTION OF TRACTION CONTROL (ASR) COMPONENTS

ASR System
The ASR system is a feature which can be
added to a vehicle installed with an ABS
system. The ABS ECU controls an extra pair of
solenoid valves and some form of independent
engine control. The ASR function operates 1
when the vehicle is attempting to accelerate and
there is insufficient road adhesion at the rear
axle to provide traction. When the ECU
calculates wheel slip it reduces the engine
demand and also applies the rear brakes to
reduce the tractive effort to a level sustainable
by the road adhesion.

3/2 Solenoid Valves

The 3/2 solenoid valves are actuated by the
ASR function of the ABS ECU when a
differential brake is required or the engine power
is too great for the available road adhesion. The
valves open to provide system air pressure to
the ABS modulator valves.

Double Check Valves

The double check valves enable the rear brake
to be operated by either the rear service brake
system or the ASR solenoid valves. The
pressure delivered to the ABS modulator valves
is the greater of the two input pressures.

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Brake system descriptions and diagrams 55 Series

AIR PRESSURE SYSTEM TEST

WARNING:

— Do NOT attempt to start or run the

engine in a confined space or
unventilated area; exhaust fumes
1 contain toxic gases which, if inhaled
may prove fatal. If the engine is to be
run in a confined space then an exhaust
extractor must be used.

— Any failures in the air pressure system

MUST be investigated and rectified
before the vehicle is put into service.

1. Chock all road wheels to prevent any

vehicle movement whilst carrying out this
test.

2. Fully deplete the vehicle air system and

apply the handbrake to the park position.

3. Start the engine to charge the vehicle air

pressure system and check the following
functions:

— The warning buzzer should cease to

sound and the low air pressure warning
light should extinguish within a
maximum period of 2 minutes;
excessive air build–up times MUST be
investigated and the cause rectified.
— Continue running the engine until the
air pressure system is fully charged;
this should be achieved within a
maximum period of 3 minutes;
excessive air build–up times MUST be
investigated and the cause rectified.
— Switch off the engine and observe the
air pressure gauges for any pressure
loss; pressure loss is NOT permissible.

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6 BRAKES
55 Series Brake system descriptions and diagrams

— With the air pressure system fully

charged and the engine stopped, fully
depress the footbrake and observe the
air pressure gauges; the air pressure
readings should drop slightly and then
remain constant, if the readings 1
continue to drop then the footbrake
system is faulty.
— With the air pressure system fully
charged and the engine stopped, move
the handbrake to the ‘OFF’ position
and observe the air pressure gauges;
the air pressure readings should drop
slightly and then remain constant, if the
readings continue to drop then the
handbrake system is faulty.

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Brake system descriptions and diagrams 55 Series

E9612
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55 Series Contents

CONTENTS Page Date

SECTION 2A—BRAKE ASSEMBLIES (Perrot)

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 1 . . . . . . 9612
Description:
Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 2 . . . . . . 9612
Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 2 . . . . . . 9612
Operation:
Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 3 . . . . . . 9612
Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overhaul:
6— 2A — 3 . . . . . . 9612
2
Automatic Expander Unit—Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 26 ..... 9612
Brake Caliper Expander Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 18 ..... 9612
Brake Caliper Guide Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 23 ..... 9612
Brake Caliper Guide Pin Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 25 ..... 9612
Removal and Refitment:
Automatic Expander Unit—Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 17 . . . . . 9612
Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 9 . . . . . . 9612
Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 10 . . . . . 9612
Front Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 4 . . . . . . 9612
Rear Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2A — 12 . . . . . 9612

SECTION 2B—BRAKE ASSEMBLIES (DAF ‘S’ Cam)

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2B — 1 . . . . . . 9612
Removal and Refitment:
Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2B — 2 . . . . . . 9612
Camshaft Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 2B — 8 . . . . . . 9612

E9612 1
2

E9612
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6 BRAKES
55 Series Brake assemblies (Perrot)

2A. BRAKE ASSEMBLIES (Perrot)

DATA

Type:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sliding caliper disc brakes
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single air wedge (SAW) drum brakes
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic
Front brake disc run–out . . . . . . . . . . . . . . . . . . . . 0,2 mm (0.008 in) maximum per–side
Front brake disc minimum thickness . . . . . . . . . . 40 mm (1.57 in)
Front brake pad minimum thickness . . . . . . . . . . 0,5 mm (0.020 in) above the base of the wear
indicator slot 2
Rear brake lining to drum clearance . . . . . . . . . . 0,2 to 2,0 mm (0.008 to 0.080 in)
Rear brake lining minimum thickness . . . . . . . . . 0,5 mm (0.020 in) above the wear indicator
slots where visible, or 5,5 mm (0.216 in) of total
lining thickness
Rear brake drum machining tolerance . . . . . . . . 3 mm (0.118 in) on diameter, maximum
diameter 363,23 mm (14.3 in)
Rear brake drum run–out . . . . . . . . . . . . . . . . . . . . 0,2 mm (0.008 in) maximum

Torque Tightening Figures Nm lbf ft

Front brake caliper assembly retaining bolts . . . 560 to 630 413 to 464
Front brake caliper expander assembly:
Brake cylinder mounting bracket
retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 74 to 102 55 to 73
Brake shaft lever retaining bolt . . . . . . . . . . . 34 to 36 25 to 27
Guide pin socket headed screw . . . . . . . . . . 320 to 380 235 to 280
Location peg socket headed screw . . . . . . . 35 25
Spreader plate socket headed screw . . . . . . 22 16
Front hub to brake disc bolts . . . . . . . . . . . . . . . . . 185 to 200 136 to 148
Rear automatic adjuster housing bolts . . . . . . . . 124 to 146 91 to 108
Rear brake drum retaining bolts . . . . . . . . . . . . . . 40 to 47 30 to 35
Rear brake shoe carrier backplate bolts . . . . . . . 229 to 243 168 to 180
Rear brake shoe steady clip retaining bolt . . . . . 65 to 75 48 to 55
Rear expander location bolts . . . . . . . . . . . . . . . . . 124 to 146 91 to 108
Spring brake wind–off bolt . . . . . . . . . . . . . . . . . . . 30 to 40 22 to 29

E9612 6–2A–1
 BRAKES 6
Brake assemblies (Perrot) 55 Series

DESCRIPTION

Front Brakes
The front axle is fitted with self–adjusting sliding
caliper disc brakes operated by diaphragm
brake actuators. The complete disc brake,
including the brake actuator and bracket
consists of two sub–assemblies, a caliper and a
brake carrier. The caliper is mounted and slides
axially on the brake carrier guide shafts. Brake
2 pads are held in position with leaf springs and
retaining pins.
The brake incorporates an automatic retracting
device which returns the caliper after brake
application ensuring that the optimum running
clearance between brake pads and brake disc is
maintained irrespective of brake pad wear. The
brake actuation mechanism incorporates an
automatic adjusting device which compensates
for brake pad wear.

Rear Brakes
The rear axle is fitted with self–adjusting single
wedge drum brakes operated by spring brake
actuators. This type of expander brake is a
leading/trailing shoe configuration; the shoe
support abutment cross–struts have sliding
faces, the brake shoes being held in these
abutments by the tension of the return springs
and are therefore referred to as sliding shoes.
Shoe return springs ensure effective retraction
of the shoes after brake application and also
supply the return load to operate the automatic
adjusters. Both shoes are held in position with
steady spring clips.

E9612
6–2A–2
6 BRAKES
55 Series Brake assemblies (Perrot)

OPERATION

Front Brakes
When the brakes are applied, linear movement
of the brake actuator rod via the brake lever is
converted into rotational movement of the
expander unit, which in turn converts from
rotational to longitudinal movement, pushing the
piston pressure plate/brake pad against the
brake disc. On completion of brake application,
the expander unit spring returns the expander
unit and brake lever to their neutral positions,
2
whilst the automatic retracting device returns the
caliper.

Rear Brakes
When the brakes are actuated the brake
chamber pushes the wedge head further in
between the rollers; this forces the rollers apart
evenly, pushing the pistons outwards forcing the
shoes against the drum, the reaction forces
from the brake shoes being absorbed by their
supports. The brake shoes move into the
applied position by ‘sliding’ across the abutment
cross–strut faces. When the brake is released
the wedge spring returns the wedge and
diaphragm back to the off position and the shoe
return springs pull the shoes back to their
original positions.

E9612 6–2A–3
 BRAKES 6
Brake assemblies (Perrot) 55 Series

REMOVAL AND REFITMENT

WARNING: Before carrying out any

maintenance/repair work on the brake
assemblies, it is essential that the following
safety precautions are strictly observed:

— Always wear protective clothing, a face

mask and safety glasses/goggles.

2 — Do NOT inhale dust from the brake

pads/linings or blow dust from the brake
assemblies; remove dust using a damp
cloth or vacuum cleaner, deposit used
rags whilst still wet, in a plastic waste
disposal bag.

— Do NOT drill or grind the brake linings.

— When replacing brake pads/linings, the

safety instructions provided by the
manufacturer must always be followed.

— If cleaning solvent is required,

methylated spirit should be used.
070437

Front Brake Pads

FIG. 1. DE–ADJUSTING FRONT BRAKES
CAUTION:
— Brake pads must be renewed as complete
axle sets.

— When renewing brake components, only

parts approved by the vehicle manufacturer
must be fitted.

To Remove (See Fig. 3)

1. Isolate the batteries.

2. Remove the road wheel(s), see

‘Maintenance Manual’.

3. Manually de–adjust the brakes as follows:

— Remove the plastic blanking plug from
the brake lever locknut.
— Using a suitable box spanner, back–off
the adjuster screw in the opposite
direction to brake lever travel, as far as
the integral stop.

E9612
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6 BRAKES
55 Series Brake assemblies (Perrot)

4. Disconnect the brake pad wear indicator at

plug connection and release lead from
plastic ties and brake pad retaining pin.

5. Remove the ‘C’–clips from the brake pad

retaining pins.

6. Using a suitable punch, drift out the

retaining pins and detach the leaf springs.
2
7. Remove the brake pads.

8. Thoroughly clean the brake pad contact

surfaces of brake caliper.

E9612 6–2A–5
 BRAKES 6
Brake assemblies (Perrot) 55 Series

Inspection (see Fig. 2.) 1 2

1. Examine the brake discs for excessive
wear, distortion or damage as follows:
— Light surface crazing or a network of
light surface cracks on the friction
surface of the brake disc are
permissible.

2 — Radial cracks over the complete friction

surface of the disc are NOT
permissible.
— The maximum width or depth of any
partial crack on the disc friction surface
must NOT exceed 0,5 mm (0.020 in).
4 3
— The width or depth of any score
(groove) in the disc friction surface B
must NOT exceed 0,5 mm (0.020 in). 5

— Penetration of the disc by any crack or

split is NOT permissible.
— The maximum distortion (run–out) of A
the disc must NOT exceed the figure
quoted in DATA.
— The minimum disc thickness must not
be less than the figure quoted in DATA.
If necessary, renew the brake disc(s), as
instructed in this Section.

2. Inspect the brake pad retaining pins and 070438

leaf springs for wear or damage, renew as

necessary. FIG. 2. CHECKING THE BRAKE DISC

1. Crazing
2. Full radial cracks
3. Partial cracks
4. Scoring
5. Disc penetration
A — Maximum disc run–out 0,2 mm (0.008 in)
per–side
B — Minimum disc thickness 40 mm (1.57 in)

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6 BRAKES
55 Series Brake assemblies (Perrot)

1 2 3

4 5 6

070436
3
1 5 4 7

FIG. 3. BRAKE PAD REMOVAL

1. Retaining pin 4. Brake pad 6. Brake pad wear indicator lead

2. Brake caliper 5. Leaf spring 7. Brake disc
3. ‘C’–clips

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 BRAKES 6
Brake assemblies (Perrot) 55 Series

To Refit
1. Locate the inner brake pad (the one with
the brake wear indicator lead) in position.

2. Carefully lever the caliper towards the brake

disc to enable the fitment of the outer brake
pad.

2 3. Refit one of the brake pad retaining pins

and secure pin with ‘C’–clips.

4. Locate the leaf springs in position, press

springs down and refit the other retaining
pin; secure retaining pin with ‘C’–clips.

5. Reset the adjuster mechanism by turning

the adjuster screw in the direction of brake
lever travel, until the brake pads contact the
brake disc, then back–off the adjuster
screw one half–turn. Refit plastic blanking
plug in brake lever locknut.

6. Connect the brake pad wear indicator lead

at plug connection, then secure lead at
brake pad retaining pin and plastic ties.

7. Connect batteries and fully charge the

vehicle air system.

8. Apply the footbrake pedal several times to

enable the adjuster mechanism to
automatically adjust the brakes to the
optimum running clearance.

9. Refit road wheel(s), see ‘Maintenance

Manual’.

10. Road test vehicle.

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6 BRAKES
55 Series Brake assemblies (Perrot)

Brake Caliper Assembly 1 2

To Remove
1. Isolate the batteries.

2. Chock the rear road wheels and fully

deplete the vehicle air system.

3. Remove road wheel(s), see ‘Maintenance

Manual’. 2
4. Remove the brake pads as instructed in this
Section.

5. Disconnect the air pipe from the brake

actuator, then position air pipe and brake
pad wear indicator cable clear of caliper 2
assembly. 070439

6. Vehicles fitted with ABS: Position ABS

FIG. 4. BRAKE CALIPER ASSEMBLY
cable clear of caliper assembly.
REMOVAL
Brake chamber omitted for clarity
7. Suitably support caliper assembly, then
remove the four bolts securing the caliper
1. Caliper
assembly to the stub axle; carefully
withdraw caliper assembly. 2. Retaining bolts

To Refit
Reverse removal procedure, noting:

1. Tighten the brake caliper assembly

retaining bolts to the torque figure quoted in
DATA.

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 BRAKES 6
Brake assemblies (Perrot) 55 Series

Brake Disc
1
To Remove
CAUTION: Axles fitted with ABS: Any
maintenance operation that exposes the ABS 8
exciter ring, the following precautions MUST be
observed:

2 — Do NOT use the exciter ring as a lever

(fulcrum) point. 7
— Do NOT strike or dent the exciter ring;
protect the ring from damage.
6
— Do NOT stand the hub on the exciter ring.

1. Isolate the batteries.

2
2. Chock the rear road wheels and fully 3
deplete the vehicle air system. 5 4 070440

3. Remove road wheel(s), see ‘Maintenance

Manual’. FIG. 5. BRAKE DISC REMOVAL

4. Remove brake caliper assembly as 1. Brake disc

instructed in this Section. 2. Hub
3. Split pin
5. Remove the front hub, see Group 7, ‘Front
4. Hub nut
Axle and Steering’.
5. Hub cap
6. Remove the flanged bolts securing brake 6. Keyed washer
disc to hub; detach brake disc from hub.
7. Bearing
7. Thoroughly clean all components in a 8. Bolt
suitable solvent and dry thoroughly.

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6 BRAKES
55 Series Brake assemblies (Perrot)

To Refit
1. Refit brake disc to hub and tighten flanged
bolts to the torque figure quoted in DATA.

2. Refit hub, see Group 7, ‘Front Axle and

Steering’.

3. Vehicles fitted with ABS: Push the ABS

sensor inwards until it just contacts the
exciter ring and then rotate the hub several 2
times to set a minimum running clearance
between the sensor and exciter ring.

4. Refit brake caliper assembly as instructed 1

in this Section. 2 070441

5. Refit road wheel(s), see ‘Maintenance

FIG. 6. SETTING ABS SENSOR
Manual’.
1. Exciter ring 2. ABS Sensor
6. Charge vehicle air system.

7. Connect batteries.

E9612 6–2A–11
 BRAKES 6
Brake assemblies (Perrot) 55 Series

Rear Brake Shoes

Service tool: 0485097
1
To Remove
1. Isolate the batteries.

2. Chock the front road wheels and fully

deplete the vehicle air system.
2 3. Remove road wheel(s), see ‘Maintenance
Manual’.

4. Manually release the spring brake actuator,

see Section 3, ‘Brake Components’,
Sub–Section 11.

5. Remove the setscrews retaining the brake

drum and then, using suitable extractor
bolts, detach the brake drum. To aid brake 070456

drum removal it may be necessary to

de–adjust the brake shoes as follows: FIG.7. REAR BRAKE SHOE
DE–ADJUSTMENT
— Insert service tool 0485097 through
inspection aperture in brake drum dust 1. Service tool 0485097
cover and locate on the automatic
expander unit, see Fig.7.
— Move the tool in an anti–clockwise
direction to de–adjust the brake shoes.

E9612
6–2A–12
6 BRAKES
55 Series Brake assemblies (Perrot)

6. Using a suitable bar located through the

loop of the single coil return spring, remove
the spring.
NOTE: A standard workshop brake shoe
‘shoe horn’ or ‘shoe expander’, will be an
additional aid to ease the shoes away from
the adjuster abutments when
removing/refitting the single coil shoe return
spring.
2

070434

FIG.8. REAR BRAKE SHOE RETURN

SPRING REMOVAL

E9612 6–2A–13
 BRAKES 6
Brake assemblies (Perrot) 55 Series

7. The brake shoes are retained with a steady

spring clip, see Fig.9. When removing the
brake shoes, it is not necessary to remove
the spring clip.

8. Remove brake shoe assembly from the

backplate; noting other dual–coil shoe
return spring.
2 9. Clean the brake backplate assembly using
a suitable solvent, then dry thoroughly.

10. Note positions, then remove the

cross–struts from the abutment housing.
Thoroughly clean abutment housing
cross–strut locations.

1
070435

FIG.9. REAR BRAKE SHOE STEADY SPRING

CLIP

1. Steady spring clip

E9612
6–2A–14
6 BRAKES
55 Series Brake assemblies (Perrot)

To Refit

CAUTION:
— Brake shoes must be renewed as complete
axle sets.

— When renewing brake components, only

parts approved by the vehicle manufacturer
must be fitted.
A
2
— The fitment of new return springs will
ensure efficient brake operation.

1. If necessary, machine brake drums, see

DATA.

2. Inspect automatic adjuster rubber gaiters;

renew as necessary.
070208
3. Inspect the abutment cross–struts for wear;
renew as necessary.
FIG.10. AUTOMATIC ADJUSTER INITIAL
4. Reset each automatic adjuster unit by SETTING DIMENSION
rotating each adjusting screw, by an equal
A = 158 mm (6.22 in)
amount, to achieve an overall setting
dimension between the brake shoe slots of
158 mm (6.22 in), see Fig.10.

5. Ensure that the bottom adjuster screw is

located in the expander housing prior to
fitting the brake shoes.

6. Apply a smear of ROCOL J166 high

temperature anti–seize grease to the
abutment cross–struts, then insert
cross–struts into the abutment housing,
noting, the angle faced cross–strut faces
the leading shoe and the straight faced
cross–strut faces the trailing shoe.

E9612 6–2A–15
 BRAKES 6
Brake assemblies (Perrot) 55 Series

7. Refit brake shoes and dual coil spring,

ensuring shoe webs locate in abutment
cross–struts and brake shoes locate in
steady spring clips.
NOTE: The brake backplate is arrowed in
direction of rotation.

8. Refit the single coil return spring; centralise

2 the brake shoe assembly.

9. Refit brake drum and secure with

setscrews.

10. Manually apply the spring brake actuator,

see Section 3, ‘Brake Components’,
Sub–Section 11.

11. Refit road wheel(s), see ‘Maintenance

Manual’.

12. Connect batteries, and fully charge the

vehicle air system.

13. Apply the footbrake several times to

take–up any excessive travel and then,
using feeler gauges through inspection hole
in brake backplate, check clearance at shoe
centre; the clearance must be within the
dimensions quoted in DATA.

14. Road test the vehicle.

E9612
6–2A–16
6 BRAKES
55 Series Brake assemblies (Perrot)

Automatic Expander Unit — Rear Brakes

To Remove
1. Remove the brake shoes as detailed in this
Section.

2. Remove the relevant brake actuator as

detailed in Section 3, ‘Brake Components’,
Sub–Section 11.
2
CAUTION: Exercise extreme care when
removing the wedge assembly as it may be
under spring tension.

3. Remove retaining bolts securing automatic

adjuster housing to brake backplate;
withdraw housing assembly.

To Refit
Reverse the removal procedure, noting:

1. Tighten retaining bolts to torque figure

quoted in DATA.

E9612 6–2A–17
 BRAKES 6
Brake assemblies (Perrot) 55 Series

OVERHAUL

Brake Caliper Expander Assembly

To Dismantle
Made
in German
y

WARNING: The expander unit repair kits are 2

available for either right–hand or left–hand
applications; ensure that the correct repair 1
kit is obtained before attempting to overhaul
the expander unit.
2 1. Remove the front brake caliper as
instructed in this Section.

2. Mount the brake caliper assembly in a 4

suitable working position in a vice. 3
070570

3. Reference mark the brake lever in

relationship to the brake shaft to facilitate FIG.11. MOUNTING BRACKET AND LEVER
refitment. Remove the brake lever retaining REMOVAL
bolt and detach the brake lever from the 1. Retaining bolt
brake shaft. 2. Mounting bracket
3. Brake lever
4. Remove the retaining bolts and detach the
brake cylinder mounting bracket from the 4. Retaining bolt
brake caliper assembly.

5. Remove the socket headed screw and Made in Germany

detach the spreader plate from the piston

end of the expander unit, see Fig.12. 3

070561

FIG.12. SPREADER PLATE REMOVAL

1. Socket headed screw
2. Compression spring
3. Spreader plate

E9612
6–2A–18
6 BRAKES
55 Series Brake assemblies (Perrot)

6. Using suitable implements, prise the

gamma seal from the brake shaft end of the
expander unit. Made
in Germa
ny

7. Using suitable implements, prise the metal

cover from the brake shaft end of the brake
caliper.

8. Carefully extract the seal from its seat on

the brake shaft end of the brake caliper, 2
taking care not to damage the seal seat.

9. Remove the dished circlip securing the

brake shaft end of the expander unit and
extract the spacer from the brake shaft
3
2

1
5
4

070563

FIG.13. BRAKE SHAFT SEAL ASSEMBLY

1. Gamma seal
2. Metal cover
3. Seal
4. Dished circlip
5. Spacer

E9612 6–2A–19
 BRAKES 6
Brake assemblies (Perrot) 55 Series

10. Remove socket headed screw from the

caliper guide peg aperture and then extract 1
the compression spring. Using a M5 bolt
fitted in the guide peg aperture, extract the
guide peg.
2
11. Push the brake expander assembly into 3 4
brake pad aperture and remove from the Made in Germany

2 caliper. Remove the thrust washer from the

brake shaft end of expander unit.
CAUTION: Ensure that expander assembly
has been removed with its axial bearing and
both bearing races.
5
12. Prise the piston gaiter out of the caliper
seat.

13. Unscrew the piston from the expander unit;

discard the expander unit.

To Inspect
1. Clean all components in a suitable solvent
and thoroughly.
5 6
2. Examine the caliper piston bearing for wear
or corrosion; renew as necessary.

070562

FIG.14. BRAKE EXPANDER REMOVAL

1. Socket headed screw

2. Compression spring
3. Guide peg
4. Piston gaiter
5. Piston
6. Axial bearing assembly

E9612
6–2A–20
6 BRAKES
55 Series Brake assemblies (Perrot)

To Reassemble
1. Fit the bearing race, axial bearing and
bearing race on the expander assembly
ensuring that the chamfer on each bearing
race faces away from the axial bearing.

2. Lubricate the piston with the grease

provided in the repair kit.

3. Screw the piston onto the new expander 2

unit.

4. Insert the expander assembly into the bore

of the caliper, ensuring that the groove in
the expander unit is aligned with the guide
peg hole in the caliper.

5. Lubricate the guide peg with grease

supplied from the repair kit. Fit a M5 bolt to
the guide peg and then insert into the guide
peg aperture; ensure that the guide peg
locates in the groove in the expander unit.
Remove the M5 bolt.

6. Insert a new compression spring into the

guide peg hole and then fit a new socket
headed screw. Tighten the socket headed
screw to a the torque figure quoted in
DATA.

7. Fit the thrust washer onto the brake shaft

end of the expander unit.

8. Fit a new dished circlip onto the brake shaft

end of the expander, ensuring that
concaved face of the circlip faces the brake
shaft.

E9612 6–2A–21
 BRAKES 6
Brake assemblies (Perrot) 55 Series

9. Fit a new brake shaft seal as follows:

 Locate the new brake shaft seal on the
seal seat, ensuring that the coil spring
in the seal faces outwards.
 Using a suitable seal replacing tool, fit A
the brake shaft seal.
 Fill the free space within the brake
shaft seal with grease.
2 10. Press a new metal cover onto the brake
shaft end of the brake caliper.

11. Fit a new gamma seal onto the brake shaft

and, using a suitable tool, push the gamma
seal until it abuts the metal cover. Continue
pushing the gamma seal until a fitting 070566
dimension of 5,6 mm " 0,4mm is attained,
see Fig.15.
FIG.15. GAMMA SEAL FITTING DIMENSION
12. Lubricate the piston gaiter seat in the brake
A = 5,6mm " 0,4mm
caliper with grease supplied in the repair kit.
Fit a new piston gaiter into its greased seat
ensuring that the retaining lip engages the
groove in the piston.

13. Fit the spreader plate and tighten the

socket headed screw to the torque figure
quoted in DATA.

14. Refit the brake cylinder mounting bracket

and tighten the retaining bolts to the torque
figure quoted in DATA.

15. Lubricate the serrations of the brake shaft

and brake lever with anti–seize grease.

16. Refit the brake lever on the brake shaft,

ensure that the reference marks made
during removal are aligned. Fit the retaining
bolt and tighten to the torque figure quoted
in DATA.

17. Refit the brake caliper as instructed in this

Section.

E9612
6–2A–22
6 BRAKES
55 Series Brake assemblies (Perrot)

Brake Caliper Guide Pins

To Dismantle, Fig.16 Made

in Germa
ny

1. Remove the front brake caliper as

instructed in this Section.

2. Mount the brake caliper assembly in a

suitable working position in a vice.

3. Using a chisel, carefully remove the guide 1

2
pin covers; do not damage the guide pin
seats.
1
4. With the brake pad carrier suitably
supported, remove the socket headed 2
screw from each guide pin; detach the
brake caliper from the brake pad carrier.
CAUTION: The guide pin socket headed
screws MUST be renewed every time they
are removed from the guide pins.

5. Extract the guide pins from the brake

carrier.

6. Remove both guide pin gaiters from the

brake carrier.

To Inspect
1. Examine the guide pin bushes for corrosion,
wear or damage; if necessary renew the
guide bushes as instructed in this Section.

3
5

4 4

070569

FIG.16. BRAKE CALIPER GUIDE PIN

REMOVAL
1. Cover
2. Socket headed screw
3. Guide pin (long)
4. Gaiter
5. Guide pin (short)

E9612 6–2A–23
 BRAKES 6
Brake assemblies (Perrot) 55 Series

To Reassemble
1. Lubricate the lips of the new guide pin
gaiters and the fit the gaiters in their
grooves in the brake caliper; ensure that
the gaiters are fitted evenly and are not
folded within the groove of the caliper.

2. Using the grease supplied in the repair kit,

2 lubricate the sliding surfaces of each new

guide pin; do NOT lubricate the ends of the
guide pins.

3. Insert the long guide pin into the long guide

pin bore of the brake caliper (the bore
containing two bushes).

4. Insert the short guide pin into the short

guide pin bore of the brake caliper (the bore
containing a single bush).

5. Locate the lip of each gaiter into the groove

of each guide pin.

6. Locate the brake pad carrier in position in

the brake caliper.
CAUTION:
— The contact areas of the guide pins
and brake pad carrier MUST be free of
grease during the assembly procedure.
— Ensure that the gaiters are NOT
crushed between the guide pins and
brake pad carrier during assembly.
7. Fit the new socket headed screws into the
guide pins. Commencing with the long
guide pin, tighten each socket headed
screw to the torque figure quoted in DATA.
CAUTION: The guide pin socket headed
screws MUST be renewed every time they
are removed from the guide pins.

8. Press the new covers fully in position within

brake carrier guide pin seats.

9. Carefully lift each gaiter from its groove in

the guide pin to enable any residual air to
be expelled.

10. Refit the brake caliper as instructed in this

Section.

E9612
6–2A–24
6 BRAKES
55 Series Brake assemblies (Perrot)

Brake Caliper Guide Pin Bushes

B
To Renew
1. Remove the brake caliper guide pins as A
instructed in this Section.

2. Using a suitable mandrel, press the guide

pin bushes out of the caliper (wheel side).
NOTE: The long guide pin bore contains
two bushes, whilst the short guide pin bore 2
contains one. 070564

3. Clean the guide pin bush bores and the FIG.17. GUIDE PIN BUSHES FITTING
guide pin gaiter grooves in the brake DIMENSIONS (Long Guide Pin)
caliper.
A (lower bush) = 59,5mm " 1mm
4. Position the brake caliper on a flat stable B (upper bush) = 19mm " 1mm
surface with the wheel side of the caliper
lowermost.

5. Lubricate all parts prior to assembly with

the grease supplied in the repair kit.

6. Using a suitable mandrel, carefully press

each bush into the caliper to the following
depths: A
— Long guide pin lower bush: Press the
lower bush to a depth of 59.5mm "
1mm, see Fig.17.
— Long guide pin upper bush: Press the
upper bush to a depth of 19mm "
070565
1mm, see Fig.17.
— Short guide pin bush: Press the short
guide pin bush to a depth of 37mm " FIG.18. GUIDE PIN BUSH FITTING
1mm, see Fig.18. DIMENSIONS (Short Guide Pin)

7. Refit the brake caliper guide pins as A = 37mm " 1mm

instructed in this Section.

E9612 6–2A–25
 BRAKES 6
Brake assemblies (Perrot) 55 Series

Automatic Expander Unit — Rear Brakes

To Dismantle
1. Withdraw wedge and return spring
assembly from adjuster.

2. Depress spring retainer and remove circlip,

spring retainer, return spring and spring
2 seat.

3. Ease leaf–spring clips from adjuster screws

and remove thrust pieces.

4. Carefully remove the rubber gaiters from

the expander housing.

5. Unscrew the adjuster screw from the ring

nut and remove rubber gaiters.
NOTE: Always fit new rubber gaiters when
reassembling the expander unit.

6. Release strap plates and remove hollow

locating screws, springs and locating pins;
then remove slotted rings, backing
washers, thrust washers and pistons from
expander housing.

Inspection
1. Clean all metal components in a suitable
solvent and dry thoroughly.

2. Renew all items supplied in the repair kit.

To Reassemble
Reverse the removal procedure noting:

1. Lubricate internal components and pack the

space between the pistons with ‘Texaco
Thermatex EP1’ or a suitable equivalent
grease.

2. Tighten hollow locating screws to torque in

DATA and secure in position with strap
plates.

E9612
6–2A–26
6 BRAKES
55 Series Brake assemblies (Perrot)

FIG.19. EXPLODED VIEW OF AUTOMATIC EXPANDER UNIT — REAR BRAKES

1. Wedge assembly 11. Strap plate

2. Circlip 12. Piston
3. Spring retainer 13. Spring thrust washer
4. Wedge return spring 14. Plain washer
5. Spring seat 15. Slotted ring
6. Expander housing 16. Ring–nut
7. Hollow locating screw 17. Rubber gaiter
8. Spring 18. Tooth wheel adjuster screw
9. Spring 19. Thrust piece
10. Locating pin 20. Leaf retaining spring

E9612 6–2A–27
 BRAKES 6
Brake assemblies (Perrot) 55 Series

E9612
6–2A–28
6 BRAKES
55 Series Brake assemblies (DAF ’S’ cam)

2B. BRAKE ASSEMBLIES (DAF ‘S’ cam)

DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum brakes, front and rear

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 mm (diameter) x 175 mm (width)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 mm (diameter) x 150 mm (width)
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic slack adjuster
Brake lining to drum clearance . . . . . . . . . . . . . . . 0,8 to 1,2 mm (0.031 to 0.047 in)
Brake lining minimum thickness . . . . . . . . . . . . . . 1,0 mm (0.040 in) above the rivet head
Rear brake drum machining tolerance . . . . . . . . 3 mm (0.118 in)
2
Torque Tightening Figures Nm lbf ft

Brake drum retaining setscrews . . . . . . . . . . . . . . 22 to 44 16 to 32

E9612 6–2B–1
 BRAKES 6
Brake assemblies (DAF ’S’ cam) 55 Series

REMOVAL AND REFITMENT

WARNING: Before carrying out any

maintenance/repair work on the brake
assemblies, it is essential that the following
safety precautions are strictly observed:
— Always wear protective clothing, a face
mask and safety glasses/goggles.
— Do NOT inhale dust from the brake
linings or blow dust from the brake
2 drums; remove dust using a damp cloth
or vacuum cleaner, deposit used rags
whilst still wet, in a plastic waste
disposal bag.
— Do NOT drill or grind the brake linings.
— When replacing brake linings, the safety
instructions provided by the
manufacturer MUST always be followed.
— If a cleaning solvent is required,
methylated spirit should be used.

Brake Shoes

To Remove
1. Isolate the batteries.

2. Remove the road wheel(s), see

‘Maintenance Manual’.

3. Fully deplete the vehicle air system.

4. Rear Brake Shoes Only: Manually release

the spring brake actuator, see Section 3,
‘Brake Components’, Sub–Section 11.

5. Remove the two setscrews and detach the

brake drum, noting, if necessary:

— Fully release the automatic slack

adjuster.
— Use two extractor bolts in the holes
provided to remove the brake drum.

E9612
6–2B–2
6 BRAKES
55 Series Brake assemblies (DAF ’S’ cam)

6. Detach the dust covers from the brake shoe

carrier back plate.

7. Release the return spring from the brake

shoes and allow the bottom shoe to swing
clear.

8. Release the lock wire and remove the

fulcrum pin lockscrews.
2
9. Remove the circlips, flat washers and felt
washers from the fulcrum pins.

10. Drift the fulcrum pin from the bottom brake

shoe and carrier backplate and withdraw
the brake shoe. Repeat the operation for
the removal of the upper brake shoe.

E9612 6–2B–3
 BRAKES 6
Brake assemblies (DAF ’S’ cam) 55 Series

To Inspect
1. Inspect the fulcrum pin bushes for wear;
renew as necessary.

2. Check the cam rollers and bushes for wear

or damage; renew as necessary. 1

3. The cam roller is retained in position with a

2 knurled edge spindle (Fig.1). The spindle
can be used a maximum three applications.
Whenever the spindle is re–used, a centre
punch mark must be made on the brake
shoe. 2
Two centre punch marks indicate that the
spindle must be fitted in the reversed
position. The spindle can be used a further 3
three applications and thereafter must be
replaced.

4
070545

FIG.1. BRAKE SHOE ROLLER

1. Brake shoe
2. Knurled edge spindle
3. Bush
4. Roller

E9612
6–2B–4
6 BRAKES
55 Series Brake assemblies (DAF ’S’ cam)

To Refit
1. If necessary, machine the brake drums, see
DATA.

2. Smear the cam rollers and fulcrum pins with

‘Copaslip’ grease.

3. Position the upper shoe on the brake carrier

backplate. Insert the fulcrum pin into the
backplate and brake shoe, ensuring the flat 2
section of the pin aligns with the lockscrew
hole in the backplate.

4. Place the lower shoe in position and fit the

return spring to the upper and lower brake
shoe. Align the lower shoe with the fulcrum
pin bore in the backplate; refit the fulcrum
pin.

5. Locate the felt washers and flat washers on

the fulcrum pins and secure with circlips.

6. Secure the fulcrum pins in position with the

lockscrews; wire lock the screws.

7. Refit the dust covers to the brake carrier

backplate.

8. Refit the brake drum and tighten the

setscrews to the torque figure quoted in
DATA.

E9612 6–2B–5
 BRAKES 6
Brake assemblies (DAF ’S’ cam) 55 Series

9. If necessary, set the lining/brake drum

clearance as follows:

— Remove the rubber grommets from the

dust covers.
— Rotate the slack adjuster worm screw
adjuster in a clockwise direction until
the brake linings contact the brake
2 drum.
— Back–off the worm screw adjuster
approximately 3/4 of a turn, until the
brake drum rotates freely.
— Using feeler gauges, check the
clearance between the brake lining and
brake drum is within a tolerance of 0,8
to 1,2 mm (0.031 to 0.047 in); if
necessary, adjust the position of the
slack adjuster to attain the correct
clearance.
— Refit the rubber grommets to the dust
covers.

10. Rear Brake Shoes Only: Manually apply the

spring brake actuator, see Section 3, ‘Brake
Components’, Sub–Section 11.

11. Refit road wheel(s), see ‘Maintenance

Manual’.

12. Connect batteries and fully charge the

vehicle air system.

E9612
6–2B–6
 6 BRAKES
55 Series Brake assemblies (DAF ’S’ cam)

5 3
6
1
2

4
3
2
1
7

9
8
10 2

11

12

18

17

9 14
8
7 15
1 13
2
3

4
3
2
1 16

5
070546

FIG.2. BRAKE CAMSHAFT ASSEMBLY

(Front camshaft assembly illustrated)

1. Circlip 10. Automatic slack adjuster

2. Flat washer 11. Shims
3. Felt washer 12. Cup washer
4. Fulcrum pin 13. Roller
5. Brake shoe 14. Bush
6. Brake chamber bracket 15. Knurled edge spindle
7. Washer 16. Return spring
8. Seal 17. Camshaft
9. Camshaft bush 18. Brake carrier backplate

E9612 6–2B–7
 BRAKES 6
Brake assemblies (DAF ’S’ cam) 55 Series

Brake Camshaft Bushes

Service tool: 0694794

To Remove
1. Remove the hub, see Group 7, Front axle
or Group 8, Rear axle.

2. Remove the brake shoes.

2 3. Disconnect the brake chamber push–rod
from the slack adjuster. Rotate the worm
screw adjuster in an anti–clockwise
direction to release the slack adjuster from
the push–rod jaw–end.

4. Remove the control arm retaining nut.

Remove the retaining bolt and cup washer
and withdraw the slack adjuster from the
camshaft; retain the shims.

5. Withdraw the camshaft from the brake

carrier backplate/brake chamber mounting
bracket.

6. Remove the washers and seals from the

backplate and brake chamber mounting
bracket.

E9612
6–2B–8
6 BRAKES
55 Series Brake assemblies (DAF ’S’ cam)

7. Using tool 0694794 remove the camshaft

bushes as follows:
Refer to Fig.3.

— Engage the wedges (5) with the split

puller (6) and retain in position with the
locknut (4); ensure the split puller is in
a released position.
— Insert the tool into the front bush with
the split puller shoulder located against
2
the back face of the bush.
— Tighten the locknut (4), using hand
pressure only, to fully engage the split
puller with the bush.
— Position the spacer sleeve (2) against
the brake carrier backplate, tighten the
locknut (1) until the bush is fully
withdrawn from the backplate.
— Repeat the operation for the removal of
the rear bush.

5
6
5
4

2 3

090192

FIG.3. SERVICE TOOL 0694794

1. Locknut 4. Locknut
2. Spacer sleeve 5. Wedge
3. Spindle 6. Split puller

E9612 6–2B–9
 BRAKES 6
Brake assemblies (DAF ’S’ cam) 55 Series

To Refit
1. Using tool 0694794 refit the camshaft
bushes as follows:
Refer to Fig.3.

— Slide the new front bush onto the split

puller (6) until it abuts the shoulder.
Tighten the locknut (4), using hand
2 pressure only, to engage the wedges
(5) with the split puller and retain the
bush in position.
— Locate the service tool/bush assembly
in the brake carrier backplate. Slide the
spacer sleeve (2) onto the spindle until
it abuts the brake chamber mounting
bracket; tighten the locknut (1) to draw
the bush into the backplate.
— Repeat the operation for the fitment of
the rear bush.

2. Press new seals into the backplate and

brake chamber mounting bracket and refit
washers.

3. Refit the brake shoes.

4. Refit the hub, see Group 7, Front axle or

Group 8, Rear axle.

5. Place the original shims on the camshaft.

6. Slide the slack adjuster on to the camshaft

and locate the control arm on the fixing
stud. Ensure the embossed arrow on the
slack adjuster is pointing in the direction of
brake application.

7. Rotate the worm screw adjuster in a

clockwise direction to align the slack
adjuster with the push–rod jaw–end. Fit the
clevis pin, but do not secure with split pin at
this stage.

E9612
6–2B–10
6 BRAKES
55 Series Brake assemblies (DAF ’S’ cam)

8. Refit the cup washer and the slack adjuster

retaining bolt.

9. Check the end–float clearance between the

slack adjuster and brake chamber bracket
is within a tolerance of 0,5 to 1,5 mm
(0.020 to 0.060 in); if necessary, adjust the
shim pack accordingly. Secure the clevis
pin with a new split pin.
2
10. Rotate the control arm as far as possible in
the direction of the embossed arrow until
abuts its internal stop. Secure the control
arm in position with the retaining nut.

11. Set the lining/brake drum clearance as

follows:

— Remove the rubber grommets from the

dust covers.
— Rotate the worm screw adjuster in a
clockwise direction until the brake
linings contact the brake drum.
— Back–off the worm screw adjuster
approximately 3/4 of a turn, until the
brake drum rotates freely.
— Using feeler gauges, check the
clearance between the brake lining and
brake drum is within a tolerance of 0,8
to 1,2 mm (0.031 to 0.047 in); if
necessary, adjust the position of the
slack adjuster to attain the correct
clearance.
— Refit the rubber grommets to the dust
covers.

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55 Series Contents

CONTENTS Page Date

SECTION 3—BRAKE COMPONENTS

4. AUTOMATIC SLACK ADJUSTER

Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 1 . . . . . . . . 9612

5. HANDBRAKE CONTROL VALVE

Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 5 — 1 . . . . . . . . 9612
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 5 — 3 . . . . . . . . 9612

6. COMPRESSOR
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 6 — 1 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 6 — 2 . . . . . . . . 9612
3
6Q. COMPRESSOR (Knorr Bremse 150 cm3 air cooled and 250 cm3 water cooled)
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 6Q— 1 . . . . . . . 9612
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 6Q— 2 . . . . . . . 9612

8. FOOTBRAKE VALVE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 8 — 3 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 8 — 1 . . . . . . . . 9612
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 8 — 4 . . . . . . . . 9612

8C. FOOTBRAKE VALVE (Knorr Bremse E–6 Type)

Bench Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 8C— 12 . . . . . . 9612
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 8C— 1 . . . . . . . 9612
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 8C— 2 . . . . . . . 9612
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 8C— 3 . . . . . . . 9612
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 8C— 6 . . . . . . . 9612

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55 Series Contents

Page Date

11. BRAKE ACTUATORS

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—11 — 1 . . . . . . . 9612
Removal and Refitment:
Front Brake Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—11 — 2 . . . . . . . 9612
Rear Spring Brake Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6—11 — 7 . . . . . . . 9612
Rear Spring Brake Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—11 — 5 . . . . . . . 9612
Overhaul:
Front Brake Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—11 — 10 . . . . . . 9612
Rear Spring Brake Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—11 — 13 . . . . . . 9612

13. AIR PRESSURE SWITCHES 3

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—13 — 1 . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—13 — 2 . . . . . . . 9612

14. RELAYED EMPTY/LOAD VALVE (Wabco)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—14 — 1 ....... 9612
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—14 — 4 ....... 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—14 — 2 ....... 9612
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—14 — 3 ....... 9612

15. RELAY VALVES

Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—15 — 1 . . . . . . . 9612

15J. RELAY VALVE (Knorr Bremse R15 Type)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—15J— 1 . . . . . . . 9612
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—15J— 2 . . . . . . . 9612

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Page Date

17. LOAD SENSING VALVE

Load Sensing Data Plate Setting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—17 — 8 . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—17 — 1 . . . . . . . 9612
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—17 — 3 . . . . . . . 9612

17C. LOAD SENSING VALVE (Knorr Bremse Inshot Type)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—17C— 1 . . . . . . 9612
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—17C— 2 . . . . . . 9612

17L. LOAD SENSING VALVE (Knorr Bremse)

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—17L— 3 . . . . . . . 9612
3
Setting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—17L— 1 . . . . . . . 9612
Valve Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—17L— 2 . . . . . . . 9612

18. AIR DRYER

Removal and Refitment:
Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—18 — 1 . . . . . . . 9612
Air Dryer Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—18 — 3 . . . . . . . 9612

18F. AIR DRYER (Knorr Bremse AD6 Type)

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—18F— 11 . . . . . . 9612
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—18F— 1 . . . . . . . 9612
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—18F— 2 . . . . . . . 9612
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—18F— 3 . . . . . . . 9612
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—18F— 5 . . . . . . . 9612

23A. DOUBLE CHECK VALVE

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—23A— 1 ...... 9612
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—23A— 3 ...... 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—23A— 2 ...... 9612
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—23A— 4 ...... 9612

27. MULTI–CIRCUIT PROTECTION VALVE (Wabco All Parallel Full Feedback Type)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—27 — 1 . . . . . . . 9612
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—27 — 2 . . . . . . . 9612
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—27 — 7 . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—27 — 6 . . . . . . . 9612
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—27 — 3 . . . . . . . 9612

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55 Series Contents

Page Date

34. AIR RESERVOIRS

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—34 — 1 . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—34 — 2 . . . . . . . 9612

40. PNEUMATIC PUSH–IN PIPE FITTINGS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—40 — 1 . . . . . . . 9612
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—40 — 2 . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—40 — 3 . . . . . . . 9612

58. 3/2 SOLENOID VALVE (Wabco)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—58 — 1 . . . . . . . 9612
3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—58 — 3 . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—58 — 2 . . . . . . . 9612

60. MODULATOR VALVES

Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—60 — 1 . . . . . . . 9612

60A. MODULATOR VALVE (Wabco)

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—60A— 1 . . . . . . 9612
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—60A— 2 . . . . . . 9612

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6 BRAKES
55 Series Automatic slack adjuster

4. AUTOMATIC SLACK ADJUSTER

REMOVAL AND REFITMENT

To Remove
1. Disconnect the batteries.

2. If removing the rear slack adjusters, chock

the road wheels and place the hand control
valve in the off position.

3. Remove the split pin and withdraw the

clevis pin securing the brake chamber
push–rod to the slack adjuster.

4. Rotate the worm screw adjuster in an

anti–clockwise direction to release the slack
adjuster from the push–rod jaw–end.
3
5. Remove the control arm retaining nut.
1
6. Remove the retaining bolt and cup washer
and withdraw the slack adjuster from the
camshaft; retain the shims.

7. Clean the camshaft splines with a suitable

solvent and dry thoroughly.
5

4 2
3

070544

FIG.1. AUTOMATIC SLACK ADJUSTER

(Front slack adjuster illustrated)

1. Slack adjuster
2. Cup washer
3. Control arm
4. Shims
5. Worm screw adjuster

E9612 6–4–1
 BRAKES 6
Automatic slack adjuster 55 Series

To Refit
1. Place the original shims on the camshaft.

2. Slide the slack adjuster on to the camshaft

and locate the control arm on the fixing
stud. Ensure the embossed arrow on the
slack adjuster is pointing in the direction of
brake application.

3. Rotate the worm screw adjuster in a

clockwise direction to align the slack
adjuster with the push–rod jaw–end. Fit the
3 clevis pin, but do not secure with split pin at
this stage.

4. Refit the cup washer and retaining bolt.

5. Check the end–float clearance between the

slack adjuster and brake chamber bracket
is within a tolerance of 0,5 to 1,5 mm
(0.020 to 0.060 in); if necessary, adjust the
shim pack accordingly. Secure the clevis
pin with a new split pin.

6. Rotate the control arm as far as possible in

the direction of the embossed arrow until it
abuts its internal stop. Secure the control
arm in position with the retaining nut.

7. Set the lining/brake drum clearance as

follows:

— Remove the rubber grommets from the

dust covers.
— Rotate the worm screw adjuster in a
clockwise direction until the brake
linings contact the brake drum.
— Back–off the worm screw adjuster
approximately 3/4 of a turn, until the
brake drum rotates freely.
— Using feeler gauges, check the
clearance between the brake lining and
brake drum is within a tolerance of
0,8 to 1,2 mm (0.031 to 0.047 in); if
necessary, adjust the position of the
slack adjuster to attain the correct
clearance.
— Refit the rubber grommets to the dust
covers.

E9612
6–4–2
6 BRAKES
55 Series Automatic slack adjuster

TESTING

Operating Test
1. Remove the rubber grommets from the dust
covers. Using feeler gauges, check the
clearance between the brake lining and
brake drum is within a tolerance of 0,8 to
1,2 mm (0.031 to 0.047 in)

2. Fully charge the air system. Apply and

release the brakes, checking that the
push–rods move smoothly and promptly
without binding and return to their fully
released position.

3. Check the camshaft rotates freely and the

3
brake shoes are not restricted.

Functional Test
1. Rotate the worm screw adjuster in an
anti–clockwise direction three complete
turns, this will give an approximate 2,5 mm
(0.100 in) clearance between the brake
lining and drum.

2. Apply and release the brakes. The worm

adjuster should be seen to rotate on the
return stroke, adjusting up the excessive
play. If the worm adjuster fails to rotate, the
slack adjuster is faulty and must be
replaced as detailed in this Section.

3. Alternatively, the slack adjuster can be

checked using a suitable dial type torque
wrench. Rotate the worm adjuster in an
anti–clockwise direction 1/8 of a turn or 1 to
2 ‘clicks’. A reading of less than 18 Nm
(13 lbf ft) indicates a faulty clutch
mechanism. Renew the slack adjuster as
detailed in this Section.
NOTE: When rotating the worm adjuster
anti–clockwise, considerably more effort will
be required than when rotating the worm
adjuster clockwise, this is a further check
that the adjuster is operating correctly.

4. If the slack adjuster is functioning correctly,

reset the brake lining/drum clearance as
detailed in the refitment procedure of the
slack adjuster.

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Automatic slack adjuster 55 Series

E9612
6–4–4
6 BRAKES
55 Series Handbrake control valve

5. HANDBRAKE CONTROL VALVE

REMOVAL AND REFITMENT

To Remove
1. Disconnect the batteries. 1 2 3
4
2. Deplete air system.
4
3. If fitted, remove headlight load levelling
control knob from the centre console.

4. Extract the cigar lighter from its unit.

5. Detach the handbrake trim panel from

beneath the handbrake control and then
remove the centre console front retaining
screw. 5 3
6. Remove the rear retaining screws from
either side of the centre console. 6

7. Carefully manoeuvre the centre console 9

from its location.

8. Remove the setscrews securing the 7 8

handbrake control valve to the support
bracket.

9. Suitably identify then disconnect the air

pipes from the handbrake control valve;
withdraw the handbrake valve.

10. If necessary, remove valve adapters.

10

070560

FIG.1. HANDBRAKE CONTROL VALVE

REMOVAL
1. Centre console
2. Headlight levelling control knob (if fitted)
3. Cigar lighter
4. Retaining screw – rear
5. Retaining screw – front
6. Handbrake trim panel
7. Handbrake support bracket
8. Setscrew
9. Handbrake control valve
10. Air pipes

E9612 6–5–1
 BRAKES 6
Handbrake control valve 55 Series

To Refit
Reverse the removal procedure, noting:

1. Check for leakage and carry out operating

test, as instructed in this Sub–Section.

2. Ensure centre console is correctly located

prior to tightening retaining screw.

E9612
6–5–2
6 BRAKES
55 Series Handbrake control valve

TESTING

Leakage Test
1. Charge air system to full working pressure
and chock all road wheels.

2. With the handbrake control valve in the off

position, test air pipe connections for
leakage, using a soap solution. No leakage
is permissible.

Operating Test
1. Chock all road wheels, charge air system to
full working pressure, raise the rear axle
and suitably support.
3
2. Rigid Vehicles: Move handbrake control
valve lever from the park position to the off
position and note that the rear brakes are
released promptly.

Move lever quickly from the off position to

the park position and note that the rear
brakes are applied promptly.

3. Drawbar Vehicles: Connect an air pressure

gauge to the trailer service (yellow)
coupling. Operate the handbrake control
valve and note the following:

Off position — No pressure reading

Park position — Pressure reading
On position — No pressure reading

System Diagnostic Test

Carry out air pressure system test, as instructed
in Section 1, ‘Brake System Descriptions and
Diagrams’.

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 BRAKES 6
Handbrake control valve 55 Series

E9612
6–5–4
6 BRAKES
55 Series Compressor

6. COMPRESSOR
DATA

Torque Tightening Figures Nm Ibf ft

Power steering pump to compressor bolts . . . . . 43 32
Compressor drive gear nut . . . . . . . . . . . . . . . . . . 125 92
Compressor mounting nuts . . . . . . . . . . . . . . . . . . 77 57

E9612 6–6–1
 BRAKES 6
Compressor 55 Series

REMOVAL AND REFITMENT

Service tool: 0192494

To Remove
1. Disconnect the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Fully deplete the air system.

4. Set the engine on ‘Top Dead Centre’

(T.D.C.) by turning the engine and pushing
in the timing pin located at the rear of the
3 timing gearcase until it locates in camshaft
gear; disengage timing pin once T.D.C. is
located.
NOTE: On vehicles fitted with a Bosch VP
14 rotary injection pump, Service tool
0192494 can be used to assist in
engaging/disengaging the timing pin.

5. Water cooled compressor only: Partially

drain the cooling system, see the
‘Maintenance Manual’, then disconnect and
remove as necessary the coolant feed and 070420
return pipes.

6. Remove the power steering pump, see FIG.1. COMPRESSOR TIMING

Group 7, noting coupling drive disc.

7. Remove compressor air intake pipe.

8. Disconnect air delivery pipe from

compressor.

9. Remove fuel injection pump support

bracket.

E9612
6–6–2
6 BRAKES
55 Series Compressor

10. Disconnect compressor oil feed pipe.

11. Remove nuts securing compressor to

gearcase; withdraw compressor and
discard O–ring.

12. If necessary, remove compressor support

bracket.

13. If necessary, remove compressor drive

gear, using a suitable puller.

To Refit
3
Reverse removal procedure, noting:

1. Fit a new compressor O–ring.

2. Ensure engine has remained on T.D.C.

3. Prior to fitting the compressor, ensure the

timing mark is in the position shown in
Fig.1.

4. Tighten nuts and bolts to torque figures

quoted in DATA.

5. Water cooled compressor only: Refill

cooling system, see ‘Maintenance Manual’.

6. Bleed the power steering system, see

Group 7.

E9612 6–6–3
 BRAKES 6
Compressor 55 Series

E9612
6–6–4
6 BRAKES
Compressor (Knorr Bremse 150 cm3 air cooled and 250 cm3 water cooled)

6Q. COMPRESSOR (Knorr Bremse 150 cm3 air cooled and 250 cm3
water cooled)
DATA

Torque Tightening Figures Nm lbf ft

Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . 16 12
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . 28 21
Drive gear nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 92
End–cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
Unloader valve cap . . . . . . . . . . . . . . . . . . . . . . . . . 63 47

Special Compounds
Unloader valve cap sealing compound . . . . . . . . Loctite 572 3
End–cover bolt locking compound . . . . . . . . . . . . Loctite 242

E9612 6–6Q–1
 BRAKES 6
Compressor (Knorrr Bremse 150 cm3 air cooled and 250 cm3 water cooled)

OVERHAUL

To Dismantle (see Fig.1.)

1. Suitably mark the compressor cylinder head
(1), valve plate (13) and bottom cover plate
(26) with the compressor (28) to aid
reassembly.

2. Remove mounting flange O–ring (29) and

coupling drive disc (22).

3. If necessary, remove drive gear securing

nut (31) and using a suitable puller,
withdraw the drive gear (30).
3 4. Remove bolts (1) securing cylinder head
and valve plate (13) to compressor, remove
cylinder head assembly and discard gasket
(27).

5. Remove screw (12), separate valve plate

(13) from cylinder head (1) and remove
gasket (7), unloader valve disc (8), unloader
spring (9), delivery spring (10) and delivery
valve disc (11).

6. Unscrew the unloader valve cap (2) and

remove the unloader piston (5), conical
spring (4), O–ring (6) and circlip (3).

7. Release setscrews securing bottom cover

plate (26) to base of compressor, remove
and discard gasket (25).

8. Turn crankshaft to bottom dead centre

(B.D.C) noting corresponding numbers on
connecting rod and cap (18) to aid
reassembly.

9. Remove connecting rod cap bolts (19) and

lockwashers (20).

E9612
6–6Q–2
6 BRAKES
Compressor (Knorr Bremse 150 cm3 air cooled and 250 cm3 water cooled)

10. Remove connecting rod cap, then turning

the crankshaft as necessary, push the
connecting rod and piston assembly up and
out of the cylinder.

11. Remove rings (14) from piston (15).

12. Remove circlips (17), knock out gudgeon

pin (16) and separate piston (15) from
connecting rod (18).

13. Remove socket head screws securing

end–cover (23) to compressor body,
withdraw from crankshaft and remove
3
O–ring (24).

Inspection
1. Clean all components in a suitable solvent
and dry thoroughly, replacing as necessary
any worn or damaged parts.

2. Always renew components with those

supplied in the service repair kit.

E9612 6–6Q–3
 BRAKES 6
Compressor (Knorrr Bremse 150 cm3 air cooled and 250 cm3 water cooled)

1 2
3

7 8
5
10 9
12
11 6
3 13

14

15

17 16

19
20 21
18

27

28

22
29
30 23
24

31 25
26

070421

FIG.1. EXPLODED VIEW OF COMPRESSOR

E9612
6–6Q–4
6 BRAKES
Compressor (Knorr Bremse 150 cm3 air cooled and 250 cm3 water cooled)

Key to Fig.1.
* 1. Cylinder head
2. Unloader valve cap
3. Circlip
4. Conical spring
5. Unloader piston
6. O–ring
7. Valve plate gasket
8. Unloader valve disc
9.
10.
Unloader spring
Delivery spring
3
11. Delivery valve disc
12. Screw—valve plate to head
13. Valve plate
14. Piston rings
15. Piston
16. Gudgeon pin
17. Circlip
18. Connecting rod and cap
19. Bolt
20. Lockwasher
21. Steady bracket
22. Coupling drive disc
23. End–cover
24. O–ring
25. Bottom cover gasket
26. Bottom cover plate
27. Cylinder head gasket
28. Compressor body
29. Sealing ring
30. Compressor drive gear
31. Nut

* Air cooled cylinder head shown

E9612 6–6Q–5
 BRAKES 6
Compressor (Knorrr Bremse 150 cm3 air cooled and 250 cm3 water cooled)

To Reassemble
Reverse the dismantling procedure, noting:

1. Fit the piston rings, ensuring that the gap in

each piston ring is NOT aligned with the
gudgeon pin and that all piston ring gaps
are opposed by 120°.

2. Lubricate the piston and, using a suitable

piston ring compressor, insert the piston
and connecting rod into cylinder.

3 3. Using locking compound quoted in DATA,

tighten end–cover bolts to torque in DATA.

4. Lubricate the connecting rod and other

bearing surfaces with clean engine oil.

5. Tighten connecting rod bolts (19) to torque

in DATA. Check the connecting rod has
end–float.

6. Tighten drive gear nut (31) to torque in

DATA.

7. Tighten cylinder head bolts to torque in

DATA.

8. Apply sealant quoted in DATA to the

underside of the unloader valve cap head
(2), then tighten to torque in DATA.

E9612
6–6Q–6
6 BRAKES
55 Series Footbrake valve

8. FOOTBRAKE VALVE
REMOVAL AND REFITMENT

To Remove 2
1. Isolate the batteries. 1

2. Deplete the air system.

3. Raise the front panel.

4. Remove the instrument panel as detailed in

Group 5, ‘Electrical System’.

5. Release the heater controls from the

instrument panel shroud, then detach the
shroud from the corner trim panel, main trim
panel and steering column bracket.
3
6. Remove the pedal cover retaining screws.
Unscrew the steering column adjustment
control handle, depress the clutch and
brake pedals and withdraw the cover.

7. Carefully lever the air vents from the main

trim panel and heater box.
3
8. Withdraw the diagnostic socket cover from 050284
the trim panel, then release the
socket/bracket assembly from the panel.
FIG.1. FOOTBRAKE VALVE REMOVAL
9. Remove retaining screws, nut and washer
securing the trim panel to the windscreen 1. Bulkhead pedal bracket
trim panel, heater box and cab. Release the 2. Cover
door seal and partially withdraw the trim 3. Footbrake valve mounting nuts
panel, disconnect the air ducting from the
air vents and withdraw the trim panel from
the cab.

10. Remove the cover plate from the bulkhead

pedal bracket to gain access to the
footbrake mounting nuts.

E9612 6–8–1
 BRAKES 6
Footbrake valve 55 Series

11. Note connections, then disconnect the air

pipes from the footbrake valve. Remove the
retaining nuts and withdraw the footbrake
valve.

12. If necessary, remove adapters from valve.

To Refit
Reverse removal procedure, noting:

1. Charge the air system to full working

3 pressure, depress the footbrake, and test
air pipe connections for leaks using a soap
solution; rectify as necessary.

2. Check stop–light micro–switch setting as

instructed in this Sub–Section.

3. Check operation of footbrake valve by

checking delivery pressures as detailed
under ‘Testing’ in this Sub–Section.

4. Refit the bulkhead pedal bracket cover plate

using ‘Kelseal Glasticon 238’ adhesive.

E9612
6–8–2
6 BRAKES
55 Series Footbrake valve

ADJUSTMENT

Stop–Light Micro–Switch Setting

To Adjust
1. Isolate the batteries.

2. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle, depress the clutch and
brake pedals and withdraw the cover.

3. Slacken the setscrews securing the

micro–switch bracket to the pedal bracket.

4. Operate the footbrake pedal until the roller

3
just contacts the footbrake valve plunger,
then swivel the micro–switch bracket
forward as far as the slotted holes allow,
until it makes contact with the pedal lever
bracket. Secure the micro–switch bracket in
this position.

5. Adjust the micro–switch to give a switch

plunger movement of 2,5 to 3,0 mm.
Secure switch in position with locknuts.
1 2
6. Refit pedal cover.

7. Connect batteries.

A
070422

FIG.2. STOP–LIGHT MICRO–SWITCH

SETTING

A = 2,5 to 3 mm
1. Micro–switch
2. Bracket

E9612 6–8–3
 BRAKES 6
Footbrake valve 55 Series

TESTING

Footbrake Valve Delivery Pressures

Service tools: Air pressure test equipment
0485052 (2 off).

1. Chock all road wheels, position the

handbrake control valve to the ‘OFF’
position.

2. Detach plastic caps from ISO test

connections situated in service line at front
brake actuator, rear service line at load
sensing valve and from ISO test connection
3 at ‘PARK’ reservoir, then carry out the
following checks:
Front service line delivery pressure:
Assemble test equipment 0485052 to the
ISO test connections at the ‘PARK’
reservoir and front brake actuator.
Disconnect the load sensing valve linkage
and retain the load sensing valve operating
lever in the 1:1 position (ie., fully laden rear
axle). Fully charge the air system, then with
the aid of an assistant, fully depress the
footbrake and observe the readings on the
test gauges. Compare the gauge reading at
the ‘PARK’ reservoir with the gauge reading
at the front brake actuator; the pressure
readings should be equal.
Rear service line delivery pressure:
Assemble test equipment 0485052 to the
ISO test connections at the ‘PARK’
reservoir and the load sensing valve. Fully
charge the air system and repeat the above
check; the pressure readings observed at
the ‘PARK’ reservoir and load sensing valve
should again be equal.

3. Dismantle test equipment from test

connections and secure plastic caps.

4. Fully charge the air system then fully

depress the footbrake; release footbrake
and note that a sudden and immediate
release of air takes place. Slow exhaust
could be due to a partial seizure of the
valve and MUST be rectified.

E9612
6–8–4
6 BRAKES
Footbrake valve (Knorr Bremse E–6 type)

8C. FOOTBRAKE VALVE (Knorr Bremse E–6 type)

DATA

Torque Tightening Figures Nm lbf ft

Bottom cover setscrews . . . . . . . . . . . . . . . . . . . . . 7 to 10 5 to 7

E9612 6–8C–1
 BRAKES 6
Footbrake valve (Knorr Bremse E–6 type)

DESCRIPTION (see Fig.1.)

The footbrake valve provides a graduated

braking control for applying and releasing the
service brakes. It serves two separate circuits
each with its own reservoir. Each circuit remains
isolated from the other by the internal sealing
arrangements of the valve. In the event of one
circuit failing the other circuit will remain intact
and capable of stopping the vehicle.

The front service brakes are served by the lower

inlet/exhaust valve assembly (22) housed in the
bottom cover (19), and the rear service brakes
3 are served by the upper inlet/exhaust valve
assembly (13) housed in the upper body (17).
The inlet valve seats are formed in their
appropriate castings of the bottom cover and the
upper body; the exhaust valve seats being
formed on the base of the relay piston (25) and
the primary piston (1) respectively.

The passage of exhaust air past the upper

exhaust valve is down through the centre of the
relay piston (25), then through the centre of the
lower inlet/exhaust valve assembly (22)
exhausting to atmosphere through the exhaust
cover (21). Exhaust air from the lower valve also
passes through the centre of the inlet/exhaust
valve assembly (22).

E9612
6–8C–2
6 BRAKES
Footbrake valve (Knorr Bremse E–6 type)

OPERATION (see Fig.1.)

The brake application force is transmitted

through spring seat (2) and rubber graduating
spring (8) to primary piston (1). As primary
piston (1) descends, it initially shuts off the
exhaust valve of the inlet/exhaust valve
assembly (13).

Further movement of primary piston (1) moves

inlet/exhaust valve (13) off its inlet valve seat
(12) permitting the flow of air to pass in through
port ‘A’ and out through port ‘E’ to actuate the
rear service brakes.

As air passes to delivery port ‘E’ it also passes

3
through transfer holes ‘F’ to the top of relay
piston (25), where together with the downward
force of spring (15) the piston moves
downwards, shutting off the exhaust valve of the
lower inlet/exhaust valve assembly (22). As air
pressure passing through transfer holes ‘F’
increases, relay piston (25) moves downwards
moving inlet/exhaust valve (22) off its inlet valve
seat (23), permitting the flow of air to pass
through port ‘B’ and out through port ‘D’ to
actuate the front service brakes.

The operation of the valves is more or less

instantaneous, with perfect balance attained
when approximately 5 bar (72 lbf/in2) pressure
has built up in the delivery circuits.

E9612 6–8C–3
 BRAKES 6
Footbrake valve (Knorr Bremse E–6 type)

The flow from delivery port ‘E’ continues until

the air pressure under primary piston (1)
together with the upward force of spring (27)
and the spring of inlet/exhaust valve assembly
(13) overcomes the brake application force on
primary piston (1). The piston then lifts
sufficiently to allow the inlet valve of
inlet/exhaust valve assembly to close on its seat
(12) without letting exhaust valve seat (11)
uncover the exhaust passage ‘C’. The rear
service brake circuit is now balanced.

3 Similarly the flow from delivery port ‘D’

continues to increase under relay piston (25)
until the upward force under the piston and the
upward force of the spring of inlet/exhaust valve
(22) overcome the downward forces of spring
(15) and the air pressure above relay piston
(25). The relay piston (25) then lifts sufficiently
to allow inlet valve of inlet/exhaust valve to close
on its seat (23) without letting exhaust valve
seat (18) uncover the exhaust passage ‘C’. The
front service brake circuit is now balanced.

E9612
6–8C–4
6 BRAKES
Footbrake valve (Knorr Bremse E–6 type)

When the brake application force is reduced

primary piston (1) will rise due to the greater
pressure under the piston and return spring
(27). Inlet/exhaust valve (13) will also rise,
shutting the inlet valve against its seat (12), the
exhaust valve is uncovered allowing the excess
pressure to exhaust away until the delivery
pressure drops sufficiently to restore the
balance of forces on primary piston (1) with the
inlet and exhaust valve shut. As pressure at ‘F’
decreases, relay piston (25) rises, the
inlet/exhaust valve will follow, shutting the inlet
valve against its seat, the exhaust valve opens
permitting excess air to exhaust until the relay
3
piston descends shutting off the exhaust valve.

Removal of brake application force allows

primary piston (1) and valve stem (6) to make a
full up–stroke, relay piston (25) follows,
exhausting all air from the delivery circuits.

Should air pressure be lost in the front service

brake circuit, the rear service brake circuit will
remain fully operational due to the seals (16),
(24) and (26) of relay piston (25).

If air pressure is lost in the rear service brake

circuit, the front service brakes will remain fully
operational by manual operation of the relay
piston (25).

E9612 6–8C–5
 BRAKES 6
Footbrake valve (Knorr Bremse E–6 type)

OVERHAUL (see Fig.1.)

CAUTION: Always quote the footbrake valve

Part Number to ensure that the correct service
overhaul kit is obtained.

To Dismantle
1. Remove operating plunger assembly from
valve.

2. Unscrew four setscrews from exhaust cover

and remove cover. Remove inlet/exhaust
valve assembly and filter from lower half
body.
3 3. Lightly grip footbrake valve horizontally in a
vice.

4. Insert a screwdriver through bottom cover

to engage with slot in base of valve stem,
take care not to damage valve seats of
bottom cover and relay piston. Unscrew
locknut from top of valve stem, and remove
spring and spring retainer.

5. Withdraw valve stem through bottom cover.

6. Taking care to retain primary piston

assembly against the influence of its return
spring, remove retaining plate and withdraw
piston and return spring.

7. Remove O–ring and piston guide from

primary piston. Unscrew spring seat nut
and remove spring seat and rubber spring.

8. Remove fibre filter from upper body.

9. Unscrew and remove four setscrews

securing bottom cover to upper body.

E9612
6–8C–6
6 BRAKES
Footbrake valve (Knorr Bremse E–6 type)

10. Remove relay piston and spring.

11. Remove two large O–rings and small

O–ring from relay piston.

12. Remove circlip retaining upper inlet/exhaust

valve assembly in upper body; withdraw
valve assembly and filter.

Inspection
1. Renew all items supplied in service kit.

2. Clean all components other than service kit

3
items thoroughly in a proprietary cleaning
fluid, and inspect for wear or damage. If any
appreciable wear is apparent on pistons,
bores or valve seats, fit a replacement
valve.

E9612 6–8C–7
 BRAKES 6
Footbrake valve (Knorr Bremse E–6 type)

FIG.1. SECTION VIEW OF E–6 DUAL FOOTBRAKE VALVE

E9612
6–8C–8
 6 BRAKES
Footbrake valve (Knorr Bremse E–6 type)

Key for Fig. 1.

1. Primary piston ‘A’ = Inlet port from reservoir
2. Spring seat ‘B’ = Inlet port from reservoir
3. Spring ‘C’ = Exhaust passage
4. Spring retainer ‘D’ = Front service brake delivery
5. Locknut ‘E’ = Rear service brake delivery
6. Valve stem ‘F’ = Transfer holes
7. Spring seat nut
8. Rubber spring
9.
10.
Air vent
Fibre filter
3
11. Exhaust valve seat
12. Inlet valve seat
13. Inlet/exhaust valve seat
14. Filter
15. Spring
16. O–ring
17. Upper body
18. Exhaust valve seat
19. Bottom cover
20. Sealing ring
* 21. Exhaust cover
22. Inlet/exhaust valve assembly
23. Inlet valve seat
24. O–ring
25. Relay piston
26. O–ring
27. Return piston
28. Piston guide
29. O–ring
30. Retaining plate

* Direction of exhaust cover will vary

dependent on application

E9612 6–8C–9
 BRAKES 6
Footbrake valve (Knorr Bremse E–6 type)

To Reassemble
1. Insert upper filter, inlet/exhaust valve
assembly and secure in place with circlip.

2. Fit two large and one small O–ring to relay

piston, and insert piston complete with
spring in place in upper body.
NOTE: On standard–type valves a spring is
fitted above piston, whereas on bias–type
valves a spring is fitted below relay piston.

3. Fit bottom cover complete with O–ring to

3 upper body ensuring that delivery port of
bottom cover and upper body are aligned.
Fit the four setscrews complete with spring
washers; torque tighten to figure quoted in
DATA.

4. Fit O–ring and piston guide to primary

piston.

5. Fit rubber graduating spring, spring seat

and spring seat nut. Tighten nut until its top
face is flush to within 0,25 mm (0.01 in) with
top of primary piston.
CAUTION: Do not allow any lubricant to
come into contact with rubber graduating
spring.

6. Fit fibre filter into groove in top face of

upper body.

7. Fit piston return spring and assembled

primary piston.

E9612
6–8C–10
6 BRAKES
Footbrake valve (Knorr Bremse E–6 type)

8. Fit retaining plate, ensure that it is firmly

secured at all three clip positions.

9. Insert valve stem from bottom of valve, with

threaded portion protruding from top of
valve.

10. With a screwdriver located in the slot of the

valve stem, position spring and spring
retainer over the valve stem and secure in
position with locknut.

11. Insert lower filter and inlet/exhaust valve

assembly into bottom cover, fit exhaust
3
cover and secure with four setscrews and
washers to torque in DATA.

12. Fit and secure operating plunger in place.

13. Bench test for leakage.

E9612 6–8C–11
 BRAKES 6
Footbrake valve (Knorr Bremse E–6 type)

BENCH TESTING

Leakage Test
1. Connect a suitable dry, clean air supply to
one of supply ports at a pressure of at least
5,5 bar (80 lbf/in2) and not exceeding 8,27
bar (120 lbf/in2). Using a soap and water
solution check for leaks at No.1 and No.2
delivery ports, the other supply port,
exhaust cover, operating plunger and body
joints. No leakage is permitted.

2. Blank off delivery port matching supply port

connected to air supply, and depress
3 operating plunger. The maximum
permissible leakage from anywhere on the
valve is a 25 mm (1 in) dia. bubble in ten
seconds.

3. Carry out same procedure as in paragraphs

1 and 2 with air supply connected to other
supply port to attain same conditions.

E9612
6–8C–12
6 BRAKES
55 Series Brake actuators

11. BRAKE ACTUATORS

DATA

11 to 15 tonne vehicles:
Type:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wabco
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knorr Bremse

17/18 tonne vehicles:

Type:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix (Type 27)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knorr Bremse

Special Compounds
11 to 15 tonne vehicles:
Rear spring brake actuator locking ring
3
sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 242

Torque Tightening Figures Nm lbf ft

11 to 15 tonne vehicles:
Front brake actuator clamping ring bolt . . . . . 11 8
Front brake actuator mounting nuts . . . . . . . . 53 39
Rear spring brake actuator clamping ring bolt . 11 8
Rear spring brake actuator locking ring
(using service tool 0484938) . . . . . . . . . . . . . . 233 172
Rear spring brake actuator release nut . . . . . 30 to 40 22 to 29

17/18 tonne vehicles:

Front brake actuator clamping ring bolt . . . . . 11 8
Front brake actuator mounting nuts . . . . . . . . 122 to 136 90 to 100
Rear spring brake actuator clamping ring bolt 11 8
Rear spring brake actuator mounting nuts . . 122 to 136 90 to 100
Rear spring brake actuator release nut . . . . . 20 to 30 15 to 22

E9612 6–11–1
 BRAKES 6
Brake actuators 55 Series

REMOVAL AND REFITMENT

Front Brake Actuator

To Remove
1. Isolate the batteries.

2. Apply the handbrake to the park position

and chock the front road wheels.

3. Fully deplete the vehicle air system.

4. Disconnect the brake hose from the

actuator and position the brake hose, brake
3 pad wear indicator cable (F56 axle) and, if
applicable the ABS cable clear of the
actuator. Suitably blank the actuator port
and brake hose to prevent the ingress of
dirt.

5. Remove split pin and extract the clevis pin

securing the actuator push–rod jaw–end to
the brake lever/slack adjuster.

6. Remove brake actuator mounting nuts and

withdraw actuator.

7. If necessary, remove the push–rod

jaw–end, locknut and gaiter (when fitted).

E9612
6–11–2
6 BRAKES
55 Series Brake actuators

2 3
2

4
6

5
3
3 7
4
7
5

A B 070559

FIG. 1. FRONT BRAKE ACTUATOR

A — F56 Axle B — F71 Axle

1. Brake pad wear indicator lead 5. Clevis pin
2. Brake hose 6. Jaw–end
3. Actuator 7. Brake lever/slack adjuster
4. Mounting nut

E9612 6–11–3
 BRAKES 6
Brake actuators 55 Series

To Refit
1. Smear the push–rod with grease, then refit
the gaiter (when fitted).

2. Screw the jaw–end on to the push–rod until

the first thread of the push–rod protrudes
through the jaw–end, then tighten the
locknut.
3. Refit actuator to mounting bracket, locating
push–rod jaw–end over brake lever/slack
adjuster. Tighten actuator mounting nuts to

3 the torque figure quoted in DATA.

4. Align jaw–end with hole in brake lever/slack

adjuster, refit clevis pin and secure with a
new split pin. Smear the jaw–end with
grease

5. Connect brake hose to actuator.

6. Fully charge the vehicle air system.

7. 11 to 15 tonne vehicles: Apply the footbrake

several times to enable the front brake pad
adjuster mechanism to automatically adjust
the brakes to the optimum running
clearance.

17/18 tonne vehicles: Check and adjust the

brakes, refer to the Automatic Slack
Adjuster ‘Removal and Refitment’
procedure, Sub–Section 4.

8. Fully charge the vehicle air system and

check the operation of brake actuator(s) as
follows:

— Apply the footbrake and check for the

simultaneous operation of both brake
actuator push–rods.
— Apply and release the footbrake and
check that the push–rods move
smoothly and promptly without binding.

E9612
6–11–4
6 BRAKES
55 Series Brake actuators

Rear Spring Brake Chamber

11 to 15 tonne vehicles

WARNING: Spring brake actuators contain

an extremely powerful coil spring. There is a
risk of serious personal injury if
inexperienced personnel attempt to release
the actuators, particularly when an actuator
has sustained accident damage.

To Remove
1. Isolate the batteries.

2. Chock road wheels.

3
3. Fully deplete the vehicle air system.

4. Using the box spanner supplied with the

vehicle tool kit, rotate the brake actuator
release nut in an anti–clockwise direction to
its maximum extension.

5. Suitably identify air pipes, then disconnect

pipes from spring brake actuator. Blank
pipes and ports of actuator to prevent the
ingress of dirt.

6. Vehicles fitted with ABS: Release ABS

electrical cable from plastic ties at actuator
air pipes and position cable clear of
actuator.

7. Suitably reference mark the spring brake

chamber in relation to the mounting tube,
then release the clamping ring and
withdraw the spring brake chamber.

8. If necessary, note positions, then remove

adapters and ISO test connector from
spring brake chamber.

9. If necessary, renew the diaphragm.

E9612 6–11–5
 BRAKES 6
Brake actuators 55 Series

To Refit
Reverse removal procedure, noting:

1. If the original spring brake chamber is being

refitted, align reference marks made on
spring brake chamber and mounting tube.

2. When connecting the air pipes to the spring

brake actuator, ensure the spring brake
steel pipe is in an unstressed condition prior
to tightening the clamping ring.

3 3. Tighten clamping ring bolt to a torque of

11 Nm (8 lbf ft).

4. ‘Wind–on’ the spring brake actuator release

nut and tighten to a torque of 41 Nm
(30 lbf ft).

E9612
6–11–6
6 BRAKES
55 Series Brake actuators

Rear Spring Brake Actuator Assembly

WARNING: Spring brake actuators contain

an extremely powerful coil spring. There is a
risk of serious personal injury if
inexperienced personnel attempt to release
the actuators, particularly when an actuator
has sustained accident damage.

To Remove
Service tool: 0484938

1. Isolate the batteries. 3

2. Chock road wheels.

3. Fully deplete the vehicle air system.

4. Using the box spanner supplied with the

vehicle tool kit, rotate the brake actuator
release nut in an anti–clockwise direction to
its maximum extension.

5. Suitably identify air pipes, then disconnect

pipes from spring brake actuator; blank
pipes and ports of actuator to prevent the
ingress of dirt.

6. Vehicles fitted with ABS: Release ABS

electrical cable from plastic ties at spring
brake actuator air pipes, then position cable
clear of actuator.

E9612 6–11–7
 BRAKES 6
Brake actuators 55 Series

7. 11 to 15 tonne vehicles: Using service tool

0484938 and a suitable wrench, unscrew
locking ring securing actuator to expander
turret.
NOTE: If difficulty is experienced releasing 2 3 4
locking ring, remove the appropriate road
wheels as instructed in the ‘Drivers
Handbook’ to gain easier access.
1
Unscrew actuator from expander turret and
discard locking ring.
CAUTION: Exercise extreme care when
3 removing the actuator as it may be under
spring tension.

8. 17/18 tonne vehicles: Remove the split pin

and withdraw the clevis pin securing the 5
brake actuator push–rod to the slack
adjuster.
Remove the retaining nuts and withdraw the 6
spring brake actuator from the mounting
bracket.

070453

FIG. 2. REAR SPRING BRAKE ACTUATOR

11 to 15 tonne vehicles

1. Release nut
2. Spring brake chamber
3. Air pipes
4. Clamping ring
5. Locking ring
6. Service tool 0484938

E9612
6–11–8
6 BRAKES
55 Series Brake actuators

To Refit
1. 11 to 15 tonne vehicles: Screw a new
locking ring fully on to brake actuator
threads, then locate, and slowly screw
actuator into expander turret until it reaches
a positive stop.

— Unscrew the actuator up to a maximum

of one full turn to align the actuator
ports with the air pipes.
NOTE: Ensure the breather hole in
non–pressure plate faces downwards.
— ‘Wind–on’ the spring brake actuator 3
release nut and tighten to a torque of
30 to 40 Nm (22 to 29 lbf ft).
— Apply Loctite 242 to actuator/locking
ring threads, then using service tool
0484938 in conjunction with a suitable
torque wrench, tighten locking ring to a
torque of 233 Nm (172 lbf ft).
NOTE: Because the service tool
contributes additional leverage, the
actual torque figure attained will be
greater than that quoted above
(approximately 292 Nm (215 lbf ft)).

2. 17/18 tonne vehicles: Assemble the spring

brake actuator to the mounting bracket;
tighten the retaining nuts to a torque of 122
to 136 Nm (90 to 100 lbf ft).

— Connect the jaw–end to the slack

adjuster and secure the clevis pin with
a new split pin. Smear the brake
actuator push–rod/jaw–end with
grease.
3. Connect air pipes to actuator.
NOTE: When connecting the air pipes,
ensure the spring brake steel pipe is in an
unstressed condition.

4. Vehicles fitted with ABS: Secure ABS

electrical cable with plastic ties.

5. Charge the vehicle air system, then road

test the vehicle.

E9612 6–11–9
 BRAKES 6
Brake actuators 55 Series

OVERHAUL

Front Brake Actuator 1

To Dismantle
1. Remove brake actuator as instructed in this 2
Section.

2. Remove jaw–end, locknut and gaiter, (when 3

fitted).
4
3. Suitably reference mark both halves of
actuator body and note position of clamping
ring for assembly.
3 4. Locate a suitable tube over the actuator
push–rod and secure tube with push–rod
jaw–end locknut.

5. Release pinch bolt and remove clamping 070455

ring.

6. Separate body and remove diaphragm. FIG. 3. PUSH–ROD RETURN SPRING IN

CLAMPED POSITION
7. Slowly release the locknut to relieve
1. Push–rod
push–rod return spring tension, then
remove push–rod and return spring. 2. Locknut
3. Tube
4. Non–pressure plate

E9612
6–11–10
6 BRAKES
55 Series Brake actuators

To Inspect
1. Examine all metal components for wear or
damage, renew as necessary.

2. Examine return spring for weakness,

distortion or corrosion and check diaphragm
for signs of perishing or abrasion, renew as
necessary.
NOTE: If either the diaphragm or return
spring is renewed, it is recommended that
the corresponding diaphragm or return
spring in the brake actuator on the opposite
side of the vehicle is also renewed,
otherwise uneven braking may occur.
3
3. Ensure that breather holes are clear.

E9612 6–11–11
 BRAKES 6
Brake actuators 55 Series

To Reassemble
1. Position the push–rod on a flat surface and
locate the return spring over the push–rod.

2. Position non–pressure plate over the

push–rod and locate on return spring. Press
the non–pressure plate down to fully
compress the return spring and retain with
tube and push–rod locknut.

3. Locate the new diaphragm on the pressure

plate, then position push–rod and
3 non–pressure plate on the diaphragm.
Loosely install clamping ring over body
flanges; remove locknut and tube. Tap the
assembly lightly with a hide mallet to
centralise the components and tighten the
clamping ring pinch bolt.
NOTE: Due to a tendency for the beaded
edge of diaphragm to ‘bed in’, the clamping
ring pinch bolt should be checked and
re–tightened after a few hours operation to
prevent bead movement causing fretting
and leakage.

4. Refit gaiter, locknut and jaw–end.

1
2

4 5

7
8
9

070454

FIG. 4. EXPLODED VIEW OF FRONT BRAKE ACTUATOR

1. Pressure plate 4. Spring 7. Gaiter
2. Diaphragm 5. Clamping ring 8. Locknut
3. Push–rod 6. Non–pressure plate 9. Jaw–end

E9612
6–11–12
6 BRAKES
55 Series Brake actuators

Rear Spring Brake Actuator

The rear spring brake chamber is NOT
serviceable, however, the diaphragm can be
renewed, as instructed in this Section under
‘Removal and Refitment’ of the ‘Spring Brake
Chamber’, 11 to 15 tonne vehicles.

17/18 tonne vehicles: Renew the service brake

diaphragm as follows:

— Remove the spring brake actuator

assembly.

— Reference mark the spring brake chamber

3
in relation to the service brake chamber.

— Locate a suitable tube over the actuator

push–rod and secure tube with push–rod
jaw–end locknut, see Fig.3.

— Note position of clamping ring for assembly.

Remove the clamping ring and separate the
spring brake chamber from the service
brake chamber.

— Release and withdraw the diaphragm from

the service brake chamber.

— Locate a new diaphragm in the service

brake chamber.

— Position the service brake chamber on the

spring brake chamber, aligning the
reference marks previously scribed. Refit
the clamping ring and tighten the clamp bolt
to a torque of 11 Nm (8 lbf ft).

— Remove the tube from the push–rod and

then fit the actuator to the axle.

E9612 6–11–13
 BRAKES 6
Brake actuators 55 Series

E9612
6–11–14
6 BRAKES
55 Series Air pressure switches

13. AIR PRESSURE SWITCHES

DATA

Air pressure switch pressure setting . . . . . . . . . . 5,5 bar

E9612 6–13–1
 BRAKES 6
Air pressure switches 55 Series

REMOVAL AND REFITMENT

To Remove
1. Disconnect the batteries.

2. Deplete the air system.

3. Remove the instrument panel as detailed in

Group 5 ‘Electrical System’.

4. Release the heater controls from the 1

instrument panel shroud, then detach the
shroud from the corner trim panel, main trim
panel and steering column bracket.
3 5. Remove screws and bolt securing the
corner trim panel to the windscreen trim
070475
panel and cab door pillar. Release the cab
door seal and partially withdraw the trim
panel, disconnect the air ducting from the FIG.1. AIR PRESSURE SWITCH
air vent and withdraw the panel from cab.
1. Low air pressure warning buzzer and light
6. Suitably identify, then disconnect electrical
leads from switch.

7. Disconnect air pipe from switch.

8. Release locknut and remove switch and

adapter from mounting plate; remove switch
from adapter.

To Refit
Reverse removal procedure, noting:

1. Fully charge the air system, then test air

pressure switch for leakage, using a soap
solution. No leakage is permissible.

E9612
6–13–2
6 BRAKES
55 Series Relayed empty/load valve (Wabco)

14. RELAYED EMPTY/LOAD VALVE (Wabco)

DESCRIPTION

The relayed empty/load valve (RELV) has two

functions in the front brake circuit. The relay
portion of the valve is used to minimise the
delay in the application of the front brakes. The
air volume required for the delivery port of the
valve is supplied directly from the front reservoir.
The pressure at the delivery port of the valve is
controlled by a signal from the footvalve and a
signal from the rear axle load sensing valve
(LSV). The signal from the load sensing valve
provides the second function of the valve. When
the vehicle is in a partially laden condition the
load sensing valve reduces the pressure at the
LSV signal port of the RELV. The empty/load
3
function senses the ratio between the LSV
signal and the footvalve pressure being fed
directly from the footvalve. When the ratio is non
1:1 the empty/load function reduces the valve
output pressure to the front brakes. This feature
provides a similar footbrake pedal ‘feel’ under all
vehicle load conditions.
If the load sensing valve signal remains at zero
pressure due to a failure in the rear brake circuit
the valve responds to the failure by returning the
valve ratio to 1:1 and therefore utilising the full
performance of the front brakes.

E9612 6–14–1
 BRAKES 6
Relayed empty/load valve (Wabco) 55 Series

REMOVAL AND REFITMENT

To Remove
1. Isolate the batteries.

2. Fully deplete the vehicle air system.

3. Suitably identify, then disconnect the air

pipes from the valve. 2 3
1
4. Remove nuts securing valve to mounting
bracket and withdraw valve.

5. If necessary, remove adapters from valve.

3
To Refit
Refitment is a reversal of the removal
procedure. 4

7
5
6 070449

FIG. 1. RELAYED EMPTY/LOAD VALVE

1. Signal line from load sensing valve

2. Mounting nuts
3. Valve
4. Signal line from footbrake valve
5. Delivery line
6. Supply line
7. Delivery line

E9612
6–14–2
6 BRAKES
55 Series Relayed empty/load valve (Wabco)

TESTING

Valve Function Check

Service tools: Air pressure test gauge 0485052.

NOTE: This check must be carried out with the

vehicle in an unladen condition, ie., load sensing
valve not at 1:1.

1. Connect test gauge 0485052 to the ISO

test connection at the front brake actuator.

2. Fully charge the vehicle air system.

3. With the aid of an assistant, apply the

footbrake and observe the pressure reading
3
on the test gauge; with the footbrake still
applied, drain the rear service reservoir and
check that the pressure reading drops, and
then rapidly increases when the reservoir is
fully depleted.

4. If the valve is not functioning as detailed

above, investigate the cause and rectify as
necessary.

E9612 6–14–3
 BRAKES 6
Relayed empty/load valve (Wabco) 55 Series

OVERHAUL

The relayed empty/load valve is not serviceable.

If the valve is found to be defective, it MUST be
renewed.

E9612
6–14–4
6 BRAKES
55 Series Relay valves

15. RELAY VALVES

REMOVAL AND REFITMENT

Relay Valve

To Remove To Refit
1. Isolate the batteries and deplete the air Reverse the removal procedure, noting:
system.
1. Fully charge the air system, check
2. Suitably identify, then disconnect all pipes connections for leakage and rectify as
from valve. necessary.

3. Remove mounting bolts and withdraw valve

from vehicle.

4. If necessary, remove pipe adapters from

valve.
3

2
2
1

11

6 5 4
10 8 070423

FIG.1. RELAY VALVES

1. Spring brake relay valve 7. Signal line to relayed empty/load valve

2. Mounting nuts 8. Delivery line to rear service brakes
3. Rear axle service relay valve 9. Signal line from hand control valve
4. Signal line from load sensing valve 10. Supply line from park reservoir
5. Supply line from rear service reservoir 11. Delivery line to hand control valve
6. Delivery line to spring brakes

E9612 6–15–1
 BRAKES 6
Relay valves 55 Series

E9612
6–15–2
6 BRAKES
Relay valve (Knorr Bremse–R15 type)

15J. RELAY VALVE (Knorr Bremse–R15 type)

DESCRIPTION

The purpose of the relay valve is to speed up

the actuation and release of the brakes by
reducing the volume of air required in the brake
control circuit. In effect it shortens the pipe run
between reservoir and brake chambers,
improving response times. The relay valve is
operated by signal line pressure from the
footbrake valve via the load sensing valve.

E9612 6–15J–1
 BRAKES 6
Relay valve (Knorr Bremse–R15 type)

OVERHAUL

NOTE: A repair kit should be obtained before

overhaul.

To Dismantle
1. Suitably mark valve body to aid
re–assembly.

2. Grip valve lightly in soft vice jaws, remove

bolts securing top and bottom halves of
valve body.

3. Separate top from bottom half of valve,

3 remove piston from top half of valve, noting
sealing rings on piston and bottom half of
valve.

4. Remove circlip from bottom of valve.

5. Withdraw exhaust valve assembly, noting:

— Exhaust diaphragm, valve guide and
O–rings.
— Plastic housing and O–rings.
— Bonded valve assembly, spring and
spring seating washer.

6. Renew valve adapters as necessary.

To Reassemble
Reverse the dismantling procedure, noting:

1. Replace all items by those contained in the

repair kit.

2. Smear all seals, sealing rings, springs and

sliding surfaces with grease provided in the
service kit.

E9612
6–15J–2
6 BRAKES
Relay valve (Knorr Bremse–R15 type)

3
2 9

10
3
11

4 12

13
5
14

15
6

16

17

18

070558

FIG.1. EXPLODED VIEW OF RELAY VALVE

1. Top cover 10. O–ring
2. O–ring 11. Plastic housing
3. Piston 12. O–ring
4. Piston sealing ring 13. Plastic housing
5. Valve body sealing ring 14. O–ring
6. Lower valve body 15. O–ring
7. Inlet/exhaust valve 16. Valve guide
8. Spring seating washer 17. Exhaust diaphragm
9. Spring 18. Circlip

E9612 6–15J–3
 BRAKES 6
Relay valve (Knorr Bremse–R15 type)

E9612
6–15J–4
6 BRAKES
55 Series Load sensing valve

17. LOAD SENSING VALVE

REMOVAL AND REFITMENT

Knorr Bremse Load Sensing Valve

(Inshot Type)

To Remove
1. Isolate the batteries and deplete the air
system.

2. Disconnect the supply and delivery pipes

from the valve.

3. Disconnect the flexible linkage from

operating lever.

4. Remove nuts and washers securing valve

3
to mounting bracket and withdraw valve.

To Refit
Reverse removal procedure, noting:

1. Carry out ‘Valve Function’ and ‘Output

Pressure Tests’ as instructed in ‘TESTING’.

E9612 6–17–1
 BRAKES 6
Load sensing valve 55 Series

Knorr–Bremse Load Sensing Valve

Air Suspension Vehicles

To Remove
1. Disconnect the batteries and deplete the air
system.

2. Suitably identify then disconnect air pipes at

valve.

3. Remove mounting nuts securing valve to

mounting bracket and withdraw from
3 vehicle.

4. Remove ISO test connector and adapters

as necessary.

To Refit
Reverse the removal procedure, noting:

1. Seal air pipe connections as necessary with

‘Loctite 572’.

2. Carry out the ‘Output Pressure Test’ as

instructed in ‘TESTING’.

E9612
6–17–2
6 BRAKES
55 Series Load sensing valve

TESTING

Checking/Adjusting the Load Sensing Valve

Service tools: Air pressure test equipment
0485052 (2 off)

— The vehicle should be preferably tested in

an unladen condition, but the following
procedures can be used for a partially or
fully laden vehicle if required.

— Obtain the part number of the load sensing

data plate (attached to the cab door
aperture). The part number will enable the
operator to select the relevant load sensing
valve setting chart, as shown in this
3
Section. Ensure that the relevant setting
chart is available before commencing work
on the vehicle.

E9612 6–17–3
 BRAKES 6
Load sensing valve 55 Series

Knorr Bremse Sensing Valve (Inshot Type)

Valve Function Test

1. Chock the road wheels and, using a
workshop air line fitted to the vehicle full
flow I.S.O. connection situated at the air
dryer, fully charge the vehicle air system.

2. Using the air pressure test gauges

0485052, connect them to the load sensing
valve (inlet), rear spring brake actuator
(outlet) and the front brake chamber (outlet)
3 I.S.O. test connections.

2
1

070548

FIG.1. LOCATION OF ISO TEST CONNECTIONS

1. ISO full–flow test connection 3. ISO test connection (outlet)
(system charging point) 4. ISO test connection (outlet)
2. ISO test connection (inlet)

E9612
6–17–4
6 BRAKES
55 Series Load sensing valve

3. Should the load sensing valve fail any of the

following tests, it must be
overhauled/renewed as instructed in
‘Sub–Section 17C’.

— Detach the load sensing valve flexible

connection link from the adjustment
screw and pull the operating lever 1
upwards to its maximum lift position.
— With the aid of an assistant, lightly
depress and then hold the footbrake
pedal stationary when a constant air
pressure of 6 bar registers on the inlet 3
air gauge; the outlet gauge (rear brake) 2
should register the same pressure.
— Release the footbrake and then push
the operating lever downwards to its 3
maximum position.
— Re–apply and then hold the footbrake
stationary when a constant air pressure
of 6 bar registers on the inlet air gauge;
the outlet gauge (rear brake) should 070428
register the unladen output pressure of
1,3 " 0,25 bar. Release the footbrake
FIG.2. LOAD SENSING VALVE LINKAGE
pedal.
1. Operating lever
4. If the load sensing valve has successfully
completed the above test re–connect the 2. Flexible connection link
flexible connection link to the adjustment 3. Adjustment screw
screw and continue testing the valve as
instructed in ‘Output Pressure Test’.

E9612 6–17–5
 BRAKES 6
Load sensing valve 55 Series

Output Pressure Test (see Fig. 3.)

1. Weigh the vehicle to obtain the actual rear
axle ground weight.
P4
2. Using the appropriate data plate setting
chart shown in this Sub–Section, select the F mm
nearest rear axle ground weight figure P2
Lm
above the actual recorded rear axle ground m
weight and note the corresponding output
pressure. L = 130 F = 68
P4 = 6 bar
3. Check and, if necessary, adjust the
3 operating lever setting dimension ‘L’, Fig.3,
to the figure quoted on the load sensing
ASLAST
AXLE LOAD
P2
UITGESTUURDE DRUK
DELIVERY PRESSURE
ACHSLAST AUSGESTEUERTER
data plate. CHARGE SOIS DRUCK
ESSIEU PRESSION DELIVREE
CARICO ASSE PRESSIONE USCITA
CARGA EJE PRESION DE SALIDA

Kg bar
1680 3.1
2000 3.3
3000 4.3
4000 5.4
5560 6.0
8240 6.0

ACHA964

C
070429

FIG.3. SETTING LOAD SENSING VALVE

E9612
6–17–6
6 BRAKES
55 Series Load sensing valve

4. Lightly depress and hold the footbrake

pedal stationary when a constant air
pressure of 6 bar registers on the inlet
pressure gauge; note the outlet pressure
reading. If the output air pressure is not
within " 0,25 bar of the required output
pressure, adjust the valve setting as
follows:
— Release the footbrake pedal; all
adjustments MUST be made whilst the
load sensing valve is unpressurised.
— Adjust the length of the adjustment
screw, dimension ‘C’, Fig.3, to modify
3
the outlet pressure; an increase in
length will increase the pressure and,
conversely, a decrease in length will
decrease the pressure.
— Repeat the output pressure test
procedure until the required pressure is
achieved.

NOTE: In certain circumstances, it may be

necessary to adjust the ‘L’ dimension to
achieve the required output pressures in
both the unladen and laden conditions.

5. When the load sensing valve has been set

correctly, check the front brake output
pressure as follows:

— Lightly depress and hold the footbrake

pedal stationary when a constant air
pressure of 6 bar registers on the inlet
pressure gauge; check the gauge
reading is within " 0,25 bar of the
required output pressure. An incorrect
reading indicates a faulty empty/load
valve; renew the valve as detailed in
Sub–Section 14.

E9612 6–17–7
 BRAKES 6
Load sensing valve 55 Series

Load Sensing Data Plate Setting Charts

Data Plate Part Number ACHA964 Data Plate Part Number ACHA965
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 1.5
Rear axle Output Pressure Rear axle Output Pressure
weight (bar) weight (bar)
kg Front Rear kg Front Rear
axle axle axle axle
8240 6,0 6,0 8500 6,0 6,0
5560 6.0 6,0 6030 6,0 6,0
3 1680
2000
4,6
4,7
3,1
3,3
1680
3000
4,8
5,1
2,3
3,4
3000 5,2 4,3 4000 5,6 4,7
4000 5,7 5,4 5000 5,8 5,5
5500 6,0 6000 6,0
5380 6,0 5870 5,9
5260 5,9 5740 5,9
5140 5,9 5610 5,8
5020 5,8 5480 5,8
4900 5,8 5350 5,7
4780 5,8 5220 5,6
4660 5,7 5090 5,5
4540 5,7 4960 5,5
4420 5,6 4830 5,4
4300 5,6 4700 5,3
4180 5,5 4570 5,2
4060 5,4 4440 5,1
3940 5,3 4310 5,0
3820 5,2 4180 4,9
3700 5,0 4050 4,8
3580 4,9 3920 4,6
3460 4,8 3790 4,4
3340 4,7 3660 4,2
3220 4,5 3530 4,0
3100 4,4 3400 3,9
2980 4,3 3270 3,7
2860 4,1 3140 3,5
2740 4,0 3010 3,4
2620 3,9 2880 3,2
2500 3,8 2750 3,1
2380 3,7 2620 3,0
2260 3,6 2490 2,9
2140 3,5 2360 2,8
2020 3,4 2230 2,7
1900 3,3 2100 2,6
1780 3,2 1970 2,5
1660 3,1 1840 2,4
1540 3,0 1710 2,3
1420 2,9 1580 2,2
1300 2,8 1450 2,2
1180 2,8 1320 2,1
1060 2,7 1190 2,0
1000 2,7 1060 2,0
1000 2,0

E9612
6–17–8
6 BRAKES
55 Series Load sensing valve

Data Plate Part Number ACHA966 Data Plate Part Number ACHA967
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 2.7
Rear axle Output Pressure Rear axle Output Pressure
weight (bar) weight (bar)
kg Front Rear kg Front Rear
axle axle axle axle
9800 6,0 6,0 9800 6,0 6,0
6400 6.0 6,0 6400 6,0 6,0
1680 4,1 2,2 1680 3,6 2,2
3000 4,6 3,2 3000 4,2 3,2
4000
5000
6400
5,3
5,6
4,5
5,2
6,0
4000
5000
6400
5,1
5,5
4,5
5,2
6,0
3
6260 6,0 6260 6,0
6120 5,9 6120 5,9
5980 5,8 5980 5,8
5840 5,8 5840 5,8
5700 5,7 5700 5,7
5560 5,6 5560 5,6
5420 5,5 5420 5,5
5280 5,4 5280 5,4
5240 5,3 5140 5,3
5000 5,2 5000 5,2
4860 5,1 4860 5,1
4720 5,0 4720 5,0
4580 4,9 4580 4,9
4440 4,8 4440 4,8
4300 4,7 4300 4,7
4160 4,6 4160 4,6
4020 4,5 4020 4,5
3880 4,3 3880 4,3
3740 4,1 3740 4,1
3600 3,9 3600 3,9
3460 3,7 3460 3,7
3320 3,5 3320 3,5
3180 3,4 3180 3,4
3040 3,2 3040 3,2
2900 3,1 2900 3,1
2760 2,9 2760 2,9
2620 2,8 2620 2,8
2480 2,7 2480 2,7
2340 2,6 2340 2,6
2200 2,5 2200 2,5
2060 2,4 2060 2,4
1920 2,3 1920 2,3
1780 2,3 1780 2,3
1640 2,2 1640 2,2
1500 2,1 1500 2,1
1360 2,0 1360 2,0
1220 2,0 1220 2,0
1080 1,9 1080 1,9
1000 1,9 1000 1,9

E9612 6–17–9
 BRAKES 6
Load sensing valve 55 Series

Data Plate Part Number ACHA968 Data Plate Part Number ACHA977
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.7 Empty/load valve ratio 2.0
Rear axle Output Pressure Rear axle Output Pressure
weight (bar) weight (bar)
kg Front Rear kg Front Rear
axle axle axle axle
10300 6,0 6,0 8500 6,0 6,0
7240 6.0 6,0 6400 6,0 6,0
1680 3,5 2,0 1680 4,1 2,2
3000 4,0 2,8 3000 4,6 3,2

3 4000
5000
7200
4,7
5,1
3,9
4,6
6,0
4000
5000
6400
5,3
5,6
4,5
5,2
6,0
7040 5,9 6260 6,0
6880 5,9 6120 5,9
6720 5,8 5980 5,8
6560 5,7 5840 5,8
6400 5,6 5700 5,7
6240 5,5 5560 5,6
6080 5,4 5420 5,5
5920 5,3 5280 5,4
5760 5,2 5140 5,3
5600 5,1 5000 5,2
5440 5,0 4860 5,1
5280 4,8 4720 5,0
5120 4,7 4580 4,9
4690 4,6 4440 4,8
4800 4,5 4300 4,7
4640 4,4 4160 4,6
4480 4,3 4020 4,5
4320 4,2 3880 4,3
4160 4,1 3740 4,1
4000 3,9 3600 3,9
3840 3,7 3460 3,7
3680 3,5 3320 3,5
3520 3,3 3180 3,4
3360 3,1 3040 3,2
3200 3,0 2900 3,1
3040 2,8 2760 2,9
2880 2,7 2620 2,8
2720 2,6 2480 2,7
2560 2,5 2340 2,6
2400 2,4 2200 2,5
2240 2,3 2060 2,4
2080 2,2 1920 2,3
1920 2,1 1780 2,3
1760 2,0 1640 2,2
1600 2,0 1500 2,1
1440 1,9 1360 2,0
1280 1,8 1220 2,0
1120 1,8 1080 1,9
1000 1,8 1000 1,9

E9612
6–17–10
6 BRAKES
55 Series Load sensing valve

Data Plate Part Number ACHA286 Data Plate Part Number ACHA288
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.7 Empty/load valve ratio 2.7
Rear axle Output Pressure Rear axle Output Pressure
weight (bar) weight (bar)
kg Front Rear kg Front Rear
axle axle axle axle
11500 6,0 6,0 11500 6,0 6,0
9160 6.0 6,0 8880 6,0 6,0
2280 3,4 1,8 2280 3,3 1,7
4000 3,9 2,7 4000 3,9 2,6
6000
8000
9100
4,6
5,4
3,8
5,1
5,9
6000
8000
8800
4,5
5,4
3,8
5,1
5,9
3
8910 5,8 8620 5,7
8720 5,6 8440 5,5
8530 5,5 8260 5,4
8340 5,3 8080 5,2
8150 5,2 7900 5,0
7960 5,0 7720 4,9
7770 4,9 7540 4,7
7580 4,8 7360 4,6
7390 4,6 7180 4,4
7200 4,5 7000 4,3
7010 4,4 6820 4,2
6820 4,3 6640 4,0
6630 4,1 6460 3,9
6440 4,0 6280 3,8
6250 3,9 6100 3,7
6060 3,8 5920 3,6
5870 3,7 5740 3,5
5680 3,6 5560 3,4
5490 3,5 5380 3,3
5300 3,4 5200 3,2
5110 3,3 5020 3,1
4920 3,3 4840 3,0
4730 3,2 4660 2,9
4540 3,1 4480 2,8
4350 3,0 4300 2,8
4160 2,9 4120 2,7
3970 2,7 3940 2,6
3780 2,6 3760 2,4
3590 2,4 3580 2,3
3400 2,3 3400 2,2
3210 2,2 3220 2,1
3020 2,1 3040 2,0
2830 2,0 2860 1,9
2640 1,9 2680 1,8
2450 1,9 2500 1,8
2260 1,8 2320 1,7
2070 1,7 2140 1,7
2000 1,7 2000 1,6

E9612 6–17–11
 BRAKES 6
Load sensing valve 55 Series

Data Plate Part Number ACHJ055 Data Plate Part Number ACHJ056
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 1.5
Rear axle Output Pressure Rear axle Output Pressure
weight (bar) weight (bar)
kg Front Rear kg Front Rear
axle axle axle axle
8240 6,0 6,0 8500 6,0 6,0
6130 6.0 6,0 1680 4,8 2,4
1680 4,4 2,8 2500 4,9 2,8
3000 4,9 3,7 4500 5,4 4,1

3 4000
5000
6100
5,3
5,7
4,6
5,4
6,0
6500
7500
8570
5,6
5,8
4,9
5,4
6,0
5960 5,9 8300 5,9
5820 5,8 8100 5,7
5680 5,7 7900 5,6
5540 5,7 7700 5,5
5400 5,6 7300 5,3
5260 5,5 7100 5,2
5120 5,4 6900 5,1
4980 5,3 6700 5,0
4840 5,3 6300 4,8
4700 5,2 6100 4,7
4560 5,1 5900 4,7
4420 5,1 5700 4,6
4280 5,0 5500 4,5
4140 4,8 5300 4,4
3860 4,5 5100 4,3
3720 4,4 4900 4,2
3580 4,2 4700 4,2
3440 4,1 4300 4,0
3300 4,0 4100 3,8
3100 3,8 3900 3,7
3020 3,7 3700 3,5
2880 3,6 3500 3,4
2740 3,5 3300 3,2
2600 3,4 3100 3,1
2460 3,3 2900 3,0
2320 3,2 2700 2,9
2180 3,1 2300 2,7
2040 3,0 2100 2,6
1900 2,9 1900 2,5
1760 2,8 1700 2,4
1620 2,8 1500 2,3
1480 2,7 1300 2,3
1340 2,6 1100 2,2
1200 2,6 1000 2,2
1060 2,5
1000 2,5

E9612
6–17–12
6 BRAKES
55 Series Load sensing valve

Data Plate Part Number ACHJ057 Data Plate Part Number ACHJ058
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.0 Empty/load valve ratio 2.7
Rear axle Output Pressure Rear axle Output Pressure
weight (bar) weight (bar)
kg Front Rear kg Front Rear
axle axle axle axle
9800 6,0 6,0 9800 6,0 6,0
8740 6.0 6,0 7350 6.0 6,0
1680 4,1 2,2 1680 3,7 2,3
2500 4,3 2,6 2500 3,9 2,7
4500
6500
8700
5,0
5,4
3,9
4,7
6,0
4500
6500
7300
4,9
5,6
4,3
5,4
6,0
3
8500 5,8 7130 5,8
8300 5,7 6960 5,7
8100 5,6 6790 5,6
7900 5,5 6620 5,5
7700 5,4 6450 5,4
7500 5,3 6280 5,3
7300 5,2 6110 5,2
7100 5,0 5940 5,1
6900 4,9 5770 5,0
6700 4,8 5600 4,9
6300 4,6 5430 4,8
6100 4,5 5260 4,7
5900 4,5 5090 4,6
5700 4,4 4920 4,6
5500 4,3 4750 4,5
5300 4,2 4580 4,4
5100 4,1 4410 4,3
4900 4,0 4240 4,2
4700 3,9 4070 4,0
4300 3,8 3900 3,8
4100 3,6 3730 3,7
3900 3,4 3560 3,5
3700 3,3 3390 3,4
3500 3,2 3220 3,2
3300 3,0 3050 3,1
3100 2,9 2880 3,0
2900 2,8 2710 2,9
2700 2,7 2540 2,8
2300 2,5 2370 2,7
2100 2,4 2200 2,6
1900 2,3 2030 2,5
1700 2,2 1860 2,4
1500 2,1 1690 2,3
1300 2,1 1520 2,2
1100 2,0 1350 2,2
1000 2,0 1180 2,1
1010 2,0
1000 2,0

E9612 6–17–13
 BRAKES 6
Load sensing valve 55 Series

Data Plate Part Number ACHJ059 Data Plate Part Number ACHJ065
Input Pressure = 6 bar Input Pressure = 6 bar
Empty/load valve ratio 2.7 Empty/load valve ratio 1.5
Rear axle Output Pressure Rear axle Output Pressure
weight (bar) weight (bar)
kg Front Rear kg Front Rear
axle axle axle axle
10300 6,0 6,0 8500 5,9 5,8
7060 6.0 6,0 1680 4,1 2,2
1680 3,4 1,9 2500 4,3 2,6
2500 3,7 2,3 4500 5,0 3,9

3 4500
6500
7000
4,8
5,7
4,1
5,5
5,9
6500
7500
8740
5,4
5,7
4,7
5,3
6,0
6840 5,8 8700 6,0
6680 5,7 8300 5,7
6520 5,5 8100 5,6
6360 5,4 7900 5,5
6200 5,3 7700 5,4
6040 5,1 7300 5,2
5880 5,0 7100 5,0
5720 4,9 6900 4,9
5560 4,8 6700 4,8
5400 4,7 6300 4,6
5240 4,6 6100 4,5
5080 4,4 5900 4,5
4920 4,3 5700 4,4
4760 4,2 5500 4,3
4600 4,1 5300 4,2
4440 4,0 5100 4,1
4280 3,9 4900 4,0
4120 3,7 4700 3,9
3960 3,5 4300 3,8
3800 3,3 4100 3,6
3640 3,2 3900 3,4
3480 3,0 3700 3,3
3320 2,9 3500 3,2
3160 2,7 3300 3,0
3000 2,6 3100 2,9
2840 2,5 2900 2,8
2680 2,4 2700 2,7
2520 2,3 2300 2,5
2360 2,2 2100 2,4
2200 2,1 1900 2,3
2040 2,0 1700 2,2
1880 2,0 1500 2,1
1720 1,9 1300 2,1
1560 1,9 1100 2,0
1400 1,8 1000 2,0
1240 1,8
1080 1,7
1000 1,7

E9612
6–17–14
6 BRAKES
55 Series Load sensing valve

Knorr–Bremse Load Sensing Valve 3. Connect three air pressure gauges

Air Suspension Models 0485052 to the following locations.

Output Pressure Test — The load sensing valve ISO test

1. Weigh the vehicle to obtain the actual rear connection at port 1 (inlet).
axle ground weight.
— The rear brake actuator ISO test
2. Chock the road wheels and, using a connection (outlet).
workshop air line connected to the vehicle — The front brake chamber ISO test
full flow ISO connection, fully charge the connection (outlet).
vehicle air system.

3
1

070549

FIG.4. LOCATION OF ISO TEST CONNECTIONS

1. ISO full–flow test connection 3. ISO test connection (outlet)

(system charging point) 4. ISO test connection (outlet)
2. ISO test connection (inlet)

E9612 6–17–15
 BRAKES 6
Load sensing valve 55 Series

4. Using the appropriate setting chart, see

Data, select the nearest rear axle ground
weight figure above the actual recorded
rear axle ground weight and note the P1
P1 = 6 bar
corresponding output pressure ‘P2’. P2
5. Depress and hold the footbrake pedal
stationary when an input pressure of 6 bar
registers on the gauge connected to port ‘1’ P3
and check that the output pressure at the P2 = UITGESTUURDE DRUK
gauge connected to the rear brake actuator DELIVERY PRESSURE
is within " 0,25 bar of the required output AUSGESTEUERTER DRUCK
PRESSION DELIVREE
3 pressure.
If the output pressure reading is not within
PRESSIONE USCITA
PRESION DE SALIDA
the required limits, the load sensing valve
P3 = BALG DRUK
MUST be re–calibrated as instructed in PRESSURE BELLOWS
‘Sub–Section 17L’. BALG DRUCK
PRESSION COUSSIN
PRESS. CUSCINI ARIA
6. If the load sensing valve has successfully PRESION FUELLES
completed the above test, check the front
brake output pressure as follows: ASLAST
AXLE LOAD
ACHSLAST
P3 P2
CHARGE SOUS ESSIEU bar bar
— Lightly depress and hold the footbrake CARICO ASSE
pedal stationary when a constant air CARGA EJE Kg

pressure of 6 bar registers on the inlet 1610 0.5 2.3

pressure gauge; check the gauge 3000 1.3 3.5
reading is within " 0,25 bar of the 4000 2.0 4.4
required output pressure. An incorrect 5000 2.6 5.2
reading indicates a faulty empty/load 5866 3.1 6.0
valve; renew the valve as instructed in 8500 4.7 6.0
‘Sub–Section 14’.
ACHA111
070506

FIG.5. LSV DATA PLATE

E9612
6–17–16
6 BRAKES
55 Series Load sensing valve

Load Sensing Data Plate Setting Charts

Data Plate Part Number ACHA110 Data Plate Part Number ACHA111

Input Pressure = 6 bar Input Pressure = 6 bar

Empty/load valve ratio 2.0 Empty/load valve ratio 1.5
Rear Bellows Output Rear Bellows Output
axle Pressure Pressure axle Pressure Pressure
weight (bar) weight (bar)
kg bar Front Rear kg bar Front Rear
axle axle axle axle
8240
5047
4,6
2,6
6,0
6,0
6,0
6,0
8500
5866
4,7
3,1
6,0
6,0
6,0
6,0
3
1610 0,5 4,6 3,1 1610 0,5 4,8 2,3
2000 0,7 4,7 3,4 3000 1,3 5,2 3,5
3000 1,3 5,2 4,3 4000 2,0 5,5 4,4
4000 2,0 5,6 5,1 5000 2,6 5,7 5,2
5000 2,6 6,0 5800 3,1 5,9
4860 2,5 5,8 5670 3,0 5,8
4720 2,4 5,7 5540 2,9 5,7
4580 2,3 5,6 5410 2,8 5,6
4440 2,2 5,5 5280 2,7 5,5
4300 2,1 5,4 5150 2,7 5,4
4160 2,1 5,3 5020 2,6 5,3
4020 2,0 5,1 4890 2,5 5,2
3880 1,9 5,0 4760 2,4 5,0
3740 1,8 4,9 4630 2,3 4,9
3600 1,7 4,8 4500 2,3 4,8
3460 1,6 4,7 4370 2,2 4,7
3320 1,5 4,5 4240 2,1 4,6
3180 1,5 4,4 4110 2,0 4,5
3040 1,4 4,3 3980 1,9 4,4
2900 1,3 4,2 3850 1,9 4,2
2760 1,2 4,1 3720 1,8 4,1
2620 1,1 4,0 3590 1,7 4,0
2480 1,0 3,8 3460 1,6 3,9
2340 0,9 3,7 3330 1,6 3,8
2200 0,9 3,6 3200 1,5 3,7
2060 0,8 3,5 3070 1,4 3,6
1920 0,7 3,4 2940 1,3 3,5
1780 0,6 3,2 2810 1,2 3,3
1640 0,5 3,1 2680 1,2 3,2
1500 0,4 3,1 2550 1,1 3,1
1360 0,3 3,1 2420 1,0 3,0
1220 0,3 3,1 2290 0,9 2,9
1080 0,2 3,1 2160 0,8 2,8
2030 0,8 2,7
1900 0,7 2,6
1770 0,6 2,4
1640 0,5 2,3
1510 0,4 2,3
1380 0,4 2,3
1250 0,3 2,3
1120 0,2 2,3
1000 0,1 2,3

E9612 6–17–17
 BRAKES 6
Load sensing valve 55 Series

Data Plate Part Number ACHA112 Data Plate Part Number ACHA113

Input Pressure = 6 bar Input Pressure = 6 bar

Empty/load valve ratio 2.0 Empty/load valve ratio 2.7
Rear Bellows Output Rear Bellows Output
axle Pressure Pressure axle Pressure Pressure
weight (bar) weight (bar)
kg bar Front Rear kg bar Front Rear
axle axle axle axle
9800 5,5 6,0 6,0 9800 5,5 6,0 6,0

3 6029
1610
3000
3,2
0,5
1,3
6,0
4,1
4,7
6,0
2,2
3,4
6029
1610
3000
3,2
0,5
1,3
6,0
3,6
4,4
6,0
2,2
3,4
4000 2,0 5,2 4,3 4000 2,0 4,9 4,3
5000 2,6 5,6 5,1 5000 2,6 5,4 5,1
6000 3,2 6,0 6000 3,2 6,0
5880 3,1 5,9 5880 3,1 5,9
5760 3,0 5,8 5760 3,0 5,8
5640 3,0 5,7 5640 3,0 5,7
5520 2,9 5,6 5520 2,9 5,6
5400 2,8 5,5 5400 2,8 5,5
5280 2,7 5,4 5280 2,7 5,4
5160 2,7 5,3 5160 2,7 5,3
5040 2,6 5,1 5040 2,6 5,1
4920 2,5 5,0 4920 2,5 5,0
4800 2,4 4,9 4800 2,4 4,9
4680 2,4 4,8 4680 2,4 4,8
4560 2,3 4,7 4560 2,3 4,7
4440 2,2 4,6 4440 2,2 4,6
4320 2,2 4,5 4320 2,2 4,5
4200 2,1 4,4 4200 2,1 4,4
4080 2,0 4,3 4080 2,0 4,3
3960 1,9 4,2 3960 1,9 4,2
3840 1,9 4,1 3840 1,9 4,1
3720 1,8 4,0 3720 1,8 4,0
3600 1,7 3,9 3600 1,7 3,9
3480 1,6 3,8 3480 1,6 3,8
3360 1,6 3,7 3360 1,6 3,7
3240 1,5 3,6 3240 1,5 3,6
3120 1,4 3,5 3120 1,4 3,5
3000 1,3 3,4 3000 1,3 3,4
2880 1,3 3,3 2880 1,3 3,3
2760 1,2 3,2 2760 1,2 3,2
2640 1,1 3,1 2640 1,1 3,1
2520 1,1 3,0 2520 1,1 3,0
2400 1,0 2,9 2400 1,0 2,9
2280 0,9 2,8 2280 0,9 2,8
2160 0,8 2,7 2160 0,8 2,7
2040 0,8 2,6 2040 0,8 2,6
1920 0,7 2,5 1920 0,7 2,5
1800 0,6 2,4 1800 0,6 2,4
1680 0,5 2,3 1680 0,5 2,3
1610 0,5 2,2 1610 0,5 2,2

E9612
6–17–18
6 BRAKES
55 Series Load sensing valve

Data Plate Part Number ACHA114 Data Plate Part Number ACHE213

Input Pressure = 6 bar Input Pressure = 6 bar

Empty/load valve ratio 2.7 Empty/load valve ratio 2.0
Rear Bellows Output Rear Bellows Output
axle Pressure Pressure axle Pressure Pressure
weight (bar) weight (bar)
kg bar Front Rear kg bar Front Rear
axle axle axle axle
10300 5,8 6,0 6,0 8500 5,5 6,0 6,0
6193
1610
3000
3,3
0,5
1,3
6,0
3,5
4,2
6,0
2,2
3,4
6029
1610
3000
3,2
0,5
1,3
6,0
4,1
4,7
6,0
2,2
3,4
3
4000 2,0 4,8 4,3 4000 2,0 5,2 4,3
5000 2,6 5,4 5,1 5000 2,6 5,6 5,1
6100 3,2 6,0 6000 3,2 6,0
5960 3,2 5,9 5880 3,1 5,9
5820 3,1 5,8 5760 3,0 5,8
5680 3,0 5,7 5640 3,0 5,7
5540 2,9 5,6 5520 2,9 5,6
5400 2,8 5,5 5400 2,8 5,5
5260 2,7 5,4 5280 2,7 5,4
5120 2,6 5,3 5160 2,7 5,3
4980 2,6 5,1 5040 2,6 5,1
4840 2,5 5,0 4920 2,5 5,0
4700 2,4 4,9 4800 2,4 4,9
4560 2,3 4,8 4680 2,4 4,8
4420 2,2 4,7 4560 2,3 4,7
4280 2,1 4,6 4440 2,2 4,6
4140 2,0 4,5 4320 2,2 4,5
4000 2,0 4,4 4200 2,1 4,4
3860 1,9 4,3 4080 2,0 4,3
3720 1,8 4,2 3960 1,9 4,2
3580 1,7 4,1 3840 1,9 4,1
3440 1,6 4,0 3720 1,8 4,0
3300 1,5 3,9 3600 1,7 3,9
3160 1,4 3,8 3480 1,6 3,8
3020 1,4 3,7 3360 1,6 3,7
2880 1,3 3,6 3240 1,5 3,6
2740 1,2 3,5 3120 1,4 3,5
2600 1,1 3,4 3000 1,3 3,4
2460 1,0 3,3 2880 1,3 3,3
2320 0,9 3,2 2760 1,2 3,2
2180 0,8 3,1 2640 1,1 3,1
2040 0,8 3,0 2520 1,1 3,0
1900 0,7 2,9 2400 1,0 2,9
1760 0,6 2,8 2280 0,9 2,8
1620 0,5 2,7 2160 0,8 2,7
1480 0,4 2,6 2040 0,8 2,6
1340 0,3 2,5 1920 0,7 2,5
1200 0,2 2,4 1800 0,6 2,4
1060 0,2 2,3 1680 0,5 2,3
1000 0,1 2,2 1610 0,5 2,2

E9612 6–17–19
 BRAKES 6
Load sensing valve 55 Series

Data Plate Part Number ACHA292

Input Pressure = 6 bar

Empty/load valve ratio 2.7
Rear Bellows Output
axle Pressure Pressure
weight (bar)
kg bar Front Rear
axle axle
11500 6,2 6,0 6,0
6988 3,6 6,0 6,0
2280 0,8 3,5 2,0

3 4000
5000
6000
1,9
2,4
3,0
4,4
4,9
5,5
3,5
4,3
5,2
6900 3,5 5,9
6760 3,5 5,8
6620 3,4 5,7
6480 3,3 5,6
6340 3,2 5,5
6200 3,1 5,4
6060 3,1 5,3
5920 3,0 5,1
5780 2,9 5,0
5640 2,8 4,9
5500 2,7 4,7
5360 2,6 4,6
5220 2,6 4,5
5080 2,5 4,4
4940 2,4 4,3
4800 2,3 4,1
4660 2,2 4,0
4520 2,2 3,9
4380 2,1 3,8
4240 2,0 3,7
4100 1,9 3,6
3960 1,8 3,4
3820 1,7 3,3
3680 1,7 3,2
3540 1,6 3,1
3400 1,5 3,0
3260 1,4 2,8
3120 1,3 2,7
2980 1,3 2,6
2840 1,2 2,5
2700 1,1 2,4
2560 1,0 2,3
2420 0,9 2,1
2280 0,8 2,0
2140 0,8 1,9
2000 0,7 1,8

E9612
6–17–20
6 BRAKES
Load sensing valve–inshot type (Knorr Bremse)

17C. LOAD SENSING VALVE—INSHOT TYPE (Knorr Bremse)

DESCRIPTION

The inshot variable load sensing valve is

designed to allow full braking to be applied at
the selected axle(s) of a fully laden vehicle and
to decrease this braking effort in proportion to
any reduction in the vehicle load.

The inshot facility is a separate piston and valve

assembly incorporated in the top cover. This
facility ensures that the delivered pressure is
equal to the foot valve braking pressure up to a
predetermined level, (typically 0,7 bar). Above
this level the effect of the inshot is progressively
reduced. 3

E9612 6–17C–1
 BRAKES 6
Load sensing valve–inshot type (Knorr Bremse)

OVERHAUL

To Dismantle (see Fig.1.)

1. Remove exhaust cover.

2. Release circlip from inshot housing and

remove inshot cover, control spring and
primary piston.

3. Remove O–ring from primary piston.

4. Release setscrews and washers and

withdraw the end cover; remove O–ring
from end cover.
3 5. Withdraw the inlet/exhaust valve assembly
and valve spring.

6. Withdraw secondary piston and remove

O–ring.

7. Remove spring operating lever and balance

tube, noting peened over washer and
O–ring.

8. Separate halves of body and lift out piston

guide, piston and diaphragm assembly.

9. Remove circlip from top of piston and

extract washer, spring and bonded valve.

10. Remove valve stem, circlip and guide from

lower half of body.

11. Remove plunger guide from lower half of

body and extract plunger, noting peened
over washer and O–ring.

12. Remove protection cap and unscrew grub

screw securing ball pin.

E9612
6–17C–2
6 BRAKES
Load sensing valve–inshot type (Knorr Bremse)

13. Drive out ball pin and extract shaft.

14. Wash metal parts in a cleaning solvent and

dry thoroughly.

15. Wipe valve stem, diaphragm and piston

assembly with clean cloth.

16. Inspect all parts for wear or deterioration,

paying particular attention to the diaphragm.
When renewing diaphragm also renew
diaphragm washer, noting that shiny side of
washer faces away from diaphragm. 3
17. Lightly smear the O–rings, packing rings,
and other working surfaces with grease,
supplied in the repair kit. Do NOT apply any
grease to the piston guide, piston,
diaphragm or diaphragm washer.

To Reassemble
Reverse dismantling procedure, noting:

1. Replace all items supplied in the repair kit.

2. Secure ball pin grub screw with Loctite 241.

3. If removed, peen washer(s) in position in

three places, prior to fitting balance tube.

4. Test valve for leakage and correct

operation.

E9612 6–17C–3
 BRAKES 6
Load sensing valve–inshot type (Knorr Bremse)

FIG.1. EXPLODED VIEW OF LOAD SENSING VALVE

1. Exhaust flap 14. Washer 27. Valve stem

2. Circlip 15. Balance tube 28. Ball pin
3. Cover 16. Circlip 29. Circlip
4. Spring–inshot control 17. Washer 30. Valve guide
5. O–ring 18. Spring 31. Packing ring
6. Primary piston 19. Bonded valve 32. Protective cap
7. Inlet/exhaust valve 20. Piston guide 33. O–ring
8. Spring 21. Packing ring 34. Plunger
9. Secondary piston 22. Piston 35. Plunger guide
10. O–ring 23. Diaphragm washer 36. Exhaust flap
11. O–ring 24. Diaphragm 37. Grub screw
12. End cover 25. Diaphragm retainer spring 38. Shaft
13. O–ring 26. O–ring 39. Lever securing cap

E9612
6–17C–4
6 BRAKES
Load sensing valve (Knorr Bremse) air suspension vehicles

17L. LOAD SENSING VALVE (Knorr Bremse Type)

Air Suspension Vehicles
DATA

Pressure Setting Chart (bar)

Data Plate Pressure First Delivery Pressure Supply Second Delivery

No. Supply Port ‘1’ Pressure Port ‘2’ Port ‘4’ Pressure Port ‘2’
ACHA 110 6 3,0 to 3,2 1,6 4,4 to 4,8
ACHA 111 6 2,2 to 2,4 1,8 4,0 to 4,4
ACHA 112 6 2,1 to 2,3 1,85 3,9 to 4,3
ACHA 113 6 2,1 to 2,3 1,85 3,9 to 4,3
ACHA 114
ACHA 213
6
6
1,9 to 2,1
2,1 to 2,3
1,9
1,85
3,8 to 4,2
3,9 to 4,3
3
ACHA 292 6 1,9 to 2,1 2,15 3,8 to 4,2

E9612 6–17L–1
 BRAKES 6
Load sensing valve (Knorr Bremse) air suspension vehicles

Valve Setting Procedure

Service Tool: 0485052

IMPORTANT: All adjustments to the load

sensing valve MUST be made whilst the valve is 3
unpressurised (air supply pressure released). 2
1. When carrying out the valve setting
procedure, refer to the ‘Pressure Setting
Chart’ for the correct port pressures.
4
2. Connect a pressure gauge to port ‘2’ then 1
with a constant 6 bar supply at port ‘1’
3 check the first delivery pressure reading at
port ‘2’. If the pressure is not correct,
release the pressure at port ‘1’ and proceed
as follows:

— Pressure too high; screw out stop

screw (4).
— Pressure too low; screw in stop screw
(4).
Repeat this operation until correct first
delivery pressure is attained and then 070543

tighten locknut (3).

FIG.1. LOAD SENSING VALVE
3. Release supply pressure from port ‘1’.
1. Adjusting screw
4. Connect a controlled pressure supply to 2. Locknut
ports ‘4.1’ and ‘4.2’. Re–apply the 6 bar
3. Locknut
supply pressure to port ‘1’ and check the
second delivery pressure at port ‘2’. If the 4. Stop screw
pressure is not correct, release the supply
pressures at ports ‘1’, ‘4.1’ and ‘4.2’ and
proceed as follows:

— Pressure too high; screw in adjusting

screw (1).
— Pressure too low; screw out adjusting
screw (1).
Repeat this operation until correct second
delivery pressure is attained.

5. Tighten locknut (2); the valve is now set.

E9612
6–17L–2
6 BRAKES
Load sensing valve (Knorr Bremse) air suspension vehicles

OVERHAUL

The manufacturer recommends that the valve is

overhauled every two years or 160 000 km
(100 000 miles).

To Dismantle, see Fig.2.

1. Remove the four socket–head screws and
lift off the cylinder housing (1). The stepped
piston (31) and control piston (26) will be
retained within the housing, leaving the
piston rod (25) in the rocker housing (18).

2. Withdraw the piston rod (25) from rocker

housing. 3
3. Withdraw the pistons from the cylinder
housing, noting sealing rings and damper
(28).

4. Remove circlip and withdraw end–cap (3),

spring (7) and O–ring (4). Carefully lift out
small spring (5), relief valve (6) and
inlet/exhaust valve assembly (9).

5. Remove the three socket–head screws

from the pressure spring cover (22), noting
that the cover is under spring tension.
Remove spring plates (21 and 19) and
graduating spring (20) from housing (18).

6. Remove the socket–head screws and

withdraw cylinder (11) and slide piston (13).
Separate slide piston from cylinder, noting
K–ring seal. Remove rocker (17), fulcrum
(14), spring (15) and seat (16) from rocker
housing (18).

E9612 6–17L–3
 BRAKES 6
Load sensing valve (Knorr Bremse) air suspension vehicles

FIG.2. EXPLODED VIEW OF LOAD SENSING VALVE

1. Cylinder housing 17. Rocker
2. Circlip 18. Rocker housing
3. End–cap 19. Spring plate
4. O–ring seal 20. Graduating spring
5. Spring 21. Spring plate
6. Relief valve 22. Spring cover
7. Spring 23. Locknut
8. O–ring seal 24. Adjusting screw
9. Inlet/exhaust valve assembly 25. Piston rod
10. Regulating stop screw 26. Control piston
11. Slider piston cylinder 27. K–ring seal
12. K–ring seal 28. Damper
13. Slider piston 29. O–ring seal
14. Pivot pin 30. K–ring seal
15. Spring 31. Stepped piston
16. Spring seat

E9612
6–17L–4
6 BRAKES
Load sensing valve (Knorr Bremse) air suspension vehicles

Inspection
1. Clean all components in a suitable solvent
and dry thoroughly.

2. Discard items which are replaced by those

in the repair kit.

3. Check components for corrosion and

excessive wear, renew as necessary.

To Reassemble
Reverse the dismantling procedure, noting:
3
1. Re–set the valve as detailed in this
Sub–Section.

E9612 6–17L–5
 BRAKES 6
Load sensing valve (Knorr Bremse) air suspension vehicles

E9612
6–17L–6
6 BRAKES
55 Series Air dryer

18. AIR DRYER

REMOVAL AND REFITMENT

WARNING:
— The air dryer and filter cartridge contain 1
pressurised air at the brake system
operating pressure. Do NOT puncture
the filter cartridge nor attempt to remove
the air dryer/filter cartridge until the
complete vehicle air system has been
depleted.

— Ensure that suitable eye protection is 2 3

worn when removing the air dryer/filter
cartridge.
3
Air Dryer

To Remove
1. Isolate the batteries.

2. Place the handbrake in the ‘PARK’ position

and chock all road wheels.

3. Fully deplete the vehicle air system.

7
4. Using a suitable filter strap wrench, slowly 5 4
release the filter cartridge to release any 6
residual pressure trapped in the cartridge.
070430
5. Suitably identify the delivery, supply and
purge supply pipes. Slowly release the
delivery pipe to release air pressure trapped FIG.1. AIR DRYER REMOVAL
between air dryer outlet and multi–circuit
1. Cartridge
protection valve, then disconnect the air
pipes from air dryer. 2. ISO test connector (full flow)
3. Delivery pipe
6. Unscrew knurled connector and disconnect 4. Purge supply pipe
the thermostat plug from air dryer.
5. Supply pipe
7. Release the mounting bolts, securing the air 6. Pressure relief (safety) valve
dryer to the chassis mounting bracket and 7. Thermostat plug
withdraw air dryer.

E9612 6–18–1
 BRAKES 6
Air dryer 55 Series

To Refit
Reverse removal procedure noting:

1. Fully charge the vehicle air system.

2. Ensure air dryer discharges through the

purge exhaust.

3. Check unions for security and air leaks and

rectify as necessary.

E9612
6–18–2
6 BRAKES
55 Series Air dryer

Air Dryer Filter Cartridge

WARNING:
— The air dryer and filter cartridge contain
pressurised air at the brake system
operating pressure. Do NOT puncture
the filter cartridge nor attempt to remove
the air dryer/filter cartridge until the
complete vehicle air system has been
depleted.

— Ensure that suitable eye protection is

worn when removing the air dryer/filter
cartridge.
3
To Remove
1. Isolate batteries and fully deplete the air
system.

2. Using a suitable filter strap wrench, located

close to the base of the cartridge, slowly
release the filter cartridge to allow any
residual air pressure trapped in the
cartridge to escape; remove and discard
the cartridge.

3. Thoroughly clean the filter cartridge contact

surface on the air dryer.

E9612 6–18–3
 BRAKES 6
Air dryer 55 Series

To Refit
1. Ensure the sealing ring in the replacement
filter cartridge is correctly seated and clean.
Lightly smear the sealing ring with clean
engine oil.

2. Screw the filter cartridge into position until

the sealing ring just contacts the air dryer
and then tighten a further one complete
revolution; do NOT overtighten.

3. Fully charge the vehicle air system and

3 check the air dryer filter cartridge for any air
leakages; rectify as necessary.

4. Ensure the air dryer discharges through the

purge exhaust.

E9612
6–18–4
6 BRAKES
Air dryer (Knorr Bremse AD6 type)

18F. AIR DRYER (Knorr Bremse AD6 type)

DATA

Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 8,4 bar

Pressure relief (safety) valve opening pressure . 14,0 bar

Heater/thermostat operating temperature:

Cut–in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7°C " 5°C
Cut–out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°C " 3°C

E9612 6–18F–1
 BRAKES 6
Air dryer (Knorr Bremse AD6 type)

DESCRIPTION

The air dryer consists of a disposable filter

cartridge screwed onto the dryer body. The air
dryer body assembly incorporates the
compressor unloader valve and system
pressure relief (safety) valve. A thermostatically
controlled electric heater element is fitted to
prevent the condensate from freezing.

E9612
6–18F–2
6 BRAKES
Air dryer (Knorr Bremse AD6 type)

OPERATION (see Fig.1.)

Warm contaminated air from the compressor

enters the dryer at port (A). As it cools,
condensate collects in the bottom of the body as
a mixture of water and oil. The air now passes
through an internal gauze strainer which
separates out any remaining oil/water droplets
and entrained debris, and up through the outer
chamber of the filter cartridge, then down
through the desiccant contained in the filter
cartridge which adsorbs the entrained water
vapour.

The cooled, clean dry air flows through a

non–return valve and passes through port (B) to
3
the multi–circuit protection valve and on to the
system reservoirs. A separate supply of dry air
passes through an internal drilling and through
port (C) to charge the purge reservoir.

Upon reaching system pressure the unloader

valve is triggered allowing air pressure to open
the purge valve. Residual pressure in the filter
cartridge ejects the accumulated condensate
and debris while the unloaded compressor now
discharges to atmosphere through the purge
valve.

E9612 6–18F–3
 BRAKES 6
Air dryer (Knorr Bremse AD6 type)

The resultant decompression allows the purge

reservoir to discharge dry air back through the
dryer body into the filter cartridge, absorbing
moisture from the desiccant, carrying the
entrained moisture to atmosphere through the
open purge valve, thus regenerating the
desiccant. The non–return valve prevents the
down–stream air pressure blowing back into the
air dryer.

Any reduction in the system pressure causes

the unloader valve to close. This cuts off air
3 pressure to the purge valve and the purge valve
closes. The compressor now recharges the
system.

This charging and regeneration cycle is

repeated each time maximum system pressure
is reached.

E9612
6–18F–4
6 BRAKES
Air dryer (Knorr Bremse AD6 type)

OVERHAUL

Ensure that the correct service kit is obtained

prior to dismantling the air dryer.

To Dismantle (see Fig.1.)

Remove the filter cartridge as instructed in
‘Sub–Section 18’.

Purge Valve
1. Remove the screws from the silencer
housing. Remove silencer cover, retainer,
silencer element and perforated plate.

2. Remove the screws retaining silencer

3
housing. Remove housing noting gasket.

3. Remove circlip, backing ring and O–ring

situated in the housing recess.

4. Withdraw purge valve assembly complete

by pulling gently with a pair of pliers on the
screw head.

5. Remove O–ring seal.

6. Place a screw driver blade uppermost in a

vice. Engage slot in purge valve on the
screw driver and remove screw. Separate
bonded purge valve, nylon purge housing
and spring from piston.

E9612 6–18F–5
 BRAKES 6
Air dryer (Knorr Bremse AD6 type)

Thermostat and Heater Assembly

Remove the screws retaining the
thermostat/heater assembly flange and
withdraw the complete unit.

Check Valve
1. Remove circlip retaining check valve guide.

2. Remove check valve guide noting the

O–ring seal.

3 3. Withdraw conical spring and check valve

assembly.

Unloader Valve
1. Remove the rubber protection cover from
the unloader housing.

2. Unscrew unloader housing. Remove O–ring

seal.

3. Remove control rod and spring.

4. Remove outer bonded valve disc.

5. Withdraw pilot valve piston and bush.

6. Extract inner bonded valve disc.

E9612
6–18F–6
6 BRAKES
Air dryer (Knorr Bremse AD6 type)

Inspection
Clean the body and all parts in a suitable solvent
and dry thoroughly. Carefully examine the body
for signs of wear or damage, paying particular
attention to the unloader valve and check valve
seats. If these are damaged the complete
assembly must be renewed.

To Reassemble
Renew all parts contained in the service kit.

Unloader Valve
3
1. Insert new inner bonded valve disc and
locate on its seat in the dryer body.

2. Fit new pilot valve bush and insert pilot

valve piston.

3. Fit new outer bonded valve disc.

4. Refit control rod together with new control

spring.

5. Using the grease supplied in the service kit,

lightly smear the new O–ring seal and
locate on the unloader housing.

6. Screw housing into dryer body and tighten

securely.

E9612 6–18F–7
 BRAKES 6
Air dryer (Knorr Bremse AD6 type)

Check Valve
1. Insert new check valve and spring.

2. Lightly smear the new O–ring seal and fit to

the new check valve guide.

3. Insert the check valve guide into the recess,

ensuring that the check valve stem locates
in the bore in the centre of the guide, and fit
the new circlip.

3 Thermostat and Heater Assembly

1. Lightly grease the O–ring seal and position
it on the new thermostat/heater assembly.

2. Insert the assembly into the body ensuring

that the thermostat leads are not trapped.

3. Secure unit in position using the new

screws.

E9612
6–18F–8
6 BRAKES
Air dryer (Knorr Bremse AD6 type)

FIG.1. AIR DRYER ASSEMBLY

A — Supply port B — Delivery port C — Purge supply

1. Cartridge 12. O–ring 23. Circlip

2. Valve disc 13. Guide 24. Joint
3. Piston 14. Circlip 25. Housing
4. Bush 15. O–ring 26. Perforated plate
5. Valve disc 16. Piston 27. Element
6. Control rod 17. Spring 28. Retainer
7. Spring 18. Housing 29. Cover
8. O–ring 19. Bonded valve 30. O–ring
9. Housing 20. Screw 31. Heater/Thermostat
10. Check valve 21. O–ring 32. Safety valve
11. Conical spring 22. Backing ring

E9612 6–18F–9
 BRAKES 6
Air dryer (Knorr Bremse AD6 type)

Purge Valve
1. Reassemble the bonded rubber metal
purge valve, nylon housing, spring and
piston. Secure with screw and lockwasher,
using the method previously described in
dismantling instructions.

2. Lightly lubricate the groove on the purge

valve piston and fit new O–ring seal.

3. Lightly lubricate the bore in housing and

insert purge valve assembly.
3 4. Lubricate the new O–ring and locate in
recess using a smooth blunt instrument.
Locate backing ring and secure with new
circlip.

5. Lightly smear surface of housing with

grease and position new gasket. Refit
silencer housing and secure with the four
screws.

6. Position perforated plate, new silencer

element, retainer and cover in housing and
secure with four screws.

7. Fit a new filter cartridge as instructed in

‘Sub–Section 18’.

E9612
6–18F–10
6 BRAKES
Air dryer (Knorr Bremse AD6 type)

ADJUSTMENT

WARNING: Do NOT run the engine in a

confined space or unventilated area.
Exhaust fumes are toxic and can, if inhaled,
may prove fatal. If the engine is to be run in
a confined ensure that a suitable exhaust
extractor is used.

1. Refit the air dryer to vehicle, see

‘Sub–Section 18’.

2. Run the engine to build–up the vehicle air

pressure to the unloader valve cut–out
pressure (8,4 bar), checking this figure with
the air gauges in the instrument panel.
3
3. If unloader valve pressure settings are
incorrect, remove the protective cap from
the end of the unloader valve housing and
adjust the pressure setting as follows:
Pressure setting too high: Stop the
engine, deplete the air system to
approximately 6,2 bar and then unscrew the
adjuster nut in the unloader housing (9) two
complete turns. Start the engine and, as the
air pressure builds, slowly screw the
adjuster nut back into the housing until the
correct cut–out pressure is achieved.

Pressure setting too low: With the engine

running, slowly screw the adjuster nut into
the housing until the correct cut–out
pressure is achieved. Refit protective cap to
the end of the unloader valve housing.

NOTE: When the maximum air system

pressure is attained (8,4 bar), the unloader
valve will open (‘cuts–out’) allowing the
compressor to discharge to atmosphere
through the purge valve. As the air system
pressure falls, during normal air system
use, the unloader valve will close (‘cut–in’)
at 7 bar allowing the compressor to
commence charging the air system to full
working pressure.

E9612 6–18F–11
 BRAKES 6
Air dryer (Knorr Bremse AD6 type)

E9612
6–18F–12
6 BRAKES
Double check valve

23A. DOUBLE CHECK VALVE

DESCRIPTION

The double check valve allows any particular air

delivery line to be supplied from two sources,
and isolates whichever source is not in use.

E9612 6–23A–1
 BRAKES 6
Double check valve

REMOVAL AND REFITMENT

To Remove
1. Deplete air system.

2. Identify and disconnect air pipes from valve.

3. Remove valve from vehicle.

To Refit
Reverse removal procedure: noting,

1. Carry out Operating and Leakage Tests.

3

E9612
6–23A–2
6 BRAKES
Double check valve

OPERATION (see Fig. 1.)

When air enters at port A, the shuttle (1) is

forced over to the seal at the other end of the
valve, isolating port B. At the same time, air
from port A is permitted to flow through port C.

If air is supplied to port B, the shuttle will move

across the valve to seal off port A and allow air
from port B to flow through port C.

3
FIG.1. SECTION THROUGH DOUBLE CHECK
VALVE

A and B = Inlet ports

C = Outlet port

1. Shuttle
2. Seal
3. End–cover
4. Valve body

E9612 6–23A–3
 BRAKES 6
Double check valve

TESTING (see Fig. 1.)

Leakage Test
1. Connect an air supply, which can be varied
between 0,7 and 7,0 bar (10 to 100 lbf/in2),
to port A and note that air flows from port C.

2. Plug port C and check for leakage at port B.

3. The test should be repeated with air supply

connected to port B, testing all joints, and
connection A for leakage.

4. Leakage at port A or B will indicate faulty

3 seal gaskets and the unit should be
discarded and replaced with a complete
new unit.

E9612
6–23A–4
6 BRAKES
55 Series Multi–circuit protection valve—All parallel full feedback type (Wabco)

27. MULTI–CIRCUIT PROTECTION VALVE—All Parallel Full

Feedback Type (Wabco)
DESCRIPTION

The multi–circuit protection valve is an all

parallel type and has the following functions:

— The valve prioritises the charging of the

front and rear service reservoirs over the
charging of the park reservoir. This priority
ensures that the service reservoirs are
charged to a pre–determined pressure
before the spring brakes can be released.

— The valve ensures that the front, rear and

park reservoirs are charged independently 3
and that a pressure failure in one reservoir
does not cause a pressure failure in any
other.

— The valve allows full feedback between all

the circuits above the closing pressure of
the valve elements.

— A feature within the valve allows for a slow

bleedback between the park reservoir and
the front reservoir. This feature operates
when the compressor is stationary and
there is an air leak in the front reservoir
system. It ensures that the vehicle spring
brakes will eventually be applied if the front
reservoir is allowed to drain whilst the
vehicle is stationary. The front reservoir will
therefore have to be replenished before the
spring brakes can be released and the
vehicle moved.

E9612 6–27–1
 BRAKES 6
Multi–circuit protection valve—All parallel full feedback type (Wabco) 55 Series

OPERATION

At the commencement of system charging, with

2.3 2.4
all reservoirs depleted: Air from the air dryer
enters the valve inlet port, it then acts on the
valve seat and through the by–pass hole in the
valve seat, lifting piston of elements (2.1) and 2.3 2.4
(2.2) giving preferential charging to the service
reservoirs. When the pressure builds to
2.1 2.2
approximately 6,5 bar it will overcome the force
of the graduating spring, both the valve seat and
piston will rise. As the air pressure builds in the 2.1 2.2
service reservoirs and the reservoir back
pressure becomes sufficient to hold the valve
3 open; air now passes into the galleries of
elements (2.3) and (2.4) and as the reservoir
1

pressure(s) reaches 6,5 bar again overcoming

the force of the graduating springs, the piston 070451

and valve seats rise. The secondary/park, the

auxiliary and the service circuits will now FIG. 1. MULTI—CIRCUIT PROTECTION
continue to charge to system cut–out pressure. VALVE
When the unloader valve cuts–out at a system
pressure of 8,5 bar, the residual pressure in the 1. Supply
reservoirs holds the pistons open, but the valve 2.1 Front service circuit
seat return springs now close the valve seat,
2.2 Rear service circuit
allowing a restricted feedback through the
by–pass hole, up to the closing pressure of that 2.3 Park circuit
valve. 2.4 Auxiliary circuit

E9612
6–27–2
6 BRAKES
55 Series Multi–circuit protection valve—All parallel full feedback type (Wabco)

TESTING

Service tools: Air pressure test gauge 0485052.

Charging Sequence Check

1. Chock all road wheels.

2. Fully deplete all the air reservoirs using the

tilt drain valves.

3. Connect air pressure test gauge 0485052 to

the ISO test connection at the park
reservoir.

4. Start the engine, charge the vehicle air

system and observe the instrument panel
3
air gauges and the test gauge at the park
reservoir. The instrument panel air gauges
will rise to approximately 7,0 bar, then
remain stationary as the park reservoir is
charged. As the park reservoir reaches
5,5 bar, the low air pressure warning buzzer
and light will cancel; when the park
reservoir reaches approximately 7,0 bar, all
three air gauges will then rise to a governor
valve cut–out pressure of 8,4 bar.

5. If the above charging sequence is attained

the multi–circuit protection valve is charging
correctly.

E9612 6–27–3
 BRAKES 6
Multi–circuit protection valve—All parallel full feedback type (Wabco) 55 Series

Pressure Protection Check

1. Chock all road wheels.

2. Connect the test gauge 0485052 to the ISO

test connection at the park reservoir.

3. Fully charge the vehicle air system and stop

the engine.

4. Turn the master/start key to energise the

auxiliary electrical circuits.

3 5. Simulate an air leak in the front service

circuit by draining the front service reservoir
using the tilt drain valve and note the
following:
— At 5,5 bar the low air pressure warning
light will illuminate.
— Air gauge 1 will drop to zero.
— Air gauge 2 will drop, then hold, at
approximately 6,5 bar.
— The test gauge at the park reservoir will
drop, then hold, at approximately
6,5 bar.
NOTE: Due to the valves bleedback
feature between the park and front
service circuits, the park brake circuit
will eventually empty, thus ensuring
that the front service reservoir will have
to be replenished before the spring
brakes can be released.

E9612
6–27–4
6 BRAKES
55 Series Multi–circuit protection valve—All parallel full feedback type (Wabco)

6. Re–charge the vehicle air system and carry

out the above check on the rear service
circuit by draining the rear service reservoir
using the tilt drain valve and note the
following:
— At approximately 5,5 bar the low air
pressure warning light will illuminate.
— Air gauge 1 will drop, then hold, at
approximately 6,5 bar.
— Air gauge 2 will drop to zero.
— The test gauge at the park reservoir will
drop, then hold, at approximately
3
6,5 bar.

7. Re–charge the vehicle air system and

repeat the check on the park brake circuit
by draining the park reservoir using the tilt
drain valve and note the following:
— Both air gauge 1 and air gauge 2 will
initially drop, and then hold, at
approximately 6,5 bar.
— When park reservoir test gauge
reaches 5,5 bar the low air pressure
warning light will illuminate.
— The park reservoir test gauge will drop
to zero.

8. If the above checks are attained, the

multi–circuit protection valve is functioning
correctly.

E9612 6–27–5
 BRAKES 6
Multi–circuit protection valve—All parallel full feedback type (Wabco) 55 Series

REMOVAL AND REFITMENT

To Remove 2
1. Isolate the batteries.
1 3
2. Fully deplete the vehicle air system.

3. Suitably identify, then disconnect the air

pipes from the valve. 4

4. Remove the setscrews securing valve to

mounting bracket and withdraw valve.

5. If necessary, remove adapters from valve.

3 6 5
To Refit
Refitment is a reversal of the removal
procedure.

070448

FIG. 2. MULTI—CIRCUIT PROTECTION

VALVE IN–SITU

1. Supply line
2. Valve
3. Park circuit
4. Front service circuit
5. Auxiliary circuit
6. Rear service circuit

E9612
6–27–6
6 BRAKES
55 Series Multi–circuit protection valve—All parallel full feedback type (Wabco)

OVERHAUL

The multi–circuit protection valve is not

serviceable. If, after testing the valve it is found
to be defective, it MUST be renewed.

E9612 6–27–7
 BRAKES 6
Multi–circuit protection valve—All parallel full feedback type (Wabco) 55 Series

E9612
6–27–8
6 BRAKES
55 Series Air reservoirs

34. AIR RESERVOIRS

GENERAL INFORMATION

At each vehicle annual service interval, it is

recommended that all air reservoirs are
removed from the vehicle and examined for
damage, corrosion or perforation; defective air
reservoirs MUST be renewed. It is also
recommended that all air reservoirs are
repainted before refitting to the vehicle.

E9612 6–34–1
 BRAKES 6
Air reservoirs 55 Series

REMOVAL AND REFITMENT

To Remove
1. Move the handbrake to the ‘Park’ position,
disconnect the batteries and deplete the air
system.

2. Identify air pipes for refitment, then

disconnect from reservoir.

3. Remove nuts/bolts securing reservoir

support straps to mounting bracket/chassis
member and manoeuvre reservoir from
vehicle.
3 4. After removal, examine reservoir,
particularly in the inaccessible areas of its
mounting, for corrosion and damage.

5. As necessary, remove adapters noting port

angles, plugs, tilt drain valves and ISO test
connector.

To Refit
Reverse the removal procedure, noting:

1. Ensure that the reservoirs are thoroughly

cleaned and exterior surfaces are repainted
as necessary.

2. Fully charge the air system, then using a

soap solution, check for leaks and rectify as
necessary.

E9612
6–34–2
6 BRAKES
55 Series Air reservoirs

‘Tilt’ Drain Valve

To Remove
1. Move the handbrake to the ‘Park’ position,
disconnect the batteries and deplete air
system.

2. Unscrew drain valve from reservoir.

To Refit
Reverse removal procedure, noting:

1. Charge the air system to working pressure

3
then, using a soap solution check for leaks;
no leaks are permissible.

E9612 6–34–3
 BRAKES 6
Air reservoirs 55 Series

E9612
6–34–4
6 BRAKES
55 Series Pneumatic push–in pipe fittings

40. PNEUMATIC PUSH–IN PIPE FITTINGS

DESCRIPTION

Push–in type fittings are used to connect

various lengths of nylon tube brake piping.

Each fitting comprises three components; a

brass body, a brass collet and a synthetic rubber
O–ring.

E9612 6–40–1
 BRAKES 6
Pneumatic push–in pipe fittings 55 Series

OPERATION (see Fig.1.)

The nylon brake pipe passes through the collet

(1) over the support tube (2) and locates within
the O–ring (3). Any attempt to pull the tube from
the fitting causes the collet to move against the
tapered bore in the body (4) thus gripping the
nylon tube. The collet’s grip on the nylon tube
will increase as greater pressure is applied to
extract the tube.

1 2 3 4 070403

3 FIG.1. PUSH–IN PIPE FITTING

1. Collet
2. Support tube
3. O–ring
4. Brass body

E9612
6–40–2
6 BRAKES
55 Series Pneumatic push–in pipe fittings

REMOVAL AND REFITMENT

To Remove
1. Deplete the air system through the drain
valves at the base of each reservoir.

2. Push the nylon brake tube in towards the

adapter body.

3. Hold the collet flange against the adapter

body, then pull the nylon tube from the
collet.

To Refit
1. Push the nylon tube into the collet and
3
through the O–ring seal. Pull the brake tube
to lock in position.

E9612 6–40–3
 BRAKES 6
Pneumatic push–in pipe fittings 55 Series

E9612
6–40–4
6 BRAKES
55 Series 3/2 solenoid valve

58. 3/2 SOLENOID VALVE

DESCRIPTION

The 3/2 solenoid valves are actuated by the

Traction Control (ASR) function of the ABS
electronic control unit (ECU) when a differential
brake is required or the engine power is too
great for the available road adhesion. The
valves open to provide system air pressure to
the ABS modulator valves.

E9612 6–58–1
 BRAKES 6
3/2 solenoid valve 55 Series

REMOVAL AND REFITMENT

CAUTION: When any maintenance/repair work 2

is carried out on the ABS/ASR system the 1 3
complete system must be checked as instructed
in Section 4, ‘Anti–lock Braking System’.

To Remove 9
1. Isolate the batteries.

2. Fully deplete the vehicle air system. 4

3. Disconnect electrical plug from solenoid

valve.
3 4. Suitably identify, then disconnect the air 8
pipes from the solenoid valve and the 7 5
double check valve. 6 070450

5. Remove nuts and bolts securing solenoid FIG. 1. 3/2 SOLENOID VALVE
valve/double check valve to mounting
bracket and withdraw valves. 1. Supply from multi circuit protection valve
2. Delivery to RH rear modulator valve
6. Separate double check valve from solenoid
valve. 3. Delivery to LH rear modulator valve
4. Electrical plug
7. If necessary, remove adapters from 5. LH 3/2 solenoid valve
solenoid valve.
6. LH double check valve
7. RH double check valve
To Refit 8. Supply from rear service relay valve
Reverse removal procedure, noting:
9. RH 3/2 solenoid valve
1. Ensure that the electrical and air
connections are connected to the correct
LH/RH valves.

2. Check the ABS system as instructed in

Section 4, ‘Anti–lock Braking System’.

E9612
6–58–2
6 BRAKES
55 Series 3/2 solenoid valve

OVERHAUL

To Dismantle (see Fig.2.) 1

1. Remove the solenoid valve as instructed in
this Section.
2
2. Separate double check valve from solenoid
valve. 3
3. Remove the protective cap.
4
4. Unscrew locknut and withdraw coil plug
from flange; discard O–rings.

5. Unscrew the flange from housing and

withdraw flange and armature; discard
3
O–ring.
7
5
To Reassemble
Reverse dismantling procedure, noting:
8
1. Renew all O–rings.

2. Assemble valve using lubricant supplied 6

9
with the service kit.

10
11 070446

FIG. 2. EXPLODED VIEW OF 3/2 SOLENOID

VALVE

1. Protective cap
2. Locknut
3. O–ring
4. Coil plug
5. O–ring
6. Flange
7. O–ring
8. Armature
9. Housing
10. Washer
11. Screw

E9612 6–58–3
 BRAKES 6
3/2 solenoid valve 55 Series

E9612
6–58–4
6 BRAKES
55 Series Modulator valves

60. MODULATOR VALVES

REMOVAL AND REFITMENT

CAUTION: When any maintenance/repair work

is carried out on the ABS system the complete
system must be checked as instructed in
Section 4 ‘Anti–lock Braking System’.

To Remove
1. Disconnect the batteries and deplete the air
system.

2. Suitably identify, then disconnect air pipe(s)

from valve.

3. Disconnect electrical connection from valve. 3

4. Release valve mounting bolts and withdraw
valve from vehicle.
NOTE: Dependent on which valve is to be
removed it may be necessary to release the
mounting bracket from the chassis frame,
to allow removal of the valve.

To Refit
Reverse the removal procedure, noting:

1. Ensure that the electrical and air

connections are connected to the correct
LH/RH rear valves.

2. Charge the air system and check for air

leaks, rectify as necessary.

3. Check the ABS system as instructed in

Section 4, ‘Anti–lock Braking System’.

E9612 6–60–1
 BRAKES 6
Modulator valves 55 Series

1 6

070431

FIG.1. MODULATOR VALVES

1. Supply line 4. Delivery to LH rear brake

2. RH rear modulator valve 5. LH rear modulator valve
3. Delivery to RH rear brake 6. Front modulator valve

E9612
6–60–2
6 BRAKES
Modulator valve (Wabco)

60A. MODULATOR VALVE (Wabco)

GENERAL INFORMATION

Application
This type of valve is fitted to vehicles which
have an Anti–Lock Braking System

Purpose
To pass the brake pressure to the brake
chambers unreduced, to reduce or to maintain
the pressure in the brake chambers, all in
response to the corresponding control signals.

Maintenance
No other special maintenance is required than a
3
periodic operational test in accordance with the
maintenance schedule.

Operational test of the component

See the test procedure of the anti–lock brake
system.

E9612 6–60A–1
 BRAKES 6
Modulator valve (Wabco)

OPERATION

In the brakes – released position rubber

diaphragms 5 and 6 bed down on seats 7 and 8
(Fig.1.). The two electro pneumatic valves 9 and
10 are not energised so that the cores 11 and
12 are pressed on their seats 15 and 16 by
springs 13 and 14. Chamber 17 below valve 9
and chamber 18 above diaphragm 5 are in open
connection with atmosphere. Chamber 19 below
valve 10 is connected with port 1. Chamber 20
above diaphragm 6 is in open connection with
atmosphere via bore 21.

FIG.1.

E9612
6–60A–2
6 BRAKES
Modulator valve (Wabco)

Application of service brake without ABS

being used.
When the service brake is applied, compressed
air enters the valve through port 1 (Fig.2).
Diaphragm 5 is lifted from seat 7, allowing the
air to pass to port 2.
Compressed air also passes between solenoid
10 and armature 12 into chamber 19 below
diaphragm 6, so that this diaphragm is held on
its seat with greater pressure.

FIG.2.

E9612 6–60A–3
 BRAKES 6
Modulator valve (Wabco)

Application of service brake with ABS being

used.
The ABS system operates, when, during a
brake application the wheels start to lock
(Fig.3.). Solenoids 9 and 10 are energised so
that armatures 11 and 12 are released from
seats 15 and 16 and forced onto seats 22 and
23. Chamber 18 above diaphragm 5 is shut off
from atmosphere and connected to port 1. As
pressure is built up in chamber 18, diaphragm 5
is forced onto seat 7, so that port 1 is shut off
from port 2.
3 Chamber 19 is shut off from port 1 and
connected to atmosphere.
As a result of the pressure in port 2, diaphragm
6 is forced off its seat, so that the air in port 2 is
exhausted through chamber 20.
The pressure in the brake chamber is reduced.
When it has been sufficiently reduced, the FIG.3.
solenoid valve again receives a signal from the
electronic unit (Fig.4.). Solenoid 10 is
de–energised, so that armature 12 is released
from seat 23 and forced onto seat 16 by the
spring. Chamber 19 is shut off from atmosphere
and reconnected to port 1.
Diaphragm 6 is lifted. Port 2 is no longer
connected to chamber 20 and the exhaust port.
Now the pressure in the brake chamber is
maintained at a constant level. Depending on
the contact between tyres and road surface the
valve positions described above may succeed
each other 3 to 5 times per second.
When the brake pedal is released the brake
chamber is vented.

FIG.4.

E9612
6–60A–4
6 BRAKES
55 Series Contents

CONTENTS Page Date

SECTION 4—ANTI–LOCK BRAKING SYSTEM (ABS)

General Information:
When to Test ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 1 ........ 9612
Specification of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 2 ........ 9612
Function of ABS Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 3 ........ 9612
Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 3 ........ 9612
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 3 ........ 9612
Location of Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 4 ........ 9612
Test Procedure:
Test 1—Earth and power supply connection of 35–pin plug . . . . . . . 6— 4 — 5 . . . . . . . . 9612
Test 2—Relay G022 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 6 . . . . . . . . 9612
Test 3—ABS warning light, relay G022 and relay G021 . . . . . . . . . . . 6— 4 — 7 . . . . . . . . 9612
Test 4—Resistance of ABS sensors and wiring . . . . . . . . . . . . . . . . . . 6— 4 — 8 . . . . . . . . 9612
Test 5—Sensors and wiring shorted to earth . . . . . . . . . . . . . . . . . . . . 6— 4 — 9 . . . . . . . . 9612
Test 6—Sensor voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6— 4 — 10 . . . . . . . 9612
Test 7—ABS controlled exhaust brake . . . . . . . . . . . . . . . . . . . . . . . . .
Test 8—Modulator valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6— 4 — 11 . . . . . . .
6— 4 — 12 . . . . . . .
9612
9612
4

E9612 1
4

E9612
2
6 BRAKES
55 Series Anti–lock braking system (ABS)

4. ANTI–LOCK BRAKING SYSTEM (ABS)

GENERAL INFORMATION

When to Test ABS

The ABS should be tested in the following
cases:

— At periodic intervals as specified in the

maintenance schedule.

— If the ABS warning light continues to

illuminate.

— In the case of wheel lock.

— At a decrease in the braking capacity.

E9612 6–4–1
 BRAKES 6
Anti–lock braking system (ABS) 55 Series

Specification of Components
The ABS is composed of the following:

Component Location

1. Warning light ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel

2. Exciter ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel hub
3. Wheel sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle housing
4. Modulator valve—R.H. front brake . . . . . . . . . . . . . . . . . R.H. frame, adjacent to engine mounting
5. Modulator valves—rear brakes . . . . . . . . . . . . . . . . . . . . L.H. frame, adjacent to rear axle
6. Modulator valve—L.H. front brake . . . . . . . . . . . . . . . . . L.H. frame, adjacent to engine mounting
7. Electronic control unit (ECU) . . . . . . . . . . . . . . . . . . . . . . L.H. side of cab rear panel
8. Printed circuit board (PCB) . . . . . . . . . . . . . . . . . . . . . . . L.H. side of cab rear panel
containing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E041 (Pin 1 of 35 way connector)
E042 (Pin 19 of 35 way connector)
and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G021 (Power supply 1)
4 G022 (Power supply 19)
G023 (Exhaust brake)
G025 (Warning light)

2 3 4 3 2

1 2 3 7 8 6 5 3 2
070462

E9612
6–4–2
6 BRAKES
55 Series Anti–lock braking system (ABS)

Function of the ABS Warning Light

— Check that the ABS warning light 1 2 3 4 5

illuminates when the contact circuits are

7 8 9 10

11 12 13 14 15

energised. 16

21
17

22
18 19 20

23 24 25

26 27 28 29 30

— Ensure that the ABS warning light 31 32 33 34 35

extinguishes when the vehicle attains

15 km/h.

ASSY 1235294
EHX

AW1274653
BRK

Test Conditions
— If possible, apply the parking brake.
LK2
UR 2

LK 1

FUSE UR 1

— Adequate supply of compressed air during

the entire test (above 7 bar).
070346

— Adequate battery voltage (above

approximately 22V).
4
— Check fuses.

— Connect up the cable tester (start switch

off).

Required Tools
1. ABS Wiring Diagram

2. Multimeter of the following specification: + v

— Effective range for AC–Voltage and
with indication of minimum and
TDA ZERO
maximum values. PM2518 X multimeter
+mv
n 100
c
— Measuring accuracy of 0.2% at an v
v A-
UP

HF A
AC–Voltage of 2V. Vma DOWN

— Minimum 5 measurements per second. MAX

AUTO

ON/OFF dB
— Integrated analogue indication. MAX

080766

E9612 6–4–3
 BRAKES 6
Anti–lock braking system (ABS) 55 Series

A multimeter which satisfies all these

conditions is the FLUKE 87.

3. ABS test box (cable tester) (DAF No.

0694974) and 4mm banana plugs with
cable and female plugs.

D
A
F

4 070354

4. Pressure Gauge (DAF No. 0485052)

4 6
60 80
40 100
8
2 20 120
PSI
0 bar
10

070466

Location of Sensors—4 Channel system

F512 F513

F514 F515
070355

E9612
6–4–4
6 BRAKES
55 Series Anti–lock braking system (ABS)

TEST PROCEDURE

ABS Warning light continues to illuminate

Test 1
Earth and power supply connection of 35–pin plug

1 2
3 4 5

6 7 8 9

11 12 13 14 15

16 17 18 19 20

21 22 23 24 25

26 27

4
31 32 33 34 35

ASSY 1235294
EHX

ECU
AW1274653
BRK

LK2
UR 2

LK 1

FUSE UR 1

070013

Operation Values/Signals Possible causes

1. Energise the contact circuits ABS warning light D Bulb defective

illuminates D Relay G025 defective

2. Measure voltage between pins 9 and 27 > 21.6V D Low battery voltage

3. Measure resistance between pin 27 and an < 25 W D Poor contact

earth connection on the vehicle D Interruption
D Poor earth connection

E9612 6–4–5
 BRAKES 6
Anti–lock braking system (ABS) 55 Series

Test 2
Relay G022
(Power supply pin 19 on multi–pin connector)

ASSY 1235294
AW1274653
EHX
BRK

RELAY
4 UR 2 G022 LK2

LK 1
10

EO42
FUSE UR 1
080095

Operation Values/Signals Possible causes

Energise the contact circuits

1. Measure voltage between pins 19 and 27 < 0.3V D Relay G022 defective

2. Connect pin 25 with pin 27 then measure > 21.6V D Relay G022 defective
voltage between pins 19 and 27 D Fuse E042 defective

Interrupt connection between pins 25 and 27.

Switch off

3. Measure resistance between pins 9 and 25 210 – 430 W D Relay G022 defective

E9612
6–4–6
6 BRAKES
55 Series Anti–lock braking system (ABS)

Test 3
ABS warning light, relay G022 and relay G021
Power supply 1)

NOTE: Relay G021 is a special over voltage protection

relay and must not be replaced with a standard relay

ASSY 1235294
AW1274653
EHX
BRK

RELAY
G025 4
LK2
UR 2

EO41 LK 1
10

RELAY
G021
FUSE UR 1
080096

Operation Values/Signals Possible causes

Energise the contact circuits ABS warning light

illuminates

1. Measure voltage between pins 1 and 27 < 0.3V D Relay G021 defective

2. Connect pins 8 and 27 ABS warning light D Relay G025 defective

extinguishes

Measure voltage between pins 1 and 27. > 21.6V D Relay G021 defective
Disconnect pins 8 and 27 D Fuse E041 defective

3. Connect pin 26 with pin 27 ABS warning light D Interruption

illuminates
Disconnect connections.
Switch off

4. Measure resistance between pins 8 and 9 120 – 157 W D Relay G021 or G025
defective

E9612 6–4–7
 BRAKES 6
Anti–lock braking system (ABS) 55 Series

Test 4
Resistance of ABS sensors and wiring

NOTE: Type of sensor identified on end

of sensor with an S or K.

070019

Operation Values/Signals Possible causes

Contact circuits off

1. Sensor F512 (Front L.H.) 1100 to 1250 W D Sensor wrongly connected

Measure resistance between pins 15 (S type) D Sensor defective
and 32 1400 to 2000 W D Interruption in
(K type) wiring/connector

2. Sensor F513 (Front R.H.) 1100 to 1250 W D Sensor wrongly connected

Measure resistance between pins 17 (S type) D Sensor defective
and 34 1400 to 2000 W D Interruption in
(K type) wiring/connector

3. Sensor F514 (Rear L.H.) 1100 to 1250 W D Sensor wrongly connected

Measure resistance between pins 18 (S type) D Sensor defective
and 35 1400 to 2000 W D Interruption in
(K type) wiring/connector

4. Sensor F515 (Rear R.H.) 1100 to 1250 W D Sensor wrongly connected

Measure resistance between pins 16 (S type) D Sensor defective
and 33 1400 to 2000 W D Interruption in
(K type) wiring/connector

E9612
6–4–8
6 BRAKES
55 Series Anti–lock braking system (ABS)

Test 5
Sensors and wiring shorted to earth

4
070019

Operation Values/Signals Possible causes

Contact circuits off

1. Sensor F512 (Front L.H.)

Measure resistance between pins 15 and 27 > 45 kW D Sensor/wiring shorted to earth
Measure resistance between pins 32 and 27 > 45 kW

2. Sensor F513 (Front R.H.)

Measure resistance between pins 17 and 27 > 45 kW D Sensor/wiring shorted to earth
Measure resistance between pins 34 and 27 > 45 kW

3. Sensor F514 (Rear L.H.)

Measure resistance between pins 18 and 27 > 45 kW D Sensor/wiring shorted to earth
Measure resistance between pins 35 and 27 > 45 kW

4. Sensor F515 (Rear R.H.)

Measure resistance between pins 16 and 27 > 45 kW D Sensor/wiring shorted to earth
Measure resistance between pins 33 and 27 > 45 kW

E9612 6–4–9
 BRAKES 6
Anti–lock braking system (ABS) 55 Series

Test 6
Sensor voltage

1 2
3 4 5

6 7 8 9 10

11 12 13 14 15

16
19 20

21 22 23 24 25

26 27 28 29 30

31 32 33

4
070463

Operation Values/Signals Possible causes

Contact circuits off. Jack up each wheel in turn

and rotate it at a speed of 30 rpm

1. Sensor F512 (Front L.H.) >100 mV * D Sensor defective

Measure voltage between pins 15 and 26 D Air gap too wide
D Faulty wiring
D Run–out too great
2. Sensor F513 (Front R.H.)
Measure voltage between pins 17 and 34 >100 mV * D Sensor defective
D Air gap too wide
D Faulty wiring
D Run–out too great
3. Sensor F514 (Rear L.H.)
Measure voltage between pins 18 and 35 >100 mV * D Sensor defective
D Air gap too wide
D Faulty wiring
D Run–out too great
4. Sensor F515 (Rear R.H.)
Measure voltage between pins 16 and 33 >100 mV * D Sensor defective
D Air gap too wide
D Faulty wiring
D Run–out too great

* Maximum signal should not be greater than 2.2 x minimum signal, ie., max/min should not be
greater than 2.2:1

E9612
6–4–10
6 BRAKES
55 Series Anti–lock braking system (ABS)

Test 7
ABS controlled exhaust brake

ASSY 1235294
AW1274653

EHX
BRK
RELAY
G023

LK2
UR 2

LK 1 4
10

FUSE UR 1 070018

Operation Values/Signals Possible causes

Run the engine at approximately 1000 rpm

1. Operate the exhaust brake Engine stalls D Relay G023 defective

D Exhaust brake solenoid
Run the engine at approximately 1000 rpm B044 defective

2. Connect pin 11 with pin 27 and pin 25 with Engine continues to D Relay G023 defective
pin 27, operate the exhaust brake run at 1000 rpm

3. Interrupt connection between pins 11 and 27 Engine stalls D Relay G023 defective
and operate the exhaust brake

E9612 6–4–11
 BRAKES 6
Anti–lock braking system (ABS) 55 Series

Test 8
Modulator valves
(Electropneumatic valve)

Each modulator valve contains two

solenoid valves that have been designated X
‘X’(inlet) and ‘Y’(outlet).

070464

Operation Values/Signals Possible causes

1. Connect pressure gauge 0485052 to the
4 relevant air actuator ISO test connection;
ensure that the actuator corresponds to the
modulator valve to be tested.
Energise the contact circuits Pressure gauge D Connections leaking
Depress the footbrake pedal, connect pin 9 gives a reading; D Valve/diaphragm in
with ‘X’* pin number. no leakage at valve modulator valve leaking
D Pressure drops, ‘X’ and
‘Y’ incorrectly connected

6
1 2 3 4
4
5
60 80
6 40 100 8
7 8 9 2 120
20
11 12 13 14 15
P.S.I. 10
0 bar
16 17 18 19 20

21 22 23

26 27 28 29 30

31 32 33 34 35

ECU
ASSY 1235294

EHX
AW1274653

BRK

LK2
UR 2

LK 1

FUSE UR 1

070347

2. With ‘X’* pin number still connected, Pressure gauge D Exhaust valve of
connect pin 9 with ‘Y’* pin number for falls to 0 bar modulator valve
approximately 5 seconds. (valve blows off) defective
D Internal duct blocked
Pressure gauge
reading remains at D Inlet part of valve leaking
0 bar
3. With ‘Y’* pin number still connected, Pressure gauge D Inlet valve of modulator
disconnect ‘X’* pin number. reading rises valve leaking
Release the footbrake pedal to the original
Switch off value

* In the conversion table X and Y correspond with the wheel to be tested and the test equipment pin

E9612
6–4–12
6 BRAKES
55 Series Anti–lock braking system (ABS)

Conversion Table ‘X’ ‘Y’

Inlet Outlet

Modulator valve, L.H. front wheel 23 24

Modulator valve, R.H. front wheel 6 7

Modulator valve, L.H. rear wheel 21 22

Modulator valve, R.H. rear wheel 4 5

Measure each modulator valve resistance, between pin 27 (earth) and the designated ‘X’ (inlet) and ‘Y’
(outlet) pin Nos., quoted above. A reading of 11.7 to 16.5 W should be achieved.

If the tests do not reveal any faults 4

90
80
0

10

70
D Check dynamic rolling radii of all the wheels

60
20
50
30 40

(Tyre size/pressure)

D Maximum permissible difference: 3% across

an axle and 6.5% front/rear

070465

No fault has been found and the red ABS light continues to illuminate

D Renew electronic control unit

E9612 6–4–13
 BRAKES 6
Anti–lock braking system (ABS) 55 Series

E9612
6–4–14
7 SUB DIVISION
55 Series

FRONT AXLE
1
2
STEERING GEAR
3
POWER STEERING SYSTEM
POWER STEERING PUMP 4
5
STEERING LINKAGE
6

E9610
7 FRONT AXLE & STEERING
55 Series Contents

CONTENTS Page Date

SECTION 1—FRONT AXLE

Removal and Refitment:
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—1—1 . . . . . . . . . 9610
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—1—2 . . . . . . . . . 9610
Overhaul:
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—1—5 . . . . . . . . . 9610
1
Hub Assembly — F56 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—1—7 . . . . . . . . . 9610
Hub Assembly — F71 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—1—12 . . . . . . . . 9610
Stub Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—1—17 . . . . . . . . 9610
Stub Axle Needle Bearings — F56 Axle . . . . . . . . . . . . . . . . . . . . . . . . 7—1—29 . . . . . . . . 9610
Stub Axle Needle Bearings and Upper bush — F71 Axle . . . . . . . . . 7—1—31 . . . . . . . . 9610
Wheel bolt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—1—16 . . . . . . . . 9610
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—1—1 . . . . . . . . . 9610

E9610 1
1

E9610
2
7 FRONT AXLE & STEERING
55 Series Front axle

1. FRONT AXLE
REMOVAL AND REFITMENT

DATA
Torque Tightening Figures Nm lbf ft
Drag–link ball pillar nut . . . . . . . . . . . . . . . . . . . . . . 200 to 240 148 to 178
Shock absorber nuts . . . . . . . . . . . . . . . . . . . . . . . .
U–bolt nuts (oiled thread condition):
47 to 57 35 to 42
1
F56 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 to 245 151 to 181
F71 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 to 490 330 to 380
Wheel disc bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 to 200 136 to 148

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE VEHICLE, BOTH BATTERY LEADS MUST BE
DISCONNECTED TO PREVENT ACCIDENTAL OR INADVERTENT STARTING OF THE
ENGINE.

2. ENSURE THAT SUITABLE PROTECTIVE CLOTHING AND A FACE MASK ARE WORN TO
PREVENT THE INHALATION OR PENETRATION OF BRAKE PAD/LINING DUST AND
PARTICLES. DO NOT INHALE THE DUST FROM THE BRAKE PADS/LININGS OR BLOW
DUST FROM THE BRAKE ASSEMBLIES; REMOVE ANY DUST USING A DAMP CLOTH OR
VACUUM CLEANER AND DISPOSE OF ALL USED CLOTHS, WHILST DAMP, INTO A
PLASTIC WASTE DISPOSAL BAG. IF A CLEANING SOLVENT IS REQUIRED, METHYLATED
SPIRIT SHOULD BE USED.

3. BEFORE ATTEMPTING TO JACK THE VEHICLE, ENSURE THE FOLLOWING:

— THE COMPLETE VEHICLE IS ON STABLE LEVEL GROUND.

— THE HANDBRAKE IS APPLIED TO THE PARK POSITION AND CHOCKS HAVE BEEN
POSITIONED BENEATH THE ROAD WHEELS.
— DO NOT USE THE JACK AS THE SOLE MEANS OF SUPPORT.

E9610 7–1–1
 FRONT AXLE & STEERING 7
Front axle 55 Series

Front Axle – Albion F56 and F71

Service tool: 0485122

To Remove
1 Chock the rear road wheels and fully deplete
1 the air system.

2. Slacken the road wheel nuts, jack the front

axle until the road wheels are clear of the
ground and position suitable supports
beneath the chassis frame. Remove the
wheel nuts and withdraw the road wheels.

3. Remove the split pin and drag–link ball pillar

nut. Using tool 0485122, separate the
drag–link ball pillar from the steering lever;
suspend the drag–link clear of the axle.

4. F56 Axle only: Separate the brake pad wear

indicator plug from the brake pad cable.

5. Vehicles fitted with ABS: Detach the

sensor/cable from the stub axle and release
the cable clips from the brake hose.

6. Disconnect the flexible brake hoses from the

chassis adapters/ABS modulator valve.

7. Remove nuts securing the shock absorbers

to the axle brackets, fully compress the shock
absorbers and retain the mounting rubbers
and washers.

8. Release the anti–roll bar link arms from the

chassis brackets.

9. Suitably support the anti–roll bar, then

remove the U–bolt nuts securing the anti–roll
bar/bracket assembly to the axle; withdraw
the anti–roll bar from the vehicle.

10. Position a suitable lifting trolley beneath the

axle and support the weight of the axle.

11. Remove the remaining U–bolt nuts, U–bolts

and spring saddles.

12. Lower and carefully manoeuvre the axle from

beneath the vehicle.

E9610
7–1–2
7 FRONT AXLE & STEERING
55 Series Front axle

1 3

8
1
6 1

7 6 020197

FIG.1. FRONT AXLE REMOVAL (Non ABS) (F56 Axle illustrated)

1. ABS Modulator valve 4. Brake pad wear indicator plug 7. Drag–link

2. Shock absorber 5. U–bolts 8. Link arm
3. Brake hose 6. Anti–roll bar

E9610 7–1–3
 FRONT AXLE & STEERING 7
Front axle 55 Series

To Refit
Reverse removal procedure, noting:

1. Refer to DATA for torque tightening figures.

1 2. Vehicles fitted with ABS: Reset the sensor by

pushing the sensor inwards until it contacts
the exciter ring, then rotate the hub several
times to set a minimum clearance between
the sensor and exciter ring.

3. Tighten the road wheel nuts to the correct

torque and in the correct sequence as
detailed in the ‘Maintenance Manual’.

4. Check the front wheel alignment, see

Section 6.

E9610
7–1–4
7 FRONT AXLE & STEERING
55 Series Front axle

OVERHAUL

DATA
Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0° (Laden)
0° 30’ (Unladen)

Hub end–float:
F56 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 to 0,25 mm (0.002 to 0.010 in)
1
F71 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1 to 0,23 mm (0.004 to 0.009 in)

Stub axle upper bush—fitted (F71 axle only):

Internal diameter (pre–finished) . . . . . . . . . . . 38,11 to 38,15 mm
(1.5004 to 1.502 in)
Upper bush maximum worn clearance . . . . . 0,127 mm (0.005 in)

Stub axle/axle beam clearance:

F56 axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 to 0,30 mm (0.002 to 0.012 in)
F71 axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 to 0,13 mm (0.002 to 0.005 in)
Stub axle/axle beam maximum worn clearance . . 0,3 mm (0.012 in)
Upper trust washers (F56 axle only) . . . . . . . . . . . 2,4 mm (0.095 in)
2,25 mm (0.089 in)
2,14 mm (0.084 in)
2,00 mm (0.079 in)
1,9 mm (0.075 in)
1,76 mm (0.069 in)
1,5 mm (0.059 in)

E9610 7–1–5
 FRONT AXLE & STEERING 7
Front axle 55 Series

Torque Tightening Figures Nm lbf ft

F56 Axle:
Brake caliper bolts . . . . . . . . . . . . . . . . . . . . . . 560 to 630 413 to 464

1 Drag–link ball pillar nut . . . . . . . . . . . . . . . . . . . 200 to 240 148 to 178

Track–rod ball pillar nut . . . . . . . . . . . . . . . . . . 200 to 300 162 to 221
Steering arm/track–rod lever bolts . . . . . . . . . 485 to 665 357 to 490
Swivel pin nut . . . . . . . . . . . . . . . . . . . . . . . . . . 370 to 510 273 to 376
Swivel pin top/bottom cover setscrews . . . . . 17 to 23 13 to 17
Wheel disc bolts . . . . . . . . . . . . . . . . . . . . . . . . 185 to 200 136 to 148

F71 Axle:
Brake drum setscrews . . . . . . . . . . . . . . . . . . . 14 to 27 10 to 20
Brake carrier bolts . . . . . . . . . . . . . . . . . . . . . . 179 to 210 132 to 155
Drag–link ball pillar nut . . . . . . . . . . . . . . . . . . . 200 to 240 148 to 178
Hub cap setscrews . . . . . . . . . . . . . . . . . . . . . . 11 to 13 8 to 10
Hub nut clamp bolt . . . . . . . . . . . . . . . . . . . . . . 27 to 41 20 to 30
Track–rod ball pillar nut . . . . . . . . . . . . . . . . . . 176 to 244 130 to 180
Steering arm/track–rod lever bolts . . . . . . . . . 488 to 542 360 to 400
Swivel pin bottom cover setscrews . . . . . . . . . 88 to 108 65 to 80
Swivel pin top cover setscrews . . . . . . . . . . . . 24 to 30 18 to 22

E9610
7–1–6
7 FRONT AXLE & STEERING
55 Series Front axle

Hub Assembly

CAUTION:
Axles fitted with ABS: Any removal/refitment or
overhaul procedure that exposes the ABS exciter
ring,the following precautions MUST be observed: 1
— Do NOT use the exciter ring as a lever
(fulcrum) point.

— Do NOT strike or dent the exciter ring;

protect the ring from damage.

— Do NOT stand the hub on the exciter ring.

F56 Axle
Service tools: 0499809, 1310430, 1310431 and
1310432

To Dismantle
1. Deplete the air system.

2. Slacken the front road wheel nuts, jack and

suitably support the front axle, remove nuts
and withdraw the road wheels.

3. ABS Axles: Separate the sensor cable plug

connection and position the cable clear of the
caliper.

4. Separate the brake pad indicator cable plug

connection and release the cable clips from
the brake hose.

E9610 7–1–7
 FRONT AXLE & STEERING 7
Front axle 55 Series

5. Disconnect the brake hose from the chassis

adapter/ABS modulator valve. Suitably
support the caliper, remove the retaining bolts
securing the caliper to the stub axle and

1 carefully withdraw the caliper assembly.

6. Prise the hub cap from the hub. Extract the

split pin and remove the hub nut and keyed
washer.

7. Withdraw the hub from the stub axle; retain

the outer bearing.

8. Extract the hub seal and inner bearing from

the hub.

9. If necessary, press the bearing races from

the hub.

E9610
7–1–8
7 FRONT AXLE & STEERING
55 Series Front axle

To Inspect
1. Thoroughly clean all components.

2. Inspect the bearings for evidence of pitting,

wear, over–heating or cage distortion; renew
the complete bearing assembly as necessary. 1
3. ABS Axles: Check the exciter ring teeth for
burrs or dents, if evident, lever the ring from
the hub. Inspect the hub exciter ring spigot
for damage; rectify as necessary.

4. Examine the abutment ring, if necessary,

remove using a suitable extractor.

5. Replace any damaged wheel bolts.

5
1 2 3 4 6 7 8 9 10 11 12

020151

FIG.2. EXPLODED VIEW OF THE HUB ASSEMBLY — F56

1. Hub cap 5. Bearing race 9. Seal

2. Hub nut 6. Hub/wheel disc assembly 10. Exciter ring (ABS only)
3. Keyed washer 7. Bearing race 11. Abutment ring
4. Outer bearing 8. Inner bearing 12. Stub axle

E9610 7–1–9
 FRONT AXLE & STEERING 7
Front axle 55 Series

To Reassemble
NOTE: ABS Axles: Exciter rings which have been
removed from the hub MUST NOT be re–used.

1. Using driver handle 0499809 with adapter

1 1310431, press the inner bearing race into
the hub. Repeat the operation for the outer
bearing race, using tools 0499809 and
1310432.

2. Thoroughly pack or inject the front and rear

inner bearing races with lithium grease
(N.L.G.I. Grade 2). Apply a light film of
grease to the internal surfaces of the hub; do
NOT pack the hub cavity with grease.

3. Locate the inner bearing into the hub.

4. Using driver handle 0499809 with adapter

1310430, press the new seal into position
until it is flush with the face of the hub.

5. ABS Axles: Using a suitable diameter tube or

flat plate press the new exciter ring onto the
hub. Check the condition of the new exciter
ring prior to fitting.
NOTE: Ensure the thickness of the tube is
sufficient to cover the ring teeth to prevent
damage when pressing the ring into position.

6. Lightly lubricate the sealing lip of the new

seal and then carefully locate the hub
assembly in position on the stub axle.

7. Locate the outer bearing in the hub, fit the

keyed washer and then secure the hub
assembly with the hub nut.

8. Whilst rotating the hub assembly, tighten the

hub nut to seat the hub bearings. Slacken the
hub nut 1/2 turn and then re–tighten.

E9610
7–1–10
7 FRONT AXLE & STEERING
55 Series Front axle

9. Attach a dial test indicator on the hub and

locate the indicator stylus on the end of the
stub axle. Measure the amount of hub
end–float; if necessary, tighten or slacken the
hub nut until the required end–float, see
DATA, is obtained. Secure the hub nut in 1
position with a new split pin and refit the hub
cap.

10. Refit the caliper to the stub axle and tighten 1

the retaining bolts to a torque of 560 to 630
Nm (413 to 464 lbf ft). Reconnect the brake
hose to the chassis adapter/ABS modulator
valve. 2
070459

11. Reconnect the brake pad wear indicator

cable plug and reconnect the brake hose to FIG.3. ABS SENSOR
the chassis adapter.
1. Exciter ring
12. ABS Axles: Reconnect the sensor cable plug. 2. Sensor
Push the sensor inwards until it just contacts
the exciter ring and then rotate the hub
several times to set a minimum running
clearance between the sensor and exciter
ring.

13. Refit the front road wheels and tighten the

road wheel nuts to the correct torque and in
the correct sequence as detailed in the
‘Maintenance Manual’.

E9610 7–1–11
 FRONT AXLE & STEERING 7
Front axle 55 Series

F71 Axle

To Dismantle
1. Slacken the front road wheel nuts, jack and
suitably support the front axle, remove nuts
1 and withdraw the road wheels.

2. Remove the two setscrews and detach the

brake drum, if necessary, use two extractor
bolts in the holes provided to remove the
brake drum.

3. Remove the setscrews and detach the hub

cap complete; discard the hub cap joint.

4. Release the lockwasher and remove the nut

and clamp bolt from the split hub nut.
Remove the split hub nut noting that the L.H.
split hub nut has L.H. threads and the R.H.
split hub nut has R.H. threads. Detach the
thrust washer.

5. Withdraw the hub assembly, complete with its

inner and outer bearings and oil seal, from
the stub axle.

6. Remove the outer bearing, leaving the

bearing race in position within the hub.

7. Remove the oil seal and inner bearing,

leaving the inner bearing race in position
within the hub.

8. If necessary, press the bearing races from

the hub.

E9610
7–1–12
7 FRONT AXLE & STEERING
55 Series Front axle

To Inspect
1. Thoroughly clean all components.

2. Inspect the bearings for evidence of pitting,

wear, over–heating or cage distortion;
renew the complete bearing assembly as 1
necessary.

3. ABS Axles: Check the exciter ring teeth for

burrs or dents, if evident, lever the ring from
the hub. Inspect the hub exciter ring spigot
for damage; rectify as necessary.

4. Examine the abutment ring, if necessary,

remove using a suitable extractor.

5. Replace any damaged wheel bolts.

1 7

2 3 4 5 6 8 9 10 11 12

020198

FIG.4. EXPLODED VIEW OF THE HUB ASSEMBLY — F71

1. Brake drum 7. Hub

2. Hub cap 8. Exciter ring (ABS only)
3. Hub cap joint 9. Inner bearing
4. Hub nut 10. Seal
5. Thrust washer 11. Abutment ring
6. Outer bearing 12. Stub axle

E9610 7–1–13
 FRONT AXLE & STEERING 7
Front axle 55 Series

To Reassemble
1. Thoroughly pack or inject the inner and outer
bearings with the correct specification grease,
see DATA. Apply a light film of grease to the

1 internal surfaces of the hub; do NOT pack

the hub with grease.

2. Locate the inner bearing in the hub.

3. Press the new oil seal into the hub. Lightly

lubricate the sealing lip of the oil seal and
then carefully locate the hub assembly in
position on the stub axle.

4. Fit the outer bearing into position in the hub,

fit the thrust washer and then secure the hub
assembly with the split hub nut. Fit and
partially tighten the clamp bolt.

5. Whilst rotating the hub assembly, tighten the

split hub nut to seat the hub bearings.
Slacken the split hub nut 1/2 turn and then
re–tighten.

6. Attach a dial test indicator on the hub and

locate the indicator stylus on the end of the
stub axle. Measure the amount of hub
end–float; if necessary, tighten or slacken the
split hub nut until the required end–float, see
DATA, is obtained. Tighten the clamp bolt to
the torque figure quoted in DATA and secure
in position with the lock washer.

E9610
7–1–14
7 FRONT AXLE & STEERING
55 Series Front axle

7. Using a new joint, refit the hub cap and

tighten the setscrews to the torque figure
quoted in DATA.

8. Fit the brake drum and tighten the setscrews

to the torque figure quoted in DATA. 1
9. ABS Axles: Push the sensor inwards (Fig.3)
until it just contacts the exciter ring and then
rotate the hub several times to set a
minimum running clearance between the
sensor and exciter ring.

10. Refit the front road wheels and tighten the

road wheel nuts to the correct torque and in
the correct sequence as detailed in the
‘Maintenance Manual’.

E9610 7–1–15
 FRONT AXLE & STEERING 7
Front axle 55 Series

Wheel Bolts

Replacement
1. Dismantle the hub as detailed in this Section.

1 2. F56 Axle: Remove bolts and separate the

wheel disc from the hub.

3. Press the defective stud(s) from the hub.

4. Thoroughly clean the wheel bolt bore.

5. Press the new wheel bolt(s) into the hub.

NOTE: The bolt must be an interference fit in
the hub bore, otherwise slackening–off will
occur, causing damage to both hub and road
wheel.

6. F56 Axle: Refit the wheel disc to the hub,

tightening the bolts to the torque figure
quoted in DATA.

7. Reassemble the hub as detailed in this

Section.

E9610
7–1–16
7 FRONT AXLE & STEERING
55 Series Front axle

Stub Axles

F56 Axle
Service tools: 0485122, 0499809, 0535891,
0694767, 1310427, 1310486 and 1310488

1
1
To Dismantle
1. Remove the hub as instructed in this Section.
2
2. Remove drag–link and track–rod ball joint
split pins and retaining nuts. Using tool
0485122, separate drag–link from steering 3
arm (steering side only) and track–rod from
track–rod lever.
4
3. Remove the retaining bolts and withdraw the
steering arm and track–rod lever from the
stub axle.

4. Remove the swivel pin top and bottom

covers.

5. Remove the swivel pin locknut.

020210
6. Locate the centralising plate on the lower
plate of the swivel pin puller.
FIG.5. REMOVING THE SWIVEL PIN
7. Position the thrust button on the swivel pin 1. Hydraulic puller 0535891
and centralise the swivel pin puller on the
stub axle; ensure the four pegs on the 2. Puller 0694767
centralising plate are correctly located in the 3. Thrust button 1310486
bottom cover bolt holes of the stub axle. 4. Centralising plate 1310488
Operate the puller to release the swivel pin
from its tapered location.

E9610 7–1–17
 FRONT AXLE & STEERING 7
Front axle 55 Series

8. Dismantle the service tool and withdraw the

swivel pin from the stub axle. Remove the
bearing sleeve from the swivel pin.

9. Withdraw the stub axle; retain the upper

1 thrust washer and bottom thrust washer
pack.

10. Remove the seal ring from the upper bore of

the stub axle.

11. Remove the abutment ring from the stub

axle.

E9610
7–1–18
7 FRONT AXLE & STEERING
55 Series Front axle

2 5

3 1
1 4

8
9

10

11
12

15

13
14

020199

FIG.6. EXPLODED VIEW OF THE STUB AXLE

1. Stub axle 9. Gamma seal

2. Top cover 10. Stepped thrust washer
3. Locknut 11. Flat thrust washer
4. Bearing sleeve 12. Cup thrust washer
5. Steering arm 13. Track–rod lever
6. Seal ring 14. Bottom cover
7. Upper thrust washer 15. Swivel pin
8. Axle beam

E9610 7–1–19
 FRONT AXLE & STEERING 7
Front axle 55 Series

To Inspect
1. Thoroughly clean all components prior to
inspection and reassembly.

2. Examine the needle bearings for wear,

1 scoring or pitting; if necessary, renew the
bearings as detailed in this Section.

3. Examine the swivel pin for wear and scoring;

renew as necessary.

4. Renew the gamma seal and upper seal ring.

E9610
7–1–20
7 FRONT AXLE & STEERING
55 Series Front axle

To Reassemble
1. To obtain the correct size of thrust washer to
be fitted between the stub axle and axle 1
beam, proceed as follows:

— Press the cup thrust washer into the

2
1
bottom bore of the stub axle.
— Smear both sides of the flat thrust
washer with grease. Place the thrust
washer in the cup thrust washer,
3
ensuring the flat thrust washer location
peg is correctly located in the cup thrust
washer. 020201

— Locate the stepped washer, without the

gamma seal, in the cup thrust washer FIG.7. THRUST WASHER PACK
and then position the stub axle on the
1. Stepped thrust washer
axle beam.
2. Flat thrust washer
— Using a suitable hydraulic jack, press the
3. Cup thrust washer
stub axle against the axle beam until all
end–play between the thrust washer
pack and axle beam is eliminated.
— Using feeler gauges, measure the
clearance, ‘A’ Fig.8, between the upper
face of the axle beam and stub axle.
— Subtract the specified clearance, see A
DATA, from the reading obtained to give
the required thrust washer.

020202

FIG.8. STUB AXLE CLEARANCE

E9610 7–1–21
 FRONT AXLE & STEERING 7
Front axle 55 Series

2. When the correct size of washer has been

attained, remove the stub axle and withdraw 1
the stepped and flat thrust washers from the
cup thrust washer.

1 3. Using driver handle 0499809 and adapter

1310427, press the gamma seal onto the
stepped thrust washer. 2

4. Locate a new seal ring in the upper bore of 3

the stub axle. 4 020209

5. Locate the flat and stepped thrust washer in

the cup thrust washer, then position the stub FIG.9. FITTING THE GAMMA SEAL
axle on the axle beam.
1. Driver handle
6. Insert and centralise the upper thrust washer 2. Seal replacer 1310427
between the stub axle and axle beam. 3. Stepped thrust washer
7. Place the bearing sleeve in the upper bore of
the stub axle.

8. Insert the swivel pin into the stub axle and

axle beam. Using a suitable hydraulic jack,
press the swivel pin up into the stub axle until
the tapered shank is in hard contact with the
tapered bore in the axle beam. Remove the
jack.

E9610
7–1–22
7 FRONT AXLE & STEERING
55 Series Front axle

9. Apply ‘Loctite 242’ to the leading two threads

of the swivel pin, fit and tighten the locknut to
the torque figure quoted in DATA.

10. Apply ‘Hylomar’ sealing compound to the joint

faces of the top and bottom covers. Refit the 1
covers and tighten the setscrews to the
torque figure quoted in DATA.

11. Locate the abutment ring on the stub axle.

12. Assemble the track–rod lever and steering

arm (steering side only) to the stub axle;
tighten the retaining bolts to the torque figure
quoted in DATA.

13. Locate the track–rod ball joint in the track–rod

lever, refit and tighten the ball pillar nut to the
minimum torque figure quoted in DATA. If
necessary, further tighten the nut to facilitate
the split pin; DO NOT back off the nut to fit
the split pin.

14. Locate the drag–link ball joint in the steering

lever, refit and tighten the ball pillar nut to the
minimum torque figure quoted in DATA. If
necessary, further tighten the nut to facilitate
the split pin; DO NOT back off the nut to fit
the split pin.

15. Refit the hub assembly as detailed in this

Section.

E9610 7–1–23
 FRONT AXLE & STEERING 7
Front axle 55 Series

Stub Axle — F71 Axle

Service tool: 0485122

To Dismantle
1 1. Remove the hub as instructed in this Section.

2. Remove the brake shoes, refer to Group 6

‘Brakes’.

3. ABS Axles: Release the clips securing the

sensor cable to the brake hose. Separate the
sensor cable plug connection and position the
cable clear.

4. Disconnect the brake hose from the chassis

adapter/ABS modulator valve.

5. Remove the retaining bolts and withdraw the

brake carrier assembly from the stub axle.

6. Remove the drag–link and track–rod ball joint

split pins and retaining nuts. Using tool
0485122, separate the drag–link from the
steering arm (steering side only) and the
track–rod from the track–rod lever.

7. Release the lockwire from the steering arm

(steering side only) and track–rod lever
retaining bolts.

8. Remove the retaining bolts and withdraw the

steering arm and track–rod lever from the
stub axle.

9. Detach the swivel pin top cover from the stub

axle.

E9610
7–1–24
7 FRONT AXLE & STEERING
55 Series Front axle

10
2
3 1
8 9

7
020200

FIG.10. EXPLODED VIEW OF THE STUB AXLE

1. Steering arm 6. Shims

2. O–ring 7. Bottom cover/thrust bearing assembly
3. Axle beam 8. Track–rod lever
4. ‘V’ ring seal 9. Stub axle
5. Swivel pin 10. Top cover

E9610 7–1–25
 FRONT AXLE & STEERING 7
Front axle 55 Series

10 Remove the bottom cover/thrust bearing

assembly and retain the shims.

11. Using suitable equipment, apply a load to the

top of the swivel pin, then shock the
1 periphery of the swivel pin housing of the axle
beam, to release the swivel pin from its
tapered location.

12. Withdraw stub axle and discard the ‘V’ ring

seal and O–ring.

13. Remove the abutment ring from the stub

axle.

To Inspect
1. Thoroughly clean all components prior to
inspection and reassembly.

2. Examine the stub axle bush and needle

bearings for wear, scoring or pitting; if
necessary, renew the upper bush and
bearings as detailed in this Section.

3. Examine the swivel pin for wear and

scoring; renew as necessary.

4. Renew the O–ring and ‘V’ ring seal.

E9610
7–1–26
7 FRONT AXLE & STEERING
55 Series Front axle

To Reassemble
1. Smear the new O–ring and ‘V’ ring seal with
grease prior to fitting.
A
2. Locate the O–ring in the upper lug of the stub
axle and insert the ‘V’ ring seal into the 1
location groove in the bottom face of the axle
beam.

3. Locate the stub axle on the axle beam,

ensuring the sealing lip of the ‘V’ ring seal is
correctly seated on the stub axle.

4. Insert the swivel pin into the stub axle and

axle beam. Using a suitable hydraulic jack,
press the swivel pin up into the stub axle until
the tapered shank is in hard contact with the 020211

tapered bore in the axle beam. Remove the

jack. FIG. 11. STUB AXLE CLEARANCE
5. Refit the original shims and bottom
cover/thrust bearing assembly; tighten the
cover setscrews to the figure quoted in
DATA.

6. Using feeler gauges, check the clearance (A)

Fig. 11, between the stub axle and axle
beam, see DATA for correct figure. Add or
subtract shims accordingly.

E9610 7–1–27
 FRONT AXLE & STEERING 7
Front axle 55 Series

7. Refit the swivel pin top cover and tighten the

setscrews to the torque figure quoted in
DATA.

8. Locate the abutment ring on the stub axle.

1
9. Fit the brake carrier assembly to the stub
axle and tighten the retaining bolts to the
torque figure quoted in DATA.

10. Assemble the track–rod lever and steering

arm (steering side only) to the stub axle;
tighten the retaining bolts to the torque figure
quoted in DATA. Wire lock the bolts.

11. Locate the track–rod ball joint in the track–rod

lever, refit and tighten the ball pillar nut to the
minimum torque figure quoted in DATA. If
necessary, further tighten the nut to facilitate
the split pin; DO NOT back off the nut to fit
the split pin.

12. Repeat the above operation for the drag–link

ball joint.

13. Refit the brake shoes detailed in Group 6

‘Brakes’.

14. Reconnect the brake hose to the chassis

adapter/ABS modulator valve. Reconnect the
ABS cable plug/socket and secure the cable
to the brake hose.

15. Refit the hub assembly as detailed in this

Section.

E9610
7–1–28
7 FRONT AXLE & STEERING
55 Series Front axle

Stub Axle Needle Bearings — F56 Axle 1

Service tools: 0499809, 1310428 and 1310433
2

To Remove
NOTE: The stub axle must be in a vertical, 3 1
centralised position whilst pressing bushes in or
out.

1. Dismantle the stub axle as detailed in this

Section.

2. Clean all paint and remove burrs from the

outer surfaces of the stub axle.

3. Place the stub axle on a press.

4. Locate tool 1310433 in the upper bearings,

using driver handle 0499809 press the upper
bearings from the stub axle.
020203
5. Invert the stub axle and repeat the procedure
for the lower bearings.
FIG. 12. REMOVING THE NEEDLE BEARINGS

1. Driver handle
2. Bearing remover 1310433
3. Needle bearings

E9610 7–1–29
 FRONT AXLE & STEERING 7
Front axle 55 Series

To Refit
1. Thoroughly clean all components and 1
lubricate the needle bearings and stub axle
bores prior to reassembly. 2

1 2. Position the stub axle on the press, with the

upper bearing bore lowermost.
3
3. Press the lower bearings into the stub axle as
follows:

Locate the inner needle bearing on the

bearing replacer 1310428, Fig. 13. Position
the needle bearing and replacer over the stub
axle bore. Insert driver handle 0499809 into
the needle bearing replacer and press the
inner needle bearing into the stub axle;
remove tools.
NOTE: The tool positions the needle
bearings at the correct depth in the stub axle
020204
bore.
Invert the bearing replacer and repeat the FIG. 13. FITTING THE INNER NEEDLE
above operation for the outer needle bearing, BEARING
see Fig.14. 1. Driver handle
4. Reposition the stub axle on the press and 2. Bearing replacer 1310428
repeat operation 3 for the lower bearings. 3. Inner needle bearing
1

020205

FIG. 14. FITTING THE OUTER NEEDLE

BEARING
1. Driver handle
2. Bearing replacer 1310428
3. Outer needle bearing

E9610
7–1–30
7 FRONT AXLE & STEERING
55 Series Front axle

Stub Axle Needle Bearings and

Upper Bush — F71 Axle 1
Service tools: 0499809, 1310434, 1310435,
2
1310436 and 1310437
3 1
To Remove
NOTE: The stub axle must be in a vertical,
centralised position whilst pressing the
bearings/upper bush in or out.

1. Dismantle the stub axle as detailed in this

Section.

2. Clean all paint and remove burrs from the

outer surfaces of the stub axle.

3. Place the stub axle, needle bearings

lowermost, on a press.

4. Locate tool 1310437 in the upper bush and,

020192
using driver handle 0499809 press the upper
bush from the stub axle. FIG. 15. REMOVING THE UPPER BUSH
5. Invert the stub axle. 1. Driver handle
2. Bush remover 1310437
6. Using tools 0499809 and 1310435, press the 3. Upper bush
needle bearings from the stub axle.
1

020193

FIG. 16. REMOVING THE NEEDLE BEARINGS

1. Driver handle
2. Bearing remover 1310435
3. Needle bearings

E9610 7–1–31
 FRONT AXLE & STEERING 7
Front axle 55 Series

To Refit
1. Thoroughly clean all components and 2
lubricate the upper bush, needle bearings
and stub axle bores prior to reassembly.

1 2. Position the stub axle on the press, with the

upper bush bore lowermost. 3

3. Locate the inner needle bearing on the

bearing replacer 1310434, Fig.17. Position
the needle bearing and replacer over the stub
axle bore. Insert driver handle 0499809 into
the needle bearing replacer and press the
inner needle bearing into the stub axle;
remove tools.
NOTE: The tool positions the needle
bearings at the correct depth in the stub axle
bore.
020196

4. Invert the bearing replacer and repeat the FIG. 17. FITTING THE INNER NEEDLE
above operation for the outer needle bearing, BEARING
see Fig.18.
1. Driver handle
2. Bearing replacer 1310434
3. Inner bearing

020195

FIG. 18. FITTING THE OUTER NEEDLE

BEARING
1. Driver handle
2. Bearing replacer 1310434
3. Outer bearing

E9610
7–1–32
7 FRONT AXLE & STEERING
55 Series Front axle

5. Reposition the stub axle on the press. 1 A

6. Place the upper bush on the bush replacer 2
1310436. Locate the bush in the stub axle A
bore, with the split (A) positioned as
illustrated in Fig.19. Insert the driver handle 3 1
into the bush replacer and press the bush 3
into the stub axle, until the replacer tool abuts
the stub axle; remove tools.
NOTE: The tool positions the upper bush at
the correct depth in the sub axle bore.

7. Reassemble the stub axle as detailed in this

Section.

020194

FIG. 19. FITTING THE UPPER BUSH

1. Driver handle
2. Bush replacer 1310436
3. Bush

E9610 7–1–33
 FRONT AXLE & STEERING 7
Front axle 55 Series

E9610
7–1–34
7 FRONT AXLE & STEERING
55 Series Contents

CONTENTS Page Date

SECTION 3—STEERING GEAR

Bleeding the Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—3—22 . . . . . . . . 9610
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—3—1 . . . . . . . . . 9610
Fault Finding Basic Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—3—23 . . . . . . . . 9610
Fault Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—3—24 . . . . . . . . 9610
Removal and Refitment:
Adjustable Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—3—16 . . . . . . . . 9610
Housing and Piston Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—3—3 . . . . . . . . . 9610
Steering Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—7—11 . . . . . . . . 9610
Telescopic Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—3—20 . . . . . . . . 9610
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7—3—2 . . . . . . . . .
7—3—1 . . . . . . . . .
9610
9610
3

E9610 1
3

E9610
2
7 FRONT AXLE & STEERING
55 Series Steering gear

3. STEERING GEAR
DATA

Steering Column
End–float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,13 to 0,25 mm (0.005 to 0.010 in)

Steering Gear
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF 8095 (11 to 15 tonne vehicles)
ZF 8098 (16 to 18 tonne vehicles)
Piston assembly end–float . . . . . . . . . . . . . . . . . . . . 0,01 to 0,015 mm (0.0004 to 0.0006 in)
Piston assembly shims . . . . . . . . . . . . . . . . . . . . . . 2,3 to 2,8 mm (0.09 to 0.11 in) in increments

Special Compounds
Steering column bearing grease . . . . . . . . . . . . . . . Lithium Grease (N.L.G.I. Grade 2) 3
Steering column upper bush retaining
compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‘Loctite 270’

Torque Tightening Figures Nm lbf ft

Drop arm nut:
8095 Steering box . . . . . . . . . . . . . . . . . . . . . . 500 to 550 368 to 405
8098 Steering box . . . . . . . . . . . . . . . . . . . . . . 550 to 600 405 to 445

Drag–link ball pillar nut . . . . . . . . . . . . . . . . . . . . . . . 200 to 240 148 to 178

Steering column universal joint clamp bolts . . . . . 24 to 30 18 to 22
Steering gear end–cover bolts . . . . . . . . . . . . . . . . 285 210
Steering box mounting bolts . . . . . . . . . . . . . . . . . . 405 to 475 300 to 352
Steering wheel retaining nut . . . . . . . . . . . . . . . . . . 58 43

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE VEHICLE, BOTH BATTERY LEADS MUST BE
DISCONNECTED TO PREVENT ACCIDENTAL OR INADVERTENT STARTING OF THE ENGINE.

2. HYDRAULIC FLUID IS A TOXIC SUBSTANCE WHICH MUST NOT BE CONSUMED OR

ALLOWED TO COME INTO SKIN CONTACT. IN THE EVENT OF SLIGHT SKIN CONTACT OR
INGESTION/INHALATION SEEK MEDICAL ATTENTION IMMEDIATELY.

3. BEFORE ATTEMPTING TO JACK THE VEHICLE, ENSURE THE FOLLOWING:

— THE COMPLETE VEHICLE IS ON STABLE LEVEL GROUND.
— THE HANDBRAKE IS APPLIED TO THE PARK POSITION AND CHOCKS HAVE BEEN
POSITIONED BENEATH THE ROAD WHEELS.
— DO NOT USE THE JACK AS THE SOLE MEANS OF SUPPORT.

4. DO NOT RUN THE ENGINE IN A CONFINED SPACE OR UNVENTILATED AREA. EXHAUST

FUMES CONTAIN TOXIC GASES WHICH, IF INHALED, MAY PROVE FATAL.

E9610 7–3–1
 FRONT AXLE & STEERING 7
Steering gear 55 Series

SERVICE INFORMATION

IMPORTANT: The ZF 8095 and 8098 power

steering boxes are considered uneconomical to
repair due to cost involved and special service
tools required, however, the housing and piston
seals can be renewed if necessary. Fault finding
diagnosis can be carried out to determine the
serviceability of the steering box prior to renewing
the seals. If after carrying out the fault diagnosis
checks, as detailed in this Section, the fault still
exists in the steering box, then a new or
exchange unit must be fitted.

E9610
7–3–2
7 FRONT AXLE & STEERING
55 Series Steering gear

REMOVAL AND REFITMENT

Housing and Piston Seals

Service tools: 0485122, 0192506, 0192507 and
0192508

To Remove (Fig.1)
CAUTION: An adequate, clean working surface is
essential and precaution must be taken against
foreign matter entering the mechanism during the
assembly procedure. Use a suitable solvent to
clean parts and blow dry. DO NOT steam clean or
high–pressure wash the hydraulic components.

1. Set the front road wheels in the straight

ahead position.
3
2. Chock the rear wheels then jack and suitably
support the front axle with the wheels just
clear of the ground.

3. Tilt the cab, see ‘Drivers Handbook’.

4. Remove the split–pin and ball pillar nut

securing the drag–link to the drop arm.

5. Using tool 0485122, separate the drag–link

from the drop arm. Secure the drag–link clear
of the steering box.

6. Using a suitable solvent clean the steering

box, pipe connections and surrounding area.

7. Suitably reference mark the steering column

lower universal joint in relation to the
centralising mark on the top face of the input
shaft, this will ensure correct alignment during
refitment.

8. Remove the clamp bolt and slide the steering

column/lower universal joint from the steering
box input shaft; remove the dust cover from
the input shaft.

E9610 7–3–3
 FRONT AXLE & STEERING 7
Steering gear 55 Series

9. Release the clamps securing the hydraulic

pipes to the chassis brackets. Position a
suitable container beneath the steering box,
disconnect the supply and return pipes and
allow the system to drain.

10. Fit protective plugs to all open pipe unions

and connections to prevent ingress of foreign
matter.

11. Remove the end cover bolts, end cover,

needle bearing and shim washer; retain the
3 shim washer for subsequent refitment.
CAUTION: Before commencing the next
operation, ensure the piston assembly is
supported to prevent the assembly falling
from the steering box housing when the
sector shaft is turned.

12. With the piston assembly supported, pull the

drop arm fully rearward and withdraw the
piston from the housing.
NOTE: The remaining amount of hydraulic
fluid, above the piston seal, will drain out of
the housing.

13. Withdraw the needle bearing and thrust

washer from the steering box housing.

14. Remove the seals from the worm shaft and

the sealing ring and O–ring from the piston.

15. Remove and discard the housing end cover

sealing ring and O–rings.

E9610
7–3–4
7 FRONT AXLE & STEERING
55 Series Steering gear

1
3

5
2

6 3

8
18
17

7
16

10
15

9
14 11

13

12

020132

FIG.1. PISTON ASSEMBLY REMOVAL

1. Lower universal joint 7. Clamp 13. O–ring

2. Dust cover 8. Return pipe 14. Shim washer
3. Input shaft oil seal 9. Drag link 15. Needle bearing
4. Thrust washer 10. Drop arm 16. Piston assembly
5. Needle bearing 11. Sealing ring & O–ring 17. Ball pillar nut
6. Supply pipe 12. End cover 18. Steering box

E9610 7–3–5
 FRONT AXLE & STEERING 7
Steering gear 55 Series

To Refit 2
CAUTION: Extreme care must be taken when
fitting new seals and sealing rings, any marks or
abrasions will render the seal unserviceable.
Lubricate all seals and sealing rings with hydraulic
fluid prior to fitting. 3
2
1. Ensure the oil seal locating grooves in the
worm shaft and steering box housing are
clean and dry.

2. Using guide sleeve 0192507 position a new

3 sealing ring over the wide end of the sleeve;
locate the sleeve over the worm shaft and
2
1 1 020133
carefully push the inner seal into the locating
groove.
FIG.2. FITTING THE WORM SHAFT SEALS
3. Fit the distance piece supplied into the bore
1. Guide sleeve
of the guide sleeve, locate the sleeve over
the worm shaft and carefully push the outer 2. Seal
seal into the locating groove. 3. Distance piece

4. Using tool 0192508 compress each sealing

ring into the worm shaft grooves.

5. Fit the original thrust washer and needle

bearing into the steering box housing bore.

6. Fit a new O–ring and sealing ring to the

piston assembly.

1
020134

FIG.3. COMPRESSING THE WORM SHAFT

SEALS

1. Tool 0192508
2. Piston assembly

E9610
7–3–6
7 FRONT AXLE & STEERING
55 Series Steering gear

7. Fit a new O–ring in the outer locating groove

of the housing end cover, then fit a new 90
80

sealing ring and O–ring in the inner locating

0

10

70
60
20
groove of the cover. 30 40
50

8. Fit the original shim washer and needle

bearing in the housing end cover.

9. Carefully push the piston into the housing

until the piston is protruding the piston bore
approximately 7 mm. Push the drop arm
forward to engage the teeth of the sector
shaft with the teeth of the piston assembly.
Continue to push the drop arm fully forward,
3
this will pull the piston into position within
the housing.

10. Fit the housing end cover and tighten each

bolt equally and in a diametrical sequence to
ensure that the end cover is square to the
steering box housing. Tighten the bolts to the
torque figure quoted in DATA.

11. Turn the steering from lock to lock to seat the

needle bearings.

12. Using a dial test indicator, attach the base to

a convenient point on the chassis, with the 020135

indicator button contacting the outer face of

the input shaft. FIG.4. CHECKING THE PISTON ASSEMBLY
END–FLOAT
13. Turn the sector shaft by pushing the drop
arm backward and forward checking that the
end– float is within 0,01 to 0,015 mm (0.0004
to 0.0006 in). Adjust if necessary, using the
range of shim washers, until the correct
end–float is obtained.
NOTE: Shim washers are available from 2,2
to 2,8 mm (0.09 to 0.11 in) in steps of 0,01
mm (0.0004 in).

E9610 7–3–7
 FRONT AXLE & STEERING 7
Steering gear 55 Series

14. Remove the end cover then pull the drop arm
fully rearward to remove the piston assembly
from the steering box housing.

15. Position a new input housing oil seal on

service tool 0192506, carefully insert the tool 2
through the piston bore and push the seal
into the locating groove in the housing.

16. Refit the piston as previously detailed, fit the

housing end cover and tighten each bolt
1
equally and in a diametrical sequence to
3 ensure that the end cover is square to the
steering box housing. Tighten the bolts to the
2

torque figure quoted in DATA.

020136

17. Grease and refit the input shaft dust cover.

FIG.5. FITTING THE INPUT SHAFT OIL SEAL
18. Connect the hydraulic supply and return
pipes to the steering box, then clamp the 1. Tool 0192506
pipes to the chassis brackets.
2. Oil seal
19. Refit the lower universal joint of the steering
column to the input shaft, aligning reference
marks. Fit and tighten the clamp bolt to the
torque figure quoted in DATA.

E9610
7–3–8
7 FRONT AXLE & STEERING
55 Series Steering gear

13

2 3

4
12

3
11

5
10

9 6

020137

FIG.6. FITTING THE PISTON ASSEMBLY

1. Lower universal joint 6. Sealing ring & O–ring 10. Needle bearing
2. Supply pipe 7. End cover 11. Piston Assembly
3. Clamp 8. O–ring 12. Steering box
4. Return pipe 9. Shim washer 13. Dust cover
5. Drop arm

E9610 7–3–9
 FRONT AXLE & STEERING 7
Steering gear 55 Series

20. Locate the drag–link ball pillar in the drop

arm, fit and tighten the ball pillar nut to the
minimum torque figure quoted in DATA. If
necessary, further tighten the nut to facilitate
the split pin. Do NOT back off the nut to fit
the split pin.

21. Lower the cab.

22. With the road wheels in the straight ahead

position, check the steering wheel alignment
(i.e. the steering wheel bar is in the horizontal
3 position). Adjust the position of the steering
wheel if necessary.

23. Fill and bleed the power steering system as

detailed in this Section.

24. Jack the front axle, remove the supports and

lower the vehicle to the ground.

E9610
7–3–10
7 FRONT AXLE & STEERING
55 Series Steering gear

Steering Box
Service tools: 0485022, 0485122

To Remove (Fig.8)
1. Set the front road wheels in the straight
ahead position.

2. 16 to 18 tonne vehicles: Remove clip and

withdraw the shunting pin.
Detach the indicator lenses from the
headlamp grille panel.
Remove retaining screws and nuts, noting
the four inner screws on the tread plate and
withdraw the headlamp grille panel.
3
3. Tilt the cab, see ‘Drivers Handbook’.

4. 16 to 18 tonne vehicles: Remove the four

bolts securing the headlamp bracket to the
pintle cross–member; position the
headlamp/indicator bracket assembly clear
of the steering box.

5. Clean all dirt from around the steering box

and its surrounding area.

6. Suitably reference mark the steering column

lower universal joint in relation to the
centralising mark on the top face of the input
shaft, this will ensure correct alignment of the
steering wheel during refitment.

7. Remove the clamp bolt and slide the steering

column/lower universal joint from the steering
box input shaft.

E9610 7–3–11
 FRONT AXLE & STEERING 7
Steering gear 55 Series

8. Remove the split pin and ball pillar nut

securing the drag–link to the drop arm. Using
tool 0485122, separate the drag–link from the
drop arm; support the drag–link clear of the 1
steering box.

9. Release the clamps securing the hydraulic

pipes to the chassis brackets. Position a
suitable container beneath the steering box,
disconnect the supply and return pipes and
allow the system to drain.

3 10. Suitably support the weight of the steering

box. Remove the steering box mounting bolts
and manoeuvre the steering box from the
vehicle.

CAUTION: Prior to removing the drop arm, the

upper and lower limiter screws MUST be
removed to prevent internal damage to the
steering box.
Note the location of the limiter screws for
subsequent refitment.
2
11. Release the drop arm retaining nut and note
the alignment marks between the sector shaft
and drop arm. Using tool 0485022, release
the drop arm from the taper splines of the
sector shaft; remove the nut and drop arm
020213
from the sector shaft.

12. If a replacement steering box is to be fitted;

remove the adapters.
FIG.7. STEERING BOX LIMITER SCREWS

1. Upper limiter screw

2. Lower limiter screw

E9610
7–3–12
7 FRONT AXLE & STEERING
55 Series Steering gear

3
3

4
8
6

7
020138

FIG.8. STEERING BOX IN POSITION

1. Lower universal joint 4. Clamps 7. Drop arm

2. Mounting bolts 5. Return pipe 8. Steeing box
3. Supply pipe 6. Drag link

E9610 7–3–13
 FRONT AXLE & STEERING 7
Steering gear 55 Series

To Refit
1. If previously removed, fit adapters to the
steering box.

NOTE: If a replacement steering box is being

fitted; remove the upper and lower limiter screws,
noting their locations for subsequent refitment.

2. Centralise the steering box by turning the

input shaft from lock to lock, counting the
number of turns, then turn the shaft back
half the number of turns from one lock.
3 Ensure the reference marks on the input
shaft and housing are aligned, see Fig.9;
this signifies that the steering box is
centralised.

3. Align the corresponding marks between the

drop arm and sector shaft, fit the drop arm
onto the sector shaft and tighten the retaining
nut to the torque quoted in DATA. Stake the
nut into the sector shaft recesses.

2 3 4

7 6 020139

FIG.9. STEERING BOX IN THE CENTRALISED POSITION

1. Input shaft 5. Sector shaft
2. Steering box 6. Sector shaft centralisation mark
3. Input shaft centralisation mark 7. Drop arm alignment mark
4. Alignment mark on casing

E9610
7–3–14
7 FRONT AXLE & STEERING
55 Series Steering gear

4. Refit the limiter screws in their original

locations.

5. Manoeuvre the steering box into position on

the mounting bracket, fit and tighten the
mounting bolts to the torque figure quoted in
DATA.

6. Connect the hydraulic supply and return

pipes to the steering box, then clamp the
pipes to the chassis brackets.

7. Check that the front wheels are in the straight

ahead position. Locate the drag–link ball pillar
3
in the drop arm, fit and tighten the ball pillar
nut to the minimum torque figure quoted in
DATA. If necessary, further tighten the nut to
facilitate the split pin. Do NOT back off the
nut to fit the split pin.

8. Refit the lower universal joint of the steering

column to the input shaft, aligning the
reference marks. Fit and tighten the clamp
bolt to the torque figure quoted in DATA.

9. 16 to 18 tonne vehicles: Refit the

headlamp/indicator bracket assembly to the
pintle cross–member.

10. Lower the cab.

11. 16 to 18 tonne vehicles: Refit the headlamp

grille, tread plate, indicator lenses and
shunting pin.

12. Refill and bleed the power steering system as

detailed in this Section.

E9610 7–3–15
 FRONT AXLE & STEERING 7
Steering gear 55 Series

Adjustable Steering Column

To Remove
1. Set the front road wheels in the straight
ahead position.

2. Remove the steering wheel centre motif; note

the position of the steering wheel bar for
subsequent refitment, then remove the
retaining nut and washer and withdraw the
steering wheel.

3 3. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle, depress the clutch and brake
pedals and withdraw the cover. Refit the
control handle.

4. Detach the protective caps and remove the

retaining screws securing the shroud covers
to the steering column.

5. Partially withdraw the L.H. shroud cover, note

connections, then disconnect the electrical
wires from the glow plug switch. Completely
remove the shrouds from the steering
column.

6. Release the clamp screw and withdraw the

combination switch from the steering column.

7. Push the steering column forward and lock in

position with the adjustment control handle.
Remove the upper universal joint clamp bolt
and separate the telescopic shaft from the
inner column shaft; retain the clamping ring
and spring.

8. Remove the upper circlip, shim and thrust

washer, then withdraw the inner column
downwards from the outer column.

9. Withdraw the bearing from the outer column.

E9610
7–3–16
7 FRONT AXLE & STEERING
55 Series Steering gear

6
1
2
3
4

7 5

8 9
10
3

14
11

13
12
15

16

020140

FIG.10. STEERING COLUMN

1. Upper circlip 7. Inner column 12. Lower universal joint

2. Shim 8. Outer column 13. Adjustment control handle
3. Thrust washer 9. Upper universal joint 14. Clamping ring
4. Bush 10. Support bracket 15. Roller bearing
5. Lower circlip 11. Telescopic shaft 16. Spring
6. Steering wheel

E9610 7–3–17
 FRONT AXLE & STEERING 7
Steering gear 55 Series

To Inspect
1. Inspect the column bush, if defective, remove
the bush using a universal slide
hammer/internal puller.
NOTE: When fitting a new upper bush,
secure the bush in the column with ‘Loctite
270’.

2. Inspect the bearing and inner column; renew

as necessary.

3 To Refit
1. Pack the column bearing with grease, see
DATA, then locate the bearing in the outer
column.

2. Insert the inner column into the outer column,

refit the thrust washer, shim and circlip.
NOTE: If necessary, additional shims can be
used to maintain the steering column
end–float quoted in DATA.

3. Locate the clamping ring on the inner column.

E9610
7–3–18
7 FRONT AXLE & STEERING
55 Series Steering gear

4. Position the spring on the inner column, then

connect the telescopic shaft to the steering
column, tighten the universal joint clamp bolt
to the torque figure quoted in DATA.
NOTE: With the start key removed, rotate the
column until the lock engages, insert the key
but do not turn. The column is now
centralised, recheck that the column universal
joints are centralised (i.e. universal joint
clamp bolts are opposed 180°), realign the
universal joints as necessary.

5. Secure the combination switch to the steering

column.
3
6. Refit the column cover shrouds, ensuring the
glow plug switch electrical connections are
reconnected to their original positions.

7. Remove the steering column adjustment

control handle and fit the pedal cover to the
column bracket. Refit and tighten the control
handle.

8. Fit the steering wheel and tighten the

retaining nut to the torque figure quoted in
DATA. Refit the centre motif.

E9610 7–3–19
 FRONT AXLE & STEERING 7
Steering gear 55 Series

Telescopic Shaft

To Remove
1. Set the front road wheels in the straight
ahead position.

2. Remove the steering wheel centre motif; note

the position of the steering wheel bar for
subsequent refitment, then remove the
retaining nut and washer and withdraw the
steering wheel.

3 3. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle, depress the clutch and brake
pedals and withdraw the cover. Refit the
control handle.

4. Detach the protective caps and remove the

retaining screws securing the shroud covers
to the steering column.

5. Partially withdraw the L.H. shroud cover, note

connections, then disconnect the electrical
wires from the glow plug switch. Completely
remove the shrouds from the steering
column.

6. Remove setscrews securing the column

gaiter and plate to the cab floor.

7. Remove the upper universal joint clamp bolt

and separate the telescopic shaft from the
inner column; retain the spring.

8. Remove the lower universal joint clamp bolt,

compress and pass the telescopic shaft up
through the cab floor aperture.

9. Check condition of the gaiter and renew if

necessary.

E9610
7–3–20
7 FRONT AXLE & STEERING
55 Series Steering gear

To Refit
Reverse removal procedure, noting:

1. Ensure the universal joints are correctly

aligned (i.e. the universal joint clamp bolts are
opposed 180°).

2. Tighten the universal joint clamp bolts to the

torque figure quoted in DATA.

E9610 7–3–21
 FRONT AXLE & STEERING 7
Steering gear 55 Series

BLEEDING THE POWER STEERING SYSTEM

Bleeding Procedure
1. Chock the rear road wheels.

2. Jack the front axle until the road wheels are

just clear of the ground and position suitable
supports beneath the front axle.

3. Fill the power steering reservoir with the

correct specification hydraulic fluid until the
fluid level registers on the maximum level
mark on the reservoir dipstick.

3 4. Start the engine and, with engine at idling

speed, turn the steering wheel from lock to
lock whilst an assistant maintains the correct
fluid level in the reservoir; continue turning
the steering wheel until the fluid levels
remains constant.

5. Stop the engine, remove the supports from

the front axle and lower the vehicle to the
ground.

6. Re–start the engine and re–check the

hydraulic fluid level; top–up as necessary.

E9610
7–3–22
7 FRONT AXLE & STEERING
55 Series Steering gear

FAULT FINDING BASIC CHECKS

Hydraulic
1. Ensure an adequate level of hydraulic fluid is
maintained in the system at all times and is
free from air.

Mechanical
1. Drag–link and track–rod should have
rotational movement in any position.

2. Swivel pins should be adequately greased for

ease of movement.

3. Check steering geometry is correct.

3
4. Check steering gear free play. The figure
quoted is measured at the rim of the steering
wheel and relates to the movement of the
steering wheel, relative to the shift in position
of the drop arm:

Free play . . . . . . . . . . . 40 mm (1.57 in) Max.

This test must be conducted with the engine

running, steering in the straight ahead
position and wheels on the ground.

Insert a suitable pressure gauge into the

pressure line of the steering system, with the
engine running at 1 000 rev/min turn the
steering wheel, a 1 bar pressure rise above
normal line pressure must not exceed 40 mm
(1.57 in) free play. If free play exceeds the
figures quoted and cannot be reduced
sufficiently by external adjustments then the
steering gear will have to be replaced.

E9610 7–3–23
 3
Steering fluid leaks
Engine oil in steering fluid
Air in steering fluid
Steering noisy
Steering wheel kick on poor roads
Steering wheel vibration
Steering box knock
Self centering unsatisfactory
Steering wander
Steering heavy if wheel is turned fast
Steering heavy - one lock
Steering heavy - both locks
STEERING COMPLAINT

Steering gear
7–3–24

FAULT DIAGNOSIS CHART

FRONT AXLE & STEERING

MECHANICAL FAULTS
Incorrect wheel balance
Incorrect tyre pressure
Faulty steering linkage
Faulty column linkage
Faulty pump drive
Hydraulic pipe damaged
Steering box or drop arm loose
HYDRUALIC FAULTS
Air in fluid
Blocked filter
Delivery line faulty
Return line faulty
Faulty steering pump or valves
High s/box internal leakage
Steering box worn
Faulty rocker shaft adjustment
Steering box hydraulic centre faulty
Pump seal faulty

55 Series
Limiting valve faulty
E9610

Pipe connections faulty

020148

Steering box seals faulty

7
7 FRONT AXLE & STEERING
55 Series Contents

CONTENTS Page Date

SECTION 4—POWER STEERING SYSTEM

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—4—1 . . . . . . . . . 9610
Overhaul:
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—4—11 . . . . . . . . 9610
Removal and Refitment:
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—4—2 . . . . . . . . . 9610
Testing:
Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—4—5 . . . . . . . . . 9610
Fault Diagnosis Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—4—10 . . . . . . . . 9610
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—4—1 . . . . . . . . . 9610

E9610 1
4

E9610
2
7 FRONT AXLE & STEERING
55 Series Power steering system

4. POWER STEERING SYSTEM

DATA

Steering Box
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF 8095 and 8098
Maximum internal leakage . . . . . . . . . . . . . . . . . . . 2,5 l/min
Pressure relief valve setting . . . . . . . . . . . . . . . . . . 150 to 160 bar

Power Steering Pump

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF 2–Line
Nominal controlled flow . . . . . . . . . . . . . . . . . . . . . . 12,6 to 16,41 l/min
Nominal displacement . . . . . . . . . . . . . . . . . . . . . . . 21, l/min at 1 000 rev/min
Maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 160 bar

Torque Tightening Figures

Steering pump retaining bolts . . . . . . . . . . . . . . . . .
Nm
46 to 58
lbf ft
34 to 43 4
WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE VEHICLE, BOTH BATTERY LEADS MUST BE
DISCONNECTED TO PREVENT ACCIDENTAL OR INADVERTENT STARTING OF THE ENGINE.

2. BEFORE ATTEMPTING TO JACK THE VEHICLE, ENSURE THE FOLLOWING:

— THE COMPLETE VEHICLE IS ON STABLE LEVEL GROUND.
— THE HANDBRAKE IS APPLIED TO THE PARK POSITION AND CHOCKS HAVE BEEN
POSITIONED BENEATH THE ROAD WHEELS.
— DO NOT USE THE JACK AS THE SOLE MEANS OF SUPPORT.

3. HYDRAULIC FLUID IS A TOXIC SUBSTANCE WHICH MUST NOT BE CONSUMED OR

ALLOWED TO COME INTO SKIN CONTACT; IN THE EVENT OF SLIGHT SKIN CONTACT,
INGESTION OR INHALATION SEEK MEDICAL ATTENTION IMMEDIATELY.

4. DO NOT RUN THE ENGINE IN A CONFINED SPACE OR UNVENTILATED AREA. EXHAUST

FUMES CONTAIN TOXIC GASES WHICH, IF INHALED, MAY PROVE FATAL.

E9610 7–4–1
 FRONT AXLE & STEERING 7
Power steering system 55 Series

REMOVAL AND REFITMENT

Power Steering Pump

To Remove
1. Tilt the cab, see ‘Drivers Handbook’. 1

2. Clean dirt from around the pump and

surrounding area.

3. Disconnect the supply hose and delivery pipe

from the power steering pump and allow the
hydraulic fluid to drain into a suitable
container; fit protective plugs to all pipes and
adapters to prevent dirt ingress.

4. Remove bolts securing the power steering

pump to the compressor. Detach the power
4 steering pump, complete with the coupling
drive disc and O–ring seal. 3
2
5. Remove any pipe adapters as necessary and
discard the O–ring seal.

6. Clean the joint faces of the compressor and

steering pump.

020142

FIG.1. POWER STEERING PUMP REMOVAL

1. Retaining bolt
2. Supply hose
3. Delivery pipe

E9610
7–4–2
7 FRONT AXLE & STEERING
55 Series Power steering system

To Refit
Reverse removal procedure, noting:

1. Fit a new O–ring seal to the power steering

pump.

2. Ensure the coupling drive disc is correctly

located on the compressor driving spigots
and that the tangs of the steering pump shaft
are correctly located in the coupling drive
disc.

3. Tighten the steering pump bolts to the torque

figure quoted in DATA.

4. Refill and bleed the power steering system as

detailed in Section 3. 4

E9610 7–4–3
 FRONT AXLE & STEERING 7
Power steering system 55 Series

1 2
12

11

8 9 10

4 7
30 40
20 30 3
20

10 40
50

0
10

0 6 8
10
60

30 40
20

OFF
50

RESET
10

TEMP
60

0 HI
LOW
VOLT BATTERY

6 5
4

020141

FIG.2. TESTING THE POWER STEERING SYSTEM USING TEST UNIT 0484852

1. Reservoir 7. Steering box

2. Test hose 8. Flow meter
3. Needle valve assembly (0484857) 9. Test unit (0484852)
4. Loading valve 10. Power steering pump
5. Pressure gauge 11. Return pipe
6. Test hoses (0484853) 12. Supply pipe

E9610
7–4–4
7 FRONT AXLE & STEERING
55 Series Power steering system

TESTING

Power Steering System (Fig.2)

Service tools: 0484852, 0484853, 0484857

1. Before installing test unit 0484852 into the

hydraulic system the following preliminary
inspection of the system should be carried
out:
— Check/top–up the power steering
hydraulic fluid level.
— Check all hydraulic lines for leaks; if
necessary, bleed the hydraulic system to
ensure it is free from air.
— Before disconnecting hydraulic lines on
the vehicle, ensure that all areas around
the connection points are thoroughly
clean. When disconnecting the hydraulic
4
lines from the test unit, do not allow any
contaminate to enter the hydraulic
system or test unit.

2. Fit adapters to the ports in 0484852; the

filtered adapter (detail 2 of 0484852) MUST
be fitted to the port marked ‘INLET’.

3. Fit needle valve assembly 0484857 to the

inlet port of the test unit; connect the return
test hose to the needle valve and secure the
opposite end of the hose in the power
steering reservoir.

4. Connect the high pressure hoses 0484853

between the power steering pump and test
unit and steering box and test unit. Ensure
that the feed line from the steering pump is
connected to the needle valve.

5. Top–up the power steering reservoir with

clean hydraulic fluid.

E9610 7–4–5
 FRONT AXLE & STEERING 7
Power steering system 55 Series

6. Check the operation of the test unit 0484852

noting the following:
— Check that the flow meter on the test
unit registers zero with the switch in the
‘OFF’ position.
— Check the condition of the battery by
turning the switch to the ‘B’ test and then
observing the meter; the gauge pointer
should register past the ‘B’ indication on
the meter. If the gauge pointer fails to
pass the ‘B’ indication, the battery in the
test unit must be renewed.
— Set the switch to the ‘HIGH’ flow
position.
4 — Fully open the loading valve.

7. Jack and suitably support the front axle, start

the engine and, with the aid of an assistant to
ensure the hydraulic fluid level in the reservoir
is maintained, turn the steering from lock to
lock to bleed the hydraulic system.

8. Set the switch on the test unit to the ‘TEMP’

position and note the hydraulic fluid
temperature; the correct temperature should
read 45° to 55°C. To increase the
temperature of the hydraulic fluid, allow the
engine to idle, then partially close the loading
valve on the test unit until a pressure reading
of 45 bar is attained, maintain this condition
until the correct temperature is achieved.

9. Before commencing the power steering test,

note the specified power steering pump
nominal flow, steering box maximum
pressure setting and maximum permissible
internal leakage as specified in DATA.

E9610
7–4–6
7 FRONT AXLE & STEERING
55 Series Power steering system

10. Systematically following the ‘FAULT

DIAGNOSIS TEST SEQUENCE’ at the end
of this Section, commence the power
steering tests to determine a power steering
fault in either the power steering pump or
steering box.

CAUTION: All readings MUST be taken within a

period of ten seconds; periods in excess of ten
seconds will cause excessively high temperatures
in the hydraulic fluid/power steering pump which
will result in inaccurate test readings.

11. Nominal Flow Test

With the loading valve of test unit 0484852
fully open and the needle valve of 0484857
closed, run the engine at 1 000 rev/min and
observe the flow meter. Compare the reading
4
taken with the nominal flow quoted in DATA.
NOTE: Switch the test unit to the ‘LOW’ flow
position if the nominal flow is less than 16
l/min.

12. Power Steering Pump Pressure Test

CAUTION: To prevent damage to the power
steering pump and test unit, do NOT exceed
the pump maximum pressure quoted in
DATA whilst carrying out this test.

— Note the power steering pump maximum

pressure quoted in DATA.
— Ensure that the needle valve of 0484857
is closed and the loading valve on the
test unit is fully open.
— With the engine running at 1 000
rev/min, slowly close the loading valve
and observe the reading on the pressure
gauge; do NOT exceed the maximum
pump pressure quoted in DATA.

E9610 7–4–7
 FRONT AXLE & STEERING 7
Power steering system 55 Series

13. Power Steering System Test

— Ensure that the needle valve of 0484857
is closed and the loading valve on the
test unit is fully open.
— With the engine running at 1 000
rev/min, turn the steering to full lock and
apply a constant load of 222 N (50 lbf)
on the rim of the steering wheel.
Observe the reading on the pressure
gauge of the test unit.
— Repeat the test on the opposite lock.
Compare the pressure readings
recorded against the pressure quoted in
DATA.

4 14. Internal Leakage Test

— Ensure that the needle valve of 0484857
is closed and the loading valve on the
test unit is fully open.
— With the engine running at 1 000
rev/min, turn the steering to full lock until
maximum system pressure registers on
the test unit pressure gauge. In this
condition, open the needle valve to
achieve a pressure drop of 20 to 30 bar,
then relax the steering from the full lock
position.
— Turn the steering back onto full lock and
apply a constant load of 222 N (50 lbf)
on the rim of the steering wheel; this
load must NOT be relaxed at any time
during the test. Observe the reading on
the flow meter and compare this reading
with the maximum internal leakage
quoted in DATA.
— Repeat the test on the opposite lock.

E9610
7–4–8
7 FRONT AXLE & STEERING
55 Series Power steering system

15. Hydraulic Centre Test

— Jack and suitably support the front axle,
ensure that the road wheels are in the
straight ahead position.
— Start the engine and observe the
steering wheel, if the hydraulic centre is
correct there should be no self–motoring
of steering wheel (i.e. the steering wheel
should not turn left or right unaided). If
the steering wheel does self–motor then
the steering box must be renewed.

16. On completion of tests, remove the steering

test unit and reconnect all hydraulic pipes.
Top–up the power steering reservoir with
clean hydraulic fluid and bleed the power
steering system. Check all connections in the
4
steering line for leaks; rectify as necessary.
Lower vehicle to ground.

17. Seal the test unit and hoses with the plastic
caps provided.

E9610 7–4–9
 FRONT AXLE & STEERING 7
Power steering system 55 Series

FAULT DIAGNOSIS TEST SEQUENCE

(Using Test Unit 0484852)

Power Steering
Fault

Connect Test
Equipment into
Power Steering
System

Carry out
‘Nominal Flow
Test’

4
Nominal flow as Carry out ‘Power
specified in DATA Steering Pump No flow or low
Pressure Test’ flow

Pressure as No pressure or
quoted in low pressure
DATA—Power
steering pump OK

Carry out ‘System Low pressure

Pressure Test’ achieved Check power Check power
steering pump steering pump
flow control valve; flow control valve;
Check steering repeat test repeat test
Full pressure
achieved box relief valve;
repeat test

Carry out ‘Internal

Leakage Test’ Fault still exists Fault still exists Fault still exists

Internal leakage Internal leakage Renew power Renew power

below maximum above the steering pump steering pump
quoted figure in maximum quoted
DATA figure in DATA

Steering box OK Renew steering

box

E9610
7–4–10
7 FRONT AXLE & STEERING
55 Series Power steering system

OVERHAUL

Power Steering Pump

Service tools: 694968, 694969, 694970

To Dismantle (Fig.3)
NOTE: Thoroughly clean the exterior of pump
prior to dismantling, ensuring that foreign matter
does not enter the inlet or outlet ports. Always
work on a clean surface under conditions of
maximum cleanliness.

1. Remove pump, as instructed in Section 4.

2. Remove snap–ring (24) securing end cover

(23), then remove spring (21), O–ring (22),
front plate (cover–end) (20), O–ring (19), cam
ring (18) and rotor (16) complete with vanes
(17). 4
3. Invert pump and release circlip (3). Using a
hide mallet, remove drive shaft (2) complete
with radial bearing (4) from the housing (8).
Using a soft metal drift, remove front plate
(drive–end) (15). Remove and discard O–ring
(13). If fitted, remove plug (9) and sealing ring
(10).

4. Carefully remove the plug (25) and sealing

ring (26) and withdraw spring (27) and flow
control valve (28).

5. Using tool 694968, remove needle roller

bearing (7) and oil seal (6).

6. Remove O–ring (12) from radial groove in

pump housing (8) and fitted pin (11) through
the drive–end of the pump housing (8).

E9610 7–4–11
 FRONT AXLE & STEERING 7
Power steering system 55 Series

To Inspect
1. Wash all components in a suitable solvent
and dry thoroughly.

2. Check all components for visible signs of

wear or distortion. Any suspect components
must be replaced. The pump rotor, cam ring
and vanes must be replaced together. Check
drive shaft for scoring, closely examining the
splines for malformation.

3. Check needle bearing for wear or pitting.

Check drive–end and cover–end front plates
for scoring or pitting. Examine rotor, running
surface of vanes and cam ring for wear or
scoring. Check flow control valve and parent
4 bore for damage. Ensure flow control valve
moves freely in the bore.

E9610
7–4–12
7 FRONT AXLE & STEERING
55 Series Power steering system

9
11 17
10

24
22 23
21
19 20
16 18
15
12 13
14
6 7
5
2
3
4 8
28
4
1

27
26
25 020212

FIG.3. EXPLODED VIEW OF STEERING PUMP (Typical illustration)

1. Drive plate 11. Fitted pin 21. Spring

2. Drive shaft 12. O–ring 22. O–ring
3. Circlip 13. O–ring 23. Cover
4. Radial bearing 14. Throttle insert 24. Snap ring
5. Snap ring 15. Front plate (drive–end) 25. Plug
6. Oil seal 16. Rotor 26. Sealing ring
7. Needle bearing 17. Vane 27. Spring
8. Housing 18. Cam ring 28. Flow control valve
* 9. Plug 19. O–ring
*10. Sealing ring 20. Front plate (cover–end)

* When fitted

E9610 7–4–13
 FRONT AXLE & STEERING 7
Power steering system 55 Series

To Reassemble
NOTE: Prior to reassembly, lubricate all
components with clean hydraulic fluid.

1. Lightly lubricate control valve with clean

hydraulic fluid and insert in housing bore. Fit
spring, plug and seal.
2. Using tool 694970 press needle bearing (7)
into housing.
3. Lubricate new oil seal (6) with suitable
bearing grease, then using tool 694970,
press oil seal into housing (8).
4. If fitted, fit a new sealing ring (10), and
tighten plug (9).
4 5. Insert a new O–ring (12) into the inner radial
groove of pump housing (8). Insert fitted pin
(11) in bore inside housing (8).
6. If removed, press radial bearing (4) onto drive
shaft (2) and fit snap ring (5). To prevent
damage to the seal (6), position sleeve
694969 over the drive shaft, then insert shaft
and bearing into housing (8). Fit retaining
circlip (3).
7. Insert O–ring (13) into radial groove of
drive–end front plate (15). Fit plate (15) into
housing (8) with fitted pin (11) protruding
through aperture in drive–end front plate (15).

E9610
7–4–14
7 FRONT AXLE & STEERING
55 Series Power steering system

8. Fit O–ring (19) in outer radial groove of

housing, insert cam ring (18) with fitted pin
(11) locating in the smaller hole of the cam
ring (18).
9. Position rotor (16), smooth bore first, onto the
drive shaft (2). Insert the vanes (17), with
rounded outer faces towards the cam ring
(18), into the slots of the rotor (16).
10. Position cover–end front plate (20) against
the cam ring (18) so that the fitted pin (11) is
locating in one of the two smaller holes.
11. Insert O–ring (22) in the housing (8), position
pressure spring (21) in the bore of the
cover–end front plate (20) and insert cover
(23) with recess facing inwards. Press cover
(23) into housing and fit snap–ring (24).
4
12. Refit pump as instructed in Section 4.

E9610 7–4–15
 FRONT AXLE & STEERING 7
Power steering system 55 Series

E9610
7–4–16
7 FRONT AXLE & STEERING
55 Series Contents

CONTENTS Page Date

SECTION 6—STEERING LINKAGE

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—6—1 . . . . . . . . . 9610
Checking Drag–link/Track–rod Ball Joint Lift . . . . . . . . . . . . . . . . . . . . . . . . 7—6—6 . . . . . . . . . 9610
Front Wheel Alignment – Checking and Adjusting . . . . . . . . . . . . . . . . . . . 7—6—8 . . . . . . . . . 9610
Wheel Lock–stops – Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . 7—6—10 . . . . . . . . 9610
Removal and Refitment:
Drag–link Ball Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—6—4 . . . . . . . . . 9610
Track–rod Ball Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—6—2 . . . . . . . . . 9610
Overhaul:
Ball Joints—Self Adjusting Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—6—11 . . . . . . . . 9610
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7—6—1 . . . . . . . . . 9610

E9610 1
6

E9610
2
7 FRONT AXLE & STEERING
55 Series Steering linkage

6. STEERING LINKAGE
DATA

Drag–link/Track–rod ball joint lift . . . . . . . . . . . . . . 2,03 mm (0.080 in) maximum

Front wheel alignment . . . . . . . . . . . . . . . . . . . . . . Parallel to 1,6 mm (0.062 in) Toe–in

Steering lock angles:

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38°
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50°

Torque Tightening Figures Nm lbf ft

F56 Axle:
Drag–link ball joint clamp bolt . . . . . . . . . . . . 80 to 95 60 to 70
Drag–link ball pillar nut . . . . . . . . . . . . . . . . . . 200 to 240 148 to 178
Track–rod ball joint clamp bolts . . . . . . . . . . 54 to 81 40 to 60
Track–rod ball pillar nut . . . . . . . . . . . . . . . . . 220 to 300 162 to 221
F71 Axle:
Drag–link ball joint clamp bolt . . . . . . . . . . . . 80 to 95 60 to 70
Drag–link ball pillar nut . . . . . . . . . . . . . . . . . . 200 to 240 148 to 178
Track–rod ball joint clamp bolt . . . . . . . . . . . 61 to 81 45 to 60
Track–rod ball pillar nut . . . . . . . . . . . . . . . . . 176 to 244 130 to 180
6
WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE VEHICLE, BOTH BATTERY LEADS MUST BE
DISCONNECTED TO PREVENT ACCIDENTAL OR INADVERTENT STARTING OF THE ENGINE.

2. BEFORE ATTEMPTING TO JACK THE VEHICLE, ENSURE THE FOLLOWING:

— THE COMPLETE VEHICLE IS ON STABLE LEVEL GROUND.
— THE HANDBRAKE IS APPLIED TO THE PARK POSITION AND CHOCKS HAVE BEEN
POSITIONED BENEATH THE ROAD WHEELS.
— DO NOT USE THE JACK AS THE SOLE MEANS OF SUPPORT.

E9610 7–6–1
 FRONT AXLE & STEERING 7
Steering linkage 55 Series

REMOVAL AND REFITMENT

Track–rod Ball Joints

Service tool: 0485122

To Remove
1. Set the road wheels in the straight ahead
position and chock the rear road wheels.

2. Slacken the road wheel nuts, jack and

suitably support the front axle. Remove the
wheel nuts and withdraw the road wheel.

3. Remove split pin and ball pillar nut. Using tool

0485122, separate the ball joint from the
track–rod lever.

4. Slacken the ball joint clamp bolt(s), then

unscrew the ball joint from the track–rod.

E9610
7–6–2
7 FRONT AXLE & STEERING
55 Series Steering linkage

To Refit
1. Screw the ball joint on to the track–rod until
the ball pillar aligns with the track–rod lever
taper.
NOTE: If both ball joints have been removed,
adjustment must be made equally at the ball
joint housings at either end of the track–rod.

2. Locate the ball pillar(s) in the track–rod

lever(s), fit and tighten the ball pillar nut(s) to
the minimum torque figure quoted in DATA. If
necessary, further tighten the nut to facilitate
the split pin. Do NOT back off nut to fit the
split pin.

3. Refit the road wheel(s) and wheel nuts, but

do not torque tighten at this stage.

4. Raise the vehicle, remove the supports and

lower the vehicle to the ground. Tighten the
road wheel nuts to the correct torque and in
the correct sequence as detailed in the
‘Maintenance Manual’.

5. Check, and if necessary, adjust the front

6
wheel alignment as instructed in this Section.

6. When front wheel alignment is correct,

tighten the ball joint clamp bolt(s) to the
torque figure quoted in DATA.

E9610 7–6–3
 FRONT AXLE & STEERING 7
Steering linkage 55 Series

Drag–link Ball Joints

Service tool: 0485122

To Remove
1. Set the road wheels in the straight ahead
position and chock the rear road wheels.

2. Remove split pin and ball pillar nut. Using tool

0485122, separate the ball pillar from the
steering lever or drop arm.

3. Slacken the clamp bolt, then remove the ball

joint from the drag–link, noting the
approximate position of the ball joint for
subsequent refitment.

E9610
7–6–4
7 FRONT AXLE & STEERING
55 Series Steering linkage

To Refit
1. Ensure the road wheels are set in the straight
ahead position.

2. Centralise the steering drop arm by counting

the number of turns made by the steering
wheel when turning from lock to lock. Rotate
the steering wheel back exactly half the
number of turns from one lock.

3. Smear the ball joint and drag–link threads

with grease. Screw the ball joint into the
drag–link until the ball pillar aligns with the
steering lever or drop arm taper.
NOTE: If both ball joints have been removed,
adjustment must be made equally at the ball
joint housing at either end of the drag–link.

4. Locate the ball pillar in the steering lever/drop

arm, refit and tighten the ball pillar nut to the
minimum torque figure quoted in DATA. If
necessary, further tighten the nut to facilitate
the split pin. Do NOT back off nut to fit the
split pin. 6
5. Turn the steering wheel from lock to lock to
check that the stub axle contacts the axle
lock stops.

6. Tighten the ball joint clamp bolt to the torque

figure quoted in DATA.

E9610 7–6–5
 FRONT AXLE & STEERING 7
Steering linkage 55 Series

Checking Drag–link/Track–rod Ball Joint Lift 2

Service tool: 0485211
1 3
To Check
NOTE: Service tool 0485211, must only be used 4
to check ‘Sealed for Life’ ball joints and NOT
‘Adjustable’ ball joints. If the ball joint rubber gaiter 5
is damaged, the ball joint must be renewed.

1. Chock the rear road wheels.

A

2. Jack the front axle until the road wheels are

clear of the ground; position suitable supports 6
beneath the axle beam.

3. Clean the ball joint and ensure that the ball 7

pillar nut split pin is clear of the top face of
the ball pillar. 8

4. Turn the steering wheel to place the relevant

ball joint in an optimum vertical position and
to give sufficient clearance to fit and operate
the tool.
6 5. Check the ball joint(s) as follows:

‘Concave’ Head Type

9
— Screw the thrust cap, detail 10 of tool
0485211, onto the adjusting screw. Insert 020144
the collet, spring and thrust pad, detail 6
of tool 0485211, in the frame, aligning
the slot on the thrust pad with the hole in FIG.1. ‘CONCAVE’ HEAD BALL JOINT
the tool. Secure the thrust pad in position Service Tool 0485211
with the setscrew. Check the thrust pad 1. Frame
moves freely, slacken the setscrew
accordingly. 2. Thrust screw
3. Collet
4. Spring
5. Setscrew
6. Thrust pad (detail 6)
7. Ball joint
8. Thrust cap (detail 10)
9. Adjusting screw

A—2,03 mm (0.080 in) maximum

E9610
7–6–6
7 FRONT AXLE & STEERING
55 Series Steering linkage

— Turn the thrust screw anti–clockwise until

2
the thrust pad abuts the face of the tool.
1
— Locate the tool on the ball joint as shown 3
in Fig.1. Tighten the adjusting screw,
using hand pressure only, until the thrust
pad firmly engages the face of the ball 4
joint.
— Fully tighten the thrust screw, then using A
feeler gauges check the clearance ‘A’
between the thrust pad and tool body.
NOTE: Renew the ball joint if the 5
clearance exceeds 2,03 mm (0.080 in)
maximum.

‘Convex’ Head Type

— Assemble the tool 0485211 as shown in
Fig.2, ensuring that the correct thrust
pad and thrust cap are selected, then
repeat the checking procedure as
detailed for the ‘Concave’ head ball joint. 6

7
6
020145

FIG.2. ‘CONVEX’ HEAD BALL JOINT

Service Tool 0485211

1. Frame
2. Thrust screw
3. Collet
4. Spring
5. Thrust cap (detail 5)
6. Ball joint
7. Thrust pad (detail 7)

A—2,03 mm (0.080 in) maximum

E9610 7–6–7
 FRONT AXLE & STEERING 7
Steering linkage 55 Series

Front Wheel Alignment—Checking and

Adjusting
NOTE: For the necessary accuracy required it is
recommended that proprietary optical or dynamic
alignment equipment is used and that in all cases
the manufacturer’s instructions and
recommendations are followed. It is also
recommended that the wheel alignment is
checked with the vehicle in an unladen condition.

1. Ensure that all the tyres are inflated to the

correct pressure, see ‘Drivers Handbook’,
and that the vehicle is standing on level, grit 020146
free ground.

2. Set the front wheels to the straight ahead FIG.3. TYPICAL OPTICAL WHEEL
position by equalising tyre to road spring ALIGNMENT GAUGE
dimension at both sides of the vehicle. To Arrow indicates front of vehicle
enable the steering linkage and suspension
to adopt their normal operating positions, roll
the vehicle forward (NOT rearward) a
minimum of one complete revolution of the
road wheels.
6

E9610
7–6–8
7 FRONT AXLE & STEERING
55 Series Steering linkage

3. Using suitable optical or dynamic alignment

equipment, determine the front wheel
alignment. Front wheel alignment should be
parallel to 1,6 mm (0.062 in) toe–in; there
must be no toe–out. If adjustment is required
slacken the track–rod ball joint clamp bolt(s)
and rotate the track–rod in the appropriate
direction until the correct alignment is
achieved. Repeat the front wheel alignment
check and, when correct, tighten the
track–rod ball joint clamp bolt(s) to the torque
figure quoted in DATA.

TOE OUT TOE IN

P
ALERFE M
IM U C E
IG N C T
IME MAXERAN
NT T OL

020147

FIG.4. TYPICAL DYNAMIC WHEEL

ALIGNMENT GAUGE

E9610 7–6–9
 FRONT AXLE & STEERING 7
Steering linkage 55 Series

Wheel Lock–stops—Checking and Adjusting

The wheel lock–stops are set by the manufacturer
when the vehicle is built and this setting must not
be altered. If, however, it is found necessary at
some time to check or readjust this setting the
use of graduated weaver plates must be adopted
and, the following procedure carried out:

1. Check the front wheel alignment; adjust as

necessary.

2. With the front wheels placed on the weaver

plates operate the steering towards the
right–hand lock. When the left–hand wheel
reaches the desired angle set the right–hand
lock–stop. The procedure for setting the
left–hand lock–stop is the opposite to the
above procedure. See DATA for steering
angles.
CAUTION: When setting the lock–stops
ensure that the wheel or components
attached to the stub axle do not foul the axle
or suspension components attached to the
6 chassis.

E9610
7–6–10
7 FRONT AXLE & STEERING
55 Series Steering linkage

OVERHAUL

Ball Joints—Self–Adjusting Type

To Dismantle
1. Remove the ball joint as detailed in this
Section.

2. Release the retainer and withdraw the rubber

gaiter.

3. Release the tab washer and remove the top

cover.

4. Remove the spring and unscrew the adjuster

from the housing; withdraw the top socket
and ball pillar.

5. Remove the top socket locating pin and

press the bottom socket from the housing.

Inspection
1. Examine the ball pillar top and bottom
sockets for wear or damage; renew as
necessary.
FIG.5. EXPLODED VIEW OF 6
2. Check that the rubber gaiter is in good SELF–ADJUSTING BALL JOINT
condition. If torn or perished the gaiter must
be renewed; a defective gaiter will allow entry 1. Top cover
of moisture and foreign matter, causing early 2. Tab washer
failure of the assembly. 3. Spring
3. Ensure that the threads of the adjuster and 4. Adjuster
the mating threads in the housing are clean 5. Top socket
and free from damage. The threads should 6. Ball pillar
be cleaned as necessary, imperfect threads
will impede the downward travel of the 7. Bottom socket
adjusting cap and render the self–adjusting 8. Ball joint housing
property ineffective. 9. Retainer
10. Rubber gaiter

E9610 7–6–11
 FRONT AXLE & STEERING 7
Steering linkage 55 Series

To Reassemble
1. Press the bottom socket into the housing and
refit the top socket locating pin.

2. Lightly smear the ball pillar and top and

bottom sockets with grease.

3. Locate the ball pillar and top socket in the

housing. Screw the adjuster into the housing
until a light pre–load is applied to the ball
pillar, ensuring the ball pillar articulates freely
in all planes under normal finger pressure.

4. Locate the centre leg of the tension spring

across two of the slots in the adjuster. Rotate
the outer leg of spring in a clockwise direction
and insert the leg into the nearest hole in the
housing. If the spring is then under only light
tension, locate the outer leg in the next hole.

5. Fit the tab washer and top cover. Tighten the

cover securely and retain in position with the
tabs of the washer.
6 6. Refit the rubber gaiter, ensuring that the
gaiter retainer is correctly located.

E9610
7–6–12
5 SUB DIVISION
55 Series

0
GENERAL INFORMATION
FAULT DIAGNOSIS 1
BATTERIES
2
CHARGING SYSTEM
3
STARTING SYSTEM
4
INSTRUMENT PANEL
5
ELECTRIC WINDOWS
6
CIGAR LIGHTER
7
FUEL PUMP SOLENOIDS
8
TACHOGRAPH
9
HORN
10
VEHICLE LIGHTING
11
AIR DRYER, HEATED FUEL SEDIMENTER AND HEATED MIRRORS
12
RADIO ELECTRICAL CIRCUITS
RELAYS 13
DIRECTION INDICATORS AND HAZARD WARNING LIGHTS
14
E9612
5 SUB DIVISION
55 Series

CARGO AREA LIGHT

15
COURTESY LIGHTS
16
PRE–GLOW SYSTEM
17
HEATER MOTOR
18
WINDSCREEN WIPERS AND WASHERS
19
ANTI–LOCK BRAKING SYSTEM (ABS)
20
ELECTRONICALLY CONTROLLED AIR SUSPENSION (ECAS)
21
ROAD SPEED LIMITER
22

E9612
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 1—GENERAL INFORMATION

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—1—1 . . . . . . . . . 9612
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—1—2 . . . . . . . . . 9612
Replacement Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—1—6 . . . . . . . . . 9612
Vehicle Wiring Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—1—8 . . . . . . . . . 9612 1
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—1—10 . . . . . . . . 9612
Vehicle Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End of Section . . . . 9612

SECTION 1A—FAULT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—1A—1 . . . . . . . . 9612

E9612 1
1

E9612
2
5 ELECTRICAL SYSTEM
55 Series General information

1. GENERAL INFORMATION
DATA

Voltage:
Vehicle electrical system . . . . . . . . . . . . . . . . 24V (nominal)
Radio power supply . . . . . . . . . . . . . . . . . . . . 12V
Cigar lighter supply . . . . . . . . . . . . . . . . . . . . . 24V (standard) or 12V (option)

Circuit polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative earth 1

Electrical storage system . . . . . . . . . . . . . . . . . . . . Two 12V ‘‘Maintenance–Free” batteries

Batteries:
Type:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 663
Heavy duty . . . . . . . . . . . . . . . . . . . . . . . . 655
Cold cranking:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 825
Heavy duty . . . . . . . . . . . . . . . . . . . . . . . . SAE 880
Reserve capacity:
Standard battery . . . . . . . . . . . . . . . . . . . 25 amps for 200 minutes
Heavy duty battery . . . . . . . . . . . . . . . . . 25 amps for 210 minutes

Starter motor:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prestolite
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 kW

Alternator:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magneti Marelli or Prestolite
Output (at 6000 rpm):
Magneti Marelli . . . . . . . . . . . . . . . . . . . . 35 amps
Prestolite . . . . . . . . . . . . . . . . . . . . . . . . . . 55 amps

E9612 5–1–1
 ELECTRICAL SYSTEM 5
General information 55 Series

CIRCUIT PROTECTION

General Information
The vehicle electrical circuits are protected by
blade type fuses. Standard circuit fuses are
located in the LH and RH instrument panel fuse

1 boxes. Specialised circuit fuses are located in

the following positions:

— Cab front RH bulkhead panel (RSL primary

fuse).
— Cab LH rear bulkhead panel (ABS ECU
power supply).
— Instrument panel R.H. printed circuit board
(ECAS enable supply).

WARNING:
— To avoid overloading the electrical
circuits and the subsequent possibility
of fire, do NOT fit a fuse that exceeds
the recommended rating.

— Repeated failure of the same fuse

indicates a circuit fault which MUST be
investigated and rectified.

Each blade type fuse is colour coded to identify

its amperage rating as follows:

— Violet (5 amp)
— Red (10 amp)
— Blue (15 amp)
— Yellow (20 amp)
— Transparent (25 amp)

E9612
5–1–2
5 ELECTRICAL SYSTEM
55 Series General information

Instrument Panel Fuse Boxes

The fuse boxes are located on either side of the
instrument panel. To gain access to each fuse
box, rotate the quick release fastener using a
suitable implement (a coin or screwdriver) and
then slide the fuse cover downwards. To aid
1 2 3 4 5 6 7 8 1
fuse removal, a fuse extraction tool is attached
to the inside of each fuse box cover.

LH Fuse Box, Fig.1

1. E233 (15A) Direction indicators and
hazard warning
2. E129 (15A) Rear fog lights, courtesy
lights and box van lamp
3. E131 (10A) Headlights (main beam)
4. E132 (10A) Headlights (dipped beam)
5. E043 (25A) ABSI (trailer)
6. E000 (10A) Side lamps (LH), 9 080825
instrument, switch and
tachograph illumination
7. E001 (10A) Side lamps (RH), front FIG.1. INSTRUMENT PANEL FUSE BOX – LH
fog lights and headlight
dim–dip 1. E233 (15A)
8. E032 (15A) Electric windows 2. E129 (15A)
9. — Spare fuses 3. E131 (10A)
4. E132 (10A)
5. E043 (25A)
6. E000 (10A)
7. E001 (10A)
8. E032 (15A)
9. Spare fuses

E9612 5–1–3
 ELECTRICAL SYSTEM 5
General information 55 Series

RH Fuse Box, Fig.2

1. E134 (15A) Windscreen wipers/washers,
heater motor and radio
2. E091 (15A) Air dryer, heated mirrors

1 3. E133 (10A)
and cold start
Reverse lights, stop lights,
1 2 3 4 5 6 7 8
ABS enable and ECAS
power supply
4. E135 (5A) Engine stop solenoid and
road speed limiter
(secondary fuse)
5. E035 (5A) Instruments, warning lights
and tachograph recording
mechanism
6. E030 (10A) Horn and automatic
lubrication
7. E066 (5A) Tachograph (clock)
8. E026 (15A) Cigar lighter and radio 9 081088

(memory supply)
9. — Spare fuses
FIG.2. INSTRUMENT PANEL FUSE BOX – RH

1. E134 (15A)
2. E091 (15A)
3. E133 (10A)
4. E135 (5A)
5. E035 (5A)
6. E030 (10A)
7. E066 (5A)
8. E026 (15A)
9. Spare fuses

E9612
5–1–4
5 ELECTRICAL SYSTEM
55 Series General information

Road Speed Limiter Primary Fuse, Fig.3

The road speed limiter (RSL) primary fuse
E087 (4A) is located on the cab front RH
bulkhead panel.
IMPORTANT: In the event of a circuit failure, the
RSL primary fuse MUST be renewed by an 1
authorised calibration centre.

081089

FIG.3 ROAD SPEED LIMITER PRIMARY FUSE

1. EO78 (4A)

ABS Power Supply Fuses, Fig.4

The ABS electronic control unit (ECU) power
supply relay (G022) and voltage protection relay
(G021) circuits are protected by two 15 amp
fuses (E041 and E042). Both fuses are attached
to the ECU printed circuit board which is located
on the rear LH side of the cab.
NOTE: The ABS enable power circuit is
protected by fuse E133 (10A); this fuse is
located in the RH instrument panel fuse box. 1

2 FUSE

080742

FIG.4. ABS POWER SUPPLY FUSES

1. E041 (15A)
2. E042 (15A)

E9612 5–1–5
 ELECTRICAL SYSTEM 5
General information 55 Series

ECAS Power Enable Fuse, Fig.5

The ECAS power enable circuit is protected by
fuse E051 (10A). This fuse is located on the
rear of the RH instrument panel printed circuit

1 board (pcb).
NOTE: The ECAS power supply circuit is
protected by fuse E133 (10A); this fuse is
located in the RH instrument panel fuse box.

1 2

080892

FIG.5. ECAS POWER ENABLE FUSE

1. Fused battery power supply

2. E051 (10A) ECAS enable supply
3. Spare fuse

E9612
5–1–6
5 ELECTRICAL SYSTEM
55 Series General information

REPLACEMENT BULBS

Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70/75W pre–focus halogen

Sidelights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4W
Cab marker lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3W
Direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Side repeater lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5W
Rear light unit:
1
Rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Reverse light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W
Stop light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21W
Courtesy lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W
Instrument panel illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2W
Warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2W
Switch illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2W
Tachograph illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2W

E9612 5–1–7
 ELECTRICAL SYSTEM 5
General information 55 Series

VEHICLE WIRING IDENTIFICATION

The electrical wiring used on the 55 Series

models is identified using numerical and colour
codes

Cable Numerical Codes

1 With the exception of some earthing cables, all
electrical cables are identified with a four digit
code printed at 50 mm intervals along the
complete length of the cable sheathing.
NOTE: The numerical codes are shown on the
vehicle Wiring Diagram.

Cable Colour Codes

All electrical cables are colour coded to identify
the electrical function of the cable. The colour
codes indicate the following general electrical
functions:

Red — Power supply

Yellow — Lighting
Blue — Warning and indicator functions
Black — Power consumers
White — Earth connections

E9612
5–1–8
5 ELECTRICAL SYSTEM
55 Series General information

The specific electrical function of each cable can

be identified using the following colour codes
and numerical codes chart:

Cable Cable 1
Colour Numerical Electrical Function
Code Code

Red 1000 to 1099 Power supply (voltage

generation)

Red 1100 to 1199 Power supply (before

contact switch)

Red 1200 to 1499 Power supply (after

contact switch)

Yellow 2000 to 2099 Direction

indicators/warning lights

Yellow 2100 to 2599 External vehicle lighting

Yellow 2600 to 2999 Internal vehicle lighting

Blue 3000 to 3399 Engine functions

Blue 3400 to 3999 Vehicle functions

Black 4000 to 4499 Engine start/stop and

pre–glow functions

Black 4500 to 5499 Vehicle functions

Black 5500 to 5999 Automatic transmission

* White 9000 to 9499 Test and signal earthing

* some earthing cables are NOT identified with a

numerical code.

E9612 5–1–9
 ELECTRICAL SYSTEM 5
General information 55 Series

COMPONENT IDENTIFICATION

All electrical and electronic components are

identified throughout this Group using the DAF
alpha–numeric component coding system. The
DAF component codes represent the following

1 electrical components:

A000 to A499 — Plugs/sockets/connectors

A500 to A999 — Batteries/ alternators

B000 to B499 — Motors/valves/electrical units

B500 to B550 — Instruments and gauges

C000 to C500 — Lighting

C501 to C999 — Switches

D000 to D499 — Warning lights

D500 to D599 — Electronic units

D600 to D799 — Diodes

D800 to D899 — Electronic units

E000 to E499 — Fuses

E500 to E999 — Operating switches

F000 to F499 — Control switches

F500 to F999 — Sensors

G000 to G499 — Relays

G500 to G999 — Connectors

E9612
5–1–10
5 ELECTRICAL SYSTEM
55 Series General information

KEY TO WIRING DIAGRAM AND GRID REFERENCE

A000(1). Trailer socket pin 1 (earth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H37

A000(2). Trailer socket pin 2 (LH tail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J23
A000(3). Trailer socket pin 3 (LH indicators) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K7
A000(4). Trailer socket pin 4 (RH stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D20
A000(5). Trailer socket pin 5 (RH indicators) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K13 1
A000(6). Trailer socket pin 6 (RH tail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J27
A001(2). Trailer socket pin 2 (ABSI warning light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H36
A001(3) Trailer socket pin 3 (reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D17
A001(4). Trailer socket pin 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H19
A001(5). Trailer socket pin 5 (earth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H38
A001(6). Trailer socket pin 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C17
A001(7). Trailer socket pin 7 (rear fog) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J14
A004(1). Trailer socket pin 1 (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H36
A004(3). Trailer socket pin (earth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H38
A004(4). Trailer socket pin 4 (ABS negative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H39
A004(5). Trailer socket pin 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H35
A021. Diagnostic test socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H40
A022(3). Accessories pin 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C13
A022(4). Accessories pin 4 (ECAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C14
A023(1). Body builders socket pin 1 (box van light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J17
A023(2). Body builders socket pin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H27
A023(3). Body builders socket pin 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J23
A500. Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4/B5
A509. Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
B000. Windscreen wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5
B001. Windscreen washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4
B003. Electric window motor– driver’s side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E14
B004. Electric window motor– passengers side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E15
B010. Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5
B011. Road speed limiter (RSL) actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C55
B012. Warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B30
B017. Heated mirror (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J20
B018. Heated mirror (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J20
B024. Radio speaker (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E10
B025. Radio speaker (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E10
B028. Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J18
B030. Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8
B034. Resistor, instrument lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G22
B038. Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
B042. Air dryer heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12
B044. Exhaust brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J43
B047. ABS modulator valve, front axle (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J53
B048. ABS modulator valve, rear axle (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J53

E9612 5–1–11
 ELECTRICAL SYSTEM 5
General information 55 Series

B049. ABS modulator valve, rear axle (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H53

B052. ECAS regulator valve, air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C42
B053. ECAS height sensor unit (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C44
B054. ECAS height sensor unit (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C42
1 B103. Engine fuel valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2
B111. ASR valve (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K47
B112. ASR valve (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K47
B145. Heater motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2
B146. ABS modulator valve, front axle (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H53
B147. Fuel sedimenter heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11
B148. Dim–dip resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H32
B149. Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C10
B176. Reversing buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E16
B203. Range–change protection solenoid (9–speed gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . D18
B208. Cross gate protection solenoid (9–speed gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D19
B501. Tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C13
B524. Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B23
C000. Dipped beam (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K33
C001. Dipped beam (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K35
C002. Main beam (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K33
C003. Main beam (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K34
C006. Auxiliary driving light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K30
C007. Auxiliary driving light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K30
C008. Fog lamp, front (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K28
C009. Fog lamp, front (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K28
C010. Side light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K24
C011. Side light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K26
C012. Roof marker light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J25
C013. Roof marker light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J25
C014. Direction indicator (LH front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K8
C015. Direction indicator (RH front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K12
C016. Direction indicator (LH side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K8
C017. Direction indicator (RH side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K12
C018. Direction indicator (LH rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K10
C019. Direction indicator (RH rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K11
C020. Stop light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E21
C021. Stop light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E21
C022. Tail light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K23
C023. Tail light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K27
C024. Rear fog light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J15
C025. Rear fog light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J15
C026. Reverse light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E17
C027. Reverse light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E18

E9612
5–1–12
5 ELECTRICAL SYSTEM
55 Series General information

C054. Interior light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H16

C055. Interior light (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H16
C132. Temperature gauge illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K22
C133. Fuel gauge illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J22
C136. Switch illumination, rear fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H22 1
C137. Switch illumination, instrument lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H22
C138. Heater operation illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J21
C502. Switch, auxiliary driving lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G30
C531. Switch, heated mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G20
C536. Switch, cargo space lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G17
C587. Switch, heater motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2
C600. Switch, front fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G28
C601. Switch, rear fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G15
C617. Switch, electric windows – passengers side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C14
C618. Switch, electric windows – driver’s side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C16
C649. Switch, lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G22
C650. Switch, instrument illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H23
C651. Switch, dipped beam, horn and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10/H18/F28
C652. Switch, windscreen wash and wipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G3/F5
C653. Switch, hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8
C654. Switch, cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
C655. Switch, steering lock/master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
C692. Switch, reversing alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C16
D000. Warning light, main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G32
D001. Warning light, indicators, tractive vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13
D002. Warning light, indicators, trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H14
D005. Warning light, park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B28
D006. Warning light, low air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B27
D020. Warning light, cab lockdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B26
D027. Warning light, low charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B31
D029. Warning light, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B29
D032. Warning light, coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B26
D037. Warning light, brake pad wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B32
D043. Warning light, ABS (tractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B35
D044. Warning light, ABSI (trailer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B35
D049. Warning light, brake fluid level & actuator travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B27
D050. Warning light, ECAS out of order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B37
D051. Warning light, ECAS ride height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B36
D057. Warning light, gearbox protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B20
D078. Warning light, differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B29
D086. Warning light, PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D31
D092. Warning light, hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7
D093. Warning light, rear fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H15

E9612 5–1–13
 ELECTRICAL SYSTEM 5
General information 55 Series

D096. Warning light, traction control (ASR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B36

D506. Electronic control unit (ECU), ECAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A41
D512. Electronic control unit (ECU), RLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A54
D529. ECAS remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H43
1 D568. Electronic control unit (ECU),ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G50
D579. Voltage convertor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7
D584. Electronic unit, windscreen wipers/washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5
D600. Diode, rear fog (dipped beam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F15
D601. Diode, front and rear fog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14
D614. Diode, coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B26
D615. Diode, brake pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B28
D628. Diode, Zener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H47
D668. Diode, alternator protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B31
D670. Diode, cab locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B26
D671. Diode, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B29
D672. Diode, brake fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B27
D673. Diode, dim–dip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G32
D732. Diode, direction indicators (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7
D733. Diode, direction indicators (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8
D734. Diode, hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G11
D753. Diode, audible relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J9
D754. Diode, audible relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J11
D835. Electronic unit, radio dropper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C9
D836. Electronic unit, direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F12
D837. Electronic unit, gearbox overspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B19
D838. Electronic unit, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B24
E000. Fuse, side/tail/roof marker light (LH) and tachograph illumination . . . . . . . . . . . . . . . . . . . . . F23
E001. Fuse, side/tail/roof marker light (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F25
E026. Fuse, cigar lighter and radio (memory supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
E030. Fuse, horn and automatic lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F19
E032. Fuse, electric windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A15
E035. Fuse, instrument panel illumination and tachograph recording mechanism . . . . . . . . . . A13
E041. Fuse, ABS ECU supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F45
E042. Fuse, ABS ECU supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F46
E043. Fuse, ABS (trailer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E36
E051. Fuse, ECAS power enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E37
E066. Fuse, tachograph clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13
E078. Fuse, road speed limiter (primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A51
E084. Fuse, lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G29
E091. Fuse, air dryer, heated mirrors and cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12
E129. Fuse, rear fog lights/interior lights/cargo light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F16
E131. Fuse, headlights main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E32
E132. Fuse, headlights dipped beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E33

E9612
5–1–14
5 ELECTRICAL SYSTEM
55 Series General information

E133. Fuse, reverse lights, stop lights, ABS enable and ECAS power supply . . . . . . . . . . . . . . A17
E134. Fuse, heater motor, windscreen wipers/washers and radio (power supply) . . . . . . . . . . . . F3
E135. Fuse, engine stop solenoid/road speed limiter (secondary fuse) . . . . . . . . . . . . . . . . . . . . . B2
E233. Fuse, direction indicators and hazard warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7
E501. Switch, reversing light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C17 1
E514. Door switch, driver’s side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J16
E515. Door switch, passenger’s side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J16
E554. Switch, stop lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C21
E562. Switch, inlet manifold temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1
F000. Switch, air pressure/parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D28
F001. Switch, air pressure warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D27
F004. Switch, differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D29
F011. Switch, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D29
F014. Switch, coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D26
F025. Switch, ECAS air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C44
F026. Switch, brake fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D27
F041. Switch, PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D30
F052. Switch, brake pad wear (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D33
F053. Switch, brake pad wear (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D32
F064. Switch, cab lock (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D26
F065. Switch, cab lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E27
F512. Sensor, ABS (LH front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E53
F513. Sensor, ABS (RH front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G53
F514. Sensor, ABS (LH rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G53
F515. Sensor, ABS (RH rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F53
F526. Sensor, ECAS height (LH rear axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C41
F527. Sensor, ECAS height (RH rear axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C41
F533. Sensor, road speed (4–pole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E14
F535. Sensor, coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E24
F540. Sensor, fuel tank supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E24
G001. Relay, headlight dipped beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F24
G002. Relay, headlight main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F33
G003. Relay, auxiliary driving light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H30
G004. Relay, front fog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H28
G005. Relay, rear fog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G15
G014. Relay, glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
G021. Relay, ABS power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H47
G022. Relay, ABS power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F47
G023. Relay, exhaust brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J47
G025. Relay, ABS warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E47
G079. Relay, starter interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6
G080. Relay, direction indicators audible warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12
G097. Relay, dim–dip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J31

E9612 5–1–15
 ELECTRICAL SYSTEM 5
General information 55 Series

G204. KSB Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1

G221. Relay, hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G8
G222. Relay, direction indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10
G223. Relay, brake pad wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C33
1 G278. Relay, radio ignition control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10

E9612
5–1–16
5 ELECTRICAL SYSTEM
55 Series General information

CIRCUIT WIRING CODES

— Wiring loom cable

— Printed Circuit Board (PCB) track

1
CONNECTOR CODES

Instrument Panel PCB Connector

C1 — Chassis 1 (13–way brown)
C2 — Chassis 2 (13–way grey)
CO — Column switch (9–way white)
CS — Cab services 1 (13–way white)
CS2 — Cab services 2 (13–way black)
E — Engine (9–way black)
FL — Front lighting (9–way brown)
H — Hazard switch (9–way grey)
K — Key switch (9–way green)
L — Lighting switch (5–way black)

Component Connector

Cab/Chassis Interface Connector

E — Engine (13–way black)
C1 — Chassis 1 (13–way grey)
C2 — Chassis 2 (13–way white)
C3 — Chassis 3 (5–way white)
R — Road speed limiter (7–way white)
S — Special vehicle equipment (13–way brown)
EC — ECAS (9–way white)

ABS Component Connector

B — Black
W — White

Earth Point

E9612 5–1–17
 ELECTRICAL SYSTEM 5
General information 55 Series

E9612
5–1–18
5 ELECTRICAL SYSTEM
Fault diagnosis

1A. FAULT DIAGNOSIS

In order to trace faults, the following testing

equipment and appliances can be used.
1. The best instrument for this purpose is a
digital universal meter (multimeter Fig.1).
With this instrument it is possible to
measure voltages, currents and resistances 1
accurately and almost all faults can be
traced.

2. Many faults, but not all can be traced in a

simple way with a pilot lamp or buzzer
(Fig.2). However, faults which are caused
by a poor earth connection cannot generally
be traced with a pilot lamp or buzzer (note,
buzzers will only operate with the correct
voltage polarity).

The most frequently occurring faults are:

a. Short circuiting.
b. Interrupted circuits.
c. Earthing problems. FIG.1. MULTIMETER

FIG.2. TEST LAMP

E9612 5–1A–1
 ELECTRICAL SYSTEM 5
Fault diagnosis

How to test and what to use.

A short circuit is caused by a positive cable
shorting somewhere to earth, in most cases this
will cause a fuse to blow. A pilot lamp or a

1 buzzer is then used to trace this fault. First

check the diagram to see what equipment is
protected by the fuse in question and then
switch off this equipment. Remove the fuse and
replace it by a pilot lamp or a buzzer (Fig.3).
Then one by one, switch the individual items of
equipment on and off, if the pilot lamp glows
brightly when switching on, it is almost certain
that the fault is in the wiring of that particular
piece of equipment. Next check the diagram to
find the connectors that are in circuit with that
item of equipment. Then disconnect the nearest
wiring connection (counting from the fuse). If the
pilot lamp still glows brightly, the fault is between
the fuse and this wiring connection. If the lamp
extinguishes however, this indicates that the
fault is located further along the wiring.
Reconnect the wiring at the wiring connection FIG.3.
and disconnect the following connection. If the
pilot lamp continues to glow brightly, the fault is
between these two connections. However if the
lamp goes out at this stage also, it again
indicates that the fault is located further along
the wiring, continue to search for the fault. In
this way (by elimination) the faulty section of
wiring is found.

E9612
5–1A–2
5 ELECTRICAL SYSTEM
Fault diagnosis

Interrupted circuits
If a piece of equipment is not functioning, the
fault may be in the equipment itself or the wiring
may be interrupted (Fig.4). First switch on the
equipment and using the pilot lamp or buzzer,
test for voltage at the equipment in question. If
FIG.4.
1
no voltage is present, first check whether the
fuse is still intact. If there is voltage at the fuse
then the cable between the fuse and the
equipment must be checked. It is important
therefore to test at every wiring connection. If
there is no voltage at one of the wiring
connections, the interruption is then between
this connection and the last connection tested.
If voltage was found at the equipment, there is
still the possibility that the negative (earth) is
interrupted (Fig.5). This can be tested with the
aid of a pilot lamp and a battery. First switch off
the equipment. Connect one end of the pilot
lamp plus battery with the negative connection
of the equipment; connect the other end of the
pilot lamp with a good earthing point. If the lamp
then glows brightly, this indicates that the
negative connection of the equipment is in good
order. If the lamp does not light up, or only
glows weakly, then the negative connection of
FIG.5.
the equipment is faulty and must be repaired. If
the positive and negative connections are both
in good order, this means that the equipment in
question is defective and must be renewed.

E9612 5–1A–3
 ELECTRICAL SYSTEM 5
Fault diagnosis

Earthing problems.
Problems with the earthing connection are
mostly caused by corrosion between the contact
surfaces of the electrical connections. Earthing

1 problems can only be traced with a (preferably

digital) universal meter. Digital, because this
kind of problem usually involves only a few volts
and this is difficult to read on a analogue meter.
To establish whether a certain earthing point has
a good earth connection, measure with a
voltmeter between the battery negative pole and
the earthing point in question (Fig.6). In this
case the equipment in question must be
switched on. In the case of a properly earthed
connection no voltage should be measured. In
this way the earth connections of all the
consumers can be tested and measured.

Semi – conductor devices.

Never use an ohm meter of type incorporating a
hand driven generator for checking rectifiers or
transistors.
FIG.6.

Diodes.
To test a diode set the multimeter to ohms
range.
NOTE: The lead polarity is reversed, check both
ways (Fig. 7).

eg. 18: Inf – OK

Inf: Inf – open circuit
Zero: Zero – short circuit

Diodes used in alternators can be of + ve or –

ve polarity depending on construction.

FIG.7.

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5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 2—BATTERIES
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—2—1 . . . . . . . . . 9612
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—2—2 . . . . . . . . . 9612
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—2—1 . . . . . . . . . 9612

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5 ELECTRICAL SYSTEM
55 Series Batteries

2. BATTERIES
DATA

Electrical storage system . . . . . . . . . . . . . . . . . . . . Two 12V ”Maintenance–Free” batteries

Battery type:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
Heavy duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655

Cold cranking:
Standard battery . . . . . . . . . . . . . . . . . . . . . . . SAE 825
Heavy duty battery . . . . . . . . . . . . . . . . . . . . . SAE 880
2
Reserve capacity:
Standard battery . . . . . . . . . . . . . . . . . . . . . . . 25 amps for 200 minutes
Heavy duty battery . . . . . . . . . . . . . . . . . . . . . 25 amps for 210 minutes

WARNINGS:
— Batteries contain electrolyte (sulphuric acid) which is a highly corrosive and toxic
substance. Accidental skin/eye contact with battery electrolyte can cause serious personal
injury.

— Always wear protective gloves and suitable eye protection when handling batteries and
wash hands after use.

— Always disconnect the batteries before commencing work on the vehicle. To minimise the
risk of accidental short circuits when disconnecting the batteries, ensure that the negative
(–) lead is disconnected first and the positive (+) lead last; reverse this procedure when
re–connecting the batteries.

— To prevent accidental short circuits do NOT place tools/metal objects on or near the battery
terminals.

— Batteries emit a highly inflammable and explosive gas whilst being charged. It is essential
that the area around the battery is well ventilated and protected against any spark, naked
flame or any intense heat source. The use of ‘boost’ chargers is not recommended.

E9612 5–2–1
 ELECTRICAL SYSTEM 5
Batteries 55 Series

DESCRIPTION

General Information
The vehicle power storage system comprises of
two 12V batteries which are connected in series
to provide a 24V (dc) output.
CAUTION: The vehicle electrical system has
negative (–) earth circuit polarity.

2 Service Precautions
To prevent damage to the alternator and vehicle
electrical circuits it is essential that the following
precautions are observed:

— Ensure that the correct battery polarity

(negative earth) is maintained at all times;
reversed battery or charger connections will
damage the alternator.

— Do NOT disconnect the batteries whilst the

engine is running nor attempt to run the FIG.1. MAINTENANCE–FREE BATTERY
engine with the batteries disconnected.

— All vehicles are equipped with sealed

‘‘Maintenance–Free” batteries as standard
factory fitted equipment. Do NOT attempt to
check or top–up the battery electrolyte
level.

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5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 3—CHARGING SYSTEM

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—3—1 . . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—3—2 . . . . . . . . . 9612

E9612 1
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E9612
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5 ELECTRICAL SYSTEM
55 Series Charging system

3. CHARGING SYSTEM
DESCRIPTION

Circuit Protection +
1000
All electrical circuits that are energised with the
master start switch (C655) in position ”2”, are

K 6/9
1000
protected by fuse E035 (5 amps); this fuse is
located in the RH instrument panel fuse box. C655
NOTE: The alternator power supply cables are A500 A500
1
equipped with 1 mm2 wire safety link; in the + -
3 2 K 7 E035
event of a major short circuit the safety link will 1010
act as a conventional fuse. - +

Electrical Circuit, Fig.1 1000

The 24V battery power supply is delivered, via D027

the starter motor solenoid and alternator (A509)
‘‘B+” terminal to the positive stud terminals. The
3
power supply from the LH positive terminal stud B010
is delivered, via terminal K.6/9 (instrument panel D668
pcb connector), to the master start switch
(C655). With the master start switch in position
‘‘2”, the power supply will be delivered via E 4B
B+
P
terminal K.7 (instrument panel pcb connector), E A7
1
fuse E035, battery warning light (D027), diode W/L 1020

D668 and terminals E.4B (instrument panel pcb + A509

connector) and E.A7 (cab/chassis interface 081031
connector) to the alternator warning light (W/L)
terminal. Whilst the engine is running, the
alternator will generate a 3–phase alternating FIG.1. CHARGING SYSTEM CIRCUIT
current (a.c) which is then rectified to direct DIAGRAM
current (d.c.). The alternator output voltage +. Positive stud terminal
(approximately 28V) will supply the vehicle
electrical system and the battery warning light A500. Battery
will extinguish. A509. Alternator
CAUTION: To prevent damage to the alternator B010. Starter motor
and vehicle electrical system, do NOT
C655. Master start switch
disconnect the batteries whilst the engine is
running nor attempt to run the engine with the D027. Battery charge warning light
batteries disconnected. D668. Diode (alternator protection)
E035. Fuse (5A)

E9612 5–3–1
 ELECTRICAL SYSTEM 5
Charging system 55 Series

REMOVAL AND REFITMENT

Alternator (A509)

To Remove, Fig.2
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries.

3. Tilt the cab, see ‘‘Driver’s Handbook”.

3 4. Note their positions and then disconnect all
electrical connections from the rear of the
alternator.

5. Insert a 3/8 in square drive knuckle bar into

the automatic tensioner. Pull the knuckle
bar upwards to release the tension from the
FIG.2. ALTERNATOR REMOVAL
drive belt and then detach the drive belt
from the alternator drive pulley. 1. Pivot bolt
6. With the alternator suitably supported, 2. Automatic tensioner
remove the pivot and link bracket bolts and 3. Link bracket
carefully detach the alternator.

To Remove
Reverse the removal procedure, noting:

1. Before fitting the drive belt, ensure that the

alternator drive pulley and drive belt are
clean and free of any contaminants
(oil/fuel/hydraulic fluid, etc).
CAUTION: The drive belt MUST be
renewed if it has been contaminated with
oil, fuel or hydraulic fluid.

2. Ensure that all electrical connections are in

the original positions and secure.

3. If applicable, re–activate the radio security

code.

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5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 4—STARTING SYSTEM

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—4—1 . . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—4—3 . . . . . . . . . 9612

E9612 1
 E9612
2
5 ELECTRICAL SYSTEM
55 Series Starting system

4. STARTING SYSTEM
DESCRIPTION

General Information
To prevent inadvertent engagement of the
starter motor whilst the engine is running, a
starter motor interlock relay has been fitted in
the starting system electrical circuits. The starter
interlock relay is located on the RH instrument
panel printed circuit board.

Master Start Switch Operation

The master start switch is a 4–position key
switch with the following operating positions:

‘OFF’ position: In this position all battery

supply electrical circuits are operative,
these include: horn, tachograph clock,
courtesy lights, headlights/sidelights, rear
fog lights, and cigar lighter.
4
1st position: In this position all auxiliary
circuits are operative, these include:
windscreen wipers/washer, heater fan
motor and radio.
NOTE: All electrical circuits in the master
start switch ‘‘off” position are also operative.

2nd position: In this position all ignition

electrical circuits, with the exception of the
starter motor, are operative.

3rd position: In this position the starter

motor electrical circuits will be energised; all
auxiliary circuits will be inoperative whilst
the starter motor energised.

E9612 5–4–1
 ELECTRICAL SYSTEM 5
Starting system 55 Series

Circuit Protection +
1000
The alternator power supply cables to the
positive terminal studs are fitted with circuit
protection in the form of a 1 mm2 wire safety 86

link; in the event of a major short circuit the G079

safety link will act as conventional fuse. A500 A500 85

+ - CS2 A7 K 2 D027

Electrical Circuit, Fig.1. - +

4002
D668

K 6/9
With the master start switch (C655) in position E A1
‘‘3”, the power supply is delivered, via terminal 1000 4002
K.2 (instrument panel pcb connector), to the C655
E 4B

starter interlock relay (G079). With the starter 3 1

2
interlock relay energised, a power supply from
the positive terminal stud will be delivered, via B010 E A7
terminals CS2.A7 (instrument panel pcb
4 connector) and E.A1 (cab/chassis interface
connector) to the starter motor solenoid causing
1000
B+ 1003
P
the engagement of the starter motor (B010).
1 W/L 1020
NOTE: The starter interlock relay is earthed via +
the alternator warning light (W/L) connector and, A509
therefore, cannot be energised whilst the engine 081032
is running (alternator charging).
FIG.1. STARTING SYSTEM CIRCUIT
DIAGRAM

+. Positive stud terminal

A500. Battery
A509. Alternator
B010. Starter motor
C655. Master start switch
G079. Starter interlock relay

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5–4–2
5 ELECTRICAL SYSTEM
55 Series Starting system

REMOVAL AND REFITMENT

Starter Motor (B010)

To Remove
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Remove the exhaust brake and exhaust

down pipe as instructed in Group 4.

3. Release the terminal covers and, noting

their positions, disconnect the electrical
cables from the starter motor and starter
motor solenoid.

4. With the starter motor suitably supported,

4
remove the bolts securing the starter motor
to the engine flywheel and carefully
withdraw the starter motor.

To Refit
Reverse the removal procedure, noting:

1. Torque tighten all starter motor retaining

bolts to 50 Nm (37 lbf ft).

2. Ensure that all electrical cables are

re–connected to their original positions and
that all terminal covers are correctly
located.

3. If applicable, re–activate the radio security

code.

E9612 5–4–3
 ELECTRICAL SYSTEM 5
Starting system 55 Series

Master Start Switch (C655)

To Remove
WARNING: The master start switch and
steering lock electrical circuits are designed
to prevent the auxiliary electrical circuits
and starter motor from being energised
whilst the steering lock is engaged. Do NOT
attempt to modify, substitute or separate the
master start switch, steering lock or any
associated electrical wiring.

1. Before disconnecting the vehicle battery

supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
4 all work.

2. Isolate the batteries.

3. Remove the retaining screws securing the

lower shroud cover to the steering column.
With the clutch and brake pedals fully
depressed, remove the lower shroud cover.

4. Detach the protective caps and remove the FIG.2. MASTER/START SWITCH AND
retaining screws securing the upper shroud STEERING LOCK
covers to the steering column; detach the
upper shroud covers.

5. Remove the knobs from the heater control

levers.

6. Release the steering column adjustment

control and move the steering column away
from the instrument panel.

7. Rotate each fuse cover quick release

fastener using a suitable implement (a coin
or screwdriver) and then slide the fuse
cover downwards to gain access to the
instrument panel retaining screws: remove
the instrument panel retaining screw from
each fuse box.

E9612
5–4–4
5 ELECTRICAL SYSTEM
55 Series Starting system

8. Carefully lift the instrument panel clear of its

internal mounting pillars and then pivot it
rearwards to gain access to the master
start switch electrical connection.

9. Disconnect the master start switch

multi–pin electrical connector from the
instrument panel printed circuit board (pcb).

10. Using an 8 mm drill, drill out the shear bolts

securing the master start switch to the
steering column.

To Refit
Reverse the removal procedure, noting:

1. Fit and then tighten the new shear bolts

4
evenly until the bolt heads are sheared from
the bolts.

2. If applicable, re–activate the radio security

code.

E9612 5–4–5
 ELECTRICAL SYSTEM 5
Starting system 55 Series

Starter Interlock Relay (G079)

To Remove
1. Remove the starter interlock relay as
instructed in Section 5 (‘‘Instrument Panel
Components”).

To Refit
Reverse the removal procedure.

E9612
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5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 5—INSTRUMENT PANEL

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—5—1 . . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—5—6 . . . . . . . . . 9612

E9612 1
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E9612
2
5 ELECTRICAL SYSTEM
55 Series Instrument panel

5. INSTRUMENT PANEL
DESCRIPTION

General Information, Figs.1 and 2

The instrument panel is a one piece moulding
housing the tachograph, switches and 3–piece
printed circuit boards (pcb’s). With the exception
of the tachograph and switches, the following
components are directly attached to the
instrument pcb’s:

— Warning lights.
— Gauge module containing the air, fuel, and
engine coolant gauges.
— Rev counter.
— Fuses.
— Relays.
— Warning buzzer.
— Warning lights.
— Component connectors.

Circuit Protection
The instrument panel printed circuit board (pcb) 5
power circuits are protected by fuse E035 (5
amps); this fuse is located in the RH instrument
panel fuse box.

Printed Circuit Boards, Fig.3

All electrical components within the instrument
panel are connected to the 3–piece instrument
panel printed circuit boards (pcb).
NOTE: Component identification and location
are printed on each pcb.

E9612 5–5–1
 ELECTRICAL SYSTEM 5
Instrument panel 55 Series

1. Rear fog light warning light 1 2 3 4 5 6 7 8 9 10

2. Main beam warning light
3. Hazard switch warning light
4. Direction indicator warning light – trailer
5. Direction indicator warning light – vehicle 20 19 18 17 16 15 14 13 12 11
6. Cab–lock warning light
7. Oil pressure warning light 21 22 23 24 25 26 27 28
8. Low air pressure warning light
9. Battery charge warning light
10. Parking brake warning light
11. Low hydraulic fluid warning light
12. Differential lock warning light
13. ABSI warning light
14. ABS warning light
15. ECAS (failure) warning light
5 16. ECAS (pressure) warning light
37 36 35 34 33 32 31 30 29
17. Coolant temperature warning light
081090
18. ASR (traction control) warning light
19. Brake pad wear warning light FIG.1. INSTRUMENT PANEL — FRONT VIEW
20. Gearbox low ratio warning light
21. Hazard warning light switch
22. Rear fog light switch
23. Rev–counter (if fitted)
24. Tachograph/speedometer/odometer/clock
25. Fuel gauge
26. Coolant temperature gauge
27. Air distribution control
28. Temperature control
29. Fan motor switch
30. Air pressure gauge ”2”
31. Fuse box cover fastener – RH
32. Fuse box – RH
33. Air pressure gauge ”1”
34. Fuse box – LH
35. Fuse box cover fastener – LH
36. Instrument panel lighting switch
37. Vehicle lighting switch

E9612
5–5–2
5 ELECTRICAL SYSTEM
55 Series Instrument panel

1 2 3
4 4

10
5
9 080721

FIG.2. INSTRUMENT PANEL — REAR VIEW

1. RH printed circuit board assembly 6. Rear fog light switch (C601)

2. Warning light printed circuit board assembly 7. Instrument panel illumination switch (C650)
3. LH printed circuit board assembly 8. Vehicle lighting switch (C649)
4. Mounting pillar 9. Tachograph (B501)
5. Hazard warning light switch (C653) 10. Heater motor switch (C587)

E9612 5–5–3
 ELECTRICAL SYSTEM 5
Instrument panel 55 Series

5 1 2 3 4 5 67 8
17

18
35 19

9 20
16 21
34
22
15
27 26 25 24 23

28
14
29
13
30

12 11 10 33 32 31
081091

FIG.3. PRINTED CIRCUIT BOARD COMPONENTS

E9612
5–5–4
5 ELECTRICAL SYSTEM
55 Series Instrument panel

FIG.3. PRINTED CIRCUIT BOARD COMPONENTS

1. RH negative (–) stud terminal
2. Warning buzzer (B012)
3. Diode D4 (D670)
4. Diode D1 (D614)
5. Diode D2 (D671)
6. Diode D3 (D615)
7. Diode D5 (D668)
8. Diode D7 (D672)
9. Terminal connector — front light (FL)
10. RH positive (+) terminal stud
11. Fuse — battery power supply
12. Fuse — ECAS power enable (E051)
13. Fuse — spare
14. Terminal connector — chassis 2 (C2)
15. Terminal connector — chassis 1 (C1) 5
16. Terminal connector — engine (E)
17. LH negative (–) terminal
18. Relay — rear fog relay (G005)
19. Terminal connector — cab services 2
(CS2)
20. Diode D11 (D734)
21. Terminal connector — hazard switch (H)
22. Terminal connector — light switch (L)
23. Relay — main beam (G002)
24. Relay — dipped beam (G001)
25. Relay — hazard warning (G221)
26. Relay — direction indicators (G222)
27. Relay — starter interlock (G079)
28. Terminal connector — cab services (CS)
29. Diode D10 (D733)
30. Diode D9 (D732)
31. Terminal connector — column switch (CO)
32. LH positive (+) stud terminal
33. Terminal connector — key switch (K)
34. Diode D6 (D600)
35. Diode D8 (D601)

NOTE: All printed circuit board retaining screws

are identified with an arrow.

E9612 5–5–5
ELECTRICAL SYSTEM 5
Instrument panel 55 Series

FIG.4. SCHEMATIC VIEW OF THE INSTRUMENT PANEL PRINTED CIRCUIT BOARDS

1. Stud terminal – LH negative (–) 42. Terminal connector – engine (E)

2. Relay (G005) – rear fog 43. Terminal connector – cab services 1 (CS)
3. Warning light (D092) – hazard 44. Terminal connector – chassis 2 (C2)
4. Warning light (D000) – main beam 45. Electronic unit (D838) – instruments
5. Warning light (D093) – rear fog 46. Relay (G079) – starter interlock
6. Warning light (D057) – gearbox low ratio 47. Resistor (B034) – instrument panel
7. Warning light (D037) – brake pad wear illumination
8. Warning light (D096) – ASR (traction 48. Diode D11 (D734) – hazard warning lights
control) 49. Diode D10 (D733) – direction indicators (RH)
9. Warning light (D005) – handbrake 50. Diode D9 (D732) – direction indicators (LH)
10. Warning light (D049) – low hydraulic fluid 51. Relay (G221) – hazard
11. Warning light (D006) – low air pressure 52. Relay (G002) – main beam
12. Warning light (D020) – cab lock 53. Relay (G001) – dip beam
13. Warning buzzer (B012) 54. Terminal stud – LH positive (+)
14. Terminal stud – RH negative (–) 55. Fuse (E233) – direction indicators and
15. Rev counter (B524) hazard warning
16. Diode D4 (D670) – cab lock 56. Fuse (E129) – rear fog lights, courtesy
17. Diode D3 (D615) – low air pressure lights and box van lamp
18. Diode D2 (D671) – oil pressure 57. Fuse (E131) – headlights (main beam)
19. Diode D1 (D614) – coolant temperature 58. Fuse (E132) – headlights (dipped beam)
20. Diode D7 (D672) – low hydraulic fluid 59. Fuse (E000) – sidelights (LH), instrument
21. Diode D5 (D668) – alternator protection and switch illumination
22. Warning light (D032) – coolant temperature 60. Fuse (E001) – sidelights lamps (RH),
23. Warning light (D029) – low oil pressure tachograph illumination and front fog lights
24. Warning light (D027) – battery charge 61. Fuse (E032) – electric windows
25. Warning light (D078) – differential lock 62. Fuse (E043) – ABSI (trailer)
26. Warning light (D051) – ECAS (pressure) 63. Fuse (E091) – air dryer, heated mirrors and
27. Warning light (D050) – ECAS (failure) cold start
28. Warning light (D043) – ABS 64. Fuse (E133) – reverse, stop lights, ABS
29. Warning light (D044) – ABSI enable and ECAS power supply
30. Warning light (D001) – trailer direction 65. Fuse (E135) – engine stop solenoid and
indicators road speed limiter
31. Warning light (D002) – vehicle direction 66. Fuse (E035) – instruments, warning lights
indicators and tachograph recording mechanism
32. Terminal connector – light switch (L) 67. Fuse (E134) – windscreen wipers/washers,
33. Relay (G222) – direction indicator heater motor and radio
34. Diode D6 (D600) – fog light 68. Fuse (E030) – horn and automatic
35. Diode D8 (D601) – fog light lubrication
36. Terminal connector – column switch (CO) 69. Fuse (E066) – tachograph (clock)
37. Terminal connector – hazard switch (H) 70. Fuse (E026) – cigar lighter and radio
38. Terminal connector – cab services 2 (CS2) (memory supply)
39. Terminal connector – front light (FL) 71. Fuse (E051) – ECAS power enable
40. Terminal connector – key switch (K) 72. Fuse (Spare)
41. Terminal connector – chassis 1 (C1) 73. Stud terminal – RH positive (+)

E9612
5–5–6
E9612 5–5–7
 E9612
5–5–8
5 ELECTRICAL SYSTEM
55 Series Instrument panel

Warning Buzzer (B012) +

The warning buzzer is attached to the front of
the instrument panel RH printed circuit board.
The warning buzzer will be activated by the
following system faults:
L A3
— Engine coolant temperature excessive. L 1B L 2B E000
— Cab lock–down mechanism not engaged.
— Low air pressure.
— Low engine oil pressure.
C649
H 4B
Instrument Panel Illumination, Fig.5
When the lighting switch (C649) is in the B034

2102
”sidelights” position, the power supply will be
delivered via terminal L.A3 (instrument panel C1 7B

pcb), fuse E000 (5 amps) and resistor (B034) to C650

C136
the instrument panel illumination circuits
2102

(reduced intensity). When the dual level lighting

2622
switch (C650) is activated the power supply will C136

2622
by–pass the resistor and illuminate the
instrument panel illumination circuits at normal 5
intensity.

H A2
C137

C138
C133
H 5B

C132

C132
081117

FIG.5. INSTRUMENT PANEL ILLUMINATION

CIRCUIT DIAGRAM

+. LH positive stud terminal

B034. Resistor
C132. Temperature gauge illumination
C133. Fuel gauge illumination
C136. Rear fog switch illumination
C137. Instrument lighting switch illumination
C138. Heater panel illumination
C649. Lighting switch
C650. Dual level lighting switch
E000. Fuse (5A)

E9612 5–5–9
 ELECTRICAL SYSTEM 5
Instrument panel 55 Series

REMOVAL AND REFITMENT

Instrument Panel

To Remove, Fig.6
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries and fully deplete the

vehicle air system.

3. Remove the knobs from the heater control

levers.

4. Release the steering column adjustment

control and move the steering column away
from the instrument panel.

5 5. Rotate each fuse cover quick release

fastener using a suitable implement (a coin
or screwdriver) and then slide the fuse
cover downwards to gain access to the
instrument panel retaining screws.

6. Remove the instrument panel retaining

screw from each fuse box.

7. Carefully lift the instrument panel clear of its

internal mounting pillars and then pivot it
rearwards to gain access to the all electrical
and air pipe connections.

8. Disconnect all multi–pin electrical

connections and air pipe connections from
the rear of the instrument panel.
NOTE: The air pipes are fitted with identity
sleeves to aid correct re–connection.

9. Disconnect all multi–pin connections from

the tachograph.
NOTE: The tachograph calibration seal will
have to be broken to enable the instrument
panel to be removed.

E9612
5–5–10
5 ELECTRICAL SYSTEM
55 Series Instrument panel

To Refit
Reverse the removal procedure, noting:

1. The tachograph MUST be calibrated and

re–sealed by qualified personnel at an
authorised Tachograph Calibration Centre.

2. Ensure that the air pipes are connected into

their correct positions as identified by their
identity sleeves.

3. If applicable, re–activate the radio security

code.

3
1 4
2 2

081092

FIG.6. INSTRUMENT PANEL REMOVAL

1. LH fuse box cover 3. Tachograph 5. Heater control knob

2. Retaining screw 4. RH fuse box cover

E9612 5–5–11
 ELECTRICAL SYSTEM 5
Instrument panel 55 Series

Printed Circuit Boards

To Remove
1. Remove the instrument panel as instructed
in this Section.

2. Position the instrument panel face

downwards on a suitable work surface.

3. Disconnect the heater switch and headlight

switch multi–pin connectors from the
printed circuit boards.

4. Remove the screws retaining the LH and

RH printed circuit boards to the instrument
panel and then manoeuvre them to gain
access to the centre printed circuit board
retaining screws.

5 5. Remove the screws retaining the centre

printed circuit board to the instrument panel
and then detach the printed circuit board
assemblies.

To Refit
Reverse the removal procedure.

E9612
5–5–12
5 ELECTRICAL SYSTEM
55 Series Instrument panel

Instrument Panel Components

To Remove
NOTE: The instrument panel components
comprise of the relays, warning buzzer, gauge
units (air pressure/fuel/temperature and rev
counter), warning lights, gauge illumination
bulbs, rotary and rocker type switches.

1. Before disconnecting the vehicle battery

supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries and fully deplete the

vehicle air system.

3. Remove the knobs from the heater control

levers.
5
4. Release the steering column adjustment
control and move the steering column away
from the instrument panel.

5. Rotate each fuse cover quick release

fastener using a suitable implement (a coin
or screwdriver) and then slide the fuse
cover downwards to gain access to the
instrument panel retaining screws.

6. Remove the instrument panel retaining

screw from each fuse box.

E9612 5–5–13
 ELECTRICAL SYSTEM 5
Instrument panel 55 Series

7. Carefully lift the instrument panel clear of its

internal mounting pillars and then pivot it 1
rearwards to gain access to the following NEG

components:
— Relays. With the exception of the REAR FOG
starter interlock relay (G014), all
remaining relays are interchangeable,
see Fig.7.
— Vehicle Light Switch (C649).
Disconnect the multi–pin connector and
remove the plastic clip retaining the
rotary light switch assembly, see Fig.8.
+VE
FLASHER A4
— Warning lights.
STARTER INT HAZARD DIP BEAM MAIN BEAM

— Instrumentation Illumination Bulbs.

— ECAS Power Enable Fuse (E051),

see Fig.9.
5
6 5 4 3 2 080722

FIG.7. INSTRUMENT PANEL RELAYS

1. Rear fog relay (G005)
2. Main beam relay (G002)
3. Dipped beam relay (G001)
4. Hazard relay (G221)
5. Direction indicator relay (G222)
6. Starter interlock relay (G079)

FIG.8. ROTARY TYPE SWITCH

1. Switch assembly 3. Multi–pin connector

2. Retaining clip

E9612
5–5–14
5 ELECTRICAL SYSTEM
55 Series Instrument panel

8. Disconnect the multi–pin connectors and air

pipe connections from the RH printed circuit
board. Remove the four retaining screws 1
and carefully lift the RH printed circuit board
from the instrument panel to gain access to
the following components:
— Fan Motor Switch (C587). Remove
plastic clip retaining the rotary fan
motor switch assembly, see Fig.8.
— Warning buzzer (B012). Extract the
warning buzzer module from its
location, see Fig.9.
— Electronic Gauge Unit (D838).
Remove the four nuts and washers and
detach the gauge unit. Failure of any
gauge will require the renewal of the
complete gauge module.

9. Disconnect the multi–pin connectors air

from the LH printed circuit board. Remove
5
the five retaining screws and carefully lift
the LH printed circuit board from the
instrument panel to gain access to the
following components:
— Rev Counter (B524). Remove the four 2 3
nuts and washers and detach the rev
counter unit.
— Rocker Switches. Remove the three 4
screws and detach the switch holder. 081093

Disconnect the multi–pin connector

from each switch and the extract the FIG.9. WARNING BUZZER AND ECAS FUSE
switches from the switch holder.
1. Warning buzzer (B012)
2. ECAS power enable fuse (E051)
To Refit
Reverse the removal procedure, noting: 3. Fused battery power supply
4. Spare fuse
1. Ensure that the air pipes are connected into
their correct positions as identified by their
identity sleeves.

2. If applicable, re–activate the radio security

code.

E9612 5–5–15
 ELECTRICAL SYSTEM 5
Instrument panel 55 Series

E9612
5–5–16
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 6—ELECTRIC WINDOWS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—6—1 . . . . . . . . . 9612

E9612 1
6

E9612
2
5 ELECTRICAL SYSTEM
55 Series Electric windows

6. ELECTRIC WINDOWS
DESCRIPTION

Circuit Protection
The electric windows electrical circuit is
+
protected by fuse E032 (15 amps) and is
located in the LH instrument panel fuse box.

K 6/9
1000
Electrical Circuit, Fig.1 E032
With the master start switch (C655) in position
”2”, the power supply is applied via terminal K.7 C655
K 7
(instrument panel pcb connector), fuse E032 3
1
CS1 5B
2
and terminal CS1.5B (instrument panel pcb 1010 1206
connector) to the following switches:
S A6

1206
— Electric window switch–passengers side A022(4)
(C617)
— Electric window switch–driver’s side (C618).

1206
1206
Operation of an electric window switch will
operate the corresponding electric window C617 C618
motor (B003 and B004).

NOTE: Each electric window motor contains an

4528

4529

4524

4525
integral current overload (”cut–out”) circuit. In the
event of any electric window becoming obstructed
whilst being raised or lowered the current overload
circuit will render the affected window inoperative B003 B004
6
for approximately 10 seconds. Should this occur,
release the electric window switch and clear the
obstruction before attempting to re–operate the 081118
window switch.
FIG.1. ELECTRIC WINDOW CIRCUIT
DIAGRAM

+. Positive stud terminal

B503. Motor, electric window (driver’s side)
B504. Motor, electric window (passengers
side)
C655. Master start switch
C617. Switch, electric window (driver’s side)
C618. Switch, electric window (passengers
side)
E032. Fuse (15A)

E9612 5–6–1
6

E9612
5–6–2
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 7—CIGAR LIGHTER

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—7—1 . . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—7—3 . . . . . . . . . 9612

E9612 1
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E9612
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5 ELECTRICAL SYSTEM
55 Series Cigar lighter

7. CIGAR LIGHTER
DESCRIPTION

General Information
All vehicles are equipped with a 24V cigar lighter
unit as standard equipment; a 12V cigar lighter
is available as an option.
CAUTION: The cigar lighter can be used as an
accessory power supply socket but, dependent
upon vehicle specification, the power supply can
either be 12V or 24V. Before attempting to
connect ancillary equipment it is essential that
the following information is observed:

— Ensure that the ancillary electrical

equipment are of the same voltage and
polarity (negative earth) as the cigar lighter
socket power supply.

— Ensure that the power consumption of any

electrical component does not exceed 10A
(5A/h per day).

NOTE: The operating voltage and power

consumption of the cigar lighter is identified with
a circular label attached to the centre console.

Circuit Protection
The cigar lighter electrical circuits are protected
by fuse E026 (15 amps); this fuse is located in
the RH instrument panel fuse box.
IMPORTANT: The 12V voltage convertor is
7
equipped with an integral overload protection
device that will automatically shut–down the
voltage convertor whenever excessive current
consumption (in excess of 10A) is detected. In
the event of a current overload shut–down, the
voltage convertor must be reset using the
following procedure:

— Disconnect the cause of the current

overload from the cigar lighter socket.

— From the instrument panel RH fuse box,

remove and then re–insert the cigar lighter
fuse (E026) to reset the voltage convertor.

E9612 5–7–1
 ELECTRICAL SYSTEM 5
Cigar lighter 55 Series

Electrical Circuits, Fig.1 +

24V Operation: The positive stud terminal
power supply is delivered, via fuse E026 and
terminals C2.1B (instrument panel pcb
E026
connector), VC.2 and VC.4 (component
connectors) to the cigar lighter unit (B030).
C2 1B
NOTE: Terminals VC.2 and VC.4 are connected
by a shorting plug. 1105
1105
12V Operation: The positive stud terminal
1153
power supply is delivered, via fuse E026 and
terminals C2.1B (pcb connector) and VC.2
VC 2 VC 4
(component connector) to the voltage converter
(D579). A 12V power output from the voltage
converter is delivered, via terminal VC.4
(component connector) to the cigar lighter unit. 1
D579

B030
31
VC 1 VC 3

9016

080704

FIG.1. CIGAR LIGHTER CIRCUIT DIAGRAM

7 +. Positive stud terminal

B030. Cigar lighter
D579. Voltage converter (24V/12V)
E026. Fuse (15A)

E9612
5–7–2
5 ELECTRICAL SYSTEM
55 Series Cigar lighter

REMOVAL AND REFITMENT

7

Cigar Lighter Unit (B030)

To Remove, Fig.2
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio 8
security code is available to enable the
radio to be re–activated upon completion of 9
all work.

2. Disconnect the batteries. 10

1
3. If fitted, remove the headlight levelling 2 3
control knob from the centre console.
3
4. Extract the cigar lighter from its unit.

5. Detach the access panel from beneath the

handbrake control and then remove the
centre console front retaining screw.

6. Remove the rear retaining screws from 4

either side of the centre console.

7. Carefully manoeuvre the centre console 6

5
from its location.
081094

8. Disconnect the electrical connections from

the cigar lighter. FIG.2. CIGAR LIGHTER UNIT REMOVAL 7
9. Unscrew the cigar lighter casing from the 1. Headlight levelling control knob
cigar lighter socket and release both
2. Cigar lighter
components from the centre console.
3. Retaining screw – rear
4. Centre console
To Refit
5. Retaining screw – front
Reverse the removal procedure, noting:
6. Access panel
1. When fitting a replacement cigar lighter unit, 7. Cigar lighter socket
ensure that the unit is compatible with the 8. Cigar lighter casing
cigar lighter supply voltage (24V or 12V).
9. Electrical connection (earth)
2. If applicable, re–activate the radio security 10. Electrical connection (power supply)
code.

E9612 5–7–3
 ELECTRICAL SYSTEM 5
Cigar lighter 55 Series

Voltage Convertor (D579)

To Remove, Fig.3
1. Remove the instrument panel as instructed
in Section 5.

2. Release the heater controls from the

instrument panel shroud and then detach
the shroud from the corner trim panel, main
trim panel and steering column bracket.

3. Remove the retaining screws and bolt

securing the corner trim panel to the
windscreen trim panel and cab door pillar. 1
Release the door seal and partially
withdraw the corner trim panel; disconnect
the air ducting from the air vent and then
withdraw the corner trim panel.

4. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle and, with the brake and 2
clutch pedals fully depressed, withdraw the
pedal trim panel.

5. Carefully extract the air vents from the main

trim panel and heater box .
7 6. Detach the diagnostic socket cover from the
081095

main trim panel; remove the retaining FIG.3. VOLTAGE CONVERTOR LOCATION
screws and release the diagnostic socket
1. Multi–pin electrical connector
and bracket assembly.
2. Voltage convertor (D579)

E9612
5–7–4
5 ELECTRICAL SYSTEM
55 Series Cigar lighter

7. Remove the retaining screws, nut and

washer securing the main trim panel to the
windscreen trim panel, heater box and cab.
Release the door seal and partially
withdraw the main trim panel; disconnect
the air ducting from the air vents and then
fully withdraw the main trim panel from the
cab.

8. Disconnect the multi–pin electrical

connector from the voltage convertor.

9. Remove the retaining screws and detach

the voltage convertor from the cab
bulkhead panel.

To Refit
Reverse the removal procedure.

E9612 5–7–5
 ELECTRICAL SYSTEM 5
Cigar lighter 55 Series

E9612
5–7–6
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 8—FUEL PUMP SOLENOIDS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—8—1 . . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—8—3 . . . . . . . . . 9612
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—8—6 . . . . . . . . . 9612

E9612 1
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2
5 ELECTRICAL SYSTEM
55 Series Fuel pump solenoids

8. FUEL PUMP SOLENOIDS

DESCRIPTION

General Information
All rotary and in–line type fuel pumps are
equipped with an engine stop solenoid. A
additional solenoid, designated the KSB
solenoid, is fitted to all rotary type fuel pumps.

Solenoid Functions
Engine fuel pumps are equipped, as applicable,
with the following electrical solenoids:

Engine Stop Solenoid. When

de–energised the engine stop solenoid
(B103) will totally restrict the fuel supply to
the fuel pump.

KSB Solenoid (Rotary Fuel Pumps

Only). To minimise white smoke exhaust
emissions when starting a cold engine, the
KSB solenoid (G204) will automatically
advance the fuel pump timing, at engine
idling speed, until the engine attains its
normal running temperature. The KSB
solenoid is inoperative at engine inlet
manifold temperatures in excess of 32°C.

Circuit Protection
The engine stop solenoid and, when applicable,
KSB solenoid electrical circuits are protected by
fuse E135 (5 amps); this fuse is located in the
RH instrument panel fuse box.
8

E9612 5–8–1
 ELECTRICAL SYSTEM 5
Fuel pump solenoids 55 Series

Engine Stop Solenoid Electrical Circuit, +

Fig.1
With the master start switch (C655) in position
‘‘2”, a power supply is delivered via terminal K.7
(instrument panel pcb connector), fuse E135

K 6/9
and terminal C2.5B (instrument panel pcb 1000

connector) to the solenoid positive (+) terminal; E135

when energised, the solenoid will be in the open C655 K 7
(engine run) position.
3
2 1

C2 A5
1010

KSB Solenoid Electrical Circuit, Fig.1

C2 5B
With the master start switch (C655) in position
‘‘2”, a power supply is delivered via terminal K.7

4001

4001
(instrument panel pcb connector), fuse E135,
and terminals C2.5B (instrument panel pcb E A2
connector) and E.A2 (cab/chassis interface
4001

connector) to the inlet manifold temperature 1

switch (E562). With the inlet manifold E562 2
B103
temperature below 32°C, the temperature switch
4004

will be in the closed position and will deliver the

power supply to the KSB solenoid (G204); when
energised, the KSB solenoid will advance the G204
fuel pump timing.
080705

FIG.1. FUEL PUMP SOLENOIDS CIRCUIT

DIAGRAM

+. Positive stud terminal

8 B103. Engine stop solenoid
C655. Master start switch
E135. Fuse (5A)
E562. Inlet manifold temperature switch
G204. KSB solenoid

E9612
5–8–2
5 ELECTRICAL SYSTEM
55 Series Fuel pump solenoids

REMOVAL AND REFITMENT

Engine Stop Solenoid (B103)

To Remove, Fig.2
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries.

3. Tilt the cab see ‘‘Driver’s Handbook”.

4. Noting their positions, remove the electrical

connections from the fuel solenoid.

5. Remove the engine stop solenoid, complete

with O–ring, and carefully extract the spring
and plunger from the fuel stop valve.

To Refit
Reverse the removal procedure, noting:

1. Fit a new O–ring to the solenoid valve. FIG.2. ENGINE STOP SOLENOID
2. Torque tighten the engine stop solenoid to 1. Solenoid 3. Spring
43 Nm (32 lbf ft). 2. O–ring 4. Plunger
3. Ensure that all electrical connections are in
their original positions.

4. If applicable, re–activate the radio security

8
code.

E9612 5–8–3
 ELECTRICAL SYSTEM 5
Fuel pump solenoids 55 Series

KSB Solenoid (G204)

To Remove, Fig.3
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries.

3. Tilt the cab, see ‘‘Driver’s Handbook”.

4. Disconnect the electrical connection from

the KSB solenoid.

5. Remove the KSB solenoid from its housing.

FIG.3. KSB SOLENOID

To Refit
Reverse the removal procedure, noting:

1. Torque tighten the KSB solenoid to 22 Nm

(16 lbf ft).

2. Ensure that the electrical connection is

secure.

3. If applicable, re–activate the radio security

code.

E9612
5–8–4
5 ELECTRICAL SYSTEM
55 Series Fuel pump solenoids

Inlet Manifold Temperature Switch (E562)

To Remove, Fig.4
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of 1
all work.

2. Isolate the batteries.

3. Tilt the cab, see ‘‘Driver’s Handbook”.

4. Disconnect the electrical connection from

the temperature switch. 2

5. Remove the temperature switch from the

engine inlet manifold.

To Refit 080726
Reverse the removal procedure, noting:

1. Torque tighten the temperature switch to FIG.4 INLET MANIFOLD TEMPERATURE

30 Nm (22 lbf ft). SWITCH

1. Electrical connector
2. If applicable, re–activate the radio security
code. 2. Inlet manifold temperature switch (E562)

E9612 5–8–5
 ELECTRICAL SYSTEM 5
Fuel pump solenoids 55 Series

TESTING

KSB Solenoid, Fig.5

1. Connect a 24V supply to the solenoid
electrical terminal and earth the solenoid
body.

2. Apply the 24V supply to the solenoid and

observe the forward movement of the
solenoid plunger. If there is no visible
movement of the solenoid plunger within
60 seconds then the complete solenoid unit
is defective and must be renewed.
NOTE: The amount of solenoid plunger
movement will vary dependent upon the FIG.5. KSB PLUNGER MOVEMENT
ambient temperature. 1. Plunger 2. Solenoid

Inlet Manifold Temperature Switch

1. Connect a multimeter to the electrical pin
connections on the temperature switch .

2. Immerse the sensor end of the temperature

switch in ice water; the multimeter should
indicate a closed circuit. Slowly heat the
water to 32°C; the multimeter should
indicate an open circuit.
NOTE: The temperature switch is
non–adjustable and must be renewed if
defective.

E9612
5–8–6
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 9—TACHOGRAPH
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—9—1 . . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—9—4 . . . . . . . . . 9612

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5 ELECTRICAL SYSTEM
55 Series Tachograph

9. TACHOGRAPH
DESCRIPTION

Circuit Protection, Fig.1

The tachograph electrical circuits are protected
by the following fuses:

— The tachograph clock power supply is

protected by fuse E066 (5 amps); this fuse
is located in the RH instrument panel fuse
box.
NOTE: If the vehicle is to be inactive for
extended periods (in excess of 5 days), it is
recommended that fuse E066 is removed to
prevent unnecessary drain from the battery.

— The tachograph road speed indicator and

recording mechanism electrical circuits are
protected by fuse E035 (5 amps); this fuse
is located in the RH instrument panel fuse
box.

— The tachograph illumination power supply is

protected by fuse E000 (10 amps); this fuse
is located in the LH instrument panel fuse
box.

E9612 5–9–1
 ELECTRICAL SYSTEM 5
Tachograph 55 Series

Electrical Circuits, Fig.1

Tachograph Clock: The positive stud

terminal power supply is delivered via fuse
E066 and terminals C2.2B (instrument
panel pcb connector) and A.1 (component
connector) to the tachograph clock.

Recording Mechanism and Road Speed

Indicator: With the master start switch
(C655) in position ‘‘2”, the power supply is
delivered via fuse E035 and terminals
C2.4B (instrument panel pcb connector)
and A.3 (component connector) to the
tachograph recording mechanism and road
speed indicator.
NOTE: The tachograph receives road
speed signals from the gearbox mounted
road speed sensor (F533).

Tachograph Illumination: With the lighting

switch (C649) is in the ‘‘sidelights” position,
the power supply will be delivered via
terminal L.A3 (instrument panel pcb
connector), fuse E000 (5 amps), resistor
(B034) and terminal C1.7B (instrument
panel pcb connector) to terminal A.2
(component connector) of the tachograph;
the tachograph bulbs will illuminate at
reduced intensity. When the dual level
lighting switch (C650) is activated, the
power supply will by–pass the resistor and
illuminate the tachograph bulbs at normal
intensity.
9

E9612
5–9–2
5 ELECTRICAL SYSTEM
55 Series Tachograph

+. Positive stud terminal +

B501. Tachograph
B034. Resistor
C649. Lighting switch

K 6/9
C650. Dual level lighting switch E066 E035
C655. Master start switch C655
E000. Fuse (10A) K 7 C2 2B C2 4B

E035. Fuse (5A) 3 1

2
E066. Fuse (5A)
1010
F533. Road speed sensor A 1 A 3

1127

1211
D 3
B501

A 5 A 6 A 2 B 4 B 1 B 2 B 3
3021

3020
3018

3019
2102

C2 3B

F533
+

L A3
L 1B L 2B E000
9
H 4B

C649 B034
2102
7B

C650
C1

2622
H A2

081116

FIG.1. TACHOGRAPH CIRCUIT DIAGRAM

E9612 5–9–3
 ELECTRICAL SYSTEM 5
Tachograph 55 Series

REMOVAL AND REFITMENT

Tachograph (B501)
IMPORTANT: The removal and refitment of the
tachograph or the gearbox mounted road speed
sensor must be carried out by qualified
personnel at an authorised Tachograph
Calibration Centre.

To Remove, Fig.2
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries.

3. Remove the knobs from the heater control

levers.

4. Release the steering column adjustment

control and move the steering column away
from the instrument panel.

5. Using a suitable implement (a coin or

screwdriver), rotate each fuse cover quick
release fastener and then slide the fuse
cover downwards to gain access to the
instrument panel retaining screws.

6. Remove the instrument panel retaining

screw from each fuse box.

7. Carefully lift the instrument panel clear of its

9 internal mounting pillars and then pivot it
rearwards to gain access to the tachograph.

8. Disconnect the multi–pin electrical

connections from the rear of the
tachograph.
NOTE: The tachograph calibration seal will
have to be broken to enable the tachograph
to be removed.

9. Remove the clamp fasteners from the

tachograph mounting clamps and withdraw
the tachograph from the instrument panel.

E9612
5–9–4
5 ELECTRICAL SYSTEM
55 Series Tachograph

To Refit
Reverse the removal procedure, noting:

1. The tachograph MUST be calibrated and

re–sealed by qualified personnel at an
authorised Tachograph Calibration Centre. 6

2. If applicable, re–activate the radio security

code.
6
24V
D C B A

>ABS<
5

9
1 4
3
2 2

081096

FIG.2. TACHOGRAPH REMOVAL

1. Fuse box cover – LH 3. Tachograph (B501) 6. Mounting clamp
2. Retaining screws 4. Fuse box cover – RH 7. Clamp fastener
5. Heater control lever knobs

E9612 5–9–5
 E9612
5–9–6
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 10—HORN
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—10—1 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—10—2 . . . . . . . . 9612

10

E9612 1
 E9612
2
5 ELECTRICAL SYSTEM
55 Series Horn

10. HORN
DESCRIPTION

General Information
+
The horn sound output and pressure level is
pre–set in accordance with current EEC
directives and is non–adjustable; the horn must
be renewed if defective.

Circuit Protection E030

The horn electrical circuits are protected by fuse
E030 (10 amps); this fuse is located in the
instrument panel RH fuse box.

C0 4
Electrical Circuit, Fig.1.
The horn switch (C651) is attached to the end of

1138
the LH multi–function switch. The positive stud
terminal power supply is delivered via fuse E030
and terminal C0.4 (instrument panel pcb
connector) to the horn switch (C651). When the C651
horn switch is activated the power supply is
delivered via terminals CO.1 and CS1.6B
(instrument panel pcb connectors) to the horn
C0 1
(B028) positive terminal.

CS1 6B
4535

1
B028 2

080707

FIG.1. HORN CIRCUIT DIAGRAM

+. Positive stud terminal

B028.
C651.
Horn
Horn switch
10
E030. Fuse (10A)

E9612 5–10–1
 ELECTRICAL SYSTEM 5
Horn 55 Series

REMOVAL AND REFITMENT

Horn Switch (C651)

NOTE: The horn switch is an integral part of the
direction indicator multi–function switch. A
defective horn switch will require the renewal of
the direction indicator multi–function switch as
instructed in Section 14.

10

E9612
5–10–2
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 11—VEHICLE LIGHTING

Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—11—1 . . . . . . . . 9612
Dim–Dip Headlight System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—11—4 . . . . . . . . 9612
Side/Tail and Roof Marker Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—11—6 . . . . . . . . 9612
Stop Lights and Reverse Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—11—8 . . . . . . . . 9612
Rear Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—11—9 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—11—14 . . . . . . . 9612

11

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5 ELECTRICAL SYSTEM
55 Series Vehicle lighting

11. VEHICLE LIGHTING

HEADLIGHTS

General Information
The headlight units are pre–focus halogen units.
Each unit is equipped with a vertical and
horizontal beam alignment control. A
hydraulically operated headlight levelling system
is a available as optional equipment.

Circuit Protection
The headlight main beam electrical circuit is
protected by fuse E131 (10 amps) whilst the
headlight dipped beam electrical circuit is
protected by fuse E132 (10 amps); both fuses
are located in the LH instrument panel fuse box.

Electrical Circuit, Fig.1.

With the lighting switch (C649) is in the
‘‘headlights” position, the power supply will be
applied via terminals L.2B and CO.2 (instrument
panel pcb connectors) to the multi–function
switch (C651). The multi–function switch has the
following operating positions:

Dipped Beam Position. With the

multi–function switch in the ‘‘dipped beam”
position, the power supply will energise, via
terminal CO.5 (instrument panel pcb
connector), the headlight dipped beam relay
(G001). With the dipped beam relay
energised, the power supply will be applied
via fuse E132 and terminals CS2.A5
(instrument panel pcb connector) and C2.7B
(cab/chassis interface connector) to the LH
and RH headlight dipped beam units (C000
and C001).

11

E9612 5–11–1
 ELECTRICAL SYSTEM 5
Vehicle lighting 55 Series

Main Beam Position. With the

multi–function switch in the ‘‘main beam”
position, the power supply will energise, via
terminal CO.3 (instrument panel pcb
connector), the headlight main beam relay
(G002) and the main warning light (D000).
With the main beam relay energised, the
power supply will be applied via fuse E131
and terminals CS1.1B (instrument panel pcb
connector) and C2.5B (cab/chassis interface
connector) to the LH and RH headlight main
beam units (C002 and C003).

Headlight ‘‘Flash” Position. When the

multi–function switch is in the headlight
‘‘flash” position, the power supply will
energise, via terminal CO.7 (instrument
panel pcb connector), the headlight main
beam relay (G002) and the main beam
warning light (D000). With the main beam
relay energised, the power supply will be
applied via fuse E131 and terminals
CS1.1B (instrument panel pcb connector)
and C2.5B (cab/chassis interface
connector) to the LH and RH headlight main
beam units (C002 and C003).

11

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5 ELECTRICAL SYSTEM
55 Series Vehicle lighting

L 1B E131 E132
30/51 87

C0 7
C0 2

L 2B 2111 85 86
G001

C0 3 C0 5
2120 85 86 G002
C651 30/51 87
C649

D000
CS2 A5
CS1 1B

C2 3B C2 7B

2117
2127

2127

2117
C002 C000 C003 C001

081103

FIG.1. HEADLIGHT CIRCUIT DIAGRAM

+. Positive stud terminal C651. Multi–function switch

C000. Headlight dipped beam unit – LH D000. Main beam warning light
C001. Headlight dipped beam unit – RH E131. Fuse (10A) – main beam
C002. Headlight main beam unit – LH E132. Fuse (10A) – dipped beam
C003. Headlight main beam unit – RH G001. Relay – dipped beam
C649. Lighting switch G002. Relay – main beam

11

E9612 5–11–3
 ELECTRICAL SYSTEM 5
Vehicle lighting 55 Series

DIM–DIP HEADLIGHT SYSTEM

Description
In accordance with current legislation, all UK
vehicles are fitted with a dim–dip headlight
system. This system will automatically illuminate
the headlights (dipped beam) at a reduced
intensity (approximately 10%) whenever the
sidelights are energised and the engine is
running.

Circuit Protection
The dim–dip headlight electrical circuit is
protected by fuse E001 (10 amps); this fuse is
located in the LH instrument panel fuse box.

Electrical Circuit, Fig.2

With the lighting switch (C649) is in the
”sidelights” position and the engine running, a
24V power supply will energise, via terminal
L.A3 (instrument panel pcb connector), fuse
E001 and terminal CS1.A3 (instrument panel
pcb connector), the dim–dip relay G097. With
the dim–dip relay energised, a 24V power
supply will be applied, via terminal CS1.A1
(instrument panel pcb connector), diode D673 to
the dim–dip resistor B148. A reduced voltage
from the dim–dip resistor will then be applied,
via terminal CS2.A5 (instrument panel pcb
connector) and C2.7B (cab/chassis interface
connector) to the LH and RH headlight dipped
beam units (C000 and C001); the headlight units
will illuminate at a reduced intensity
(approximately 10%).

11

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5 ELECTRICAL SYSTEM
55 Series Vehicle lighting

-
B524
+

CS2 A1

2101

L 1B L 2B
1003

L A3
E001
CS2 A5

C649 D673 CS1 1B

CS1 A3 C2 7B
2128

C2 5B
2103

B148
2126

86 87

G097
2127

2117

2127

2117
85 30/51
2117

2127

C002 C000 C003 C001

081104

FIG.2. HEADLIGHT DIM–DIP CIRCUIT DIAGRAM

+. Positive stud terminal C002. Headlight main beam unit – LH

B148. Resistor – dim–dip C003. Headlight main beam unit – RH
B524. Rev. counter (if fitted) D673. Diode – dim–dip
C000. Headlight dipped beam unit – LH E001. Fuse (10A)
C001. Headlight dipped beam unit – RH G097. Relay – dim–dip
11

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 ELECTRICAL SYSTEM 5
Vehicle lighting 55 Series

SIDE/TAIL AND ROOF MARKER LIGHTS

Circuit Protection
The LH side/tail and roof marker light electrical
circuits are protected by fuse E000 (10 amps)
whilst the RH side/tail and roof marker light
electrical circuits are protected by fuse E001 (10
amps); both fuses are located in the LH
instrument panel fuse box.

Electrical Circuits — LH, Fig.3

With the lighting switch (C649) is in the
‘‘sidelights” position, the power supply will be
applied via terminal L.A3 (instrument panel pcb
connector) and fuse E000 to:

— Terminals CS1.A5 (instrument panel pcb

connector) and C1.A7 (cab/chassis
interface connector) to supply the LH
sidelight (C010) and LH tail lights (C022).

— Terminal CS1.4B (instrument panel pcb

connector) to supply the LH roof marker
light (C012).

Electrical Circuits — RH, Fig.3

With the lighting switch (C649) is in the
‘‘sidelights” position, the power supply will be
applied via terminal L.A3 (instrument panel pcb
connector) and fuse E001 to:

— Terminal CS1.A1 (instrument panel pcb

connector) to supply the RH roof marker
light (C013) .

— Terminals CS1.A2 (instrument panel pcb

connector) and C1.A6 (cab/chassis
interface connector) to supply the RH
sidelight (C011) and RH tail lights (C023).

11

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5 ELECTRICAL SYSTEM
55 Series Vehicle lighting

L 1B L 2B

L A3
E000 E001

C649
CS1 3B

CS1 A5 CS1 4B CS1 A1

CS1 A2
2102

2103

2103
2102

2102

2103
C1 A7 S 3B S 4B C1 A6

2103

A023(2)
A023(3)
C012 C013
2102

2102

A000(6)
2103

2103
A000(2)

C010 C011 C023

C022

081106

FIG.3. SIDE/TAIL AND ROOF MARKER LIGHTS CIRCUIT DIAGRAM

+. Positive stud terminal C022. Tail light – LH

C010. Sidelight – LH C023. Tail light – RH
C011. Sidelight – RH C649. Lighting switch
C012. Roof marker light – LH E000. Fuse (10A) – LH circuits
C013. Roof marker light – RH E001. Fuse (10A) – RH circuits
11

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 ELECTRICAL SYSTEM 5
Vehicle lighting 55 Series

STOP LIGHTS AND REVERSE LIGHTS

Circuit Protection +
The stop lights and reverse lights electrical
circuits are protected by fuse E133 (10 amps);

K 6/9
this fuse is located in the RH instrument panel 1000

fuse box. E133

K 7
1

2 C655
Stop Light Electrical Circuit, Fig.4 C2 A7 C2 6B
With the master start switch (C655) in position 1253

1253
‘‘2”, the power supply is applied via terminal K.7 1010
1253
(instrument panel pcb connector), fuse E133 C1 3B
1 2
1253
and terminal C2.6B (instrument panel pcb E554
4 3
connector) to the stop light switch (E554). When A001(6) E501
the stop light switch is activated, the power
supply will be applied, via terminal C1.A3 C1 A3 S 2B
(cab/chassis interface connector) to the LH and 4591 4601
C2 4B
RH stop lights (C020 and C021).
A001(3) A000(4)
4591

Reverse Lights Electrical Circuit, Fig.4

With the master start switch (C655) in position C692 C027 C020
‘‘2”, the power supply is applied via terminal K.7
5104

(instrument panel pcb connector), fuse E133, C026 C021

and terminals C2.A7 (instrument panel pcb
connector) and C1.3B (cab/chassis interface S A5
connector) to the reverse light switch (E501). B176
When the reverse light switch is activated, the
power supply will be applied to the LH and RH
reverse lights (C026 and C027) and, if fitted, to
the reversing buzzer switch (C692); the 081107
reversing buzzer (B176) will be activated when
the switch is in the on position.
FIG.4. STOP LIGHTS AND REVERSE LIGHTS
CIRCUIT DIAGRAM

+. Positive stud terminal

B176. Reversing buzzer (if fitted)
C020. Stop light – LH
C021. Stop Light – RH
C026. Reverse light – LH
C027. Reverse light – RH
11 C655. Master start switch
C692. Reversing buzzer switch (if fitted)
E133. Fuse (10A)
E501. Reverse light switch
E554. Stop light switch

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5–11–8
5 ELECTRICAL SYSTEM
55 Series Vehicle lighting

REAR FOG LIGHTS

Operation
The rear fog lights can only be operated whilst
the headlights or front fog lights are illuminated.

Circuit Protection
The rear fog light electrical circuit is protected by
fuse E129 (15 amps); this fuse is located in the
LH instrument panel fuse box.

Electrical Circuits, Fig.5

With the lighting switch (C649) in the
‘‘headlights” position, the power supply is
applied via terminal L.2B (instrument panel pcb
connector), diode D600 and terminal H.3B
(instrument panel pcb connector) to the rear fog
light switch (C601). When the rear fog light
switch is activated the power supply will be
applied, via terminal H.4A (instrument panel pcb
connector) to the connector 85 on the rear fog
light relay (G005). When the rear fog relay is
energised, the stud terminal power supply will
be applied through fuse E129 and via terminals
CS2.5B (instrument panel pcb connector) and
C1.A5 (cab/chassis interface connector) to the
LH and RH rear fog lights (C024 and C025); the
rear fog warning light (D093) will illuminate
whilst the rear fog light circuits are energised.

11

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 ELECTRICAL SYSTEM 5
Vehicle lighting 55 Series

Alternative Electrical Circuits, Fig.5

With the lighting switch (C649) in the ‘‘sidelights”
position, the power supply is applied via terminal
L.A3 (instrument panel pcb connector), fuse
E001 and terminal CS1.2B (instrument panel
pcb connector) to the front fog light switch
(C600). With the front fog switch activated, the
power supply will be applied via terminal
CS2.4B (instrument panel pcb connector), diode
D601 and terminal H.3B (instrument panel pcb
connector) to the rear fog light switch (C601).
When the rear fog light switch is activated the
power supply will be applied, via terminal H.4A
(instrument panel pcb connector) to the
connector 85 on the rear fog light relay (G005).
When the rear fog relay is energised, the stud
terminal power supply will be applied through
fuse E129 and via terminals CS2.5B (instrument
panel pcb connector) and C1.A5 (cab/chassis
interface connector) to the LH and RH rear fog
lights (C024 and C025); the rear fog warning
light (D093) will illuminate whilst the rear fog
light circuits are energised.

11

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5–11–10
5 ELECTRICAL SYSTEM
55 Series Vehicle lighting

D601 D600
CS2 4B H 3B
E129 E001
2115

C601
CS1 2B
5
L 1B L 2B
2150

L A3

2103
H A4
85 30/51

G005
86 87
D093 C649
C600
CS2 5B

C1 A5

2152 2140

A001(7)

C024 CO25

2140 081105

FIG.5. REAR FOG LIGHT CIRCUIT DIAGRAM

+. Positive stud terminal D093. Warning light

C024. Rear fog light — LH D600. Diode — rear fog (dipped beam)
C025.
C600.
Rear fog light — RH
Front fog light switch (if fitted)
D601.
E129.
Diode — front and rear fog
Fuse (15A)
11
C601. Rear fog light switch G005. Rear fog light relay
C649. Lighting switch

E9612 5–11–11
 ELECTRICAL SYSTEM 5
Vehicle lighting 55 Series

REMOVAL AND REFITMENT

Headlight Units

To Remove, Fig.6
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries.

3. Remove the headlight grille panel as

instructed in Group 1.

4. Remove the headlight alignment screws,

complete with springs, securing the
headlight unit to the mounting plate.

5. If fitted, remove the headlight levelling

screw, complete with plain washers and
locknut, securing the headlight unit to the
mounting plate.
CAUTION: Do NOT attempt to disconnect
any hydraulic pipes from the headlight
levelling actuators. The ingress of air into
the hydraulic system will necessitate the
renewal of the complete headlight levelling
system.

6. Detach the headlight unit from its location

and disconnect the electrical
multi–connection and sidelight bulb holder
from the rear of the headlight unit.

7. Remove the rubber shroud cover and

extract the headlight bulb from the headlight
unit.

11

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5–11–12
5 ELECTRICAL SYSTEM
55 Series Vehicle lighting

To Refit
Reverse the removal procedure, noting:

1. Ensure the new headlight unit is correctly

positioned on the location pins before fitting
the alignment screws.

2. Check/adjust the headlight unit beam

alignment as instructed in the ‘‘Maintenance
Manual”.

3. If applicable, re–activate the radio security

code.

4 5

6
10 7
9
8
080728

FIG.6. HEADLIGHT UNIT REMOVAL

1. Multi–pin connector 6. Headlight unit 11

2. Rubber shroud cover 7. Headlight levelling screw
3. Headlight bulb 8. Plain washer
4. Spring 9. Locknut
5. Headlight alignment screw 10. Sidelight bulb and holder

E9612 5–11–13
 ELECTRICAL SYSTEM 5
Vehicle lighting 55 Series

Headlight Dipped Beam Relay (G001)

To Remove
1. Remove the dipped beam relay as
instructed in Section 5 (”Instrument Panel
Components”)

To Refit
Reverse the removal procedure.

Headlight Main Beam Relay (G002)

To Remove
1. Remove the main beam relay as instructed
in Section 5 (”Instrument Panel
Components”)

To Refit
Reverse the removal procedure.

Multi–Function Switch (C651)

To Remove
1. Remove the multi–function switch as
instructed in Section 14.

To Refit
Reverse the removal procedure.

Headlight Levelling System

IMPORTANT: The headlight levelling system is
a fully sealed and integral hydraulic system. The
headlight levelling system comprises of a
hydraulic actuator at each headlight unit and a
11 hydraulic control unit in the cab. The complete
hydraulic system must be renewed if any unit
becomes defective or if the hydraulic system is
degraded by the ingress of air.

E9612
5–11–14
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 12—AIR DRYER, HEATED FUEL SEDIMENTER AND HEATED MIRRORS

Air dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—12—1 . . . . . . . . 9612
Heated mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—12—2 . . . . . . . . 9612
Heated fuel sedimenter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—12—3 . . . . . . . . 9612

12

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5 ELECTRICAL SYSTEM
55 Series Air dryer, heated fuel sedimenter and heated mirrors

12. AIR DRYER, HEATED FUEL SEDIMENTER AND HEATED MIRRORS

AIR DRYER

General Information, Fig.1

The air dryer is equipped with a thermostatically
controlled 100W heating element. The heating
element is automatically activated when the
ambient air temperature is between 10° to 29°C.

Circuit Protection
The air dryer electrical circuits are protected by
fuse E091 (15 amps). This fuse is located in the
RH instrument panel fuse box.

Electrical Circuits, Fig.2

With the master start switch (C655) in position
‘‘2”, the power supply will be delivered via
terminal K.7 (instrument panel pcb connector),
fuse E091 and terminals C2.7B (instrument
panel pcb connector) and C2.A5 (cab/chassis
interface connector) to the air dryer unit (B042).

1
080729

FIG.1. AIR DRYER

1. Thermostatically controlled heating element

12

E9612 5–12–1
 ELECTRICAL SYSTEM 5
Air dryer, heated fuel sedimenter and heated mirrors 55 Series

HEATED MIRRORS

General Information +
Each heated mirror is equipped with a 30W
heating element attached to the rear face of the

K 6/9
mirror. 1000

E091
K 7
1
Circuit Protection
3 2
Each heated mirror element electrical circuit is C655 C2 7B
protected by fuse E091 (15 amps). This fuse is

1252
1010
located in the RH instrument panel fuse box.
S 6B

C2 A5
Electrical Circuits, Fig.2

1252
With the master start switch (C655) in position
‘‘2”, the power supply will be delivered via C1 A1

terminal K.7 (instrument panel pcb connector), C531

1252

1252

1252
fuse E091 and terminal C1.A1 (instrument panel
pcb connector) to the heated mirror switch
(C531). When activated, the heated mirror
switch will illuminate and the power supply will B3 2

be delivered to the LH and RH mirror heating

elements (B017 and B018). B147
B042
4532

4532

B017 B018

081038

FIG.2. AIR DRYER, HEATED FUEL

SEDIMENTER AND HEATED MIRRORS
CIRCUIT DIAGRAM

+. Positive stud terminal

B017. Heated mirror element — RH
B018. Heated mirror element — LH
B042. Air dryer
B147. Fuel sedimenter heater
C531. Heated mirror switch
C655. Master start switch
12 E091. Fuse (15A)

E9612
5–12–2
5 ELECTRICAL SYSTEM
55 Series Air dryer, heated fuel sedimenter and heated mirrors

HEATED FUEL SEDIMENTER

General Information, Fig.3

The heated fuel sedimenter is equipped with a
thermostatically controlled 180W heating
element. The heating element will automatically
activate at an ambient air temperature of
approximately 0°C and will remain operative
until the air temperature attains 18°C.
NOTE: The fuel sedimenter heating element
and thermostat are renewable components

Circuit Protection
The heated fuel sedimenter electrical circuits
are protected by fuse E091 (15 amps). This fuse
is located in the RH instrument panel fuse box.

Electrical Circuits, Fig.2

With the master start switch (C655) in position
‘‘2”, the power supply will be delivered via
terminal K.7 (instrument panel pcb connector),
fuse E091 and terminals C2.7B (instrument
panel pcb connector) and C2.A5 (cab/chassis
interface connector) to the heated fuel
sedimenter unit (B147). FIG.3. HEATED FUEL SEDIMENTER

1. Heating element
2. Thermostat

12

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 ELECTRICAL SYSTEM 5
Air dryer, heated fuel sedimenter and heated mirrors 55 Series

12

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5–12–4
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 13—RADIO ELECTRICAL CIRCUITS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—13—1 . . . . . . . . 9612
Radio Fitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—13—2 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—13—4 . . . . . . . . 9612

SECTION 13A—RELAYS
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—13A—1 . . . . . . . 9612

13

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5 ELECTRICAL SYSTEM
55 Series Radio electrical circuit

13. RADIO ELECTRICAL CIRCUIT

DESCRIPTION

Circuit Protection +
The radio ignition control power circuit is
protected by fuse E134 (15 amps) whilst the
radio memory power supply is protected by fuse

K 6/9
1000
E026 (15 amps); both fuses are located in the
RH instrument panel fuse box. E026

NOTE: The radio dropper unit incorporates C655

internal electronic protection against transient C2 1B
voltages and an internal fuse to prevent 3
1 30/51 86
electrical abuse. Failure of the internal fuse will 2 G278
necessitate the renewal of the complete radio

1105
1130 87 85
dropper unit.

K4 RD 3

Radio Electrical Circuits, Fig.1 1143

C1 2B

Power Supply
With the master start switch (C655) in D835 1108
position ”1”, a 24V power supply will E134
energise, via terminal K.4 (instrument panel
pcb connector), fuse E134 and terminal RD 2 RD 1
C1.2B (instrument panel pcb connector) the A4 A7 A8

ignition control relay (G278); with the

1108
ignition control relay energised, a 12V
power supply from the radio dropper unit
will be delivered to the radio (B149). B149
B5 B6 B3 B4

Memory Supply 4541

4542
4540

A 24V power supply from the positive 4543

terminal stud is applied, via fuse E026 and + _ + _
terminals C2.1B (instrument panel pcb
connector) and RD.1 (component
connector) to the radio dropper unit (D835); B024 B025
081046
a voltage converted 12V power supply is
then applied to the radio memory circuit and FIG.1. RADIO CIRCUIT DIAGRAM
ignition control relay (G278).
+. Positive stud terminal
CAUTION: Radios equipped with a security B024. Radio speaker — LH
code will require re–activating whenever the
memory power supply has been interrupted. B025. Radio speaker — RH
B149. Electronic radio
C655. Master start switch
D835. Radio dropper unit
E026. Fuse (15A)
E134. Fuse (15A)
G278. Relay
13

E9612 5–13–1
 ELECTRICAL SYSTEM 5
Radio electrical circuit 55 Series

RADIO FITMENT

General Information
The cab roof centre panel contains a standard
DIN ‘E’ audio component aperture which is
sealed with a blanking plate. All the necessary
electrical wiring and speaker cables are
contained in the radio aperture. All cables are
terminated with DIN standard connectors which
will enable the fitment of a 12V (negative earth)
audio component (radio/cassette/CD player).

NOTE: All vehicles are fitted with a roof

mounted aerial and, located in the DIN ‘E’
aperture, a fully screened extension aerial lead.

Electrical Connections B
To ensure safe electrical connections and also
to prevent irreparable damage to any audio
3

2
4

equipment being fitted, it is essential that the 6

8

1 08

following recommendations are observed: 3

5 =A
M
P
96
44

3
2
7 4
6
8

1. Before attempting to fit any audio A 1

3
M
P
96
44
08

5 =A

component it is essential that the electrical 7

DIN connectors on the rear of the audio 081020

equipment are correctly identified in
accordance with the audio manufacturers
FIG.2. DIN CONNECTOR IDENTIFICATION
instructions.
DIN connector A (brown) – loudspeakers
2. The colour coded DIN connectors contained
DIN connector B (grey) – power supply
in the radio aperture, see Fig.2, provide the
following functions:
– Brown (A): Loudspeakers
– Grey (B): Power supply
Connect the DIN connectors to the
corresponding connectors on the rear of the
audio component.

3. To enable the radio to be ignition controlled,

an electrical relay (Part No. 0515912) will
be required. The ignition control relay must
be connected to the pre–wired position on
the instrument panel mounting bracket as
instructed in ‘REMOVAL AND REFITMENT’
within this Section.

4. After fitting a security coded radio, the

security code will require activating. The
security code will require re–activating
whenever the memory power supply has
been interrupted.
13

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5 ELECTRICAL SYSTEM
55 Series Radio electrical circuit

Loudspeakers
All cabs are equipped with two loudspeaker
enclosures, complete with all necessary wiring,
at either side of the cab header rail. Before
attempting to fit any loudspeakers ensure that
the following information is observed:

— Ensure that the impedance and the power

handling capacity of each loudspeaker is
suitable for the audio component
application; refer to the manufacturers
technical literature.

— To maintain maximum sound quality, it is

important that the loudspeaker cables are
correctly connected to the corresponding
positive (+) and negative (–) loudspeaker
terminals; incorrect connection will result
poor sound quality.
NOTE: The positive (+) loudspeaker cables
are number coded ‘‘4540” (LH speaker) and
‘‘4541” (RH speaker). Loudspeaker positive
terminals can normally be identified by
either a red dot or a ‘‘+” mark.

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 ELECTRICAL SYSTEM 5
Radio electrical circuit 55 Series

REMOVAL AND REFITMENT

Main Trim Panel

To Remove, Fig.3
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Remove the instrument panel as instructed

in Section 5.

3. Release the heater controls from the

instrument panel shroud and then detach
the shroud,from the corner trim panel, main
trim panel and steering column bracket.

4. Remove the retaining screws and bolt

securing the corner trim panel to the
windscreen trim panel and cab door pillar.
Release the door seal and partially
withdraw the corner trim panel; disconnect
the air ducting from the air vent and then
withdraw the corner trim panel.

5. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle and, with the brake and
clutch pedals fully depressed, withdraw the
pedal trim panel.

6. Carefully extract the air vents from the main

trim panel and heater box .

7. Detach the diagnostic socket cover from the

main trim panel; remove the retaining
screws and release the diagnostic socket
and bracket assembly.

8. Remove the retaining screws, nut and

washer securing the main trim panel to the
windscreen trim panel, heater box and cab.
Release the door seal and partially
withdraw the main trim panel; disconnect
the air ducting from the air vents and then
fully withdraw the main trim panel from the
cab.

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55 Series Radio electrical circuit

To Refit
Reverse the removal procedure, noting:

1. If applicable, re–activate the radio security

code.

050574

FIG.3. EXPLODED VIEW OF THE MAIN TRIM PANEL

1. Air vent 4. Diagnostic socket cover 13

2. Main trim panel 5. Air vent
3. Diagnostic socket/bracket assembly

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 ELECTRICAL SYSTEM 5
Radio electrical circuit 55 Series

Radio Dropper Unit (D835)

To Remove, Fig.4
1. Remove the main trim panel as instructed
in this Section.

2. Disconnect the multi–pin connector from

the radio dropper unit.

3. Remove the retaining screws and detach

the radio dropper unit from the bulkhead
panel.

To Refit
Reverse the removal procedure, noting:
2
1. If applicable, re–activate the radio security
code.

1
081097

FIG.4. RADIO DROPPER UNIT AND FUSE

LOCATION

1. Radio dropper unit (D835)

2. Multi–pin electrical connection

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5 ELECTRICAL SYSTEM
55 Series Radio electrical circuit

Ignition Control Relay (G278)

To Remove, Fig.5
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries and fully deplete the air

system. 2 2 1
3 3
3. Remove the knobs from the heater control
levers.

4. Release the steering column control and

then move the steering column away from 4
the instrument panel.

5. Release the quick release fasteners and

slide the fuse covers downwards to gain
access to the instrument panel retaining
screws; remove instrument panel retaining
screw from each fuse box.

6. Carefully lift the instrument panel clear of its

internal mounting pillars and the pivot it
forwards to gain access the instrument
panel mounting bracket.

7. Extract the ignition control relay from its 5

position on the mounting panel connector
(adjacent to the direction indicator audible
relay). 081099

FIG.5. INSTRUMENT PANEL MOUNTED

To Refit RELAYS
Reverse the removal procedure, noting:
1. Heater control knob
1. If applicable, re–activate the radio security 2. Retaining screw
code.
3. Fuse box cover
4. Radio ignition control relay (G278)
5. Audible warning relay (G080)

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 ELECTRICAL SYSTEM 5
Radio electrical circuit 55 Series

13

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5 ELECTRICAL SYSTEM
Relays

13A. RELAYS
TESTING

1. Coil continuity. With a multimeter switched

to ohms, apply probes to terminal blades 85
and 86; the reading should be between 198
and 242 ohms.

2. Normally open contacts (relay not

energised). Connect a 24V positive supply
to terminal 30/51. Connect a multimeter set
to 24V DC between terminal 87 and
negative supply; multimeter should register
no voltage.

3. Normally closed contacts (relay not

energised). connect a 24V positive supply FIG.1. TYPICAL RELAY CIRCUIT
to terminal 30/51. Connect a multimeter
switch to DC volts between relay terminal
87A and negative supply terminal; the
meter should register the supply voltage.

4. Closed contacts (relay energised). Connect

a 24V positive supply across relay terminals
30/51 and 85 and negative to terminal 86.
Connect a multimeter switch to DC volts
between relay terminal 87 and supply
negative. The meter should register supply
voltage.

5. Open contacts (relay energised). Connect a

24V positive supply to relay terminals 30/51
and 85 and a negative to relay terminal 86.
Connect a multimeter switched to DC volts
between relay terminal 87A and supply
negative. The meter should not register.

13

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 ELECTRICAL SYSTEM 5
Relays

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5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 14—DIRECTION INDICATORS AND HAZARD WARNING LIGHTS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—14—1 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—14—4 . . . . . . . . 9612

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55 Series Direction indicators and hazard warning lights

14. DIRECTION INDICATORS AND HAZARD WARNING LIGHTS

DESCRIPTION

Circuit Protection
The direction indicators and hazard warning
electrical circuits are protected by fuse E233
(15 amps); this fuse is located in the LH
instrument panel fuse box.

Direction Indicators Electrical Circuit, Fig.1.

With the master start switch (C655) in position
‘‘2”, a power supply will be applied, via terminal
K.7 (instrument panel pcb connector) to relay
(G222); with the relay energised, the positive
stud terminal power supply will be applied via
fuse E233, terminal H.1B (instrument panel pcb
connector), hazard warning light switch (C653)
and terminals H.2B and CS2.A6 (instrument
panel pcb connectors) to terminal 49 of the
direction indicator relay (D836) and
subsequently applied, via terminal 49A and
terminal CS2.A2 (instrument panel pcb
connector), to the direction indicator
multi–function switch (C651). Operation of the
multi–function switch which will activate the
following circuits:

LH Direction Indicators. With the direction

indicator multi–function switch (C651) in the LH
position, the power supply will be applied, via
terminals CO.6 and CS1.7B (instrument panel
pcb connectors) to:
1. The power supply will be applied via diode
D753 to relay G080; this relay will emit an
audible warning whilst the circuit is
energised.

2. The power supply will be applied, via C1.2B

(cab/chassis interface connector), to the
following circuits:

— LH Front direction indicator lights

(C014).

— LH Side direction indicator lights

(C016).

— LH Rear direction indicator lights

(C018).

— Direction indicator warning light –

vehicle (D001)

— Direction indicator warning light –

trailer (D002)
14
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 ELECTRICAL SYSTEM 5
Direction indicators and hazard warning lights 55 Series

RH Direction Indicators. With the direction

indicator multi–function switch in the RH
position, the power supply will be applied, via
terminals CO.9 and CS1.A6 (instrument panel
pcb connectors) to:
1. The power supply will be applied via diode
D754 to relay G080; this relay will emit an
audible warning whilst the circuit is
energised.

2. The power supply will be applied, via C1.1B

(cab/chassis interface connector), to the
following circuits:

— RH Front direction indicator lights

(C015).

— RH Side direction indicator lights

(C017).

— RH Rear direction indicator lights

(C019).

— Direction indicator warning light –

vehicle (D001)

— Direction indicator warning light –

trailer (D002)

Hazard Warning Light Electrical Circuit,

Fig.1
The positive stud terminal power supply is
applied, via fuse E233 and terminal H.1B
(instrument panel pcb connector), to the hazard
warning light switch (C653). When the switch is
activated, the power supply will energise relay
G221 and will also be applied, via diode D734
and terminal CS2.A3 (instrument panel pcb
connector), to terminal 30B on the direction
indicator relay (D836). The power supply from
the direction indicator relay (terminal 49A) will
simultaneously activate, via diodes (D732 and
D733), the following circuits:

— All RH direction indicator circuits.

— All LH direction indicator circuits.

— Hazard warning light (D092).

— Audible warning relay (G080).

14
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 5 ELECTRICAL SYSTEM
55 Series Direction indicators and hazard warning lights

K 6/9
1000

C655 K 7

49A
30B
3 1

C1

C2
31
49
2 1010
D836
3 1 2 5 7 6
G222
2000

3401
2003

3400
E233 C653 2025
CS2 A6
2B

H 1B 7 2023 CS2 A3
CS2 A2
1102 5
H
H A1

2024
1
FL 5B
G221 D734
FL 4B

G080
C0 8

D732 D733 C651

C0 6 C0 9
D092 2030

2030 D001 D002

CS1 7B CS1 A6

D753 2006 2007 D754

2006

2007

2006 2007

C1 2B C1 1B

A000(3)
C015 C017 A000(5)

C016 C014
C018 C019
081045

FIG.1. DIRECTION INDICATORS AND HAZARD WARNING LIGHT CIRCUIT DIAGRAM

+. Positive stud terminal D092. Hazard warning light
C014. Front direction indicator lights (LH) D732. Diode (D9)
C015. Front direction indicator lights (RH) D733. Diode (D10)
C016. Side direction indicator lights (LH) D734. Diode (D11)
C017. Side direction indicator lights (RH) D753 Diode
C018. Rear direction indicator lights (LH) D754 Diode
C019. Rear direction indicator lights (RH) D836. Direction indicator electronic unit
C651. Direction indicator multi–function switch E233. Fuse (15A)
C653. Hazard warning light switch G080 Audible warning relay
C655. Master start switch G221. Hazard warning relay
D001. Direction indicator warning light (vehicle) G222. Direction indicator relay
D002. Direction indicator warning light (trailer)
14
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 ELECTRICAL SYSTEM 5
Direction indicators and hazard warning lights 55 Series

REMOVAL AND REFITMENT

Direction Indicator Multi–Function Switch

(C651)

To Remove, Fig.2
NOTE: Ensure that the vehicle road wheels are
in the straight ahead position before attempting
to remove the multi–function switches.

1. Before disconnecting the vehicle battery

supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries and fully deplete the

vehicle air system.

3. Prise the motif cover from the steering

wheel.

4. Remove the nut securing the steering wheel

to the column and then detach the steering
wheel.

5. Remove the retaining screws securing the

lower shroud cover to the steering column.
With the clutch and brake pedals fully
depressed, remove the lower shroud cover.

6. Release the steering column adjustment

control and move the steering column away
from the instrument panel.

7. Remove the control knob from steering

column adjustment control.

8. Detach the protective caps and remove the

retaining screws securing the steering
column LH and RH shroud covers.

9. Vehicles fitted with a Glow Plug Switch:

Partially withdraw the LH shroud cover from
the steering column to gain access to the
glow plug switch and then, noting their
positions, disconnect the electrical
connections from the glow plug switch.

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5 ELECTRICAL SYSTEM
55 Series Direction indicators and hazard warning lights

10. Remove the LH and RH shroud covers from

the steering column.
NOTE: The retaining screw holes in each
shroud cover are reinforced with a plain
washer which is positioned within the
internal surface of each shroud cover.
Ensure that the washers are retained with
the shroud covers.

11. Remove the knobs from the heater control

levers.

12. Using a suitable implement (a coin or

screwdriver), rotate each fuse cover quick
release fastener and then slide the fuse
cover downwards to gain access to the
instrument panel retaining screws.

13. Remove the instrument panel retaining

screw from each fuse box.

14. Carefully lift the instrument panel clear of its

internal mounting pillars and then pivot it
rearwards to gain access to the
multi–function switch electrical connections.

15. Disconnect the multi–function switch

electrical connections from the instrument
panel binnacle.

16. Release the clamp screw securing the

multi–function switches to the steering
column and detach the complete switch
assembly.

17. Remove the screws retaining the

washer/wiper switch to the mounting plate
and separate the multi–function switches;
do NOT remove the screws securing the
direction indicator switch to the mounting
plate.

14
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 ELECTRICAL SYSTEM 5
Direction indicators and hazard warning lights 55 Series

To Refit
Reverse the removal procedure, noting:

1. Ensure that the location pin in the steering 3. Ensure that the plain washers are in
shaft is correctly located in centre of the position on the shroud cover; if necessary,
switch cancellation sleeve. lightly grease the washers to hold in
position whilst fitting the shroud cover.
2. If applicable, ensure that the glow plug
switch electrical connections are in their 4. If applicable, re–activate the radio security
original positions. code.

INT
.

081120

FIG.2. EXPLODED VIEW OF THE MULTI–FUNCTION SWITCHES

1. Direction indicator multi–function switch 3. Wiper/washer multi–function switch

2. Retaining screw 4. Mounting plate

14
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5 ELECTRICAL SYSTEM
55 Series Direction indicators and hazard warning lights

Direction Indicator Electronic Unit (D836)

To Remove, Fig.3
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries.

3. Remove the knobs from the heater control 1

levers.

4. Using a suitable implement (a coin or

screwdriver), rotate each fuse cover quick
release fastener and then slide the fuse
cover downwards to gain access to the
instrument panel retaining screws. 2

5. Remove the instrument panel retaining

screw from each fuse box.

6. Carefully lift the instrument panel clear of its

internal mounting pillars and then pivot it
rearwards to gain access to the direction
indicator electronic unit.

7. Disconnect the multi–pin electrical

connector from the electronic unit.

8. Remove the nuts and detach the electronic

unit from the mounting bracket.

To Refit
Reverse the removal procedure, noting:

1. If applicable, re–activate the radio security 081098

code.
FIG.3. DIRECTION INDICATOR ELECTRONIC
UNIT LOCATION

1. Multi–pin electrical connection

2. Electronic unit (D836)

14
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 ELECTRICAL SYSTEM 5
Direction indicators and hazard warning lights 55 Series

Direction Indicator Relay (G222)

To Remove
1. Remove the direction indicator relay as
instructed in Section 5 (‘‘Instrument Panel
Components”)

To Refit
Reverse the removal procedure.

Hazard Warning Relay (G221)

To Remove
1. Remove the hazard warning relay as
instructed in Section 5 (‘‘Instrument Panel
Components”)

To Refit
Reverse the removal procedure.

14
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5 ELECTRICAL SYSTEM
55 Series Direction indicators and hazard warning lights

Audible Warning Relay (G080)

To Remove, Fig. 4
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries and fully deplete the air

system. 2 2 1
3 3
3. Remove the knobs from the heater control
levers.

4. Release the steering column control and

then move the steering column away from 4
the instrument panel.

5. Release the quick release fasteners and

slide the fuse covers downwards to gain
access to the instrument panel retaining
screws; remove instrument panel retaining
screw from each fuse box.

6. Carefully lift the instrument panel clear of its

internal mounting pillars and then pivot it
forwards to gain access to the instrument
panel mounting bracket.

7. Connect the audible warning relay G080 in 5

position on the mounting panel connector
(adjacent to the radio ignition control relay –
if fitted). 081099

FIG.4. INSTRUMENT PANEL MOUNTED

To Refit RELAYS
Reverse the removal procedure, noting:
1. Heater control knob
1. If applicable, re–activate the radio security 2. Retaining screw
code.
3. Fuse box cover
4. Radio ignition control relay (G278) – if fitted
5. Audible warning relay (G080)

14
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 ELECTRICAL SYSTEM 5
Direction indicators and hazard warning lights 55 Series

14
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5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 15—CARGO AREA LIGHT

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—15—1 . . . . . . . . 9612 15
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—15—2 . . . . . . . . 9612

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55 Series Cargo light area

15. CARGO AREA LIGHT

DESCRIPTION

Circuit Protection
The cargo area light electrical circuit is protected
by fuse E129 (15 amps); this fuse is located in
+ 15
the LH instrument panel fuse box.

E129
Electrical Circuit, Fig.1
The positive stud terminal power supply is
delivered via fuse E129 and terminal E.1B
E 1B
(instrument panel pcb connector) to the cargo
area light switch (C536). When activated, the 1145
switch will illuminate and deliver the power
supply, via terminal C1.6B (cab/chassis
interface connector), to the body builder socket C536
(A023/1).

C1 6B

1146

A023(1) 081039

FIG.1. CARGO AREA LIGHT CIRCUIT

DIAGRAM

+. Positive stud terminal

C536. Cargo area light switch
E129. Fuse (15A)

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 ELECTRICAL SYSTEM 5
Cargo light area 55 Series

REMOVAL AND REFITMENT

Cargo Area Light Switch (C536)

15 To Remove, Fig.2
8

1. Before disconnecting the vehicle battery 01

301 2
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.
7
2. Disconnect the batteries.

3. If fitted, remove the headlight levelling

control knob from the centre console.

4. Extract the cigar lighter from its unit. 1

5. Detach the access panel from beneath the 2 3
handbrake control and then remove the
centre console front retaining screw. 3

6. Remove the rear retaining screws from

either side of the centre console.

7. Carefully manoeuvre the centre console

from its location.
4
8. Remove the four retaining screws and
detach the switch mounting plate.
5 6
9. Noting their positions, disconnect the
081100
electrical connections from the cargo area
light switch.
FIG.2. CARGO AREA LIGHT SWITCH
10. Depress the retaining lugs and extract the
cargo area light switch from the switch 1. Headlight levelling control knob
mounting plate. 2. Cigar lighter
3. Retaining screw – rear
To Refit 4. Centre console
Reverse the removal procedure, noting: 5. Retaining screw – front
6. Access panel
1. If applicable, re–activate the radio security
code. 7. Switch mounting plate
8. Switch

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5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 16—COURTESY LIGHTS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—16—1 . . . . . . . . 9612

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55 Series Courtesy lights

16. COURTESY LIGHTS

DESCRIPTION

Circuit Protection +
The courtesy lights electrical circuits are
protected by fuse E129 (15 amps); this fuse is
located in the LH instrument panel fuse box.

Electrical Circuit, Fig.1.

E129
16
The positive stud terminal power supply is
applied via fuse E129 and terminal E.A1
(instrument panel pcb connector) to the RH and E A1
LH courtesy light switches (C054 and C055).
Each courtesy light switch has the following 1145
operating positions:

1145
— Position ‘‘2”: In this position the courtesy 1 1

light will be operated by the appropriate C054 C055

door sensor (E514 or E515); the courtesy 3 3
2 2
light will illuminate when the cab door is
opened and extinguish when the cab door 2614

2615
is closed.

— Central Position: Off position.

E514 E515
— Position ‘‘3”: Courtesy lights illuminated
continuously. 081040

FIG.1. COURTESY LIGHT CIRCUIT DIAGRAM

+. Positive stud terminal

C054. Courtesy light switch – RH
C055. Courtesy light switch – LH
E129. Fuse (15A)
E514. Door sensor – LH
E515. Door sensor – RH

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 ELECTRICAL SYSTEM 5
Courtesy lights 55 Series

16

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55 Series Contents

CONTENTS Page Date

SECTION 17—PRE–GLOW SYSTEM

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—17—1 . . . . . . . . 9612
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—17—2 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—17—3 . . . . . . . . 9612

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55 Series Pre–glow system

17. PRE–GLOW SYSTEM

DESCRIPTION

General Information +
The pre–glow system is utilised in sub–zero
temperatures to assist in starting the engine

K 6/9
A500 A500 1000
and, if required, to minimise white smoke

1000
exhaust emissions after the engine has started. C655
The pre–glow system comprises of the glow 86

plug switch (C654), glow plug relay (G014) and K 7

two 12V glow plugs (B038). G014 3 1 E091

1000
C2 A7
85
2 1010
17

4014
Circuit Protection

4013
30
The pre–glow control circuit is protected by fuse 1000
4002
E091 (15 amps); this fuse is located in the RH CS1 A7 50

instrument panel fuse box. B038 K3

4013
B038 C654 B010
Electrical Circuit, Fig.1 1252
With the master start switch (C655) in position
‘‘2” and the engine stopped, a power supply will K 8
be delivered via terminal K.7 (instrument panel 081041
pcb connector), fuse E091 and terminal K.8
(instrument panel pcb connector) to the
pre–glow switch (C654). When the pre–glow FIG.1. PRE–GLOW CIRCUIT DIAGRAM
switch is activated the power supply is +. Positive stud terminal
delivered, via terminals K.3 and CS1.A7
(instrument panel pcb connectors) and C2.A7 A500. Battery
(cab/chassis interface connector) to the B010. Starter motor
pre–glow relay (G014). With the pre–glow relay B038. Glow plug
energised, the power supply from the starter
C654. Pre–glow switch
motor (B010) + terminal will be delivered to the
glow plugs (B038). C655. Master start switch
NOTE: The glow plugs are 12V units which are E091. Fuse (15A)
connected in series to be compatible with the G014. Pre–glow relay
vehicle 24V system.

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 ELECTRICAL SYSTEM 5
Pre–glow system 55 Series

OPERATING PROCEDURES

Pre–Glow Cold Start System

In sub–zero temperatures the pre–glow (cold
start) system must be activated before starting
the engine. Operate the pre–glow system using
the following procedure:

1. Switch on the contact.

17 2. Dependent upon the ambient air

temperature, depress the spring loaded
pre–glow button for the appropriate
duration:

Temperature Duration
0°C to –5°C up to 20 secs
–6°C to –12°C 20 to 40 secs
–13°C to –20°C 40 to 90 secs

3. With the pre–glow button still depressed,

start the engine using the recommended
procedure. Immediately the engine starts
and runs release the pre–glow button.

4. To reduce the emission of white exhaust

smoke once the engine has started, the use
of the pre–glow system can be prolonged,
dependent upon ambient air temperature,
for the following durations:

Temperature Duration
0°C to –5°C up to 1 min
–6°C to –12°C 1 to 2 mins
–13°C to –20°C 2 to 5 mins

For temperatures above 0°C, the cold start

system can also be used for pre–glowing
and prolonged glowing at the discretion of
the driver.

CAUTION: Prolonged and excessive use of

the pre–glow system, particularly at low
ambient temperatures, will degrade the
performance of the batteries.

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5 ELECTRICAL SYSTEM
55 Series Pre–glow system

REMOVAL AND REFITMENT

Glow Plug Switch (C654)

To Remove, Fig.2
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Disconnect the batteries. 17

3. Remove the retaining screws securing the
lower shroud cover to the steering column.
With the clutch and brake pedals fully
depressed, remove the lower shroud cover.

4. Detach the protective caps and remove the

retaining screws, complete with the cup
washers and plain washers, securing the
LH upper shroud cover to the steering
column.

5. Partially withdraw the LH shroud cover from

the steering column to gain access to the
glow plug switch and then, noting their
positions, disconnect the electrical
connections from the glow plug switch.

6. Remove the LH shroud cover from the

steering column.
NOTE: Each retaining screw hole in the
shroud cover is reinforced with a plain
washer which is positioned on the internal
surface of the shroud cover. Ensure that the
plain washers are retained with the shroud
cover.

7. Depress the retaining lugs and extract the

glow plug switch from the shroud cover.

E9612 5–17–3
 ELECTRICAL SYSTEM 5
Pre–glow system 55 Series

To Refit
Reverse the removal procedure, noting:

1. Ensure all electrical connections are

re–connected to their original positions.

2. Ensure that the plain washers are in

position on the shroud cover; if necessary,
17 lightly grease the washers to hold in
position whilst fitting the shroud cover.

3. If applicable, re–activate the radio security

code.

4 5 7
2 3

6
080734

FIG.2. GLOW PLUG SWITCH REMOVAL

1. Glow plug switch (C654)

2. Protective cap
3. Retaining screw
4. Cup washer
5. Plain washer
6. LH shroud cover
7. Electrical connections

E9612
5–17–4
5 ELECTRICAL SYSTEM
55 Series Pre–glow system

Glow Plugs (B038)

To Remove, Fig.3
1. Before disconnecting the vehicle battery 1
supply, ensure that, if applicable, the radio 2 3
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries. 17

3. Fully tilt the cab as instructed in the
‘‘Driver’s Handbook”. 4

4. Release the rubber boot from each glow

plug and remove the remove the offset 5
slotted fastenings retaining the electrical 7 6 080735
cables.

5. Disconnect the electrical cable from each FIG.3. EXPLODED VIEW OF THE GLOW
glow plug and detach the ceramic insulators PLUG ASSEMBLY
and connecting link from the glow plugs.
1. Glow plug
6. Remove the glow plugs from the engine 2. Connecting link
inlet manifold. 3. Ceramic insulator
4. Offset slotted fastening
To Refit 5. Rubber boot
Reverse the removal procedure, noting: 6. Electrical cable (power supply)
7. Electrical cable (earth)
1. Ensure that the ceramic insulators are fitted
with the ceramic surface facing the
connecting link.

2. If applicable, re–activate the radio security

code.

E9612 5–17–5
 ELECTRICAL SYSTEM 5
Pre–glow system 55 Series

Glow Plug Relay (G014)

To Remove, Fig.4
WARNING: To prevent accidental short
circuits, do NOT place tools or metal objects
on or near the battery terminals.

1. Before disconnecting the vehicle battery

17 supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Remove the battery cover.

3. Isolate the batteries.

4. If fitted, release the battery anti–theft

device.

5. Remove the batteries.

6. Noting their positions, disconnect the 081121

electrical connections from the glow plug
relay.
FIG.4. GLOW PLUG RELAY
7. Remove the retaining screws and detach
the glow plug relay from the rear of the
battery carrier.

To Refit
Reverse the removal procedure, noting:

1. Ensure that the glow plug relay electrical

connections are in their original positions.

2. If applicable, re–activate the radio security

code.

E9612
5–17–6
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 18—HEATER MOTOR

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—18—1 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—18—2 . . . . . . . . 9612

18

E9612 1
18

E9612
2
5 ELECTRICAL SYSTEM
55 Series Heater motor

18. HEATER MOTOR

DESCRIPTION
+

K 6/9
1000

Circuit Protection
C655
The fan heater motor electrical circuit is
protected by fuse E134 (15 amps); this fuse is
1130
located in the RH instrument panel fuse box.
3 1
K 4
2

Electrical Circuit, Fig.1.

With the master start switch (C655) in position
‘‘1”, the power supply will be delivered via E134
terminal K.4 (instrument panel pcb connector),
fuse E134 and terminals C1.A2 (instrument
panel pcb connector) and HS.A1 (component
connector) to the heater motor switch (C587).
The heater motor switch has the following
C1 A2 18

1254
operating positions:

— Off Position. HS A1

C587
— 1st Position (Slow Speed). The power
supply will be delivered via terminals HS.1B
(component connector), E.4B (cab/chassis
interface connector), HM.3 (component HS 1B HS 2B HS A3

connector) and two integral resistors to the

heater motor (B145).
4651
4650

4652

— 2nd Position (Intermediate Speed). The

power supply will be delivered via terminals
E 4B E 3B E 2B
HS.2B (component connector), E.3B
(cab/chassis interface connector), HM.2
4650

4651

4652

(component connector) and a single integral

resistor to the heater motor (B145).
HM 3 HM 2 HM 1
— 3rd Position (Fast Speed). The power
supply will be delivered via terminals HS.A3
(component connector), E.2B (cab/chassis
interface connector) and HM.1 (component
connector) directly to the heater motor
(B145).
B145

HM 4

080718

FIG.1. HEATER MOTOR CIRCUIT DIAGRAM

+. Positive stud terminal

B145. Heater motor
C587. Heater motor switch
C655. Master start switch
E134. Fuse (15A)

E9612 5–18–1
 ELECTRICAL SYSTEM 5
Heater motor 55 Series

REMOVAL AND REFITMENT

Heater Motor Switch (C587)

To Remove
1. Remove the heater motor switch as
instructed in Section 5 (‘‘Instrument Panel
Components”).

To Refit
Reverse the removal procedure.

18 Heater Motor (B145)

To Remove, Fig.2
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio 080737

security code is available to enable the

radio to be re–activated upon completion of FIG.2. HEATER MOTOR REMOVAL
all work.

2. Disconnect the batteries.

3. Tilt the cab, see ‘‘Driver’s Handbook”.

4. Disconnect the heater motor multi–pin

connector and release the electrical cable
from its retaining clip.

5. Remove the nuts and bolts and detach the

heater motor assembly from the cab floor.

6. Remove the retaining screws and separate

the heater motor and mounting plate.

To Refit
Reverse the removal procedure, noting:

1. If applicable, re–activate the radio security

code.

E9612
5–18–2
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 19—WINDSCREEN WIPERS AND WASHERS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—19—1 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—19—3 . . . . . . . . 9612

19

E9612 1
19

E9612
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5 ELECTRICAL SYSTEM
55 Series Windscreen wipers and washers

19. WINDSCREEN WIPERS AND WASHERS

DESCRIPTION

Circuit Protection
The windscreen wipers and washers electrical
circuits are protected by fuse E134 (15 amps);
this fuse is located in the RH instrument panel
fuse box.

Windscreen Wipers Electrical Circuit, Fig.1.

With the master start switch (C655) in position
‘‘1”, the power supply will be delivered via fuse
E134 and terminals C1.1B (instrument panel
pcb connector) and terminal WS.1 (component
connector) to the windscreen wipers and
washers multi–function switch (C652). The
multi–function switch has the following
functions:
Wipers—off position. In this position, the
19
multi–function switch is connected to
terminal WS.4 and WS.5 (component
connectors), to terminals IS.4 and IS.5 on
the wiper/washer relay (D584); this enables
the wiper motor (B000) to operate to the
‘‘self–park” position.

Wipers—intermittent position. In this

operating position the power supply from
the multi–function switch is delivered, via
terminal WS.3 (component connector), to
terminal IS.3 on the wiper/washer relay
(D584). The wiper/washer relay is
connected, via terminal IP.3, to the wiper
motor (B000).
NOTE: A single operation of the
multi–function switch will activate the
intermittent wipe mode.

E9612 5–19–1
 ELECTRICAL SYSTEM 5
Windscreen wipers and washers 55 Series

K 6/9
1000
Wipers—slow speed position. In this
operating position the power supply from
the multi–function switch is delivered, via C655
terminal WS.5 (component connector), to
terminal IS.5 on the wiper/washer relay 3 1

(D584). The wiper/washer relay is

1130
2
connected, via terminal IP.5, to the wiper
K 4
motor (B000).
C652
Wipers—fast speed position. In this E134
operating position the power supply from
the multi–function switch is delivered, via
terminal WS.3 (component connector), to
terminal IS.3 on the wiper/washer relay C1 1B
(D584). The wiper/washer relay is
connected, via terminal IP.3, to the wiper
19
1254
motor (B000). WS 3 WS 4 WS 5
WS 1

4575

4576

4577
4503
Washers. The power supply is delivered,
via terminal WS.1 (component connector)
to the washer switch (C652). When the C652
washer switch is activated the power supply IS1 IS2 IS3 IS4 IS5
will be delivered, via terminal WS.2 D584
IP1 IP2 IP3 IP4 IP5
(component connector), to terminal IS.2 on WS 2

the wiper/washer relay (D584). The wiper 4503

1254
relay will deliver power, via terminal IP.2, to
4509
4508

4507
the windscreen washer pump (B001).
NOTE: When the windscreen washers are
4503

activated, the windscreen wipers will also 53b 31b 53 53a

operate for 3 to 4 sweeps of the
windscreen.

B001 B000
1254

081042

FIG.1. WINDSCREEN WIPERS AND

WASHERS CIRCUIT DIAGRAM

+. Positive stud terminal

B000. Wiper motor
B001. Washer pump
C652. Wiper/washer switch
C655. Master start switch
D584. Relay, wiper/washer
E134. Fuse (15A)

E9612
5–19–2
5 ELECTRICAL SYSTEM
55 Series Windscreen wipers and washers

REMOVAL AND REFITMENT

Wiper/Washer Multi–Function Switch (C652)

To Remove, Fig.2
NOTE: Ensure that the vehicle road wheels are
in the straight ahead position before attempting
to remove the multi–function switches.

1. Before disconnecting the vehicle battery

supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Isolate the batteries and fully deplete the

vehicle air system.

3. Prise the motif cover from the steering

wheel.
19
4. Remove the nut securing the steering wheel
to the column and then detach the steering
wheel.

5. Remove the retaining screws securing the

lower shroud cover to the steering column.
With the clutch and brake pedals fully
depressed, remove the lower shroud cover.

6. Release the steering column adjustment

control and move the steering column away
from the instrument panel.

7. Remove the control knob from steering

column adjustment control.

8. Detach the protective caps and remove the

retaining screws securing the steering
column LH and RH shroud covers.

9. Vehicles fitted with a Glow Plug Switch:

Partially withdraw the LH shroud cover from
the steering column to gain access to the
glow plug switch and then, noting their
positions, disconnect the electrical
connections from the glow plug switch.

E9612 5–19–3
 ELECTRICAL SYSTEM 5
Windscreen wipers and washers 55 Series

10. Remove the LH and RH shroud covers from

the steering column.
NOTE: The retaining screw holes in each
shroud cover are reinforced with a plain
washer which is positioned within the
internal surface of each shroud cover.
Ensure that the washers are retained with
the shroud covers.

11. Remove the knobs from the heater control

levers.

12. Rotate each fuse cover quick release

fastener using a suitable implement (a coin
or screwdriver) and then slide the fuse
cover downwards to gain access to the
19 instrument panel retaining screws; remove
the instrument panel retaining screw from
each fuse box.

13. Carefully lift the instrument panel clear of its

internal mounting pillars and then pivot it
rearwards to gain access to the
multi–function switch electrical connections.

14. Disconnect the multi–function switch

electrical connections from the instrument
panel binnacle.

15. Release the clamp screw securing the

multi–function switches to the steering
column and detach the complete switch
assembly.

16. Remove the screws retaining washer/wiper

switch to the mounting plate and separate
the multi–function switches; do NOT
remove the screws securing the direction
indicator switch to the mounting plate.

E9612
5–19–4
5 ELECTRICAL SYSTEM
55 Series Windscreen wipers and washers

To Refit
Reverse the removal procedure, noting:

1. Ensure that the location pin in the steering 3. Ensure that the plain washers are in
shaft is correctly located in centre of the position on the shroud cover; if necessary,
switch cancellation sleeve. lightly grease the washers to hold in
position whilst fitting the shroud cover.
2. If applicable, ensure that the glow plug
switch electrical connections are in their 4. If applicable, re–activate the radio security
original positions. code.

1
19
2

INT
.

081120

FIG.2. EXPLODED VIEW OF THE MULTI–FUNCTION SWITCHES

1. Direction indicator multi–function switch 3. Wiper/washer multi–function switch

2. Retaining screw 4. Mounting plate

E9612 5–19–5
 ELECTRICAL SYSTEM 5
Windscreen wipers and washers 55 Series

Main Trim Panel

To Remove, Fig.3
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Remove the instrument panel as instructed

in Section 5.

3. Release the heater controls from the

instrument panel shroud and then detach
the shroud from the corner trim panel, main
trim panel and steering column bracket.
19 4. Remove the retaining screws and bolt
securing the corner trim panel to the
windscreen trim panel and cab door pillar.
Release the door seal and partially
withdraw the corner trim panel; disconnect
the air ducting from the air vent and then
withdraw the corner trim panel.

5. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle and, with the brake and
clutch pedals fully depressed, withdraw the
pedal trim panel.

6. Carefully extract the air vents from the main

trim panel and heater box.

7. Detach the diagnostic socket cover from the

main trim panel; remove the retaining
screws and release the diagnostic socket
and bracket assembly.

8. Remove the retaining screws, nut and

washer securing the main trim panel to the
windscreen trim panel, heater box and cab.
Release the door seal and partially
withdraw the main trim panel; disconnect
the air ducting from the air vents and then
fully withdraw the main trim panel from the
cab.

E9612
5–19–6
5 ELECTRICAL SYSTEM
55 Series Windscreen wipers and washers

To Refit
Reverse the removal procedure, noting:

1. If applicable, re–activate the radio security

code.

3
19
1

050574

FIG.3. EXPLODED VIEW OF THE MAIN TRIM PANEL

1. Air vent 4. Diagnostic socket cover

2. Main trim panel 5. Air vent
3. Diagnostic socket/bracket assembly

E9612 5–19–7
 ELECTRICAL SYSTEM 5
Windscreen wipers and washers 55 Series

Windscreen Wiper/Washer Relay (D584)

To Remove, Fig.4
1. Remove the main trim panel as instructed
in this Section.

2. Disconnect the electrical connectors from

the relay.

3. Remove the retaining screws and detach

the relay from the cab bulkhead panel.

To Refit
Reverse the removal procedure.

19

081101

FIG.4. WINDSCREEN WIPER/WASHER

RELAY LOCATION

E9612
5–19–8
5 ELECTRICAL SYSTEM
55 Series Windscreen wipers and washers

Windscreen Wiper Motor (B000)

To Remove, Fig.5
1. Remove the main trim panel as instructed
in this Section.

2. Remove the nuts and release the cable

clips retaining the cable looms to the wiper
motor bracket.

3. Disconnect the electrical multi–pin

connection from the windscreen wiper
motor.

4. Release the ball joints and detach the wiper

arm linkages from the windscreen wiper
motor lever arm. 19
5. Remove the retaining screws securing the
windscreen wiper motor and mounting
bracket assembly to the cab bulkhead.

6. Remove the retaining screws and separate

the windscreen wiper motor and mounting
bracket.

To Refit
Reverse the removal procedure.

E9612 5–19–9
 ELECTRICAL SYSTEM 5
Windscreen wipers and washers 55 Series

Wiper Arm Linkage

To Remove, Fig.5
1. Remove the main trim panel as instructed
in this Section.

2. Open the cab front access panel and

secure in position with the panel stay.

3. Remove centre access panel from the cab

bulkhead.

4. Remove the two setscrews securing the

heater distribution housing to the cab
bulkhead.

19 5. From within the cab, remove the two

retaining screws and manoeuvre the heater
distribution housing assembly aside.

6. Release the ball joints from the wiper

spindle(s) and wiper motor lever arm and
detach the required wiper arm linkage.

To Refit
Reverse the removal procedure.

E9612
5–19–10
5 ELECTRICAL SYSTEM
55 Series Windscreen wipers and washers

2
1
2

4
19

080739

FIG.5. WINDSCREEN WIPER MOTOR, LINKAGE AND SPINDLE ASSEMBLY

1. Spindle assembly — LH 3. Spindle assembly — RH

2. Wiper arm linkage 4. Wiper motor (B000)

E9612 5–19–11
 ELECTRICAL SYSTEM 5
Windscreen wipers and washers 55 Series

Wiper Spindle Assembly — LH Side

To Remove, Fig.5
1. Remove the instrument panel as instructed
in Section 5.

2. Release the heater controls from the

instrument panel shroud and then detach
the shroud from the corner trim panel, main
trim panel and steering column bracket.

3. Remove the retaining screws and bolt

securing the corner trim panel to the
windscreen trim panel and cab door pillar.
Release the door seal and partially
withdraw the corner trim panel; disconnect
19 the air ducting from the air vent and then
withdraw the corner trim panel.

4. Release the wiper linkage ball joint from the

wiper spindle.

5. Disconnect the washer pipe from the wiper

arm.

6. Remove retaining nut and detach the wiper

arm and spindle cover.

7. Remove the wiper spindle retaining nut and

detach the wiper spindle assembly.

To Refit
Reverse the removal procedure.

E9612
5–19–12
5 ELECTRICAL SYSTEM
55 Series Windscreen wipers and washers

Wiper Spindle Assembly — RH Side

To Remove, Fig.5
1. Remove the main trim panel as instructed
in this Section.

2. Open the cab front access panel and

secure in position with the panel stay.

3. Remove centre access panel from the cab

bulkhead.

4. Remove the two setscrews securing the

heater distribution housing to the cab
bulkhead.

5. From within the cab, remove the two

retaining screws and manoeuvre the heater
19
distribution housing assembly aside.

6. Release the wiper linkage ball joint from the

wiper spindle.

7. Disconnect the washer pipe from the wiper

arm.

8. Remove retaining nut and detach the wiper

arm and spindle cover.

9. Remove the wiper spindle retaining nut and

detach the wiper spindle assembly.

To Refit
Reverse the removal procedure.

E9612 5–19–13
 ELECTRICAL SYSTEM 5
Windscreen wipers and washers 55 Series

19

E9612
5–19–14
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 20—ANTI–LOCK BRAKING SYSTEM (ABS)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—20—1 . . . . . . . . 9612

20

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5 ELECTRICAL SYSTEM
55 Series Anti–lock braking system (ABS)

20. ANTI–LOCK BRAKING SYSTEM (ABS)

DESCRIPTION

General Information 1
The anti–lock braking system (ABS) used on the
55 Series is a WABCO 4–channel air controlled
system which has individual road wheel control
on both front and rear axles. The ABS conforms 2
to the requirements of a Category 1 system.

System Components
The anti–lock braking system comprises of the
following major components:
Wheel Sensors and Exciter Rings. Each
road wheel hub is equipped with a wheel
sensor and exciter ring. Rotation of the
exciter ring in proximity with the wheel 081122

sensor will generate electrical impulses

which are transmitted to the electronic FIG.1. ABS ECU COMPONENTS
control unit (ECU).
NOTE: For further information refer to 1. ABS electronic control unit (D568)
Group 6. 2. ABS printed circuit board 20
Electronic Control Unit (ECU), Fig.1. The
electrical impulses received from each wheel
sensor enable the ECU to compute the
speed, acceleration and/or deceleration of
each road wheel. The resultant information is
used to generate a vehicle reference speed
and wheel slip threshold values. When a
wheel deceleration or wheel slip threshold
value is exceeded, the ECU will activate the
modulator control valve.
NOTE: The ECU is attached to the LH side
of the cab rear bulkhead.

Modulator Valves. The vehicle is equipped

with 4 modulator valves which, under wheel
slip conditions, control the air pressure in
each brake actuator. In event of a detected
wheel slip condition the relevant modulator
valve(s) will be activated in response to the
control signals from the ECU and will
modulate the air pressure to the brake
actuator irrespective of the amount of
braking demanded by the driver.
NOTE: For further information refer to
Group 6.

E9612 5–20–1
 ELECTRICAL SYSTEM 5
Anti–lock braking system (ABS) 55 Series

Relays, Fig.2. The ABS warning light relay

(G025), exhaust brake solenoid relay
(G023), ECU power supply relay (G022)
and ECU voltage protection relay (G021)
are attached to the printed circuit adjacent 1

ASSY 1235294
AW1274653
to the ECU. EHX
BRK
NOTE: With the exception of the ECU
voltage protection relay (G021), all 2
remaining relays are interchangeable.
3
Diagnostic Test Socket. All 55 Series
vehicles are equipped with an electronic LK2
UR 2
diagnostic test socket which is located
above the glovebox on the cab fascia. The 6 LK 1 4
diagnostic test socket MUST only be used 5
in conjunction with authorised DAF FUSE UR 1
070033
electronic test equipment and prescribed
procedures as instructed in Group 6.
CAUTION: An additional test socket is FIG.2. ABS PRINTED CIRCUIT BOARD

20 fitted adjacent to the diagnostic test socket.

This test socket is used to input test
1.
COMPONENTS

Relay, exhaust brake (G023)

signals during the factory validation of the
ABS and is incapable of delivering the 2. Relay, ABS warning light (G025)
required output test signals used for 3. Relay, ABS power supply (G022)
routine ABS diagnostic testing.
4. Relay, ABS power supply (G021)
5. Fuse, ABS ECU power supply (E042)
Circuit Protection 6. Fuse, ABS ECU power supply (E041)
The vehicle ABS power enable circuit is
protected by fuse E133 (10 amps); this fuse is
located in the RH instrument panel fuse box.
The ABS electronic control unit (ECU) power
supply relay (G022) and voltage protection relay
(G021) power supplies are protected by fuses
E041 (15 amps) and E042 (15 amps); both
fuses are attached to the printed circuit board
adjacent to the ABS ECU.

E9612
5–20–2
5 ELECTRICAL SYSTEM
55 Series Anti–lock braking system (ABS)

Electrical Circuit, Fig.3.

The positive stud terminal power supply is
applied, via terminal B.A1 (ABS pcb connector)
and fuses E041 and E042, to terminal 30 of the
power supply relays (G021 and G022). When
the master start key (C655) is in position ”2”, a
power supply will be applied, via fuse E133, to
the following circuits:
— The power supply will be applied via
terminal B.1B (ABS pcb connector) to
terminal 85 of the ABS power supply relays
(G021 and G022) and ABS warning light
relay (G025); a power supply is also applied
to terminal 9 of the ABS electronic control
unit (D568).
— The power supply will illuminate the ABS
warning light (D043) and will be applied via
terminals FL.2B (instrument panel pcb
connector) and B.3B (ABS pcb connector)
to terminal 30 of the ABS warning light relay 20
(G025) and terminal 26 of the ABS
electronic control unit (D568).

Relay Functions
The function of each ABS relay is as follows:
Relay G021: When energised, this relay will
apply the power supply, via fuse E133, to
terminal 1 of the ABS ECU (D568).

Relay G022: When energised, this relay will

apply the power supply, via fuse E133, to
terminal 19 of the ABS ECU (D568) and
terminal 87 of relay G023.

Relay G023: When this relay is energised

by the relay G022 and ABS ECU terminal
11, a power supply is applied to the exhaust
brake valve (B044).

Relay G025: This relay is energised via

terminal 26 of the ABS ECU (D568) when
the vehicle road speed attains 15 km/h; if
no faults have been detected the ABS
warning light (D043) will extinguish.

E9612 5–20–3
 ELECTRICAL SYSTEM 5
Anti–lock braking system (ABS) 55 Series

D043 D096

1 2 7 3 5

3425
FL 2B CS2 1B
B A5

3471 A021
B 5B

3425

G025
B 3B

86

W 3B
3427 85 4612 8

L1 A2
15 4620 4620

+ F512

L1 A1
87A 4621 4621

W A2
3471 3
32
B A1

1000
30 87
26

W 1B
3427
A6

L1 A5
16
B 1B

1253 4630 4630

C2

G022 F515

L1 A3
E133 4631 4631
25
W 5B

85 86 4613 33

E041 E042 87A

L1 2B
17 4622 4622
19
W A5

4616

20 F513

L1 1B
30 87 4623 4623

34
W 4B

1211 9

18

L1 4B
4628 4628
B A2

D568 F514
W A1

L1 3B
3425 13 4629 4629
G021
85 86 35
14
31
B146
L2 1B

23 4633 4633
D628
L2 A7
W A4

4615 1 4632 4632

30 87 24

B049
L2 5B

4 4643 4643
L2 4B

4642 4642
G023 5
11
W 2B

85 86 4614
21 B048
L2 3B

4641 4641
27
B044 87A
L2 2B

4640 4640
L2 A6

B 4B

4617 4617 22

30 87 B047
L2 7B

6 4635 4635
B112
L2 6B

2 1 4634 4634
2
L2 A3

4924 4924
7

28 3460
2 1 20
L2 A5

4923 4923
3461
29
B111 081113

FIG.3. ANTI–LOCK BRAKING SYSTEM (ABS) CIRCUIT DIAGRAM

E9612
5–20–4
5 ELECTRICAL SYSTEM
55 Series Anti–lock braking system (ABS)

Key to Fig.3
+. Positive stud terminal
A021. ABS diagnostic test socket
B044. Exhaust brake valve
B047 ABS modulator valve, RH front axle
B048. ABS modulator valve, LH rear axle
B049. ABS modulator valve, RH rear axle
B111. ASR valve, rear axle RH
B112. ASR valve, rear axle LH
B146. ABS modulator valve, LH front axle
D043. Warning light, ABS
D096. Warning light, ASR (traction control)
D568. ABS electronic control unit (ECU)
D628. Diode, Zener
E041. Fuse (10A), ECU power supply
E042. Fuse (10A), ECU power supply 20
E133. Fuse (10A), ABS enable power supply
F512. Sensor, ABS LH front
F513. Sensor, ABS RH front
F514. Sensor, ABS LH rear
F515. Sensor, ABS RH rear
G021. Relay, ECU power supply
G022. Relay, ECU power supply
G023. Relay, exhaust brake
G025. Relay, ABS warning light

E9612 5–20–5
 ELECTRICAL SYSTEM 5
Anti–lock braking system (ABS) 55 Series

20

E9612
5–20–6
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 21—ELECTRICALLY CONTROLLED AIR SUSPENSION (ECAS)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—21—1 . . . . . . . . 9612

21

E9612 1
21

E9612
2
5 ELECTRICAL SYSTEM
55 Series Electrically controlled air suspension (ECAS)

21. ELECTRONICALLY CONTROLLED AIR SUSPENSION (ECAS)

DESCRIPTION

General Information
The electronically controlled air suspension
(ECAS) system comprises of an electronic
control unit (ECU), height sensor units,
regulating valve, remote control and air bellows.
For a complete system description refer to
”Frame and Suspension” (Group 9).

Circuit Protection, Fig.1

The ECAS electrical power circuits are
protected by the following fuses:

— The power enable electrical circuit is

protected by fuse E051 (10 amps); this fuse
is located on the RH instrument panel
printed circuit board.

— The ECAS power supply electrical circuit is

protected by fuse E133 (10 amps); this fuse 1 2
is located in the RH instrument panel fuse
box.
3

080892
21
FIG.1. ECAS POWER ENABLE FUSE

1. Fused battery power supply

2. E051 (10A) power enable fuse
3. Spare fuse

E9612 5–21–1
 ELECTRICAL SYSTEM 5
Electrically controlled air suspension (ECAS) 55 Series

Electrical Circuit, Fig.2

The positive stud power enable supply is applied
via fuse E051 and terminal C2.A1 (instrument
panel pcb) to terminal 1 on the ECAS electronic
control unit (D506).
With the master start switch (C655) in position
”2”, the ECAS power supply is applied via fuse
E133 and terminal C2.A6 (instrument panel pcb)
to terminal 9 on the ECAS ECU and terminal 1
on the diagnostic test socket (A021).
The tachograph road speed signal is applied via
terminals D.3 (instrument panel pcb connector)
and S.A1 (cab/chassis interface connector) to
terminal 22 on the ECAS ECU.

With the master start switch (C655) in position

”2”, the power supply is applied, via terminal K.7
(instrument panel pcb connector) and fuse
E035, to the ECAS warning lights (D050 and
D051); the warning lights are connected to
terminals 33 and 34 of the ECAS ECU.

21 The left–hand and right–hand chassis height

sensors (F526 and F527) are connected via
terminals EC.A1, EC.A2 and EC.A4
(cab/chassis interface connectors) to terminals
8, 32 and 25 of the ECAS ECU.

E9612
5–21–2
 5 ELECTRICAL SYSTEM
55 Series Electrically controlled air suspension (ECAS)

+
D506
E051
C2 A1 1 27 33 34 9 22 35 8 32 25 31 15 4 10 20 21 3 13

4741
9108
4736

4738

4739

4734

4730
4731
4732
4740
4742
D051 D050
1117 EC 1B
EC A1 EC A2 EC A4 EC 2B EC 3B

FL 1B FL A1
3431
F527 F526 F025
E133 3432
B054 B052 B053
C2 A6

1253
1253

3500
3500

4697
S A1

A022(3) 4732
1127

1211

D3 1253
B501
3425

B4 B1B2 B3

21
3020

3019
3021
3018

1 2 7 3 5 1 2 3 4

A021 D529
F533 081115

FIG.2. ECAS CIRCUIT DIAGRAM

+. Positive stud terminal D506. ECAS electronic control unit

A021. Diagnostic test socket D529. Remote control unit
B052. ECAS regulator valve E051. Fuse (10A)
B053. ECAS regulator valve – LH E133. Fuse (10A)
B054. ECAS regulator valve – RH F025. Air pressure switch
B053. ECAS height sensor unit F526. Height sensor – LH
B501. Tachograph F527. Height sensor – RH
D050. Warning light F533. Sensor, road speed
D051. Warning light

E9612 5–21–3
 ELECTRICAL SYSTEM 5
Electrically controlled air suspension (ECAS) 55 Series

ECAS Electronic Control Unit Terminal

Connections

Terminal Terminal Connection

Number
1 Power enable supply (via fuse
E051)
3 Air pressure switch (F025)
4 Diagnostic test socket (A021)
8 Height sensor – RH (F527)
9 Power supply (via fuse E133) to
ECAS ECU and diagnostic test
socket (A021)
10 Remote control unit (D529)
13 ECAS regulator valve – LH
(B053)
15 ECAS regulator valve (B052)
21 20 Remote control unit (D529)
21 Remote control unit (D529)
22 Tachograph road speed signal
25 Height sensor – LH (F526)
27 Earth connection (via ECAS
ECU terminal 35)
31 ECAS regulator valve – RH
(B054)
32 Height sensors (F526 and F527)
33 Warning light (D050)
34 Warning light (D051)
35 Earth connection

E9612
5–21–4
5 ELECTRICAL SYSTEM
55 Series Contents

CONTENTS Page Date

SECTION 22—ROAD SPEED LIMITER

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—22—1 . . . . . . . . 9612
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5—22—4 . . . . . . . . 9612

22

E9612 1
22

E9612
2
5 ELECTRICAL SYSTEM
55 Series Road speed limiter

22. ROAD SPEED LIMITER

DESCRIPTION

General Information
In accordance with current legislation, all
vehicles over 12 tonnes gross vehicle weight
(GVW) are fitted with a road speed limiter SPEED LIMITER FITTED
device. All vehicles equipped with a road speed
limiter are fitted with an identification label
attached to the cab windscreen.

The road speed limiter (RSL) system governs

the maximum vehicle road speed to a pre–set
85 KM/H
speed limit. The RSL system has been designed
with a fail–safe default mode to ensure that, in
the event of a major electrical failure, the RSL
081111
system will revert to a non–intrusive mode and
allow normal, unrestricted, accelerator pedal
movement. FIG.1. ROAD SPEED LIMITER
IDENTIFICATION LABEL
IMPORTANT: Any vehicle with an inoperative
road speed limiter must NOT be driven on a
public road, unless:

— The vehicle is completing a journey in which

the RSL has accidentally ceased to function,
or
— When taking the vehicle to an authorised
calibration centre for repair of the RSL
system.
22

E9612 5–22–1
 ELECTRICAL SYSTEM 5
Road speed limiter 55 Series

System Description
The road speed limiter system consists of the
following major components:
Electronic Control Unit (ECU). The road
speed limiter ECU is supplied with electrical
impulses from the tachograph from which
the actual vehicle road speed is computed
and compared to the pre–set road speed
limit. When the vehicle attains a road speed
within the pre–set speed limit, the ECU will
activate the fuel pump actuator to control
the maximum vehicle road speed.

Actuator. When activate by the ECU, the

electrically operated actuator will disengage
the accelerator pedal linkage and limit the
movement of the fuel pump throttle lever to
the pre–set speed setting. At vehicle road
speeds below the pre–set setting, the
actuator will be in the disengaged position
and the accelerator pedal will fully control
the fuel pump throttle setting.

22

E9612
5–22–2
5 ELECTRICAL SYSTEM
55 Series Road speed limiter

Circuit Protection
The road speed limiter (RSL) electrical circuits
are protected by primary fuse E078 (4 amps)
and secondary fuse E135 (5 amps). The primary
fuse (E078) is located on the cab RH bulkhead
panel whilst the secondary fuse (E135) is
located in the RH instrument panel fuse box.
IMPORTANT: The primary fuse (E078) must
only be renewed at an authorised calibration
centre.

Electrical Circuit, Fig.2.

With the master start switch (C655) in position
‘‘2”, the power supply is applied via terminal K.7
(instrument panel pcb connector), fuses E135
and E078 to terminal 1 on the RSL electronic
control unit (D512). The tachograph (B501)
delivers the road speed signal to terminal 21 on
the ECU. The ECU is earthed via terminal 14.

22

E9612 5–22–3
 ELECTRICAL SYSTEM 5
Road speed limiter 55 Series

+ D512
1 21 14 23 10 22 2 15 11 24 12
K 6/9

1000

3461

4671
3460

4670

4672

4673
4001

3500

4697

4674
C655

3 1 K 7 R A3 R A1 R 2B R 1B R A4
2

1010

E135
E078
C2 A5

4001

3500

1 2 7 6 5

S A1 B011

D3

B501
22 1 2 7 3 5

A021
081112

FIG.2. ROAD SPEED LIMITER (RSL) CIRCUIT DIAGRAM

+. Positive stud terminal C655. Master start switch

A021. Diagnostic socket D512. RSL ECU
B011. RSL actuator E135. Fuse (5A) — secondary
B501. Tachograph E078. Fuse (4A) — primary

E9612
5–22–4
5 ELECTRICAL SYSTEM
55 Series Road speed limiter

REMOVAL AND REFITMENT

Main Trim Panel

To Remove, Fig.3
1. Before disconnecting the vehicle battery
supply, ensure that, if applicable, the radio
security code is available to enable the
radio to be re–activated upon completion of
all work.

2. Remove the instrument panel as instructed

in Section 5.

3. Release the heater controls from the

instrument panel shroud and then detach
the shroud from the corner trim panel, main
trim panel and steering column bracket.

4. Remove the retaining screws and bolt

securing the corner trim panel to the
windscreen trim panel and cab door pillar.
Release the door seal and partially
withdraw the corner trim panel; disconnect
the air ducting from the air vent and then
withdraw the corner trim panel.

5. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle and, with the brake and
clutch pedals fully depressed, withdraw the
22
pedal trim panel.

6. Carefully extract the air vents from the main

trim panel and heater box.

7. Detach the diagnostic socket cover from the

main trim panel; remove the retaining
screws and release the diagnostic socket
and bracket assembly.

8. Remove the retaining screws, nut and

washer securing the main trim panel to the
windscreen trim panel, heater box and cab.
Release the door seal and partially
withdraw the main trim panel; disconnect
the air ducting from the air vents and then
fully withdraw the main trim panel from the
cab.

E9612 5–22–5
 ELECTRICAL SYSTEM 5
Road speed limiter 55 Series

To Refit
Reverse the removal procedure, noting:

1. If applicable, re–activate the radio security

code.

22
5

050574

FIG.3. EXPLODED VIEW OF THE MAIN TRIM PANEL

1. Air vent 4. Diagnostic socket cover

2. Main trim panel 5. Air vent
3. Diagnostic socket/bracket assembly

E9612
5–22–6
5 ELECTRICAL SYSTEM
55 Series Road speed limiter

RSL Primary Fuse (E078)

To Remove, Fig.4
IMPORTANT: The road speed limiter primary
fuse must be security sealed at an authorised
calibration centre.

1. Remove the main trim panel as instructed

in this Section.

2. Extract the fuse and holder assembly from

the road speed limiter electronic control unit
(ECU). 1
3. Break the security seal and remove the
fuse from its holder. 2

To Refit
Reverse the removal procedure, noting:

1. Ensure that the replacement fuse is of the

correct fuse rating (4 amps).
081102

2. The replacement fuse must be security

sealed in its holder at an authorised FIG.4. ELECTRONIC CONTROL UNIT
calibration centre. LOCATION

1. Electronic control unit (D512)

22
2. Primary fuse (E078)

E9612 5–22–7
 ELECTRICAL SYSTEM 5
Road speed limiter 55 Series

Electronic Control Unit (D512)

To Remove, Fig.4
1. Remove the main trim panel as instructed
in this Section.

2. Break the security seal and disconnect the

multi–pin connector from the electronic
control unit (ECU).

3. Remove the retaining screws and detach

the ECU from the cab bulkhead panel.

To Refit
Reverse the removal procedure, noting:

1. The multi–pin connector must be security

sealed in position on the ECU at an
authorised calibration centre.

22

E9612
5–22–8
2 SUB DIVISION
55 Series

GENERAL INFORMATION
1
COOLING SYSTEM
2
CYLINDER HEAD
3
CRANKCASE ASSEMBLY
4

E9703
2 ENGINE
55 Series Contents

CONTENTS Page Date

SECTION 1—GENERAL INFORMATION

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—1—1 ......... 9703
Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—1—7 ......... 9703
Removal and Refitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—1—3 ......... 9703
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—1—2 ......... 9703 1

E9703 1
1

E9703
2
2 ENGINE
55 Series General information

1. GENERAL INFORMATION
DATA

Engine
Types:
Euro I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CS 134L and CS 156L
Euro II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CS 107, CS 118M, CS 134M, CS 158M
and CS 173M
1
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged and intercooled
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 6
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm (4.02 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.72 in)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,88 litres (359 in3)
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1—5—3—6—2—4
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 : 1
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 to 800 rev/min
Maximum governed speed (no load) . . . . . . . . . . 2 825 to 2 925 rev/min
Minimum oil pressure (engine hot):
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 bar (7 lbf in2)
Normal running speed . . . . . . . . . . . . . . . . . . 2,0 bar (30 lbf in2)
* Net (declared) bhp:
CS 107M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 kW (145 ps) @ 2 500 rev/min
CS 118M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 kW (160 ps) @ 2 500 rev/min
CS 134L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 kW (182 ps) @ 2 500 rev/min
CS 134M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 kW (182 ps) @ 2 500 rev/min
CS 156L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 kW (212 ps) @ 2 500 rev/min
CS 158M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 kW (215 ps) @ 2 500 rev/min
CS 173M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 kW (235 ps) @ 2 500 rev/min
* Maximum (declared) torque:
CS 107M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520 Nm (384 lbf ft) @ 1 500 rev/min
CS 118M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570 Nm (421 lbf ft) @ 1 500 rev/min
CS 134L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630 Nm (464 lbf ft) @ 1 500 rev/min
CS 156L and CS 158M . . . . . . . . . . . . . . . . . 700 Nm (516 lbf ft) @ 1 500 rev/min
CS 173M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 Nm (590 lbf ft) @ 1 500 rev/min
* ECE R24.03 and EEC 88/77 (Euro I and II Emissions)

Torque Tightening Figures Nm lbf ft

Front engine mounting nuts . . . . . . . . . . . . . . . . . . 50 to 60 37 to 44
Rear engine centre mounting bolts . . . . . . . . . . . 220 to 250 162 to 184

E9703 2–1–1
 ENGINE 2
General information 55 Series

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE ENGINE WHILST INSTALLED IN THE

VEHICLE, BOTH BATTERY LEADS MUST BE DISCONNECTED TO PREVENT ACCIDENTAL
OR INADVERTENT STARTING OF THE ENGINE.
1
2. WHEN THE ENGINE IS AT ITS NORMAL OPERATING TEMPERATURE THE INTERNAL
PRESSURE WITHIN THE COOLING SYSTEM WILL EXPEL SCALDING COOLANT IF THE
FILLER CAP OR ANY DRAIN PLUGS ARE REMOVED. THE COOLANT MUST ONLY BE
RENEWED WHILST THE ENGINE IS STOPPED AND IN A COLD CONDITION.

3. ANTI–FREEZE CONTAINS TOXIC CHEMICALS WHICH MUST NOT BE CONSUMED OR

ALLOWED TO COME INTO SKIN CONTACT. USE IMPERVIOUS PROTECTIVE CLOTHING
AND GLOVES WHEN HANDLING ANTI–FREEZE. IN THE EVENT OF SLIGHT SKIN
CONTACT, THOROUGHLY RINSE THE AFFECTED AREA WITH CLEAN WATER. IF THERE IS
EXCESSIVE SKIN CONTACT OR INGESTION/INHALATION SEEK MEDICAL ADVICE
IMMEDIATELY.

4. AVOID UNNECESSARY CONTACT WITH USED ENGINE OIL. PROLONGED AND REPEATED
CONTACT WITH USED ENGINE OIL MAY CAUSE SERIOUS SKIN DISORDERS.

5. THE ENGINE WEIGHS APPROXIMATELY 520 kg (1147 lb), ENSURE SUITABLE EQUIPMENT
IS USED WHILST RAISING OR SUPPORTING THE ENGINE.

6. DO NOT RUN THE ENGINE IN A CONFINED SPACE OR UNVENTILATED AREA. EXHAUST

FUMES CONTAIN TOXIC GASES WHICH, IF INHALED, MAY PROVE FATAL.

7. FUEL SPILLAGES ARE HIGHLY INFLAMMABLE AND MUST NOT BE EXPOSED TO A

NAKED FLAME, SPARK OR INTENSE HEAT SOURCE.

8. HYDRAULIC FLUID IS A TOXIC SUBSTANCE WHICH MUST NOT BE CONSUMED OR

ALLOWED TO COME INTO SKIN CONTACT. IN THE EVENT OF SLIGHT SKIN CONTACT,
THOROUGHLY RINSE THE AFFECTED AREA WITH WATER. IF THERE IS EXCESSIVE SKIN
CONTACT OR INGESTION/INHALATION SEEK MEDICAL ATTENTION IMMEDIATELY.

9. SYNTHETIC RUBBER SEALS, O–RINGS AND GASKETS WHICH HAVE COME INTO
CONTACT WITH DIRECT HEAT, i.e., FIRE DAMAGE, MAY PRODUCE HAZARDOUS FUMES
AND HIGHLY CORROSIVE CHEMICALS. ALLOW BURNT OR DECOMPOSED SEALS ETC.,
TO COMPLETELY COOL, USE IMPERVIOUS PROTECTIVE CLOTHING AND GLOVES AND
WORK IN A WELL VENTILATED AREA WHEN HANDLING THESE COMPONENTS. IN THE
EVENT OF SKIN CONTACT/INHALATION SEEK MEDICAL ATTENTION IMMEDIATELY.

CAUTION: To prevent the ingress of foreign matter, always thoroughly clean the exterior of engine
components prior to dismantling and ensure that all open ports and pipework are suitably blanked.

NOTE: Before disconnecting the vehicle battery supply, ensure that, if applicable, the radio security
code is available to enable the radio to be re–activated upon completion of all work.

E9703
2–1–2
2 ENGINE
55 Series General information

REMOVAL AND REFITMENT

To Remove
1. Isolate batteries.

2. Tilt cab, see ‘Drivers Handbook’.

3. Drain cooling system, refer to the 1

‘Maintenance Manual’.

4. Deplete the air system.

5. Remove the rear and bottom noise

suppression panels, when fitted.

6. Remove the gearbox, see Group 3.

7. Vehicles fitted with a Bosch P–7100 In–line

injection pump: Disconnect the air pipe from
the stop control cylinder and release the clips
securing the pipe to the electrical harness.

8. Note connections, then disconnect electrical

leads from the following:

— Alternator.
— Temperature switch at cylinder head.
— Glow plugs (when fitted) at air induction
pipe.
— Oil switch at crankcase.
Vehicles fitted with a Bosch VP 14 injection
pump:

— Thermal sensor at induction manifold,

when applicable.
— Fuel shut–off and KSB solenoids at
injection pump.
Release harness from all clips and brackets
and position harness clear of engine.

E9703 2–1–3
 ENGINE 2
General information 55 Series

9. Remove the gear–change lever assembly.

10. Remove radiator top hose.

11. Remove radiator bottom water pipe

1 assembly.

12. Detach the air induction pipe from the

intercooler and induction manifold.

13. Remove turbocharger/exhaust manifold heat

shield.

14. Detach the air induction pipe from the

turbocharger and intercooler.

15. Remove radiator stabiliser.

16. Disconnect heater hoses from engine.

17. Release fan cowl from radiator.

18. Remove nuts securing the fan assembly to

the crankshaft flange, then withdraw fan
assembly and fan cowl.

19. Note connections, then disconnect electrical

leads from starter motor, release cable
support bracket and position harness clear
of engine.

20. Disconnect air pipe from exhaust brake

actuating cylinder and release air pipe from
clip at coolant elbow.

21. Remove exhaust down–pipe and exhaust

brake assembly.

22. Remove header tank de–aeration/vent

pipes and bracket assemblies.

23. Disconnect compressor air intake pipe and

air restriction indicator pipe from air
filter/turbocharger intake hose.

E9703
2–1–4
2 ENGINE
55 Series General information

24. Remove air filter assembly and air intake

hose.

25. Vehicles fitted with a Bosch VP 14 injection

pump: Release accelerator cable return
spring from gear cover, then disconnect 1
accelerator cable from injection pump control
lever; release cable slide block from injection
pump bracket.

26. Disconnect the accelerator cable from the

road speed limiter (RSL) pivot lever and
remove the setscrews securing the slide
block to the RSL mounting bracket.

27. Release RSL electrical cable from the

mounting bracket. Detach the RSL mounting
bracket from the crankcase and position RSL
assembly clear of the engine, taking care not
to damage the cable.

28. Vehicles fitted with an exhaust brake:

Disconnect air pipe from injection pump stop
control cylinder and release the plastic ties
securing the air pipe to the compressor air
intake pipe.

29. Release the plastic tie securing the air

restrictor indicator pipe and dipstick tube to
the oil filler pipe.

30. Disconnect the dipstick tube from the

crankcase tube.

31. Disconnect the flexible pipe from the oil filler

tube. Release the oil filler tube brackets from
the header tank bracket and withdraw the oil
filler/dipstick tube assembly.

32. Detach the coolant filler pipe from the header

tank and engine crankcase brackets.

33. Disconnect the compressor air outlet pipe

from the compressor and the connection
adjacent to the flywheel housing; release the
pipe from the brackets at the crankcase and
withdraw the pipe assembly.

E9703 2–1–5
 ENGINE 2
General information 55 Series

34. Position a suitable container beneath engine,

then disconnect the pipes from power
steering pump.

35. Disconnect fuel supply and return pipes from

1 connections at rear engine mounting bracket
and release pipe clamp from mounting
bracket.

36. Using suitable overhead lifting equipment,

support weight of engine.

37. Remove rear engine mounting bracket centre

bolts.

38. Remove front engine mounting brackets and

mounting pads.

NOTE: On 17/18 Tonne vehicles the front

cross–member bolts secure the footstep
mounting bracket to the chassis frame.

39. Remove nuts and bolts securing front engine

mounting cross–member to chassis frame,
then position cross–member as far forward
as possible to enable the engine to be
removed.

40. Ensuring the unit is completely unrestricted,

carefully manoeuvre the engine out of
chassis.

To Refit
Reverse removal procedure, noting:

1. Tighten the front and rear engine mounting

bolts to the torque figures quoted in DATA.

2. Refill engine cooling and lubricating systems,

refer to the ‘Maintenance Manual’.

3. Bleed the fuel system, see Group 4.

4. Refill and bleed power steering system, refer

to the ‘Maintenance Manual’.

5. Adjust RSL cables, see Group 4.

6. Run the engine and test for leaks at all pipe

and hose connections; rectify as necessary.

E9703
2–1–6
2 ENGINE
55 Series General information

FAULT DIAGNOSIS

Symptom Possible Cause Remedy

Difficult starting or Electrical Fault
failure to start
D
D
Faulty or discharged batteries
Corroded/insecure battery or
D
D
Renew or re–charge batteries.
Clean/secure all electrical
1
startermotor electrical connections connections as necessary.
D Defective starter motor D Renew/overhaul starter motor.
Induction/Exhaust System Fault
D Low atmospheric D Use cold start equipment as
temperature/incorrect use of cold instructed in the Driver’s
start equipment Handbook.
D Air intake restriction D Examine air filter, air inlet piping
and turbocharger for restrictions;
rectify as necessary.
D Exhaust system restriction D Examine exhaust system for
restrictions, rectify as necessary.
Fuel System Fault
D Fuel tank empty D Refill with the correct specification
fuel.
D Poor quality/contaminated fuel D Drain fuel system and refill with
the correct specification fuel and
renew fuel filter.
D Air in fuel system D Examine complete fuel system for
leakages, loose or damaged
pipes/connections; rectify as
necessary.
D Restricted/obstructed fuel lines D Check the supply and delivery
fuel lines for restrictions or
obstructions; rectify as necessary.
D Defective injector(s) D Test injectors; rectify or renew as
necessary.
D Obstructed fuel filter/fuel tank D Renew fuel filter cartridge and
sedimenter clean fuel tank sedimenter, refer
to the Maintenance Manual.
D Defective engine stop control D Check operation of engine stop
control; rectify or renew as
necessary.
D Defective lift pump D Renew lift pump.
D Defective fuel injection pump D Calibrate/overhaul fuel injection
pump as necessary.
D Defective fuel pump drive D Rectify/renew fuel pump drive as
necessary.
D Fuel injection pump timing D Check/adjust fuel injection pump
incorrect timing.
Continued

E9703 2–1–7
 ENGINE 2
General information 55 Series

Symptom Possible Cause Remedy

Difficult starting Mechanical Fault
or failure to

1 start—Continued
D Valve clearances incorrect D Check/adjust valve clearances.
D Worn/damaged valves D Pressure test cylinder head to
locate any valve leakages;
renew/re–grind valves as
necessary.
D Worn or damaged piston D Compression test each cylinder
rings/cylinder liners and, if necessary, rectify faulty
piston rings/cylinder liners.
D Incorrect valve timing D Check and, if necessary, adjust
valve timing.
Engine misfires at Induction/Exhaust System Fault
idling speed
D Defective turbocharger D Examine turbocharger for ingress
of excessive dirt (unfiltered air)
and inspect turbocharger bearing
clearances.
D Incorrect use or faulty cold start D Use cold start equipment as
equipment instructed in the Drivers
Handbook.
Fuel System Fault
D Poor quality/contaminated fuel D Drain fuel system and refill with
the correct specification fuel and
renew fuel filter.
D Idling speed too low D Check/adjust idling speed to
specified rating.
D Air in fuel system D Examine complete fuel system for
leakages, loose or damaged
pipes/connections; rectify as
necessary.
D Restricted/obstructed fuel lines D Check the supply and delivery
fuel lines for restrictions or
obstructions; rectify as necessary.
D Defective injector(s) D Test injectors; rectify or renew as
necessary.
D Defective lift pump D Renew lift pump.
D Defective fuel injection pump D Calibrate/overhaul fuel injection
pump as necessary.
Continued

E9703
2–1–8
 2 ENGINE
55 Series General information

Symptom Possible Cause Remedy

Engine misfires at Fuel System Fault
idling speed–
Continued
D Fuel injection pump timing D Check/adjust fuel injection pump
1
incorrect timing.
D Obstructed fuel filter/fuel tank D Renew fuel filter cartridge and
sedimenter clean fuel tank sedimenter refer
to the Maintenance Manual.
Mechanical Fault
D Valve clearances incorrect D Check/adjust valve clearances.
D Incorrect valve timing D Check and, if necessary, adjust
valve timing.
D Worn or damaged piston D Compression test each cylinder and,
rings/cylinder liners if necessary, rectify faulty piston
rings/cylinder liners.
D Worn/damaged valves D Pressure test cylinder head to locate
any valve leakages; renew/re–grind
valves as necessary.
Engine misfires Induction/Exhaust System Fault
under load
D Turbocharger gasket leakage D Renew turbocharger gasket. Ensure
turbocharger is secure and that the
mounting flange is not cracked or
damaged.
D Air intake restriction D Examine air filter, air inlet piping and
turbocharger for restrictions; rectify
as necessary.
D Incorrect use or faulty cold start D Use cold start equipment as
equipment instructed in the Drivers Handbook.
D Defective turbocharger D Examine turbocharger for ingress of
excessive dirt (unfiltered air) and
inspect turbocharger bearing
clearances.
Fuel System Fault
D Restricted/obstructed fuel lines D Check the supply and delivery fuel
lines for restrictions or obstructions;
rectify as necessary.
D Air in fuel system D Examine complete fuel system for
leakages, loose or damaged
pipes/connections; rectify as
necessary.
Continued

E9703 2–1–9
 ENGINE 2
General information 55 Series

Symptom Possible Cause Remedy

Engine misfires Fuel System Fault
under load–
Continued
1 D Defective injector(s) D Test injectors; rectify or renew as
necessary.
D Defective lift pump D Renew lift pump.
D Defective fuel injection pump D Calibrate/overhaul fuel injection
pump as necessary.
D Defective fuel pump drive D Rectify/renew fuel pump drive as
necessary.
D Fuel injection pump timing D Check/adjust fuel injection pump
incorrect timing.
D Obstructed fuel filter/fuel tank D Renew fuel filter cartridge and
sedimenter clean fuel tank sedimenter, refer
to the Maintenance Manual.
Mechanical Fault
D Valve clearances incorrect D Check/adjust valve clearances.
D Cylinder head gasket failure D Renew cylinder head gasket.
D Incorrect valve timing D Check, and if necessary, adjust
valve timing.
D Worn/damaged valves D Pressure test cylinder head to
locate any valve leakages;
renew/re–grind valves as
necessary.
Engine runs Induction/Exhaust System Fault
erratically
D Air intake restriction D Examine air filter, air inlet piping
and turbocharger for restrictions;
rectify as necessary.
D Incorrect use or faulty cold start D Use cold start equipment as
equipment instructed in the Drivers
Handbook.
Fuel System Fault
D Restricted/obstructed fuel lines D Check the supply and delivery
fuel lines for restrictions or
obstructions; rectify as necessary.
D Defective lift pump D Renew lift pump.
Continued

E9703
2–1–10
2 ENGINE
55 Series General information

Symptom Possible Cause Remedy

Engine runs Fuel System Fault
erratically–
Continued
D Obstructed fuel filter/fuel tank D Renew fuel filter cartridge and 1
sedimenter clean fuel tank sedimenter refer
to the Maintenance Manual.
D Air in fuel system D Examine complete fuel system for
leakages, loose or damaged
pipes/connections; rectify as
necessary.
D Defective injector(s) D Test injectors; rectify or renew as
necessary.
D Defective fuel injection pump D Calibrate/overhaul fuel injection
pump as necessary.
D Defective fuel pump drive D Rectify/renew fuel pump drive as
necessary.
Mechanical Fault
D Accelerator linkage worn or D Renew or adjust accelerator
incorrectly adjusted linkage as necessary.
D Valve clearances incorrect D Check/adjust valve clearances.
D Worn/damaged valves D Pressure test cylinder head to
locate any valve leakages;
renew/re–grind valves as
necessary.
D Worn or damaged piston D Compression test each cylinder
rings/cylinder liners and, if necessary, rectify faulty
piston rings/cylinder liners.
D Cylinder head gasket failure D Renew cylinder head gasket.
Low or loss of Induction/Exhaust System Fault
power
D Air intake restriction D Examine air filter, air inlet piping
and turbocharger for restrictions;
rectify as necessary.
D Thin air in hot weather or operation D Vehicle operation in thin air or
at high altitudes high altitudes will affect engine
performance. Reduce vehicle
load to compensate.
D Air leak between air cleaner and D Check security/condition of all
engine hoses, clamps and connections;
secure or renew as necessary.
D Defective turbocharger D Examine turbocharger for ingress
of excessive dirt (unfiltered air)
and inspect turbocharger bearing
clearances.

E9703 2–1–11
 ENGINE 2
General information 55 Series

Symptom Possible Cause Remedy

Low or loss of Induction/Exhaust System Fault
power–
Continued
1 D Exhaust system restriction D Examine exhaust system for
restrictions, rectify as necessary.
Fuel System Fault
D Poor quality/contaminated fuel D Drain fuel system and refill with
the correct specification fuel and
renew fuel filter.
D Air in fuel system D Examine complete fuel system for
leakages, loose or damaged
pipes/connections; rectify as
necessary.
D Restricted/obstructed fuel lines D Check the supply and delivery
fuel lines for restrictions or
obstructions; rectify as necessary.
D Obstructed fuel filter/fuel tank D Renew fuel filter cartridge and
sedimenter clean fuel tank sedimenter refer
to the Maintenance Manual.
D Defective injector(s) D Test injectors; rectify or renew as
necessary.
D Defective fuel injection pump D Calibrate/overhaul fuel injection
pump as necessary.
D Fuel injection pump timing D Check/adjust fuel injection pump
incorrect timing.
Mechanical Fault
D Cylinder head gasket failure D Renew cylinder head gasket.
D Worn or damaged piston D Compression test each cylinder
rings/cylinder liners and, if necessary, rectify faulty
piston rings/cylinder liners.
D Worn/damaged valves D Pressure test cylinder head to
locate any valve leakages;
renew/re–grind valves as
necessary.
D Incorrect valve timing D Check and, if necessary, adjust
valve timing.
D Valve clearances incorrect D Check/adjust valve clearances.
D Accelerator linkage worn or D Renew or adjust accelerator
incorrectly adjusted linkage as necessary.

E9703
2–1–12
2 ENGINE
55 Series General information

Symptom Possible Cause Remedy

Excessive black Induction/Exhaust System Fault
exhaust smoke
D Air intake restriction D Examine air filter, air inlet piping
and turbocharger for restrictions; 1
rectify as necessary.
D Defective turbocharger D Examine turbocharger for ingress
of excessive dirt (unfiltered air)
and inspect turbocharger bearing
clearances.
D Incorrect use or faulty cold start D Use cold start equipment as
equipment instructed in the Drivers
Handbook.
D Exhaust system restriction D Examine exhaust system for
restrictions, rectify as necessary.
Fuel System Fault
D Restricted/obstructed fuel lines D Check the supply and delivery
fuel lines for restrictions or
obstructions; rectify as necessary.
D Defective injector(s) D Test injectors; rectify or renew as
necessary.
D Poor quality/contaminated fuel D Drain fuel system and refill with
the correct specification fuel and
renew fuel filter.
D Defective fuel injection pump D Calibrate/overhaul fuel injection
pump as necessary.
D Fuel injection pump timing D Check/adjust fuel injection pump
incorrect timing.
Mechanical Fault
D Worn or damaged piston D Compression test each cylinder
rings/cylinder liners and, if necessary, rectify faulty
piston rings/cylinder liners.
D Valve clearances incorrect D Check/adjust valve clearances.
D Incorrect valve timing D Check, and if necessary, adjust
valve timing.
D Cylinder head gasket failure D Renew cylinder head gasket.
D Worn/damaged valves D Pressure test cylinder head to
locate any valve leakages;
renew/re–grind valves as
necessary.

E9703 2–1–13
 ENGINE 2
General information 55 Series

Symptom Possible Cause Remedy

Excessive blue or Induction/Exhaust System Fault
white exhaust
smoke
1 D Low atmospheric D Use cold start equipment as
temperature/incorrect use of cold instructed in the Driver’s
start equipment Handbook.
D Defective turbocharger D Examine turbocharger for ingress
of excessive dirt (unfiltered air)
and inspect turbocharger bearing
clearances.
Cooling System Fault
D Engine coolant temperature too D Test thermostat and renew as
low necessary.
Fuel System Fault
D Poor quality/contaminated fuel D Drain fuel system and refill with
the correct specification fuel and
renew fuel filter.
D Defective injector(s) D Test injectors; rectify or renew as
necessary.
D Fuel injection pump timing D Check/adjust fuel injection pump
incorrect timing.
Mechanical Fault
D Incorrect valve timing D Check and, if necessary, adjust
valve timing.
D Cylinder head gasket failure D Renew cylinder head gasket.
D Worn or damaged piston D Compression test each cylinder and,
rings/cylinder liners if necessary rectify faulty piston
rings/cylinder liners.
D Worn/damaged valves D Pressure test cylinder head to locate
any valve leakages; renew/re–grind
valves as necessary.

E9703
2–1–14
2 ENGINE
55 Series General information

Symptom Possible Cause Remedy

Excessive oil Induction/Exhaust System Fault
consumption
D Defective turbocharger D Examine turbocharger for ingress
of excessive dirt (unfiltered air) 1
and inspect turbocharger bearing
clearances.
Lubrication System Fault
D Engine oil level excessively high D Check oil level and drain excess
engine oil as necessary.
D External/internal oil leaks D Examine engine for external oil
leaks and oil dilution. Rectify as
necessary; ensure engine oil is
maintained at an acceptable
level.
D Incorrect oil viscosity for prevailing D Renew engine oil with correct
weather conditions specification oil as instructed in
the Maintenance Manual.
Mechanical Fault
D Cylinder head gasket failure D Renew cylinder head gasket.
D Worn or damaged piston D Compression test each cylinder
rings/cylinder liners and, if necessary, rectify faulty
piston rings/cylinder liners.
Excessive fuel Induction/Exhaust System Fault
consumption
D Air intake restriction D Examine air filter, air inlet piping
and turbocharger for restrictions;
rectify as necessary.
D Defective turbocharger D Examine turbocharger for ingress
of excessive dirt (unfiltered air)
and inspect turbocharger bearing
clearances.
D Incorrect use or faulty cold start D Use cold start equipment as
equipment instructed in the Drivers
Handbook.
D Exhaust system restriction D Examine exhaust system for
restrictions, rectify as necessary.
D Air leak between air cleaner and D Check security/condition of all
engine hoses, clamps and connections;
secure or renew as necessary.
Cooling System Fault
D Engine coolant temperature too D Test thermostat and renew as
low necessary.
Continued

E9703 2–1–15
 ENGINE 2
General information 55 Series

Symptom Possible Cause Remedy

Excessive fuel Fuel System Fault
consumption–
Continued
1 D Poor quality/contaminated fuel D Drain fuel system and refill with
the correct specification fuel and
renew fuel filter.
D Restricted/obstructed fuel lines D Check the supply and delivery
fuel lines for restrictions or
obstructions; rectify as necessary.
D Fuel leakages D Examine complete fuel system for
internal/external fuel leakages;
rectify as necessary.
D Defective injector(s) D Test injectors; rectify or renew as
necessary.
D Defective fuel injection pump D Calibrate/overhaul fuel injection
pump as necessary.
D Fuel injection pump timing D Check/adjust fuel injection pump
incorrect timing.
Lubrication System Fault
D Engine oil level excessively high D Check oil level and drain excess
engine oil as necessary.
Mechanical Fault
D Incorrect valve timing D Check and, if necessary, adjust
valve timing.
D Valve clearances incorrect D Check/adjust valve clearances.
D Cylinder head gasket failure D Renew cylinder head gasket.
D Worn/damaged valves D Pressure test cylinder head to
locate any valve leakages;
renew/re–grind valves as
necessary.
D Worn or damaged piston D Compression test each cylinder
rings/cylinder liners and, if necessary, rectify faulty
piston rings/cylinder liners.
D Air leak between air cleaner and D Check security/condition of all
engine hoses, clamps and connections;
secure or renew as necessary.
Low oil pressure Lubrication System Fault
D Obstructed oil cooler D Clean and inspect oil cooler;
rectify as necessary.
D Low engine oil level D Check/top–up engine with correct
specification oil to an acceptable
level.
Continued

E9703
2–1–16
2 ENGINE
55 Series General information

Symptom Possible Cause Remedy

Low oil pressure– Lubrication System Fault
Continued
D External/internal oil leaks D Examine engine for external oil
leaks and oil dilution. Rectify as 1
necessary; ensure engine oil is
maintained at an acceptable
level.
D Incorrect oil viscosity for prevailing D Renew engine oil with correct
weather conditions specification oil as instructed in
the Maintenance Manual.
D Contaminated/restricted oil filter D Renew oil filter as instructed in
the Maintenance Manual.
D Defective oil pump or oil pressure D Check oil pressure regulating
regulating valve valve for correct operation.
Renew oil pump as necessary.
D Restricted oil pump suction pipe or D Rectify as necessary.
strainer
Mechanical Fault
D Main/connecting rod bearings D Renew main/connecting rod
damaged or worn bearings.

E9703 2–1–17
 ENGINE 2
General information 55 Series

Symptom Possible Cause Remedy

High coolant Cooling System Fault
temperature
D D
1 Low coolant level or restricted
radiator matrix
Check/top up coolant level, clean
radiator matrix; if necessary flush
engine cooling system.
D Defective water pump D Renew water pump.
D Defective thermostat D Test thermostat and renew as
necessary.
D Broken or insufficiently tensioned D Renew drive belt and check
drive belt operation of belt tensioner.
D Defective fan drive or multistat D Renew/overhaul fan drive.
valve
D External coolant leaks/air in D Examine external cooling system
cooling system for leakages; rectify as
necessary.
Lubrication System Fault
D Low engine oil level D Check/top–up engine with correct
specification oil to an acceptable
level.
Fuel System Fault
D Fuel injection pump timing D Check/adjust fuel injection pump
incorrect timing.
Low coolant Cooling System Fault
temperature
D Defective thermostat D Test thermostat and renew as
necessary.

E9703
2–1–18
2 ENGINE
55 Series Contents

CONTENTS Page Date

SECTION 2—COOLING SYSTEM

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—1 . . . . . . . . . 9703
Overhaul:
Belt Tensioner Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—13 . . . . . . . . 9703
Removal and Refitment:
Automatic Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—4 ......... 9703
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—3 ......... 9703
Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Header Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2—2—5
2—2—8
.........
.........
9703
9703 2
Radiator/Intercooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—6 ......... 9703
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—9 ......... 9703
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—2 ......... 9703
Testing:
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—12 . . . . . . . . 9703
Viscous Fan Drive Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—10 . . . . . . . . 9703
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2—1 . . . . . . . . . 9703

E9703 1
2

E9703
2
2 ENGINE
55 Series Cooling system

2. COOLING SYSTEM
DATA

Thermostat
Thermostat opening temperature:
Begins to open . . . . . . . . . . . . . . . . . . . . . . . . . 83°C (181°F)
Fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)

Torque Tightening Figures Nm lbf ft

Belt tensioner mounting bolt . . . . . . . . . . . . . . . . . 43 32
Fan to viscous drive unit nuts . . . . . . . . . . . . . . . .
Fan assembly to crankshaft flange nuts . . . . . . .
18 to 22
60 to 75
13 to 16
44 to 55 2
Thermostat housing bolts . . . . . . . . . . . . . . . . . . . . 24 18
Water pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE ENGINE WHILST INSTALLED IN THE

VEHICLE, BOTH BATTERY LEADS MUST BE DISCONNECTED TO PREVENT ACCIDENTAL
OR INADVERTENT STARTING OF THE ENGINE.

2. WHEN THE ENGINE IS AT ITS NORMAL OPERATING TEMPERATURE THE INTERNAL

PRESSURE WITHIN THE COOLING SYSTEM WILL EXPEL SCALDING COOLANT IF THE
FILLER CAP OR ANY DRAIN PLUGS ARE REMOVED. THE COOLANT MUST ONLY BE
RENEWED WHILST THE ENGINE IS STOPPED AND IN A COLD CONDITION.

3. ANTI–FREEZE CONTAINS TOXIC CHEMICALS WHICH MUST NOT BE CONSUMED OR

ALLOWED TO COME INTO SKIN CONTACT. USE IMPERVIOUS PROTECTIVE CLOTHING
AND GLOVES WHEN HANDLING ANTI–FREEZE. IN THE EVENT OF SLIGHT SKIN
CONTACT, THOROUGHLY RINSE THE AFFECTED AREA WITH CLEAN WATER. IF THERE IS
EXCESSIVE SKIN CONTACT OR INGESTION/INHALATION SEEK MEDICAL ADVICE
IMMEDIATELY.

4. DO NOT RUN THE ENGINE IN A CONFINED SPACE OR UNVENTILATED AREA. EXHAUST

FUMES CONTAIN TOXIC GASES WHICH, IF INHALED, MAY PROVE FATAL.

CAUTION: To prevent the ingress of foreign matter, always thoroughly clean the exterior of engine
components prior to dismantling and ensure that all open ports and pipework are suitably blanked.

NOTE: Before disconnecting the vehicle battery supply, ensure that, if applicable, the radio security
code is available to enable the radio to be re–activated upon completion of all work.

E9703 2–2–1
 ENGINE 2
Cooling system 55 Series

REMOVAL AND REFITMENT

Water Pump

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Drain the cooling system, refer to the

1
2 ‘Maintenance Manual’.

4. Using a 3/8 in square drive knuckle bar, raise

the automatic drive belt tensioner/pulley and 2
release the drive belt from the water pump
pulley.

5. Remove the bolts securing the water pump to

the gear case and withdraw the pump.
040628

6. Remove and discard the water pump O–ring

and thoroughly clean the sealing area of FIG.1. WATER PUMP
cylinder block.
1. Water pump
7. Check the drive belt for contamination,
2. O–ring
cracks, damage or excessive wear: renew as
necessary.

To Refit
Reverse removal procedure, noting:

1. Fit a new water pump O–ring.

2. Tighten the water pump retaining bolts to

the torque figure quoted in DATA.

E9703
2–2–2
2 ENGINE
55 Series Cooling system

Drive Belt

Replacement
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Remove nuts securing the fan assembly to

the crankshaft flange, position the fan
assembly in fan cowl, taking care not to 2
damage radiator.

4. Using a 3/8 in square drive knuckle bar, raise

the automatic drive belt tensioner/pulley and
remove the drive belt.
040629
5. Raise the automatic drive belt
tensioner/pulley to allow the new belt to be
fitted; when the belt is correctly positioned, FIG.2. DRIVE BELT REPLACEMENT
release the tensioner.

6. Refit the fan assembly to the crankshaft

flange and tighten the retaining nuts to the
torque figure quoted in DATA.

E9703 2–2–3
 ENGINE 2
Cooling system 55 Series

Automatic Belt Tensioner

To Remove
1
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Using a 3/8 in square drive knuckle bar,

2 raise the tensioner/pulley and remove the
drive belt.

4. Remove the centre bolt securing

tensioner/pulley to support bracket and
withdraw the tensioner/pulley from its 2 3
dowelled location.
040630
5. Check the drive belt for cracks, damage or
excessive wear: renew as necessary.
FIG.3. AUTOMATIC BELT TENSIONER

To Refit 1. Support bracket

Reverse removal procedure, noting: 2. Belt tensioner
3. Bolt
1. Ensure integral dowel on rear of tensioner
is correctly located in support bracket.

2. Tighten the tensioner/pulley centre bolt to

the torque figure quoted in DATA.

3. Check that the pulley rotates freely.

E9703
2–2–4
2 ENGINE
55 Series Cooling system

Fan Assembly

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Drain the cooling system, refer to the

‘Maintenance Manual’.
2
4. Remove the bottom noise suppression panel,
when fitted.

5. Release hose clips and remove radiator top

hose.

6. Disconnect the heater hose from the

thermostat housing.

7. Remove radiator stabiliser bracket.

8. Remove nuts securing the fan assembly to

the crankshaft flange.

9. Remove the fan cowl setscrews; release

the fan assembly from the mounting studs
and carefully withdraw the fan cowl/fan
assembly from the vehicle, taking care not
to damage the radiator.

10. If necessary, remove the nuts and separate

fan from viscous drive.

To Refit
Reverse removal procedure, noting:

1. If necessary, tighten the nuts securing the

fan to the viscous drive to the torque figure
quoted in DATA.

2. Tighten the nuts securing the fan assembly

to crankshaft flange to the torque figure
quoted in DATA.

3. Refill cooling system, refer to the

‘Maintenance Manual’.

E9703 2–2–5
 ENGINE 2
Cooling system 55 Series

Radiator/Intercooler Assembly

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Drain the cooling system, refer to the

2 ‘Maintenance Manual’.

4. Remove the bottom noise suppression panel.

5. Disconnect radiator bottom hose and remove

radiator top hose.

6. Release hose clips and disconnect hoses

from heater pipes at radiator, then remove
heater pipes/bracket assembly from radiator.

7. Remove radiator stabiliser bracket.

8. Remove air induction pipes, turbocharger to

intercooler and intercooler to induction
manifold.

9. Release fan cowl from radiator, then position

cowl over fan assembly.

10. Using suitable overhead lifting equipment,

support the weight of radiator/intercooler
assembly.

11. Remove setscrews and detach radiator

mounting clamp plates.

12. Raise the radiator/intercooler assembly from

the mounting bosses and withdraw from
vehicle.

13. If necessary, separate intercooler from

radiator.

To Refit
Reverse removal procedure, noting:

1. Refill cooling system, refer to the

‘Maintenance Manual’.

E9703
2–2–6
2 ENGINE
55 Series Cooling system

10
2
3

9
4

040631

FIG.4. RADIATOR/INTERCOOLER

1. Intercooler 5. Radiator top hose 9. Radiator

2. Air induction hose 6. Radiator bottom hose 10. Air induction hose
3. Heater pipes 7. Fan cowl
4. Stabiliser bracket 8. Radiator mounting

E9703 2–2–7
 ENGINE 2
Cooling system 55 Series

Header Tank 2
1 3
To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Drain the cooling system, refer to the

2 ‘Maintenance Manual’.

4. Release hose clips and disconnect all

hoses from header tank.

5. Remove bolts securing header tank to

support bracket, then withdraw header tank.

4
To Refit
Refitment is a reversal of the removal 6 5 040632

procedure.
FIG.5. HEADER TANK

1. Filler cap
2. Pressure cap
3. Header tank
4. De–aeration/vent pipes
5. Filler hose
6. Support bracket

E9703
2–2–8
2 ENGINE
55 Series Cooling system

Thermostat

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

1
3 4
3. Drain the cooling system, refer to the
‘Maintenance Manual’.
2 5 2
4. Release hose clips and disconnect radiator
top hose from thermostat housing. 6

5. Release the alternator support bracket from

thermostat housing. 7 040633

6. Disconnect de–aeration/vent pipe from

thermostat housing. FIG.6. THERMOSTAT

1. De–aeration/vent pipe
7. Release electrical harness bracket from
thermostat housing. 2. Thermostat
3. Seal
8. Remove bolts and withdraw thermostat
housing and engine lifting bracket. 4. Engine lifting bracket
5. Alternator support bracket
9. Extract rubber seal and thermostat from
housing. 6. Radiator top hose
7. Thermostat housing
10. Thoroughly clean joint surfaces.

To Refit
Reverse removal procedure, noting:

1. Ensure the thermostat is correctly located in

the housing.

2. Ensure the rubber seal is fitted with step

towards thermostat.

3. Tighten the thermostat housing bolts to the

torque figure quoted in DATA.

E9703 2–2–9
 ENGINE 2
Cooling system 55 Series

TESTING

Viscous Fan Drive Clutch

Operating Procedure
The viscous fan clutch is designed to sense air
temperature behind the radiator and, to control
the fan speed according to this temperature. An
increase or decrease in radiator coolant
temperature produces a corresponding increase
2 or decrease in air temperature behind the
radiator which the clutch senses. At a specified
temperature the clutch engages to increase air
flow and, at a lower temperature, disengages to
decrease air flow through the radiator.
NOTE: The viscous fan clutch will only operate
correctly, if all other aspects of the cooling
system are serviceable and working normally.

Diagnostic Procedure
WARNING: Exercise extreme caution when
carrying out the following operations,
ensure all personnel are clear of any rotating
parts or moving components.
1. With the engine off and the batteries
isolated, rotate the fan by hand. It should
have slight resistance, but rotate smoothly.
If it does not rotate smoothly, or does not
rotate at all, or shows signs of bearing
wear, the clutch is defective and must be
renewed.

E9703
2–2–10
2 ENGINE
55 Series Cooling system

2. To check the fan clutch is operating at the

correct coolant and air temperatures,
proceed as follows:

— Ensure the coolant temperature is

below 60°C (140°F) and the ambient
atmospheric temperature is above
10°C (50°F).
— Suitably restrict the air flow through the
radiator, leaving a 178 mm (7 in)
2
diameter hole directly opposite the fan
clutch.
— Position a suitable temperature probe
approximately 13 mm (0.5 in) from the
fan clutch sensor to determine at what
air temperature the fan clutch engages.
— Run the engine at approximately 80%
of maximum governed speed, retaining
the accelerator in this position.
— Monitor the coolant and air
temperatures and observe the
following:
— If the fan clutch engages at a
coolant temperature below
approximately 96°C (205°F) and
disengages at approximately 88°C
(190°F) or below, the fan clutch is
working correctly.
— The fan clutch should engage at
an air temperature of
approximately 54 to 60°C (130 to
140°F). If the fan clutch does not
engage within 30 seconds of
reaching this temperature, the fan
clutch is defective and must be
renewed.

E9703 2–2–11
 ENGINE 2
Cooling system 55 Series

Thermostat
NOTE: Prior to testing the thermostat, ensure
the vent pins are securely in place and both the
pins and vent holes are free of corrosion.

1. Suspend thermostat in a clear container of

water.

2 2. Heat water gradually, stirring to ensure

uniformity of temperature.

3. Using a thermometer, note temperature of

water when thermostat begins to open and
again when fully open.

4. If the temperatures noted differ from the

figures quoted in DATA, the thermostat is
faulty and must be replaced.

E9703
2–2–12
2 ENGINE
55 Series Cooling system

OVERHAUL

Belt Tensioner Pulley 6

To Dismantle
1. Remove belt tensioner, as instructed in this
Section.
4
2. Remove bearing dust cover. 3
1
2
3. Using an appropriate ‘Torx–head’ adapter,
remove the centre shaft. 2
3
4
4. Remove bearing outer snap–ring.

5. Press bearings from pulley. 5 040634

6. Remove inner snap–ring from pulley. FIG.7. BELT TENSIONER PULLEY

1. Dust cover
To Reassemble
2. Centre shaft
Reverse removal procedure, noting:
3. Snap–ring
1. Press the new bearings into pulley against 4. Bearing
the outer race only.
5. Pulley
2. Ensure pulley rotates freely. 6. Tensioner

E9703 2–2–13
 ENGINE 2
Cooling system 55 Series

E9703
2–2–14
2 ENGINE
55 Series Contents

CONTENTS Page Date

SECTION 3—CYLINDER HEAD

Adjustment:
Valve/Rocker Lever Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3—14 . . . . . . . . 9703
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3—1 . . . . . . . . . 9703
Overhaul:
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3—19 . . . . . . . . 9703
Rocker Shaft Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3—18 . . . . . . . . 9703
Removal and Refitment:
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3—7 . . . . . . . . . 9703
Rocker Shaft Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3—5 . . . . . . . . . 9703
Testing:
Diesel Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3—16 . . . . . . . . 9703 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—1—4 . . . . . . . . . 9703

E9703 1
3

E9703
2
2 ENGINE
55 Series Cylinder head

3. CYLINDER HEAD
DATA

Cylinder Head
Maximum permissible distortion overall length . 0,30 mm (0.012 in)
Maximum permissible distortion overall width . . 0,08 mm (0.003 in)
Maximum reface of combustion face . . . . . . . . . . 1,0 mm (0.039 in)
Minimum depth of cylinder head after refacing . 93,75 to 94,25 mm (3.691 to 3.711 in)
Surface finish of combustion face . . . . . . . . . . . . . 1,5 to 3,2 Micrometres (60 to 128 Microinches)

Rocker Levers
Maximum worn clearance between rocker lever and
rocker shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,10 mm (0.004 in) 3
Valves
Valve clearance (cold):
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,50 mm (0.020 in)
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm (0.010 in)
Valve face angle:
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve head depth from combustion face:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,52 mm (0.066 in)
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,00 mm (0.039 in)
Valve rim thickness . . . . . . . . . . . . . . . . . . . . . . . . . 0,79 mm (0.031 in) Minimum
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . 7,94 mm (0.312 in) Minimum

Valve Guides
Valve guide bore diameter . . . . . . . . . . . . . . . . . . . 8,039 mm (0.316 in) Maximum

Valve Seats
Valve seat angle:
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve seat face width:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,0 mm (0.080 in)
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5 mm (0.060 in)
Valve seat grinding depth . . . . . . . . . . . . . . . . . . . . 0,254 mm (0.010 in) Maximum

Valve Springs
Maximum inclination . . . . . . . . . . . . . . . . . . . . . . . . 1,00 mm (0.039 in)
Valve spring free–length (approximate) . . . . . . . . 55,63 mm (2.190 in)
Valve spring tension . . . . . . . . . . . . . . . . . . . . . . . . A minimum load of 290 N (65 lbf) is required to
compress the spring to a height of 49,25 mm
(1.94 in)

E9703 2–3–1
 ENGINE 2
Cylinder head 55 Series

Special Compounds
Core plug sealing compound . . . . . . . . . . . . . . . . . Loctite 242
Induction manifold bolts . . . . . . . . . . . . . . . . . . . . . Loctite RTV superflex clear

Service Valve Seat Insert Installation

Dimensions
A — 8,029 " 0,010 mm (0.3161 " 0.0004 in)
B —0,38 mm (0.0015 in) Max radius
C — Inlet 10,40 " 0,10 mm
(0.4094 " 0.0039 in)
Exhaust 10,20 " 0,10 mm
3 (0.4015 " 0.0039 in)
D — Inlet 47,0 " 0,013 mm
(1.8504 " 0.0005 in) dia
Exhaust 43,65 " 0,013 mm
(1.7185 " 0.0005 in) dia
E — Inlet 48,0 " 0,13 mm
(1.8898 " 0.005 in) dia
Exhaust 44,55 " 0,13 mm
(1.7539 " 0.005 in) dia
F —Inlet 3,82 " 0,13 mm
(0.1504 " 0.005 in)
Exhaust 3,63 " 0,13 mm
(0.1429 " 0.005 in)
G — 0,40 mm (0.0157 in) Max radius
H — 3,2 micrometres (128 microinch)
surface finish

E9703
2–3–2
2 ENGINE
55 Series Cylinder head

Service Valve Guide Installation Dimensions C

A —Lubricate with oil and press the guides flush
to the bottom of the valve guide bores B

B —12,0 " 0,75 mm (0.4724 " 0.0295 in)

C — Machine flush to top of valve guide bore as

necessary.

D — 8,029 " 0,010 mm (0.3161 " 0.0004 in) D

E
E — First machining for thin wall valve guides
11,125 " 0,013 mm (0.4380 " 0.0005 in)
Second machining for thick wall valve
A
3
guides 14,0 " 0,013 mm
(0.5512 " 0.0005 in) 040648

NOTE: Initial machining of valve guide bores

and final bore size of the valve guide inserts
after reaming must be concentric with the valve
seats within 0,35 mm (0.0138 in) diameter and
to be square with the combustion face within
0,10 mm (0.004 in) at 50,0 mm (1.9685 in)
radius.
Torque Tightening Figures Nm lbf ft
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Rocker lever adjusting nut . . . . . . . . . . . . . . . . . . . 24 18
Rocker pedestal bolt (8 mm) . . . . . . . . . . . . . . . . . 24 18
Cylinder head bolts *:
Stage 1—All bolts . . . . . . . . . . . . . . . . . . . . . . 90 66
Stage 2—Long bolts only (rocker pedestals) 120 88
Final stage—All bolts Angle torque a further 90°
Exhaust manifold bolts ** . . . . . . . . . . . . . . . . . . . . 43 32
Induction manifold bolts . . . . . . . . . . . . . . . . . . . . . 24 18

** Refer to Fig.2. for correct torque tightening

sequence
* Refer to Fig.3. for correct torque tightening
sequence

E9703 2–3–3
 ENGINE 2
Cylinder head 55 Series

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE ENGINE WHILST INSTALLED IN THE

VEHICLE, BOTH BATTERY LEADS MUST BE DISCONNECTED TO PREVENT ACCIDENTAL
OR INADVERTENT STARTING OF THE ENGINE.

2. WHEN THE ENGINE IS AT ITS NORMAL OPERATING TEMPERATURE THE INTERNAL

PRESSURE WITHIN THE COOLING SYSTEM WILL EXPEL SCALDING COOLANT IF THE
FILLER CAP OR ANY DRAIN PLUGS ARE REMOVED. THE COOLANT MUST ONLY BE
RENEWED WHILST THE ENGINE IS STOPPED AND IN A COLD CONDITION.

3 3. ANTI–FREEZE CONTAINS TOXIC CHEMICALS WHICH MUST NOT BE CONSUMED OR

ALLOWED TO COME INTO SKIN CONTACT. USE IMPERVIOUS PROTECTIVE CLOTHING
AND GLOVES WHEN HANDLING ANTI–FREEZE. IN THE EVENT OF SLIGHT SKIN
CONTACT, THOROUGHLY RINSE THE AFFECTED AREA WITH CLEAN WATER. IF THERE IS
EXCESSIVE SKIN CONTACT OR INGESTION/INHALATION SEEK MEDICAL ADVICE
IMMEDIATELY.

4. DO NOT RUN THE ENGINE IN A CONFINED SPACE OR UNVENTILATED AREA. EXHAUST

FUMES CONTAIN TOXIC GASES WHICH, IF INHALED, MAY PROVE FATAL.

5. FUEL SPILLAGES ARE HIGHLY INFLAMMABLE AND MUST NOT BE EXPOSED TO A

NAKED FLAME, SPARK OR INTENSE HEAT SOURCE.

CAUTION: To prevent the ingress of foreign matter, always thoroughly clean the exterior of engine
components prior to dismantling and ensure that all open ports and pipework are suitably blanked.

NOTE: Before disconnecting the vehicle battery supply, ensure that, if applicable, the radio security
code is available to enable the radio to be re–activated upon completion of all work.

E9703
2–3–4
2 ENGINE
55 Series Cylinder head

REMOVAL AND REFITMENT

Rocker Shaft Assemblies 1

To Remove
1. Isolate the batteries.
2
2. Tilt the cab, see ‘Drivers Handbook’.

3. Remove the coolant de–aeration/vent pipe

support bracket from rear rocker cover.
3
4. Vehicles fitted with a Bosch P–7100 In–line
injection pump: Disconnect the hose pipe 4
from the turbocharger wastegate pipe and
position the hose clear of the rocker covers.
3
5. L.H.D Vehicles No. 1 and 2 rocker shaft
assemblies only: Remove the radiator 5
stabiliser and release the steady bracket from
the air induction manifold.
Release the gear–change lever support
bracket from the induction manifold. 6
Remove nuts and bolts securing the
gear–change assembly to the belt tensioner
bracket; position the gear–change assembly
clear of the rocker covers.

6. Remove the bolts securing the rocker covers,

then withdraw covers and seals.

7. Release locknuts securing rocker lever 040649

adjusting screws, then fully release the
adjusting screws.
FIG.1. ROCKER GEAR REMOVAL
8. Remove the bolts securing rocker shaft
pedestals to cylinder head; withdraw the 1. Bolt
rocker shaft assemblies. 2. Rocker cover
3. Seal
To Refit 4. Rocker shaft assembly
1. Refit rocker shaft assemblies ensuring the
pedestal locating shoulder is located in the 5. Push rods
cylinder head. 6. Cylinder head

2. Lightly lubricate the threads and beneath the

head of the rocker shaft assembly bolts with
clean engine oil.

3. Tighten the rocker pedestal bolts to the

torque figures quoted in DATA.

E9703 2–3–5
 ENGINE 2
Cylinder head 55 Series

4. Adjust the valve/rocker lever clearances as

instructed in this Section.

5. Clean rocker covers and cylinder head

sealing surfaces.

6. Examine rocker cover seals; renew as

necessary.

7. Refit rocker covers and seals.

8. Using new O–rings, refit rocker cover

3 retaining bolts and tighten to the torque figure
quoted in DATA.

9. L.H.D. Vehicles: Refit the gear–change

assembly to the belt tensioner bracket. Refit
the radiator stabliser and secure the steady
bracket to the air induction manifold.

10. Refit coolant pipe support bracket.

11. Vehicles fitted with a Bosch P–7100 In–line

injection pump: Connect the hose pipe to the
turbocharger wastegate pipe.

12. Lower and secure cab, see ‘Drivers

Handbook’.

13. Connect batteries.

E9703
2–3–6
2 ENGINE
55 Series Cylinder head

Cylinder Head

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Drain the cooling system, refer to the

‘Maintenance Manual’.

4. Remove the rear noise suppression panel.

5. Note connections, then disconnect electrical

leads from the following:
3
— Temperature switch at thermostat
housing.
— Glow plugs at air induction pipe (when
fitted).
— Vehicles fitted with a Bosch VP 14 rotary
injection pump: KSB thermal sensor at
induction manifold and release cable
from fuel injection pipe clamp.
6. Remove the radiator stabiliser.

7. Remove bolts securing gear–change lever

assembly to belt tensioner mounting bracket
and release gear lever assembly steady
bracket from engine. Disconnect control tube
ball–joint from gear selector lever and release
reaction rod from control tube; withdraw
change–speed assembly from vehicle.

8. Detach the air induction pipe from the

intercooler and induction manifold.

9. Remove rocker shaft assemblies as

instructed in this Section.

10. Release hose clips and remove radiator top

hose.

E9703 2–3–7
 ENGINE 2
Cylinder head 55 Series

11. Disconnect heater hose from cylinder head.

12. Using a 3/8 in square drive knuckle bar, raise

the automatic drive belt tensioner/pulley and
release the drive belt from the pulley.

13. Release alternator harness from thermostat

housing bracket.

14. Remove belt tensioner/support bracket

assembly.

3 15. Release alternator link bracket from

thermostat housing.

16. Release the compressor air intake pipe and

the air restriction indicator pipe from the air
filter intake hose. Remove the air filter
assembly and air intake hose.

17. Remove exhaust manifold/turbocharger

heat shield.

18. Remove the air induction pipe from the

turbocharger and intercooler.

19. Remove header tank de–aeration/vent

pipes and bracket assemblies.

20. Remove turbocharger exhaust elbow.

21. Disconnect oil feed and return pipes from

turbocharger.

22. Vehicles fitted with a Bosch P–7100 in–line

injection pump: Remove the turbocharger
wastegate cylinder pipe.

23. Remove fuel leak–off pipe.

24. Remove fuel injection pipes and injectors,

see Group 4.

25. Remove the fuel feed pipe from fuel filter

head and injection pump.

E9703
2–3–8
2 ENGINE
55 Series Cylinder head

26. Remove fuel supply pipe, lift pump to filter

head.

27. Vehicles fitted with a Bosch VP 14 rotary

injection pump: Release fuel vent pipe from
induction manifold bracket.

28. Remove the fuel filter cartridge, refer to the

‘Maintenance Manual’.

29. Remove boost control pipe.

30. Vehicles fitted with a water cooled

compressor: Remove coolant pipe cylinder
3
head to compressor.

31. Remove the push–rods and retain them in

their installed position.

32. Remove the remaining cylinder head bolts.

Using suitable overhead lifting equipment,
carefully remove cylinder head; discard the
cylinder head gasket.

33. If necessary, remove the following from

cylinder head:

— Thermostat housing, thermostat, seal

and front lifting bracket.
— Induction manifold, gasket and rear lifting
bracket.
— Exhaust manifold/turbocharger assembly.
34. Clean all gasket faces.

E9703 2–3–9
 ENGINE 2
Cylinder head 55 Series

To Refit 12 8 4 1 5 9
1. If necessary refit the following to cylinder
head:

— Adapters, plugs and temperature

switches.
— Induction manifold and new gasket; 11 7 3 2 6 10
apply sealant quoted in DATA to the 040967

threads of induction manifold bolts.

FIG.2. EXHAUST MANIFOLD TORQUE
— Exhaust manifold/turbocharger assembly
TIGHTENING SEQUENCE
and new gaskets; tighten exhaust
3 manifold bolts in the sequence shown in
Fig.2 and to the torque figure quoted in
DATA.
— Rear lifting bracket.
— Thermostat housing, thermostat, seal
and front lifting bracket; ensure the step
of the thermostat housing seal is fitted
towards thermostat.

2. Ensure the cylinder block and cylinder head

combustion face are clean and dry.

3. Position a new cylinder head gasket over

the locating dowels, ensuring that the holes
in the cylinder block align with the
corresponding holes in the gasket.

4. Using suitable overhead lifting equipment,

refit cylinder head, ensuring it is correctly
seated on the locating dowels.

5. Insert the push–rods into the cam followers,

lubricate the push–rod sockets with clean
engine oil.

6. Lightly lubricate the threads and beneath

the bolt head of the cylinder head and
rocker shaft assembly bolts with clean
engine oil.

E9703
2–3–10
2 ENGINE
55 Series Cylinder head

7. Refit the rocker shaft assemblies as

instructed in this Section.

8. Refit the remaining cylinder head bolts and

tighten as follows:

— Tighten all bolts in the sequence shown

in Fig.3, to a torque figure of 90 Nm
(66 lbf ft).
— Re–check all bolts are tightened to
90 Nm (66 lbf ft).
— Further tighten the long bolts securing
the rocker pedestals (white fastenings,
3
see Fig.3), starting at the centre and
working outwards to a torque of
120 Nm (88 lbf ft).
— Re–check long bolts are tightened to
120 Nm (88 lbf ft).
— Suitably reference mark bolts and
cylinder head as shown in Fig.3, then
tighten all bolts in the sequence shown a
further 90°.

22 14 6 3 11 19
26 18 10 2 7 15 23

25 17 9 1 8 16 24
21 13 5 4 12 20

90

040651

FIG.3. CYLINDER HEAD TORQUE TIGHTENING SEQUENCE

E9703 2–3–11
 ENGINE 2
Cylinder head 55 Series

9. Adjust the valve clearances as instructed in

this Section.

10. Refit injectors and fuel injection pipes, see

Group 4.

11. Vehicles fitted with a water cooled

compressor: Refit coolant pipe cylinder head
to compressor.

12. Refit boost control pipe.

3 13. Fit a new fuel filter cartridge, refer to the

‘Maintenance Manual’.

14. Vehicles fitted with a Bosch VP 14 rotary

injection pump: Secure fuel vent pipe at
cylinder head bracket.

15. Refit fuel supply pipe lift pump to fuel filter

head.

16. Refit fuel feed pipe fuel filter head to injection

pump.

17. Refit fuel leak–off pipe.

18. Vehicles fitted with a Bosch P–7100 in–line

injection pump: Refit the turbocharger
wastegate cylinder pipe.

19. Prime the turbocharger with clean engine oil

through the oil feed pipe port.

20. Connect turbocharger oil feed pipe, then

using a new gasket connect oil return pipe.

21. Refit turbocharger exhaust elbow.

22. Refit header tank de–aeration/vent pipes.

23. Refit the air induction pipe to the turbocharger

and intercooler.

24. Refit air intake hose/air filter assembly,

connect the compressor air intake pipe and
air restriction indicator pipe to the air intake
hose.

E9703
2–3–12
2 ENGINE
55 Series Cylinder head

25. Refit turbocharger/exhaust manifold heat

shield.

26. Secure alternator link bracket at thermostat

housing.

27. Refit belt tensioner/support bracket assembly.

28. Secure alternator electrical harness at

thermostat housing bracket.

29. Refit drive belt.

30. Connect heater hose at cylinder head.

3
31. Refit radiator top hose.

32. Refit air induction pipe to the intercooler and

induction manifold.

33. Refit gear–change lever assembly.

34. Refit radiator stabiliser bracket.

35. Connect electrical leads to the following:

— Temperature switch at thermostat

housing.
— Glow plugs at air induction pipe (when
fitted).
— Vehicles fitted with a Bosch VP 14 rotary
injection pump: KSB thermal sensor at
induction manifold and secure the cable
to the fuel injection pipe clamp.

36. Refill cooling system, refer to the

‘Maintenance Manual’.

37. Bleed the fuel system, see Group 4.

38. Fit the rear noise suppression panel.

39. Lower and secure cab, see ‘Drivers

Handbook’.

40. Connect batteries.

E9703 2–3–13
 ENGINE 2
Cylinder head 55 Series

ADJUSTMENT

Valve/Rocker Lever Clearances

Service tool: 0192494

NOTE: Always check/adjust the valve

clearances with the engine in a cold condition.

1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Remove the rocker covers and seals.

3 4. Locate ‘Top Dead Centre’ (T.D.C.) for No.1

cylinder by turning the engine slowly and
4
pressing in the timing pin at rear of
gearcase cover until the timing pin locates
in the camshaft gear; disengage timing pin
after locating T.D.C.
NOTE:
— On vehicles fitted with a Bosch VP 14
1
rotary injection pump Service tool
0192494 can be used to assist in
engaging/disengaging the timing pin.
2
— Insert a suitable bar through the holes
in the fan adapter to turn the engine; if
the fan adapter has two machined flats,
use a suitable open ended spanner. Do
NOT use the fan blades to turn the
engine.
4
3

040652

FIG.4. LOCATING ‘TOP DEAD CENTRE’

1. Camshaft gear
2. Timing pin
3. Timing pin housing
4. Timing pin extension tool (rotary injection
pump only)

E9703
2–3–14
2 ENGINE
55 Series Cylinder head

5. Using feeler gauges with a pre–set value of

0,25 mm (0.010 in) for the inlet valves and
0,50 mm (0.020 in) for the exhaust valves,
check the clearance between the rocker
levers and the valve stems; the feeler
gauge should be a sliding fit. Check the
valve clearances in the following sequence;
see Fig.5:
6 5 4 3 2 1
040653
Cylinder Inlet valve Exhaust
valve
No.1
No.2
1
3
2
—
FIG.5. VALVE CLEARANCE
CHECKING SEQUENCE 3
No.3 — 6
No.4 7 —
1 2
No.5 — 10
No.6 — —

6. To adjust valve clearances slacken the

locknut and turn the adjusting screw in the
appropriate direction until the correct
clearance is obtained. Hold the adjusting
screw against rotation, tighten locknut then
re–check the valve clearance.

040654

FIG.6. ADJUSTING VALVE CLEARANCES

1. Locknut
2. Adjusting screw

E9703 2–3–15
 ENGINE 2
Cylinder head 55 Series

7. Suitably reference mark the crankshaft

pulley in relationship to the gearcase front
cover, then rotate the crankshaft, clockwise
viewed from the front 360° until the
reference marks are re–aligned. Check, as
previously described, the clearance of the
remaining valves in the following sequence;
see Fig.7:

6 5 4 3 2 1 040655
Cylinder Inlet valve Exhaust
valve
FIG.7. VALVE CLEARANCE
3 No.1
No.2
—
—
—
4
CHECKING SEQUENCE

No.3 5 —
No.4 — 8
No.5 9 —
No.6 11 12

8. Refit rocker covers and seals; tighten

rocker cover retaining bolts to the torque
figure quoted in DATA.

E9703
2–3–16
2 ENGINE
55 Series Cylinder head

TESTING

Diesel Compression Test

Service tools: 0109747, 0192492, 0499811,
0694972.

NOTE: Measuring the compression is a method

of checking the sealing of the valves, the
cylinder head gasket and the piston rings. The
measured results may only be used to compare
the compression of cylinders against each other
on any one engine.

1. Run the engine until it reaches its normal

operating temperature (when the
temperature gauge pointer registers within
3
the black sector).

2. Tilt the cab, see ‘Drivers Handbook’.

3. Remove the injectors as instructed in

Group 4.

4. To prevent fuel spillage during the test

procedure, blank the fuel injection pipes
and retain the stop control cable in the fuel
shut–off position.

5. Ensure the injector seat is free from carbon

deposit; if necessary, clean injector seat
using injector bore brush 0192492.

6. Assemble test adapter 0499811 and

adapter 0694972 to compression tester
0109747, fit an appropriate copper seating
washer to adapter 0499811, then locate and
secure in injector bore.

7. Turn/crank the engine, using the starter

motor, until the pointer of the compression
tester stops rising; record the reading.
Repeat this method for remaining cylinders.

8. To calculate the average compression the

total of the values is divided by 6.
NOTE: The difference between the highest
and lowest values measured must not
exceed 15% of the average compression.

E9703 2–3–17
 ENGINE 2
Cylinder head 55 Series

OVERHAUL

Rocker Shaft Assemblies 3 6 7

4
To Dismantle
1. Prior to dismantling, note positions of
exhaust and inlet rocker levers for
subsequent reassembly.

2. Remove circlips and withdraw thrust

washers and rocker levers from rocker
shaft.

3. Remove locknut and adjusting screw from 1 2

3
040656
rocker lever. 5

4. Clean all components in a suitable solvent FIG.8. EXPLODED ROCKER SHAFT

and dry thoroughly. ASSEMBLY
5. Check the clearance between the rocker 1. Circlip
levers and rocker shafts is within the
2. Thrust washer
tolerance quoted in DATA; renew rocker
levers/rocker shaft assemblies as 3. Adjusting screw
necessary, noting, the rocker shaft and 4. Locknut
pedestal are renewed as an assembly.
5. Exhaust rocker lever
6. Rocker pedestal and shaft
To Reassemble
1. Fit adjusting screw and locknut in rocker 7. Inlet rocker lever
levers.

2. Lubricate the rocker shafts with clean

engine oil.

3. Assemble rocker levers and thrust washers

on rocker shaft, ensuring the exhaust and
inlet rocker levers are in their correct
positions, then refit circlips.

E9703
2–3–18
2 ENGINE
55 Series Cylinder head

Cylinder Head

Valves, Valve Springs and Valve Seats

To Remove
1. Using a suitable valve spring compression
tool, compress the valve springs and
remove the split collets.

2. Release tension from valve springs, then

remove the valve spring retainers and valve
springs.

3. Remove and discard the valve stem seals.

3
4. Identify the valves with their cylinder
positions, then remove from cylinder head.

5. Clean any carbon deposit from valves.

To Inspect
1. Examine valve springs for damage, cracks
or distortion; renew as necessary.

2. Measure the valve spring free length; renew

any valve spring that is not within the limits
quoted in DATA.

E9703 2–3–19
 ENGINE 2
Cylinder head 55 Series

3. Examine valve head contact surfaces,

stems and collet grooves for pitting,
damage or distortion; renew as necessary.

4. Check the valves are within the limits

quoted in DATA. If necessary, grind valve
faces using suitable valve grinding
equipment, removing the minimum amount
of material necessary to restore the valve
face; see DATA for valve face angles.

5. Examine valve seats for pitting or excessive

3 wear. If necessary, grind valve seats to
remove minor imperfections; refer to DATA
for valve seat angle and width.
NOTE: The cylinder head has integral valve
seats which can only be re–ground once.
Once the valve seat has been re–ground,
the cylinder head must be stamped with an
‘X’ adjacent to the valve concerned. Valve
seats which have previously been
re–ground must be replaced with service
valve seat inserts, refer to ‘Service Valve
Seat Inserts and Valve Guides’, in this
Section.

6. Inspect the valve guides for excessive

wear, scoring or damage, measure the
valve guide bore, if not within the tolerances
quoted in DATA, the cylinder head can be
machined for the fitment of service valve
guides, refer to ‘Service Valve Seat Inserts
and Valve Guides’, in this Section.

E9703
2–3–20
2 ENGINE
55 Series Cylinder head

To Refit
1. Refit valves in their original positions and
measure the valve head ‘stand–down’ from
combustion face of cylinder head. Ensure
the valve head ‘stand–down’ is within the
tolerances quoted in DATA; if the figure is
above the maximum quoted in DATA,
replace the valve, then measure the
‘stand–down’ again. If the figure is still
above the maximum a service valve seat 040657
insert must be fitted.

2. Lap valves to seats using a fine valve

grinding paste, then remove valves and
FIG.9. MEASURING VALVE HEAD
‘STAND–DOWN’
3
clean grinding paste from valves and seats.

3. Fit new valve stem seals.

4. Lightly oil valve stems with clean engine oil

and fit valves into their original positions.

5. Refit valve springs and valve spring

retainers.

6. Using valve spring compression tool,

compress springs and fit new split collets.

E9703 2–3–21
 ENGINE 2
Cylinder head 55 Series

Cylinder Head Combustion Face

To Inspect
1. Clean cylinder head in a suitable solvent
and dry thoroughly.

2. Ensure all residual gasket material is

removed from cylinder head contact
surfaces.

3. Remove any excessive carbon deposits

from cylinder head combustion face.
3 4. Examine cylinder head for cracks or
corrosion; renew as necessary.

5. Check the cylinder head for distortion, see

DATA; if necessary the combustion face
can be machined in any increments
necessary to maintain flatness up to a
maximum of 1,00 mm (0.039 in). The
amount of material removed should be
stamped on the rear face of cylinder head.
CAUTION: If the cylinder head combustion
face is machined, ensure the valve head
‘stand–down’ is maintained within the limits
quoted in DATA.

6. Inspect cylinder head core plugs for

leakage; replace as necessary using
sealing compound quoted in DATA.

E9703
2–3–22
2 ENGINE
55 Series Cylinder head

Service Valve Seat Inserts and Valve Guides

Valve seats which have previously been
re–ground must be replaced with service valve
seat inserts, after which the cylinder head must
be stamped with two ‘X’s adjacent to the valve
concerned.

Valve seat inserts can only be re–ground once,

after which the cylinder head must be stamped
with three ‘X’s. Previously re–ground valve seat
inserts must, when necessary, be replaced with
new service valve seat inserts.

It is recommended that the machining of the

3
cylinder head for the fitment of service valve
seat inserts and valve guides, be entrusted to
an engine reconditioning agent with the
necessary expertise and equipment, to conform
with the engine manufacturers
recommendations. Refer to DATA for service
valve seat insert and service valve guide
installation dimensions.

For further information on the reclamation of the

cylinder head a Cummins Bulletin No.
3810234–02 can be obtained from the following
address:

Cummins Engine Co. Ltd.,

Royal Oak Way South,
Daventry, Northants, NN11 5NU,
England.

E9703 2–3–23
 ENGINE 2
Cylinder head 55 Series

E9703
2–3–24
2 ENGINE
55 Series Contents

CONTENTS Page Date

SECTION 4—CRANKCASE ASSEMBLY

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—1 . . . . . . . . . 9703
Overhaul:
Cylinder Bores and Service Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—51 . . . . . . . . 9703
Removal and Refitment:
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—14 . . . . . . . . 9703
Cam–Followers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—18 . . . . . . . . 9703
Connecting Rod Big–End Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—30 . . . . . . . . 9703
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—41 . . . . . . . . 9703
Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—22 . . . . . . . . 9703
Crankshaft Rear Oil Seal Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—24 . . . . . . . . 9703
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—20 . . . . . . . . 9703
Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—21 . . . . . . . . 9703
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—39 . . . . . . . . 9703
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—26 . . . . . . . . 9703
Oil Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2—4—29 . . . . . . . .
2—4—13 . . . . . . . .
9703
9703
4
Pistons and Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—33 . . . . . . . . 9703
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—25 . . . . . . . . 9703
Setting Top Dead Centre (T.D.C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—48 . . . . . . . . 9703
Timing Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—19 . . . . . . . . 9703
Timing Gear Cover and Front Crankshaft Oil Seal . . . . . . . . . . . . . . . 2—4—9 . . . . . . . . . 9703
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—47 . . . . . . . . 9703
Vibration Damper/Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—8 . . . . . . . . . 9703
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—4—7 . . . . . . . . . 9703

E9703 1
4

E9703
2
2 ENGINE
55 Series Crankcase assembly

4. CRANKCASE ASSEMBLY
DATA

Camshaft
End–float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,12 to 0,33 mm (0.005 to 0.013 in)
Gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,08 to 0,33 mm (0.003 to 0.013 in)
Bearing bush (No.1 journal) . . . . . . . . . . . . . . . . . . 54,107 to 54,146 mm (2.1302 to 2.1317 in)
Service bush available—rebore to . . . . . . . . 57,722 to 57,758 mm (2.2726 to 2.2737 in)
Remainder of journals . . . . . . . . . . . . . . . . . . . . . . 53,962 to 54,013 mm (2.1245 to 2.1265 in)
Maximum worn limit . . . . . . . . . . . . . . . . . . . . 54,164 mm (2.1324 in)
Service bushes available—rebore to . . . . . . 57,222 to 57,258 mm (2.2523 to 2.2537 in)
Surface finish all journals to . . . . . . . . . . . . . . . . . . 2,3 micrometre (92 microinch)
Camshaft lobes minimum diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47,040 mm (1.852 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,770 mm (1.841 in)
Lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35,500 mm (1.398 in)

Connecting rod and bearings

4
Big–end bearing clearance . . . . . . . . . . . . . . . . . . 0,114 mm (0.0045 in)
Small–end bush internal diameter:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,092 mm (1.5784 in)
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,053 mm (1.5769 in)
Side clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1 to 0,3 mm (0.004 to 0.012 in)

Crankshaft
Main journals:
Standard size . . . . . . . . . . . . . . . . . . . . . . . . . . 82,987 to 83,013 mm (3.2672 to 3.2682 in)
Maximum worn limit . . . . . . . . . . . . . . . . . . . . 82,962 mm (3.2662 in)
Permissible re–grind undersize: Regrind to:
1st – 0,25 mm (0.0098 in) . . . . . . . . . . . . . . . 82,737 to 82,763 mm (3.2574 to 3.2584 in)
2nd – 0,50 mm (0.0197 in) . . . . . . . . . . . . . . . 82,487 to 82,513 mm (3.2475 to 3.2485 in)
3rd – 0,75 mm (0.0295 in) . . . . . . . . . . . . . . . 82,237 to 82,263 mm (3.2376 to 3.2386 in)
4th – 1,00 mm (0.0394 in) . . . . . . . . . . . . . . . 81,987 to 82,013 mm (3.2278 to 3.2288 in)
Thrust journal:
Permissible re–grind undersize: Regrind to:
0,50 mm (0.0197 in) . . . . . . . . . . . . . . . . . . . . 82,487 to 82,513 mm (3.2475 to 3.2485 in)
diameter
37,975 to 38,025 mm (1.4950 to 1.4952 in)
width
1,00 mm (0.0394 in) . . . . . . . . . . . . . . . . . . . . 81,987 to 82,013 mm (3.2278 to 3.2288 in)
diameter
38,475 to 38,525 mm (1.5148 to 1.5168 in)
width
Surface finish journals and thrust face of thrust
journal to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 micrometre (16 microinch)

E9703 2–4–1
 ENGINE 2
Crankcase assembly 55 Series

Main journal fillet radii . . . . . . . . . . . . . . . . . . . . . . . 4,180 to 4,220 mm (0.1646 to 0.1662 in)

Surface finish to . . . . . . . . . . . . . . . . . . . . . . . . 0,8 micrometre (32 microinch)
Main bearing cap bearing diameter . . . . . . . . . . . 83,106 mm (3.272 in)
Standard and oversize bearings available
Main journal bearings . . . . . . . . . . . . . . . . . . . Standard plus 0,25, 0,50, 0,75 and 1,00 mm
(Standard plus 0.0098, 0.0197, 0.0295 &
0.0394 in)
Main journal thrust bearing . . . . . . . . . . . . . . Standard plus 0,50 mm (0.019 in) and 1.00 mm
(0.0394 in)
NOTE: When installing main bearings, ensure piston cooling nozzles are level with, or slightly below the
bearing saddle surface.
Crankshaft end–float . . . . . . . . . . . . . . . . . . . . . . . . 0,13 to 0,35 mm (0.005 to 0.014 in)
Crankpin (connecting rod) journals
4 Standard size . . . . . . . . . . . . . . . . . . . . . . . . . . 68,987 to 69,013 mm (2.716 to 2.717 in)
Maximum worn limit . . . . . . . . . . . . . . . . . . . . 68,962 mm (2.715 in)
Permissible re–grind undersize: Regrind to:
1st—0,25 mm (0.0098 in) . . . . . . . . . . . . . . . 68,737 to 68,763 mm (2.7062 to 2.7072 in)
2nd—0,50 mm (0.0197 in) . . . . . . . . . . . . . . . 68,487 to 68,513 mm (2.6964 to 2.6974 in)
3rd—0,75 mm (0.0295 in) . . . . . . . . . . . . . . . 68,237 to 68,263 mm (2.6865 to 2.6875 in)
4th—1,00 mm (0.394 in) . . . . . . . . . . . . . . . . 67,987 to 68,013 mm (2.6767 to 2.6777 in)
Surface finish journals to . . . . . . . . . . . . . . . . 0,4 micrometre (16 microinch)
NOTE: All journals must be ground in the opposite direction of rotation, anti–clockwise viewed from
front of crankshaft. Polish journals in direction of rotation, clockwise viewed from front of crankshaft.
Crankpin fillet radii . . . . . . . . . . . . . . . . . . . . . . . . . . 3,980 to 4,020 mm (0.1563 to 0.1583 in)
Surface finish to . . . . . . . . . . . . . . . . . . . . . . . . 0,8 micrometre (32 microinch)
Standard and oversize bearings available . . . . . Standard, 0,25, 0,50, 0,75 and 1,00 mm
(Standard, 0.0098, 0.0197, 0.0295 and
0.0394 in)

Pistons
Skirt diameter of piston: Nominal Worn Limits
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101,880 mm (4.0110 in) 101,823 mm (4.0088 in)
0,5 mm (0.0197 in) oversize . . . . . . . . . . . . . . 102,380 mm (4.0307 in) 102,323 mm (4.0285 in)
1,00 mm (0.0394 in) oversize . . . . . . . . . . . . . 102,880 mm (4.0504 in) 102,823 mm (4.0481 in)
Gudgeon pin bore diameter:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,025 mm (1.576 in)
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,006 mm (1.575 in)
Gudgeon pin diameter—minimum . . . . . . . . . . . . 39,990 mm (1.5745 in)
Ring groove clearance—maximum:
Top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No check required
Intermediate ring . . . . . . . . . . . . . . . . . . . . . . . 0,150 mm (0.006 in)
Oil ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,130 mm (0.005 in)
Ring gap:
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm (0.010 in)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,55 mm (0.021 in)

E9703
2–4–2
2 ENGINE
55 Series Crankcase assembly

Cylinder block
Combustion deck: The combustion face of the cylinder block can be refaced twice and should be
stamped in the upper right hand corner with a single ‘X’ for the first reface and with two ‘XX’s signifying
the second reface.
First reface ‘A’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 mm (0.006 in)
Second reface ‘A’ . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm (0.014 in)
Maximum reface allowed ‘A’ . . . . . . . . . . . . . . . . . 0,50 mm (0.020 in)
Standard block ‘B’ . . . . . . . . . . . . . . . . . . . . . . . . . . 323 " 0,1 mm (12.7165 " 0.0039 in)
Block first reface ‘B’ . . . . . . . . . . . . . . . . . . . . . . . . 322,85 " 0,1 mm (12.7106 " 0.0039 in)
Block second reface ‘B’ . . . . . . . . . . . . . . . . . . . . . 322,50 " 0,1 mm (12.6968 " 0.0039 in)
A surface finish of 1,5 to 3,2 micrometres (60 to 120 microinch) must be obtained.
Distortion of combustion deck must not exceed 0,010 mm (0.0004 in) in any 50 mm (2 in) diameter.
4
Maximum permissible bow, length and width 0,075 mm (0.003 in)

Gaskets available for cylinder block:

Standard
0,15 mm (0.006 in) oversize
0,50 mm (0.020 in) oversize A
XX

040658

E9703 2–4–3
 ENGINE 2
Crankcase assembly 55 Series

Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . 102 to 102,116 mm (4.0157 to 4.0203 in)

Boring dimension (A):
1st re–bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102,469 mm (4.0342 in)
2nd re–bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 102,969 mm (4.0539 in)
Honing dimension (B) 15° to 25° cross–hatch:
Standard cylinder bore . . . . . . . . . . . . . . . . . . 102 to 102,040 mm (4.0157 to 4.0173 in)
1st re–hone . . . . . . . . . . . . . . . . . . . . . . . . . . . 102,500 to 102,540 mm (4.0354 to 4.0370 in)
2nd re–hone . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 to 103,04 mm (4.0551 to 4.0567 in)
A 1,2 maximum micrometre (48 microinch) surface finish must be obtained
NOTE: After boring use a honing stone to chamfer bore to dimension (C)
Dimension (C) . . . . . . . . . . . . . . . . . . . . . . . . . 1,25 mm (0.049 in) x 15° approx.
Rough hone . . . . . . . . . . . . . . . . . . . . . . . . . . . Use 80 grit honing stone
Finish hone . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use 280 grit honing stone
NOTE: After honing, clean the bores using a detergent solution, then dry thoroughly.
4 A
B

15°

15° - 25°

040659

E9703
2–4–4
2 ENGINE
55 Series Crankcase assembly

Cylinder liner installation:

When more than 1,00 mm (0.039 in) bore oversize is required the block must be re–bored and a
cylinder liner fitted and finished bored to 102 to 102,040 mm (4.0157 to 4.0173 in). A standard diameter
piston and ring set must now be used.
Cylinder block re–bore for cylinder liner:
(D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,500 to 104,515 mm (4.1142 to 4.1148 in)
(E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,35 mm (0.250 in)
NOTE: After boring, clean thoroughly prior to fitting liners.
Finish bore liner to . . . . . . . . . . . . . . . . . . . . . . 101,956 mm (4.014 in)
Finish hone liner to . . . . . . . . . . . . . . . . . . . . . 102 to 102,020 mm (4.0157 to 4.0173 in)
Use a honing stone to chamfer a lead of 1,25 mm (0.049 in) x 15° on liner
NOTE: A 1,2 maximum micrometre (48 microinch) surface finish must be obtained.
Liner stand–proud:
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . Zero (flush with block)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm (0.0019 in)
4
D

040660

Flywheel Housing
Run–out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm (0.008 in)

Oil Pump
Gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . 0,76 to 0,45 mm (0.030 to 0.018 in)

E9703 2–4–5
 ENGINE 2
Crankcase assembly 55 Series

Sealing Compounds
Core plug locking/sealing compound . . . . . . . . . . Loctite 242
Front crankshaft oil seal retaining compound . . . Loctite 290
Liner retaining compound . . . . . . . . . . . . . . . . . . . Loctite 620
Engine side cover sealing compound . . . . . . . . . Hylomar
Sump jointing compound:
Between rear oil seal housing and block . . . Hylomar
Between front gear housing and block . . . . Hylomar
Coat both sides of sump joint with . . . . . . . . Hylomar
Timing pin housing ‘Torkscrews’ . . . . . . . . . . . . . . Loctite 242

Torque Tightening Figures Nm lbf ft

4 Camshaft thrust plate setscrews . . . . . . . . . . . . . .
Compressor gear nut . . . . . . . . . . . . . . . . . . . . . . .
24
126
18
93
Compressor mounting nuts . . . . . . . . . . . . . . . . . . 78 57
Connecting rod bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 52
Final stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 73
Crankshaft damper/pulley bolts . . . . . . . . . . . . . . 137 101
Crankshaft main bearing cap bolts*:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 88
Final stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 129
Drive belt tensioner centre bolt . . . . . . . . . . . . . . . 43 32
Fan assembly to crankshaft flange retaining
nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 to 75 44 to 55
Flywheel bolts ** . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 101
Flywheel housing bolts ** . . . . . . . . . . . . . . . . . . . . 60 45
Front gear cover and housing setscrews . . . . . . 24 18
Oil cooler setscrews . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Oil pressure regulator plug . . . . . . . . . . . . . . . . . . 80 59
Oil pump retaining bolts . . . . . . . . . . . . . . . . . . . . . 24 18
Oil suction pipe and support bracket setscrews . 24 18
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59
Sump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Rear engine mounting bracket centre bolts . . . . 220 to 250 162 to 184
Rear engine mounting to flywheel housing bolts 80 to 110 59 to 81
Rear oil seal housing setscrews . . . . . . . . . . . . . . 9 7
Timing pin housing ‘Torkscrews’ T–25 . . . . . . . . . 5,4 4
* Refer to Fig.16. for correct torque tightening sequence
** Refer to Figs.7 and 8. for correct torque tightening sequence

E9703
2–4–6
2 ENGINE
55 Series Crankcase assembly

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE ENGINE WHILST INSTALLED IN THE

VEHICLE, BOTH BATTERY LEADS MUST BE DISCONNECTED TO PREVENT ACCIDENTAL
OR INADVERTENT STARTING OF THE ENGINE.

2. WHEN THE ENGINE IS AT ITS NORMAL OPERATING TEMPERATURE THE INTERNAL

PRESSURE WITHIN THE COOLING SYSTEM WILL EXPEL SCALDING COOLANT IF THE
FILLER CAP OR ANY DRAIN PLUGS ARE REMOVED. THE COOLANT MUST ONLY BE
RENEWED WHILST THE ENGINE IS STOPPED AND IN A COLD CONDITION.

3. ANTI–FREEZE CONTAINS TOXIC CHEMICALS WHICH MUST NOT BE CONSUMED OR

ALLOWED TO COME INTO SKIN CONTACT. USE IMPERVIOUS PROTECTIVE CLOTHING
AND GLOVES WHEN HANDLING ANTI–FREEZE. IN THE EVENT OF SLIGHT SKIN
CONTACT, THOROUGHLY RINSE THE AFFECTED AREA WITH CLEAN WATER. IF THERE IS
EXCESSIVE SKIN CONTACT OR INGESTION/INHALATION SEEK MEDICAL ADVICE
IMMEDIATELY.
4
4. DO NOT RUN THE ENGINE IN A CONFINED SPACE OR UNVENTILATED AREA. EXHAUST
FUMES CONTAIN TOXIC GASES WHICH, IF INHALED, MAY PROVE FATAL.

5. FUEL SPILLAGES ARE HIGHLY INFLAMMABLE AND MUST NOT BE EXPOSED TO A

NAKED FLAME, SPARK OR INTENSE HEAT SOURCE.

6. AVOID UNNECESSARY CONTACT WITH USED ENGINE OIL. PROLONGED AND REPEATED
CONTACT WITH USED ENGINE OIL MAY CAUSE SERIOUS SKIN DISORDERS.

7. THE ENGINE WEIGHS APPROXIMATELY 520 kg, (1147 lb) ENSURE SUITABLE EQUIPMENT
IS USED WHILST RAISING OR SUPPORTING THE ENGINE.

8. SYNTHETIC RUBBER SEALS, O–RINGS AND GASKETS WHICH HAVE COME INTO
CONTACT WITH DIRECT HEAT, i.e., FIRE DAMAGE, MAY PRODUCE HAZARDOUS FUMES
AND HIGHLY CORROSIVE CHEMICALS. ALLOW BURNT OR DECOMPOSED SEALS ETC.,
TO COMPLETELY COOL, USE IMPERVIOUS PROTECTIVE CLOTHING AND GLOVES AND
WORK IN A WELL VENTILATED AREA WHEN HANDLING THESE COMPONENTS. IN THE
EVENT OF SKIN CONTACT/INHALATION SEEK MEDICAL ATTENTION IMMEDIATELY.

CAUTION: To prevent the ingress of foreign matter, always thoroughly clean the exterior of engine
components prior to dismantling and ensure that all open ports and pipework are suitably blanked.
NOTE: Before disconnecting the vehicle battery supply, ensure that, if applicable, the radio security
code is available to enable the radio to be re–activated upon completion of all work.

E9703 2–4–7
 ENGINE 2
Crankcase assembly 55 Series

REMOVAL AND REFITMENT

Vibration Damper/Crankshaft Pulley

To Remove
1. Isolate the batteries. 1

2. Tilt the cab, see ‘Drivers Handbook’. 2

3. Remove nuts securing the fan assembly to

crankshaft flange; withdraw fan assembly and 3
position in fan cowl, taking care not to
damage radiator. 4

4. Using a 3/8 in square drive knuckle bar, raise

the automatic drive belt tensioner/pulley and
remove the drive belt.

4 5. Remove bolts securing crankshaft flange and

damper/pulley to crankshaft, then withdraw
040662

flange and damper/pulley. FIG.1. VIBRATION DAMPER

1. Reference lines
6. Check that the reference lines scribed on the
inertia member and damper hub are aligned; 2. Inertia member
the maximum misalignment of the reference 3. Damper hub
lines must not exceed 1,6 mm (0.062 in).
4. Rubber member
7. Examine the rubber member for damage or
deterioration. The vibration damper must be
renewed if pieces of the rubber member are
missing or if the rubber member has receded
more than 3,2 mm (0.125 in) below the
surfaces of the inertia member and the
damper hub.

8. Check the drive belt for cracks, damage or

excessive wear: renew as necessary.

To Refit
Reverse removal procedure, noting:

1. Tighten the crankshaft flange and

damper/pulley bolts to the torque figure
quoted in DATA.

2. Tighten the fan assembly to crankshaft flange

nuts to the torque figure quoted in DATA.

E9703
2–4–8
2 ENGINE
55 Series Crankcase assembly

Timing Gear Cover and Front Crankshaft Oil

Seal
Service tool: 0694942

To Remove (Fig.3)
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Remove the vibration damper/crankshaft

pulley, as instructed in this Section.

4. Remove the centre bolt and withdraw the

belt tensioner and pulley.

5. Vehicles fitted with a Bosch VP 14 rotary

injection pump: Release accelerator return
4
spring bracket from front cover.

6. Vehicles fitted with a Bosch P–7100 In–line

injection pump: Release clips securing the
engine stop control cylinder air pipe to the
electrical harness.

7. Release electrical harness from clips at

front cover; position harness clear of front
cover.

8. Remove setscrews securing timing gear

cover, withdraw cover and discard gasket.

9. Extract crankshaft oil seal from front cover.

10. Thoroughly clean gasket faces, seal

housing and seal track of crankshaft.

11. If necessary remove the fuel injection pump

gear cover and renew the seal.

E9703 2–4–9
 ENGINE 2
Crankcase assembly 55 Series

To Refit
1. Using a new gasket refit the timing gear
cover; do not fully tighten setscrews at this
stage.
2
2. Using the metal installer provided in the
new oil seal kit, align the timing gear cover
seal housing to the crankshaft; tighten the
timing gear cover setscrews to the torque
figure quoted in DATA and remove the
metal installer.

3. Apply sealing compound quoted in DATA to 1

the outside diameter of the crankshaft oil
seal prior to fitting.
CAUTION: Crankshaft oil seals are
4 supplied with a plastic guide sleeve, this
protects the seal during shipment and also
aids in the fitment of the seal. The seal
should be fitted dry and the lip of the seal
must NOT be handled.

4. Position oil seal and plastic guide sleeve

onto crankshaft, then remove plastic guide
sleeve. Using the metal installer provided in
the seal kit and seal replacer 0694942, fit
the seal. The metal installer ensures the
seal is fitted to the correct depth.

5. Remove seal replacer 0694942 and metal

installer. 3

4
040664

FIG.2. FITTING FRONT CRANKSHAFT

OIL SEAL

1. Seal
2. Guide sleeve
3. Metal installer
4. Seal replacer 0694942

E9703
2–4–10
2 ENGINE
55 Series Crankcase assembly

7
6
5

9
3 4
8 4
1 2

040663

FIG.3. TIMING GEAR COVER

1. Fan assembly 4. Front crankshaft oil seal 7. Gearcase

* 2. Crankshaft flange 5. Timing gear cover 8. Fuel injection pump gear cover
* 3. Crankshaft damper/pulley 6. Gasket 9. Seal

* One piece unit on later models

E9703 2–4–11
 ENGINE 2
Crankcase assembly 55 Series

6. Vehicles fitted with a Bosch VP 14 rotary

injection pump: Secure the accelerator
return spring bracket and connect spring.

7. Secure electrical harness at front cover

clips.

8. Vehicles fitted with a Bosch P–7100 In–line

injection pump: Secure the engine stop
control cylinder air pipe to the electrical
harness .

9. Refit the belt tensioner and pulley,

tightening centre bolt to the torque figure
quoted in DATA.

4 10. Refit the vibration damper/crankshaft pulley,

as instructed in this Section.

E9703
2–4–12
2 ENGINE
55 Series Crankcase assembly

Oil Pump

To Remove 2
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Remove timing gear cover, as instructed in 1

this Section.

4. Remove retaining bolts and withdraw oil

pump.

To Refit 040665

Reverse removal procedure, noting:

1. Lubricate oil pump with clean engine oil, FIG.4. OIL PUMP
4
and check oil pump gear backlash is within
the limits quoted in DATA. 1. Oil pump
2. Retaining bolt
2. Tighten oil pump retaining bolts to the
torque figure quoted in DATA.

E9703 2–4–13
 ENGINE 2
Crankcase assembly 55 Series

Camshaft
Service tool: 0192494

To Remove
1. Remove the engine, see Section 1.

2. Drain the engine oil, refer to the

‘Maintenance Manual’.

3. Remove the timing gear cover, as

instructed in this Section.

4. Remove rocker shaft assemblies, see

Section 3.

4 5. Remove the push–rods and retain them in

their installed positions.

6. Remove injectors, see Group 4.

7. The following are removed to enable the

engine to be suitably supported,
horizontally, on its exhaust side:

— Alternator.
— Starter motor.
— Oil filter element.
— Turbocharger.

8. Using suitable overhead lifting equipment,

carefully position engine on suitable
supports on its exhaust side.
CAUTION: Ensure engine is supported so
that the cam–followers will not drop whilst
the camshaft is being removed.

9. Remove fuel lift pump, see Group 4.

10. Remove sump, as instructed in this Section.

11. Push the cam–followers upwards to the top

of their bores, turning engine as necessary
to gain access.

E9703
2–4–14
2 ENGINE
55 Series Crankcase assembly

12. Vehicles fitted with a Bosch VP 14 rotary

injection pump: Set the engine on ‘Top Dead
Centre’ (T.D.C.) by turning the engine and 4
pushing in the timing pin located at the rear
3
of the timing gear case using timing pin
extension tool 0192494, until it locates in
camshaft gear; disengage timing pin once E
T.D.C. is located. 2 0
1
— Ensure the timing marks on the
camshaft and crankshaft gears are
correctly aligned.
00
13. Vehicles fitted with a Bosch P–7100 In–line 0
injection pump:
5
— Set the engine on ‘Top Dead Centre’
(T.D.C.) by turning the engine and
6
040667
4
pushing in the timing pin located at the
rear of the timing gear case until it FIG.5. GEARTRAIN
locates in camshaft gear; disengage
timing pin once T.D.C. is located. 1. Timing gearcase
— Suitably reference mark the fuel injection 2. Oil pump gears
pump drive gear in relation to the 3. Camshaft gear
camshaft gear.
4. Fuel injection pump gear
— Ensure the timing marks on the
camshaft and crankshaft gears are 5. Compressor gear
correctly aligned. 6. Crankshaft gear
14. Suitably reference mark compressor gear in
relation to camshaft gear.

15. Remove camshaft thrust plate setscrews,

then carefully withdraw camshaft from
engine, retaining thrust plate.

To Inspect
1. Check camshaft lobes and journals are within
the tolerances quoted in DATA.
NOTE: If a new camshaft is to be fitted, then
new cam–followers must also be fitted.

2. If after inspection, the camshaft gear must be

renewed, use a suitable press to remove the
gear.

3. Check camshaft bearing bush and remainder

of journal bores are within the tolerances
quoted in DATA.
NOTE: If a new bearing bush is fitted ensure
oil holes in bush are aligned with oil holes in
crankcase. The remainder of the journal
bores can be repaired, see DATA for
machining tolerances and Service bush sizes.

E9703 2–4–15
 ENGINE 2
Crankcase assembly 55 Series

To Refit
Reverse removal procedure, noting:

0
1. If removed, refit a new camshaft gear as

0
0
follows:

— Fit a new camshaft gear key. 1 E

0
— Heat the gear in an oven, set at 121°C
(250°F) for approximately 45 minutes.
WARNING: Do not use a welding or
cutting torch to heat the camshaft
gear. Do not overheat the camshaft 0
00

gear. Always wear protective gloves

E
when handling heated components.

0
4 — Fit the gear with the timing marks facing
away from the camshaft, and ensure the 2
gear is correctly seated on the camshaft 040666
shoulder.
FIG.6. TIMING GEAR ALIGNMENT
2. Ensure the cam–followers have remained at
the top of their bores. 1. Crankshaft and camshaft gear alignment
3. Lightly smear camshaft with clean engine oil, 2. Camshaft and injection pump gear
then carefully guide camshaft into crankcase. alignment (rotary injection pump)
Prior to the camshaft being fully located,
locate the camshaft thrust plate in position
and ensure that the timing marks on
camshaft gear are aligned as follows:

Vehicles fitted with a Bosch VP 14 rotary

injection pump:

— Ensure the double timing mark on

camshaft gear aligns with the single
timing mark on crankshaft gear.
— Align the single timing mark on camshaft
gear with the letter ‘E’ on fuel injection
pump drive gear.
— Align the reference marks on camshaft
and compressor gears.

E9703
2–4–16
2 ENGINE
55 Series Crankcase assembly

Vehicles fitted with a Bosch P–7100 In–line

injection pump:

— Ensure the double timing mark on

camshaft gear aligns with the single
timing mark on crankshaft gear.
— Align the single timing mark on the
camshaft gear with the reference mark
on fuel injection pump drive gear.
— Align the reference marks on camshaft
and compressor gears.
NOTE: If the position of the Bosch P–7100
injection pump drive gear is in doubt, prior
to fully locating the camshaft, proceed as
follows:
4
— Remove the plug from the governor
housing timing aperture.
— Remove the timing location device from
the timing aperture.
— Rotate the injection pump until the
timing pointer is visible in the timing
aperture.
— Reverse the timing location device and
insert it into the timing aperture. Rotate
the pump as necessary until the slot of
the timing location device fully engages
the timing pointer.
— Fully locate the camshaft, then remove,
reverse and refit the timing location
device; refit the aperture plug.

E9703 2–4–17
 ENGINE 2
Crankcase assembly 55 Series

4. Tighten the thrust plate setscrews to the

torque figure quoted in DATA.

5. Check the camshaft end–float and gear

backlash are within the tolerances quoted in
DATA.

6. Check that the timing pin locates in the

camshaft gear.

Cam–Followers

To Remove
1. Remove the camshaft, as instructed in this
Section.

4 2. Withdraw cam–followers from crankcase.

3. Inspect cam–followers for excessive wear

or damage, renew as necessary.

To Refit
Reverse removal procedure, noting:

1. Lubricate cam–followers with clean engine

oil prior to refitting.

E9703
2–4–18
2 ENGINE
55 Series Crankcase assembly

Timing Gear Case

To Remove
1. Remove the camshaft, as instructed in this
Section.

2. Remove compressor, see Group 6.

3. Remove the fuel injection pump, see

Group 4.

4. Remove the bolts securing gear case to

crankcase, then withdraw gear case from
its dowelled location and discard gasket.
CAUTION: Do not remove the timing pin
housing, unless the gear case is being
replaced; if necessary, remove the timing
pin housing as instructed in this Section.
4
5. Clean gasket faces.

To Refit
Reverse removal procedure, noting:

1. Fit new gaskets.

2. Tighten gear case bolts to the torque figure

quoted in DATA.

E9703 2–4–19
 ENGINE 2
Crankcase assembly 55 Series

Flywheel

To Remove
1. Remove the clutch, see Group 3.

2. Remove the bolts securing flywheel to

crankshaft, then withdraw flywheel. 1
3 5

To Inspect 8 7
1. Using a magnetic or dye penetrant method,
crack detect flywheel. 6 4
2
2. Inspect flywheel spigot bearing for wear or
damage, renew as necessary.

4 3. Examine starter ring for cracks or broken

teeth, if necessary, renew the starter ring as
follows:
040668

— Using a suitable soft metal drift, drive

the starter ring from flywheel. FIG.7. FLYWHEEL TIGHTENING SEQUENCE
— Check mating faces of new starter ring
and flywheel are clean and free from
burrs.
— Uniformly heat the starter ring to 127°C
(260°F); check temperature using a
heat sensitive crayon.
WARNING: Do not use a welding or
cutting torch to heat the starter ring.
Do not overheat the starter ring.
Always wear protective gloves when
handling heated components.
— When the starter ring has reached the
required temperature, quickly position
starter ring onto flywheel, ensuring the
bevel on teeth of starter ring is towards
crankshaft.

To Refit
Reverse removal procedure, noting:

1. Tighten the flywheel bolts in sequence

shown in Fig.7. and to torque figure quoted
in DATA.

E9703
2–4–20
2 ENGINE
55 Series Crankcase assembly

Flywheel Housing

To Remove 6 3
1. Remove the clutch, see Group 3.

2. Remove the engine mounting centre bolts. 8 7

Raise the rear of the engine until the
mounting brackets are clear of the chassis
brackets, place suitable packing beneath 2 1
sump and then lower the engine on to the
packing. Do NOT support the engine 4 5
beneath the flywheel housing.

3. Remove flywheel as instructed in this

Section.

4. Note connections, then disconnect electrical

cables from starter motor.
040669 4
FIG.8. FLYWHEEL HOUSING TIGHTENING
5. Remove bolts securing starter motor to
SEQUENCE
flywheel housing, then withdraw starter
motor.

6. Release engine breather pipe from flywheel

housing.

7. Remove the flywheel housing retaining

bolts, then withdraw the flywheel housing
from its dowelled location.

8. If necessary, remove the rear engine

mounting brackets.

To Refit
Reverse removal procedure, noting:

1. Ensure the O–ring seal located in the rear

seal housing is serviceable, renew if
necessary.

2. Tighten flywheel housing bolts, in sequence

shown in Fig.8. and to torque figure quoted
in DATA.

3. Tighten bolts securing rear engine mounting

brackets to the torque figures quoted in
DATA.

4. Check flywheel housing run–out is within

the tolerance quoted in DATA.

E9703 2–4–21
 ENGINE 2
Crankcase assembly 55 Series

Crankshaft Rear Oil Seal

Service tools: 0484899, 0535684, 0694928

To Remove
1. Remove flywheel, as instructed in this
Section.

2. Drill the oil seal for fitment of adapter

0484899. Assemble slide hammer 0694928
to adapter 0484899, then remove oil seal.

3. Thoroughly clean oil seal housing and seal

track of crankshaft.

4 To Refit
CAUTION: Crankshaft oil seals are supplied
with a plastic guide sleeve, this protects the seal
during shipment and also aids the fitment of the
seal. The seal should be fitted dry and the lip of
the seal must NOT be handled.

1. Position oil seal and plastic guide sleeve

onto crankshaft, then remove plastic guide
sleeve. Using the metal installer provided in
the seal kit and seal replacer 0535684, fit
the seal. The metal installer ensures the
seal is fitted to the correct depth.

2. Remove seal replacer 0535684 and metal

installer.

3. Refit flywheel, as instructed in this Section.

E9703
2–4–22
2 ENGINE
55 Series Crankcase assembly

3 4
1

4 6
4 5 5
6

040670

FIG.9. CRANKSHAFT REAR OIL SEAL

1. Adapter 0484899 4. Oil seal

2. Slide hammer 0694928 5. Metal installer
3. Plastic pilot 6. Seal replacer 0535684

E9703 2–4–23
 ENGINE 2
Crankcase assembly 55 Series

Crankshaft Rear Oil Seal Housing

To Remove
1. Remove flywheel housing, as instructed in
this Section.

2. Remove sump, as instructed in this Section.

3. Remove oil seal housing and discard

gasket and O–ring.

4. Remove oil seal from housing.

5. Clean joint faces in a suitable solvent and

dry thoroughly.

4 To Refit
1. Fit seal housing and new gasket to cylinder
block, but do not tighten setscrews.

2. Align seal housing to crankshaft using metal

installer provided in the seal kit, ensure
housing is level with crankcase sump face,
then tighten setscrews to torque figure
quoted in DATA.

3. Remove metal installer and, if necessary,

trim the gasket to the crankcase sump face.

4. Fit a new oil seal, as instructed in this

Section and renew O–ring.

5. Refit sump, as instructed in this Section.

6. Refit flywheel, as instructed in this Section.

E9703
2–4–24
2 ENGINE
55 Series Crankcase assembly

Sump

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Drain the engine oil, refer to the ‘Maintenance

Manual’.

4. Remove setscrews securing sump to

crankcase; withdraw sump and discard
gasket.

5. Clean gasket faces of sump and crankcase.

To Refit
4
1. Apply jointing compound quoted in DATA to
joints between crankcase and timing gear
case and rear oil seal housing.

2. Apply jointing compound quoted in DATA to

both sides of new sump gasket.

3. Refit sump and tighten setscrews to the

torque figure quoted in DATA.

4. Fit and tighten sump drain plug to the torque

figure quoted in DATA.

5. Renew the engine oil, refer to the

‘Maintenance Manual’.

6. Lower and secure cab, see ‘Drivers

Handbook’.

7. Connect batteries.

E9703 2–4–25
 ENGINE 2
Crankcase assembly 55 Series

Oil Cooler

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Drain the engine oil and coolant, refer to the

‘Maintenance Manual’.

4. Remove turbocharger/exhaust manifold

heat shield (if fitted).

5. Remove air intake pipe turbocharger to

intercooler.

4 6. Release alternator harness from bracket at

thermostat housing.

7. Using a 3/8 in square drive knuckle bar,

raise the drive belt tensioner and release
the drive belt from the pulleys.

8. Remove the alternator mounting and link

bolts, then suitably support alternator clear
of oil cooler.

9. Using a suitable filter wrench remove the oil

filter element.

10. Disconnect turbocharger oil feed pipe from

oil cooler.

11. Remove setscrews securing oil cooler to

crankcase, then withdraw oil cooler cover
and oil cooler; discard gaskets.

12. Thoroughly clean all gasket faces.

13. If necessary remove the by–pass valve and

the pressure regulating valve from the oil
cooler cover.

E9703
2–4–26
2 ENGINE
55 Series Crankcase assembly

1
7
6

5
4

2 3

040671

FIG.10. OIL COOLER

1. By–pass valve 5. Oil cooler

2. Cover 6. Gasket
3. Pressure regulating valve 7. Crankcase
4. Gasket

E9703 2–4–27
 ENGINE 2
Crankcase assembly 55 Series

To Refit
1. If removed, refit the by–pass valve and
pressure regulating valve.

2. Using new gaskets refit the oil cooler and oil

cooler cover; tighten setscrews to the
torque figure quoted in DATA.

3. Connect turbocharger oil feed pipe.

4. Renew oil filter element, refer to the

‘Maintenance Manual’.

5. Refit the alternator.

6. Using a 3/8 in square drive knuckle bar,

4 raise the drive belt tensioner and refit the
drive belt; when the drive belt is correctly
positioned, release the tensioner.

7. Secure alternator harness at thermostat

housing.

8. Refit air intake pipe, turbocharger to

intercooler.

9. Refit turbocharger/exhaust manifold heat

shield.

10. Renew engine oil and coolant, refer to the

‘Maintenance Manual’.

11. Lower and secure cab, see ‘Drivers

Handbook’.

12. Connect batteries.

E9703
2–4–28
2 ENGINE
55 Series Crankcase assembly

Oil Pressure Regulating Valve

To Remove 1
1. Tilt the cab, see ‘Drivers Handbook’.
2
2. Remove the pressure regulating valve plug
and washer, then extract the spring and 3
valve.

3. Clean components using a suitable cleaning 4

solvent and dry thoroughly.

4. Renew spring if necessary, and ensure the

valve moves freely in the valve bore. 5

To Refit
1. Lubricate the valve with clean engine oil.
040672

4
FIG.11. OIL PRESSURE REGULATING VALVE
2. Refit valve, spring, plug and washer; tighten 1. Plug
plug to the torque figure quoted in DATA.
2. Sealing washer
3. Lower and secure cab, see ‘Drivers 3. Spring
Handbook’.
4. Valve
5. Oil cooler cover

E9703 2–4–29
 ENGINE 2
Crankcase assembly 55 Series

Connecting Rod Big–end Bearings

To Remove 2668
1. Isolate the batteries.

2. Tilt cab, see ‘Drivers Handbook’.

2668
3. Remove injectors, see Group 4.

4. Remove sump as instructed in this Section.

5. Remove oil suction pipe and gasket.

040673

6. Turn engine until two pistons are at Bottom

Dead Centre (B.D.C.) and remove
connecting rod bearing caps. FIG.12. CONNECTING ROD
4 NOTE: Connecting rods have correlation
numbers stamped on both rod and cap,
CORRELATION NUMBERS

ensure each cap is assembled to its

corresponding rod.

7. Push piston/connecting rod assemblies

upwards until clear of crankshaft.

8. Discard upper and lower bearing shells.

9. Thoroughly clean crankshaft journals,

connecting rods and caps.

E9703
2–4–30
2 ENGINE
55 Series Crankcase assembly

To Refit
1. Fit a new upper bearing shell to each
connecting rod, ensuring tang of bearing
shell is correctly located in slot of
connecting rod. Lubricate upper bearing
shells with clean engine oil.

2. Pull connecting rods into position on

crankshaft journals.

3. Fit a new lower bearing shell to each

connecting rod bearing cap, ensuring tang
of bearing shell is correctly located in slot of
bearing cap.

4. Apply clean engine oil to lower bearing

shells, and to the connecting rod bolt
threads and the underside of the bolt
4
heads.

5. Fit the bearing cap and bolts ensuring

correlation numbers stamped on cap
correspond with numbers on connecting
rod.

6. Progressively tighten bearing cap bolts to

the torque figure quoted in DATA.

7. Measure the side clearance between the

connecting rod and the crankshaft; refer to
DATA. Do NOT measure the side clearance
between the connecting rod cap and the
crankshaft.
CAUTION: Connecting rods must move
freely from side to side on their crankshaft
journals. If connecting rod is binding or
seized, remove bearing cap, check that
correct size bearing shells have been fitted
and examine bearing shells for burrs,
foreign matter or damage; renew bearing
shells as necessary.

E9703 2–4–31
 ENGINE 2
Crankcase assembly 55 Series

8. Repeat the above removal and refitment

operations for the remaining connecting rod
big–end bearings.

9. Using a new gasket refit oil suction pipe.

10. Refit sump, as instructed in this Section.

11. Refit injectors, see Group 4.

12. Lower and secure cab, see ‘Drivers

Handbook’.

13. Connect batteries.

E9703
2–4–32
2 ENGINE
55 Series Crankcase assembly

Pistons and Connecting Rods

1
To Remove
1. Remove cylinder head, see Section 3. 2
2. Remove the sump, as instructed in this 3
Section.

3. Remove oil suction pipe and gasket. FRO

NT

4. Carefully remove any carbon deposit from 4

top of cylinder bores, taking care not to
damage the bores.

5. Suitably identify each piston with its

6
corresponding bore. 5

6. Turn crankshaft until two pistons are at

4
Bottom Dead Centre (B.D.C.) and remove
connecting rod bearing caps. Push piston
assemblies upwards until piston rings are 5
clear of cylinder block, then withdraw
7
piston/connecting rod assemblies; repeat
the operation for the remaining piston
assemblies.
NOTE: Connecting rods have correlation 8
numbers stamped on both rod and cap,
ensure each cap is assembled to its
corresponding rod.
040674
7. Discard bearing shells.

8. Using a suitable piston ring expander,

remove and discard piston rings.
FIG.13. EXPLODED VIEW OF PISTON AND
CONNECTING ROD
9. Remove both gudgeon pin circlips; remove
gudgeon pin and separate piston from 1. Top ring
connecting rod.
2. Intermediate ring
3. Oil control ring
4. Piston
5. Circlip
6. Gudgeon pin
7. Connecting rod
8. Bearing shells

E9703 2–4–33
 ENGINE 2
Crankcase assembly 55 Series

To Inspect
1. De–carbonise pistons by immersing in an
approved aluminum cleaning solvent.

2. Using a hot water and soap solution

thoroughly clean pistons and ring grooves
with a soft bristle brush.
CAUTION: Do not use a wire brush or
abrasive compounds to clean pistons.
040675

3. Examine pistons for excessive wear or

scores; renew as necessary. FIG.14. PISTON RINGS

4. Using a new piston ring, check piston ring

grooves are not worn beyond limits quoted
in DATA.
4 5. Measure piston ring gap by entering each
ring, in turn, into cylinder bore. Use a piston
to position ring square in bore, then
measure gap; refer to DATA for limits.

E9703
2–4–34
2 ENGINE
55 Series Crankcase assembly

6. Clean connecting rods, bearing caps and

bolts in a suitable cleaning solvent.

7. Inspect connecting rods, bearing caps and

bolts for cracks, damage or distortion;
renew as necessary.

8. Check the gudgeon pin is within the limits

quoted in DATA.

9. Measure the internal diameter of the

connecting rod small–end bush; if worn
beyond the limit quoted in DATA, it will be
necessary to renew the connecting rod
assembly.

10. Check connecting rod big–end bearing

clearance, see DATA.
4

E9703 2–4–35
 ENGINE 2
Crankcase assembly 55 Series

To Refit
1. Insert circlip into groove of gudgeon pin
bore.

2. Lubricate connecting rod small–end bush

and gudgeon pin with clean engine oil.

3. Assemble piston to connecting rod as

illustrated in Fig.15., then insert gudgeon
pin through piston and connecting rod;
secure with circlip in groove opposite end of
gudgeon pin bore.

4. Using a suitable piston ring expander,

carefully fit oil control, intermediate and top
compression rings, noting:
4 — When fitting the two piece oil control
ring ensure expander ring gap is 180°
opposed to the gap of the oil ring.
— The top compression ring is wedge
shaped.
— The top inner edge of the intermediate
compression ring is chamfered.
— All the rings are marked ‘TOP’ ensure
they are fitted with this uppermost.
— Position each piston ring so that gaps
are NOT aligned with either gudgeon
pin or any other piston ring gap.

5. Fit a new upper bearing shell to each

connecting rod, ensuring tang of bearing
shell is correctly located in slot of
connecting rod. Lubricate upper bearing
shells with clean engine oil.

6. Sparingly lubricate the piston skirts, piston

rings and cylinder bores with clean engine
oil.

7. Using a suitable piston ring compressor

sleeve, compress the piston rings, then
insert piston/connecting rod assemblies into
their original cylinders.

8. Rotate crankshaft until appropriate

crankshaft journal is at Bottom Dead Centre
(B.D.C.).

E9703
2–4–36
2 ENGINE
55 Series Crankcase assembly

9. Carefully push piston through sleeve until

top compression ring is completely in
cylinder bore.
NOTE: Ensure that the correlation numbers
stamped on the connecting rod are towards
the oil cooler side of engine, and that the
word ‘FRONT’ stamped on the piston crown
is towards the front of the engine.

10. Ensure piston moves freely within cylinder

bore.

11. Ensuring the crankshaft journal is

thoroughly clean, pull connecting rod into
position on crankshaft journal.

12. Fit a new lower bearing shell to each

connecting rod cap, ensuring tang of
4
bearing shell is correctly located in slot of
bearing cap.

13. Apply clean engine oil to lower bearing

shells, and to the connecting rod bolt
threads and the underside of the bolt
heads. 040676

FIG.15. ASSEMBLY OF PISTON AND

CONNECTING ROD

E9703 2–4–37
 ENGINE 2
Crankcase assembly 55 Series

14. Fit the bearing cap and bolts ensuring

correlation numbers stamped on cap
correspond with numbers on connecting
rod.

15. Progressively tighten bearing cap bolts to

the torque figure quoted in DATA.

16. Measure the side clearance between

connecting rod and crankshaft; refer to
DATA. Do NOT measure the side clearance
between the connecting rod cap and the
crankshaft.
CAUTION: Connecting rods must move
freely from side to side on their crankshaft
journals. If connecting rod is binding or
4 seized, remove bearing cap, check that
correct size bearing shells have been fitted
and examine bearing shells for burrs,
foreign matter or damage; renew bearing
shells as necessary.

17. Using a new gasket refit oil suction pipe.

18. Refit sump, as instructed in this Section.

19. Refit cylinder head, see Section 3.

E9703
2–4–38
2 ENGINE
55 Series Crankcase assembly

Main Bearings

To Remove
1. Remove sump, as instructed in this Section.

2. Remove oil suction pipe and discard

gasket.

3. The main bearing caps should be

numbered 1 to 7, if not, suitably reference
mark them.

4. Release bolts and withdraw all main bearing

caps from their dowelled location, except
Nos.1 and 7; Nos. 1 and 7 are not removed
at this stage so that the crankshaft remains
supported.
CAUTION: Do not lever the main bearing
4
caps to free them from their dowelled
location.

5. Detach bearing shells from bearing caps.

6. Noting locating tangs, carefully remove

upper main bearing shells.

7. Thoroughly clean crankshaft journals, main

bearing caps and bolts.

To Refit
1. Lubricate new upper main bearing shells
with clean engine oil.

2. Fit upper main bearing shells, ensuring that

each bearing shell tang is correctly located
in the slot in crankcase.
NOTE: No.6 upper main bearing shell is a
combined main/thrust bearing.

E9703 2–4–39
 ENGINE 2
Crankcase assembly 55 Series

3. Lubricate new lower main bearing shells

with clean engine oil and insert shells in
main bearing caps, ensuring each bearing
shell tang is correctly located in the slot in 12 8 4 2 6 10 14
bearing cap.
11 7 3 1 5 9 13
4. Lubricate main bearing cap bolt threads and
the underside of the bolt heads with clean
engine oil.
040678

5. Refit main bearing caps in their correctly

identified positions; do not fully tighten the FIG.16. MAIN BEARING CAP
bolts at this stage. TIGHTENING SEQUENCE

6. Remove Nos.1 and 7 main bearing caps;

renew the bearing shells as previously
4 described, then refit bearing caps.

7. Tighten all main bearing cap bolts in the

sequence shown in Fig.16 and to the torque
figure quoted in DATA.

8. Check that the crankshaft rotates freely.

9. Using a dial test indicator gauge, check the

crankshaft end–float is within the limits
quoted in DATA. If the end–float is less than
the minimum quoted in DATA, proceed as
follows:

— Slacken the main bearing cap bolts one

turn, then push crankshaft towards
front of engine and then towards rear.
— Tighten main bearing cap bolts, as
instructed in operation 7.
— Re–check crankshaft end–float.
NOTE: If the crankshaft end–float is above
the maximum quoted in DATA, it will be
necessary to re–grind crankshaft and fit
Service main bearing shells.

10. Using a new gasket refit oil suction pipe.

11. Refit sump, as instructed in this Section.

E9703
2–4–40
2 ENGINE
55 Series Crankcase assembly

Crankshaft

To Remove 2668
1. Remove engine, see Section 1.

2. Remove the following, as instructed in this

Section: 2668

— Timing gear case.

— Rear crankshaft oil seal housing.
— Oil pump.
040673

3. Remove oil suction pipe and gasket.

4. Turn engine until two pistons are at Bottom FIG.17. CONNECTING ROD
Dead Centre (B.D.C.) and remove
connecting rod bearing caps.
CORRELATION NUMBERS 4
NOTE: Connecting rods have correlation
numbers stamped on both rod and cap,
ensure each cap is assembled to its
corresponding rod.

5. Push piston/connecting rod assemblies

upwards until clear of crankshaft.

6. Discard upper and lower bearing shells.

7. Using suitable lifting equipment, support

weight of crankshaft.

8. The main bearing caps should be

numbered 1 to 7, if not, suitably reference
mark them.

E9703 2–4–41
 ENGINE 2
Crankcase assembly 55 Series

9. Release bolts and withdraw all main bearing

caps from their dowelled location.
CAUTION: Do not lever the main bearing
caps to free them from their dowelled
location.

10. Carefully withdraw crankshaft from

crankcase.

11. Remove and discard upper and lower main

bearing shells.

12. If necessary, remove crankshaft gear using

a suitable puller.

4 To Refit
1. Prepare and clean crankshaft using a
suitable cleaning solution, ensure oil holes
are clean and free from blockage.
CAUTION: If crankshaft has been
re–ground, ensure that the correct size
main and big–end bearing shells are fitted.

2. If the piston cooling nozzles are renewed,

ensure that they are flush with, or just
below the crankcase bearing saddle.

E9703
2–4–42
2 ENGINE
55 Series Crankcase assembly

3. If removed refit the crankshaft gear as

follows:

— Fit a new crankshaft gear pin/dowel.

— Heat the gear in an oven, set at 148°C
(300°F) for approximately 45 minutes.
WARNING: Do not use a welding or
cutting torch to heat the gear. Do
not overheat the gear. Always wear
protective gloves when handling
heated components.
— Apply a smear of clean engine oil to the
crankshaft gear journal.
— Once the gear is sufficiently heated,
quickly position the gear onto the
crankshaft, ensuring that the timing
4
mark on crankshaft gear faces
outward.

4. Thoroughly clean main bearing journals and

main bearing caps.

5. Insert new upper main bearing shells in

crankcase, ensuring that each bearing shell
tang is correctly located in the slot in
crankcase.
NOTE: No.6 upper main bearing shell is a
combined main/thrust bearing.

6. Lubricate upper main bearing shells with

clean engine oil.

7. Lubricate new lower main bearing shells

with clean engine oil, then insert bearing
shells in main bearing caps, ensuring each
bearing shell tang is correctly located in the
slot in bearing cap.

8. Lubricate main bearing cap bolt threads and

the underside of the bolt heads with clean
engine oil.

E9703 2–4–43
 ENGINE 2
Crankcase assembly 55 Series

9. Ensure the crankshaft journals are

thoroughly clean, then using suitable lifting
equipment, carefully position crankshaft in
crankcase. 12 8 4 2 6 10 14
10. Fit main bearing caps in their correctly 11 7 3 1 5 9 13
identified positions, then tighten main
bearing cap bolts in the sequence shown in
Fig.18 and to the torque figure quoted in
040678
DATA.

11. Check that the crankshaft rotates freely. FIG.18. MAIN BEARING CAP
TIGHTENING SEQUENCE
12. Using a dial test indicator gauge, check the
crankshaft end–float is within the tolerance
quoted in DATA. If the end–float is less than
4 the minimum quoted in DATA, proceed as
follows:

— Slacken the main bearing cap bolts one

turn, then push crankshaft towards
front of engine and then towards rear.
— Tighten main bearing cap bolts, as
instructed in operation 10.
— Re–check crankshaft end–float.
NOTE: If the crankshaft end–float is above
the maximum quoted in DATA, it will be
necessary to re–grind crankshaft and fit
Service main bearing shells.

13. Fit a new upper bearing shell to each

connecting rod, ensuring tang of bearing
shell is correctly located in slot of
connecting rod. Lubricate upper bearing
shells with clean engine oil.

E9703
2–4–44
2 ENGINE
55 Series Crankcase assembly

14. Pull connecting rods into position on

crankshaft journals.

15. Fit a new lower bearing shell to each

connecting rod bearing cap, ensuring tang
of bearing shell is correctly located in slot of
bearing cap.

16. Apply clean engine oil to lower bearing

shells, and to the connecting rod bolt
threads and to the underside of the bolt
heads.

17. Fit the bearing cap and bolts, ensuring

correlation numbers stamped on cap
correspond with numbers on connecting
rod. 4
18. Progressively tighten bearing cap bolts to
the torque figure quoted in DATA.

19. Measure the side clearance between the

connecting rod and the crankshaft; refer to
DATA. Do NOT measure the side clearance
between the connecting rod cap and the
crankshaft.
CAUTION: Connecting rods must move
freely from side to side on their crankshaft
journals. If connecting rod is binding or
seized, remove bearing cap, check that
correct size bearing shells have been fitted
and examine bearing shells for burrs,
foreign matter or damage; renew bearing
shells as necessary.

E9703 2–4–45
 ENGINE 2
Crankcase assembly 55 Series

20. Position the crankshaft with the crankshaft

gear pin/dowel vertical, pointing towards the
top of the engine.

21. Using a new gasket, refit the oil suction

pipe.

22. Refit the following, as instructed in this

Section:

— Oil pump.
— Rear crankshaft oil seal housing.
— Timing gear case.

23. Refit engine, see Section 1.

4

E9703
2–4–46
2 ENGINE
55 Series Crankcase assembly

Timing Pin

To Remove
1. Remove compressor, see Group 6.

2. Clean area around timing pin.

3. Remove retaining ring and withdraw timing

pin and O–ring from housing.
NOTE: Do not remove the timing pin
housing from the timing gear case unless
the timing gear housing is being replaced.

To Refit
Reverse removal procedure, noting:

1. Lubricate timing pin housing with clean

4
engine oil prior to fitting a new timing pin,
O–ring and retaining ring.
1
2. Check timing pin locates in camshaft gear.
NOTE: If the old timing pin locating peg has
broken off, and is stuck in the camshaft 2 3
gear, it is permissible to remove the timing
pin housing for access to the camshaft
gear, providing its location is accurately
marked in relation to the timing gear case,
by scribing around it. This ensures an
accurate location for refitment.
5 4

040679

FIG.19. TIMING PIN

1. Camshaft gear
2. Timing pin
3. Timing pin housing
4. Retaining ring
5. O–ring
6. Timing gear case

E9703 2–4–47
 ENGINE 2
Crankcase assembly 55 Series

Setting Top Dead Centre (T.D.C.)

If the timing pin housing assembly is removed
from the rear of the timing gear case. It must be
reset precisely to obtain the exact Top Dead
Centre (T.D.C.) position.

The method of determining T.D.C. will depend

on:
— The job being done, as to convenience
of method, or
— Stage of rebuild of an overhauled
engine.

Method 1
With rocker cover removed from No.1 cylinder
4 carry out the following operations to determine
T.D.C.

1. Adjust the exhaust rocker lever to have

‘Zero’ valve clearance.

2. Remove injectors, see Group 4. This

ensures crankshaft can be rotated
smoothly.

3. Temporarily install a fabricated wire pointer

on the front gear cover, with the pointer just
touching the crankshaft damper/pulley.

4. Turn crankshaft one–quarter of its rotation,

anti–clockwise viewed from front.

5. Tighten the adjusting screw of the exhaust

valve six complete turns of the screw.

6. Rotate engine slowly in direction of rotation

(clockwise viewed from front) until piston
just contacts the exhaust valve. Reference
mark the crankshaft damper/pulley.
CAUTION: Use extreme care when
carrying out this operation as excessive
force will bend the push rod.

E9703
2–4–48
2 ENGINE
55 Series Crankcase assembly

7. Rotate crankshaft almost one full turn in the

opposite direction until piston just contacts
the exhaust valve. Reference mark the
crankshaft damper/pulley.
CAUTION: Use extreme care when
carrying out this operation as excessive
force will bend the push rod.

8. Measure the distance between the two

marks on the damper/pulley and reference
mark the damper/pulley halfway between
them. This mark is T.D.C.

9. Completely loosen the exhaust valve

adjusting screw.

10. Rotate crankshaft in direction of engine

rotation until pointer is aligned with newly
4
scribed T.D.C. mark. Look through rear of
gear case for timing pin hole in the
camshaft gear, if the hole is not visible, the
crankshaft must be rotated one complete
revolution.

11. With timing pin located in camshaft gear,

align the housing, apply locking compound
quoted in DATA to ‘Torkscrews’ and tighten
to torque figure quoted in DATA.

12. Adjust valve clearances, as instructed in

Section 3.

E9703 2–4–49
 ENGINE 2
Crankcase assembly 55 Series

Method 2
This method is preferable when a complete
rebuild of the engine is necessary and is carried
out with the cylinder head removed.

1. Temporarily install the crankshaft

damper/pulley and a fabricated wire pointer
with a flat washer between the pointer and
gear case.

2. Fabricate a steel plate and secure it in

position on cylinder block over No.1
cylinder.

3. Rotate crankshaft in direction of rotation

(clockwise viewed from front of crankshaft)
4 until piston contacts plate. Reference mark
the damper/pulley.

4. Rotate crankshaft in opposite direction until

piston contacts plate. Reference mark the
damper/pulley.

5. Reference mark the damper/pulley for

T.D.C. which is halfway between the first
two marks.

6. Remove the plate and rotate the engine

until the pointer aligns with the T.D.C. mark.
Look through rear of gear case for timing
pin hole in camshaft gear. If the hole is not
visible, the crankshaft must be rotated one
revolution.

7. Install timing pin housing assembly pushing

pin into the hole in camshaft gear to align
housing. Hold pin in its location, coat
‘Torkscrews’ with locking compound quoted
in DATA, fit ‘Torkscrews’ and tighten to
torque in DATA.

8. Disengage timing pointer. Remove wire

pointer and the crankshaft damper/pulley.

E9703
2–4–50
2 ENGINE
55 Series Crankcase assembly

OVERHAUL

Cylinder Bores and Service Liners

The cylinder block can be re–bored and
oversize pistons and rings fitted, see DATA for
bore sizes and Service pistons available.
Alternatively, or after two re–bores, Service
cylinder liners must be fitted, see DATA for
machining and honing dimensions. A standard
diameter piston and ring set must be used when
cylinder liners have been fitted.
NOTE: If only one cylinder needs to be rebored.
It should be overbored and a liner fitted. A
standard piston and ring set can now be used.
Whatever alternative is chosen, either, oversize
pistons or liner and standard pistons; all pistons
must be the same size. Do NOT mix different
size pistons or the engine will become 4
imbalanced.

E9703 2–4–51
 ENGINE 2
Crankcase assembly 55 Series

Service Cylinder Liners

To Remove
1. If liner(s) have already been fitted and need
to be removed, the old liner(s) can be
machined out, until they collapse, the
bore(s) can now be cleaned out ready to
accept new liner(s).

To Refit
Liners must be frozen for a minimum of one
hour at a temperature of –12°C (10°F) prior to
installation in block.
NOTE: A liner driver may be needed when
installing the liner. Manufactured to the following
4 specifications:
A = 127 mm (5 in)
B

B = 38 mm (1.5 in)
C = 6,35 mm (0.25 in)
F E D
D = 25,4 mm (1.00 in)
E = 101 mm (3.976 in)
F = 107,343 mm (4.226 in) C A
1. Apply a coat of locking compound quoted in
DATA, to the cylinder bore prior to fitting the 040677

liner.
FIG.20. LINER INSTALLATION
2. Using protective gloves, push the frozen
liner into the bore as far as possible; then
using a suitable liner driver, carefully press
or drive liner into bore until it contacts step
at bottom of cylinder bore.

3. Check stand–proud of liner, see DATA.

4. Finish bore the liner to dimensions quoted

in DATA.

5. Finish hone the liner, see DATA.

E9703
2–4–52
4 SUB DIVISION
55 Series

FUEL SYSTEM
1
INDUCTION AND EXHAUST SYSTEMS
TURBOCHARGER 2

E9703
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Contents

CONTENTS Page Date

SECTION 1—FUEL SYSTEM

Adjustment:
Road Speed Limiter Control Cables:
Bosch P–7100 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . 4—1—35 . . . . . . . . 9703
Bosch VP 14 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . .
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4—1—34 . . . . . . . . 9703
4—1—1 . . . . . . . . . 9703
1
Removal and Refitment:
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—29 . . . . . . . . 9703
Fuel Injection Pipes—Bosch P–7100 Fuel Injection Pump . . . . . . . . 4—1—19 . . . . . . . . 9703
Fuel Injection Pipes—Bosch VP 14 Fuel Injection Pump . . . . . . . . . . 4—1—20 . . . . . . . . 9703
Fuel Injection Pump—Bosch P–7100 . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—3 . . . . . . . . . 9703
Fuel Injection Pump—Bosch VP 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—10 . . . . . . . . 9703
Fuel Injection Pump Timing Check—Bosch VP 14 . . . . . . . . . . . . . . . 4—1—16 . . . . . . . . 9703
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—22 . . . . . . . . 9703
Fuel Sedimenter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—25 . . . . . . . . 9703
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—27 . . . . . . . . 9703
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—23 . . . . . . . . 9703
Road Speed Limiter Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—32 . . . . . . . . 9703
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—1—2 . . . . . . . . . 9703

E9703 1
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E9703
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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

1. FUEL SYSTEM
DATA

Injection Pump
Type:
CS 107M, CS 118M, CS 134L and
CS 134M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch VP 14
CS 156L, CS 158M and CS 173M . . . . . . . .
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch P–7100
740 to 800 rev/min
1
Maximum governed speed . . . . . . . . . . . . . . . . . . 2 825 to 2 925 rev/min
IInjection timing—Bosch VP 14:
CS 107M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of injection 1,0 to 1,3 mm plunger travel
CS 118M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of injection 1,1 to 1,5 mm plunger travel
CS 134M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of injection 1,2 to 1,6 mm plunger travel
CS 134L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of injection 1,5 to 1,9 mm plunger travel

Injectors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch 7mm (6 hole) nozzles
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 260 to 275 atm

Special Compounds
Injector anti–seize grease . . . . . . . . . . . . . . . . . . . Rocol J 166

Torque Tightening Figures Nm lbf ft

Fuel injection pipes . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Fuel injection pump drive gear nut:
Bosch P–7100 . . . . . . . . . . . . . . . . . . . . . . . . . 165 122
Bosch VP 14 . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48

Fuel injection pump mounting nuts:

Bosch P–7100 . . . . . . . . . . . . . . . . . . . . . . . . . 43 32
Bosch VP 14 . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18

Injector locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44
Lift pump mounting setscrews . . . . . . . . . . . . . . . . 24 18

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 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE ENGINE WHILST INSTALLED IN THE

VEHICLE, BOTH BATTERY LEADS MUST BE DISCONNECTED TO PREVENT ACCIDENTAL
OR INADVERTENT STARTING OF THE ENGINE.
1
2. DO NOT RUN THE ENGINE IN A CONFINED SPACE OR UNVENTILATED AREA. EXHAUST
FUMES CONTAIN TOXIC GASES WHICH, IF INHALED, MAY PROVE FATAL.

3. FUEL SPILLAGES ARE HIGHLY INFLAMMABLE AND MUST NOT BE EXPOSED TO A

NAKED FLAME, SPARK OR INTENSE HEAT SOURCE.

CAUTION: To prevent the ingress of foreign matter, always thoroughly clean the exterior of fuel system
components prior to dismantling and ensure that all open ports and pipework are suitably blanked.

NOTE: Before disconnecting the vehicle battery supply, ensure that, if applicable, the radio security
code is available to enable the radio to be re–activated upon completion of all work.

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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

REMOVAL AND REFITMENT

Fuel Injection Pump—Bosch P–7100

Service tool: 0499900.

NOTE: When carrying out maintenance/repair

work around the engine compartment, it will be
necessary to remove the noise suppression 1
panels.

To Remove (Fig.2)
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Deplete the air system.

4. Vehicles fitted with a water cooled

compressor: Drain the cooling system, see
‘Maintenance Manual’.

5. Disconnect the air pipe from engine stop

control cylinder.

6. Disconnect the road speed limiter control

rod from the injection pump control lever.

7. Remove and discard the fuel filter cartridge.

8. Vehicles fitted with a water cooled

compressor: Remove compressor coolant
pipes.

9. Release the fuel injection pipe support

brackets from induction manifold, then
disconnect injection pipes from injection
pump; blank the fuel ports of injection pump
to prevent the ingress of dirt.

10. Disconnect injection pump oil feed pipe at

rear of pump.

11. Remove the fuel feed pipe, fuel filter head

to injection pump.

12. Disconnect fuel return pipe at connection

adjacent to fuel filter.

E9703 4–1–3
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

13. Remove boost control pipe and disconnect

the turbocharger wastegate hose from
injection pump.

14. Locate ‘Top Dead Centre’ (T.D.C.) for No.1

1 cylinder by turning the engine slowly and
pressing in the timing pin at rear of
gearcase cover until the timing pin locates
in the camshaft gear; disengage timing pin
after locating T.D.C.

NOTE:
— Insert a suitable bar through the holes
in the fan adapter to turn the engine; if
the fan adapter has two machined flats,
use a suitable open ended spanner. Do
NOT use the fan blades to turn the
engine.

2
3

040945

FIG.1. LOCATING ‘TOP DEAD CENTRE’

1. Camshaft gear 2. Timing pin 3. Timing pin housing

E9703
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 4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

1
5

12

11

9
10

8 7 6 040943

FIG.2. FUEL INJECTION PUMP—BOSCH P–7100

1. Oil feed pipe 7. Mounting bolt
2. Fuel return pipe 8. Support bracket
3. Fuel feed pipe 9. Stop control cylinder *
4. Turbocharger wastegate hose 10. Mounting nut
5. Boost control pipe 11. Stop control air pipe *
6. Control lever 12. Fuel injection pipes

* Exhaust brake application only

E9703 4–1–5
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

15. Unscrew and remove fuel injection pump

gear cover and seal. Remove fuel injection
pump gear retaining nut and washer; using 6
a suitable bridge puller and bolts detach the

1 gear from injection pump shaft.

16. Remove injection pump support bracket.

17. Remove nuts securing injection pump to

timing gear case, then ensuring the pump is
completely unrestricted, carefully withdraw
injection pump.

18. Detach fuel return pipe from injection pump.

19. Detach engine stop control cylinder/bracket

from injection pump.

20. Thoroughly clean the gear case injection

pump bore.

5
4
3
2
1 040946

FIG.3. INJECTION PUMP DRIVE GEAR

REMOVAL

1. Cover
2. Gear retaining nut
3. Washer
4. Fuel injection pump shaft
5. Gear
6. Bridge puller

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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

To Refit
NOTE: The Bosch P–7100 injection pump is
fitted with a timing location device located in the
governor housing.

1. Set the injection pump timing as follows: 1

— Remove the plug from the governor
housing timing aperture and withdraw
the timing location device from the
timing aperture.
— Rotate the pump shaft until the timing
pointer is visible in the timing aperture.
— Reverse the timing location device and
insert it into the timing aperture. Rotate
the pump as necessary until the slot of
the timing location device fully engages
the timing pointer. Refit the aperture
plug.
CAUTION: Once the injection pump has
been fitted to the engine the timing location
device MUST be removed, reversed and
refitted.

1 2

3 4

040606

FIG.4. INJECTION PUMP TIMING—BOSCH P–7100

1. Removing timing location device 3. Incorrect location

2. Inserting timing location device 4. Correct location

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 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

2. Fit fuel return pipe and engine stop control

cylinder to injection pump.

3. Verify that the engine is at T.D.C. by

engaging the timing pin; disengage timing
1 pin once T.D.C. is located.

4. Lightly smear the injection pump mounting

flange with clean engine oil.

5. Refit injection pump, ensuring the pump

shaft aligns with the drive gear.
NOTE: The Bosch P–7100 injection pump
shaft has provision for a ‘Woodruff’ key, for
this application none is required.

6. Refit injection pump mounting nuts and

tighten to the torque figure quoted in DATA.

7. Refit injection pump drive gear nut and

washer, tighten the drive gear nut to an
initial torque of 10 to 15 Nm (7 to 11 lbf ft);
do not fully tighten the gear nut at this
stage.

8. Remove the plug from the governor housing

timing aperture, then remove, reverse and
refit timing location device; refit the plug.

9. Fully tighten the injection pump drive gear

nut to the torque figure quoted in DATA.

10. Refit the injection pump support bracket.

11. Refit injection pump gear cover and seal.

12. Refit boost control pipe and connect

turbocharger wastegate hose.

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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

13. Connect fuel return pipe at connection

adjacent to fuel filter.

14. Refit fuel feed pipe.

15. Connect oil feed pipe. 1

16. Connect fuel injection pipes and secure
injection pipe support brackets.

17. Vehicles fitted with a water cooled

compressor: Refit compressor coolant
pipes.

18. Fit a new fuel filter cartridge.

19. Connect road speed limiter control rod to

injection pump control lever.

20. Connect air pipe at engine stop control

cylinder.

21. Vehicles fitted with a water cooled

compressor: Refill the cooling system, see
‘Maintenance Manual’.

22. Bleed the fuel system as instructed in this

Section.

23. Lower and secure cab, see ‘Drivers

Handbook.

24. Connect batteries.

E9703 4–1–9
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

Fuel Injection Pump—Bosch VP 14

Service tools: 0192494, 0499900

To Remove
1. Isolate the batteries.
1
2. Tilt the cab, see ‘Drivers Handbook’.

3. Disconnect the thermal sensor electrical

leads from the KSB valve/switch and stop
solenoid switch. Release the cable clip from
the injection pipe bracket and position the
cable clear of the pump.

4. Release the accelerator and engine stop

control return springs, then disconnect the
accelerator and engine stop control rods
from injection pump control levers. Remove
the two nuts and bolts securing the
accelerator and stop control cylinder
brackets to the injection pump, then
position accelerator and stop control
cylinder clear of injection pump.

5. Disconnect the electrical lead from the stop

solenoid and release the cable from the fuel
pump bracket clip.

6. Remove the fuel injection pipes, as

instructed in this Section.

7. Remove the boost control pipe.

8. Disconnect vent pipe from injection pump.

9. Remove injection pump fuel feed pipe.

10. Unscrew and remove injection pump gear

cover and seal, then remove the gear
retaining nut and washer (Fig.7).

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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

2 3

1 1

5
7 6

9 10 11
8

12

19
13

18
14
17

15
16 040950

FIG.5. FUEL INJECTION PUMP—BOSCH VP 14

1. Accelerator return spring 8. Fuel feed pipe 14. Fuel injection pipes
2. Accelerator cable 9. Vent pipe 15. Support bracket
3. Accelerator cable slide block 10. Boost control pipe 16. KSB electrical lead
4. Accelerator and stop 11. Cable clip 17. Injection pump lockscrew
control mounting brackets * 12. Thermal sensor electrical 18. Mounting nut
5. Stop control air pipe * lead 19. Timing marks
6. Stop control cylinder * 13. Stop solenoid electrical
7. Stop control return spring * lead
* Exhaust brake application only

E9703 4–1–11
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

11. Locate ‘Top Dead Centre’ (T.D.C.) for No.1 12. Slacken the injection pump shaft lockscrew
cylinder by turning the engine slowly and and remove the special washer from behind
pressing in the timing pin at the rear of the the lockscrew head, see Fig 8; tighten the
gearcase cover using tool 0192494, until lockscrew to hold the injection pump shaft

1 the timing pin locates in the camshaft gear;

disengage timing pin after locating T.D.C.
in position.

NOTE:
— Insert a suitable bar through the holes
in the fan adapter to turn the engine; if
the fan adapter has two machined flats,
use a suitable open ended spanner. Do
NOT use the fan blades to turn the
engine.

4
4
3

040030

FIG.6. LOCATING ‘TOP DEAD CENTRE’

1. Camshaft gear 3. Timing pin housing

2. Timing pin 4. Timing pin extension tool

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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

13. Using tool 0499900, detach the injection 16. Remove nuts securing injection pump to
pump drive gear from the injection pump timing gear case, then carefully withdraw
shaft. injection pump.
NOTE: A 13 mm ’Crows Foot’ socket will
14. Remove the injection pump support
bracket.
be required to remove the bottom nut
securing the injection pump to the gear 1
case.
15. Note alignment marks on injection pump
mounting flange and rear of timing gear 17. Remove the injection pump gasket and
case, if necessary, reference mark clean gasket faces.
mounting flange in relation to gear case.

5
4
3
2
6
1
040026

FIG.7. INJECTION PUMP DRIVE GEAR REMOVAL

1. Cover 3. Washer 5. Gear

2. Gear retaining nut 4. Fuel injection pump shaft 6. Tool 0499900

E9703 4–1–13
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

To Refit
1. Verify that the engine is at T.D.C. by
engaging the timing pin; disengage timing
pin once T.D.C. is located. 2
1 2. Using a new gasket refit the injection pump, 2
ensuring the drive shaft key aligns with the
keyway of drive gear. Fit, but do not fully
tighten the nuts securing the injection pump
to the gear case.
NOTE: The drive shaft of a new or 1
reconditioned injection pump is locked in
position with a lockscrew to facilitate correct
alignment of the pump shaft with the drive 040025
gear.

3. Fit, but do not fully tighten the injection FIG.8. DRIVE SHAFT LOCKSCREW
pump drive gear nut and washer.
1. Lockscrew 2. Washer
4. When fitting the original injection pump,
align the timing mark on the pump flange
with the timing mark on gear case. If
installing a new injection pump with no
timing mark on pump flange, rotate the
pump against the direction of pump rotation
to take–up any gear lash. Tighten the
injection pump mounting nuts to the torque
figure quoted in DATA and if necessary,
mark the injection pump flange in relation to
the timing mark on gear case.

5. Slacken the injection pump drive shaft

lockscrew, position the special washer
behind the lockscrew head, then tighten the
lockscrew.

E9703
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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

6. Assemble support bracket to injection pump

and engine block; tighten the setscrews
securing the bracket to the engine block
first, then the setscrew securing the bracket
to the injection pump.
1
7. Fully tighten the injection pump drive gear
nut to the torque figure quoted in DATA,
then fit the gear cover and seal.

8. Connect the vent pipe and refit fuel feed

pipe.

9. Refit boost control pipe.

10. Refit fuel injection pipes, as instructed in

this Section.

11. Connect accelerator and engine stop

control linkage to injection pump control
levers and secure support brackets at
pump.

12. Connect electrical leads at injection pump.

13. Bleed the fuel system, as instructed in this

Section.

14. Lower and secure cab, see ‘Drivers

Handbook’.

15. Connect batteries.

E9703 4–1–15
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

Fuel Injection Pump Timing Check—Bosch

VP 14
Service tools: 0192494, 0485149

1. Isolate the batteries.

1
2. Tilt cab, see ‘Drivers Handbook’.

3. Locate ‘Top Dead Centre’ (T.D.C.) for No.1

cylinder by turning the engine slowly and
pressing in the timing pin at the rear of the
gearcase cover using tool 0192494, until
the timing pin locates in the camshaft gear;
disengage timing pin after locating T.D.C.
040027
NOTE:
— Insert a suitable bar through the holes FIG.9. TIMING PLUG
in the fan adapter to turn the engine; if
the fan adapter has two machined flats,
use a suitable open ended spanner. Do
NOT use the fan blades to turn the
engine.
4. Remove boost control pipe.

5. Disconnect vent pipe and fuel feed pipe

from injection pump.

6. Disconnect fuel injection pipes from

injection pump.

7. Release stop solenoid cable from the pump

bracket and slacken the setscrew securing
injection pump to support bracket.

8. Remove the plug from the timing aperture

at rear of injection pump.

E9703
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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

9. Assemble timing extension tool 0485149

and a suitable Dial Test Indicator (D.T.I.) to
the rear of the pump.
NOTE: When assembling the timing tool
and D.T.I. to the injection pump allow for
sufficient travel of the D.T.I. plunger. 1
10. Turn the engine in the opposite direction to
engine rotation (anti–clockwise viewed from
the front) until the D.T.I. needle stops
moving. Adjust the D.T.I. to read zero.
Carefully rotate the engine back, in the
direction of engine rotation to T.D.C., and
observe the reading on the D.T.I. when the 1 2
timing pin engages the camshaft. The 040024

reading observed on the D.T.I. is the

amount of plunger travel the injection pump FIG.10. TIMING FUEL INJECTION
has at that point; disengage timing pin. PUMP—BOSCH VP 14

11. Slacken the nuts securing the injection 1. Tool 0485149

pump to the gear case. 2. Dial test indicator
12. Rotate the injection pump on the mounting
studs until the correct plunger travel for the
start of injection is achieved; see DATA.

13. Tighten the nuts securing the injection

pump to the gear case to the torque figure
quoted in DATA.

14. If necessary re–mark the injection pump

mounting flange in relation to the timing
mark on gear case.

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 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

15. Dismantle the D.T.I. and timing extension

tool from the injection pump, then refit the
plug.

16. Tighten the injection pump support bracket

1 setscrew.

17. Connect fuel injection pipes to injection

pump.

18. Connect vent pipe and fuel feed pipe to

injection pump.

19. Refit boost control pipe.

20. If necessary, bleed the fuel system as

instructed in this Section.

21. Lower and secure cab, see ‘Drivers

Handbook’.

22. Connect batteries.

E9703
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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

Fuel Injection Pipes—Bosch P–7100

Injection Pump

To Remove
NOTE: The following operations are for the
removal of all six fuel injection pipes. 1
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. L.H.D. Vehicles Only: Remove the radiator

stabiliser.
Release the gear–change lever support
bracket from the induction manifold.
Remove nuts and bolts securing the
gear–change assembly to the belt tensioner
bracket; position the gear–change
assembly clear of the rocker covers.

4. Remove air intake pipe, intercooler to

induction manifold.

5. Disconnect turbocharger wastegate hose

from injection pump and position hose clear
of injection pipes.

6. Release injection pipe support brackets

from induction manifold.

7. Disconnect the injection pipes from injectors

and injection pump, then remove injection
pipes.

8. Blank the fuel ports of injectors and fuel

injection pump to prevent the ingress of dirt.

9. Remove injection pipe support brackets and

clamps, then separate fuel injection pipes.

To Refit
Refitment is a reversal of the removal
procedure.

E9703 4–1–19
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

Fuel Injection Pipes—Bosch VP 14 Injection

Pump

To Remove
NOTE: The following operations are for the
1 removal of all six fuel injection pipes.

1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Note connections, then disconnect the

thermal sensor electrical leads from the
KSB valve/switch and the injection pump
stop solenoid. Release the electrical
harness from the injection pipe clamp
bracket and position the harness clear of
the injection pump.

4. Release the accelerator and engine stop

control return springs, then disconnect the
accelerator and engine stop control rods
from injection pump control levers. Remove
the two nuts and bolts securing the
accelerator and stop control cylinder
brackets to the injection pump, then
position accelerator and stop control clear
of injection pipes.

5. L.H.D. Vehicles Only: Remove the radiator

stabiliser and release the steady bracket
from the induction manifold.
Release the gear–change lever support
bracket from the induction manifold.
Remove nuts and bolts securing the
gear–change assembly to the belt tensioner
bracket; position the gear–change
assembly clear of the rocker covers.

6. Remove air intake pipe, intercooler to

induction manifold.

7. Release fuel injection pipe support brackets

from induction manifold.

E9703
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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

8. Disconnect the fuel injection pipes from

injectors and injection pump, then remove
the fuel injection pipes.

9. Blank the fuel ports of injectors and

injection pump to prevent the ingress of dirt. 1
10. Remove injection pipe support brackets and
clamps, then separate the fuel injection
pipes.

To Refit
Refitment is a reversal of the removal
procedure.

E9703 4–1–21
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

Fuel Lift Pump

To Remove
1. Isolate the batteries.

1 2. Tilt the cab, see ‘Drivers Handbook’.

3. Disconnect and remove the fuel feed pipe

from the lift pump and fuel filter head.

4. Disconnect the fuel supply pipe from the lift

pump.

5. Remove the setscrews securing lift pump to

crankcase; withdraw lift pump and discard
A
2
gasket.

6. Clean gasket faces.

To Refit 3
1. Using a new gasket, locate the lift pump in
crankcase.
4
2. Fit and progressively tighten the mounting
setscrews to the torque figure quoted in
DATA.
CAUTION: Failure to tighten the mounting 1
setscrews evenly will result in damage to
the lift pump plunger. B 2

3. Connect the fuel supply pipe.

4. Refit the fuel feed pipe. 4

5. Bleed the fuel system, as instructed in this

Section.

6. Lower and secure cab, see ‘Drivers

Handbook’.

7. Connect batteries.
1
3
040948

FIG.11. FUEL LIFT PUMP

1. Gasket 3. Fuel supply pipe
2. Fuel feed pipe 4. Lift pump

A — Bosch VP Injection Pump

B — Bosch P–7100 Injection Pump

E9703
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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

Injectors
Service tool: 0192492

To Remove
1. Isolate the batteries. 5. Disconnect fuel injection pipe and leak–off
pipe from injector. 1
2. Tilt the cab, see ‘Drivers Handbook’.
6. Release injector locknut, extract injector
3. Release fuel injection pipe clamp brackets and discard seating washer.
from induction manifold. CAUTION: To prevent the injector turning in
its bore, and the locating ball of the injector
4. Clean dirt from around injectors and pipe causing damage to the cylinder head, hold
unions. the injector body with a spanner whilst
releasing the injector locknut.

3
4

8
6
9
040611

FIG.12. FUEL INJECTOR

1. Fuel injection pipe 4. Sealing washer 7. Injector locating ball

2. O–ring 5. Leak–off pipe 8. Injector
3. Injector locknut 6. Banjo bolt 9. Seating washer

E9703 4–1–23
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

To Refit
1. Clean the injector bore using injector bore
brush 0192492.

2. Apply anti–seize grease quoted in DATA to

1 the threads of injector locknut.

3. Fit a new O–ring into the injector locknut

prior to fitting the injector.

4. Using a new injector seating washer insert

the injector into the bore, ensuring the
injector locating ball aligns with the notch in
the bore. Hold the injector body with a
spanner and tighten the injector locknut to
the torque figure quoted in DATA.

5. Connect the fuel injection pipe and leak–off

pipe to the injector.
CAUTION: When connecting the leak–off
pipe to the injector, ensure that the loop in
each sealing washer is in the upright
position and does NOT foul the leak–off
pipe.

6. Secure the fuel injection pipe clamp

brackets at induction manifold.

7. Lower and secure cab, see ‘Drivers

Handbook’.

8. Connect batteries.

E9703
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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

Fuel Sedimenter

To Remove
1. Isolate the batteries.

2. Disconnect fuel pipes from sedimenter. 1

3. Remove nuts securing sedimenter to fuel
tank, then withdraw sedimenter.

To Dismantle
1. Remove the drain plug and allow the
fuel/condensate to drain into a suitable
container.

2. Remove the sedimenter bowl retaining bolt,

then detach bowl and sealing ring.

3. Clean all components in a suitable solvent

and dry thoroughly.

4. Examine the retaining bolt sealing ring,

sedimenter bowl sealing ring and drain plug
sealing ring for damage or deterioration;
renew as necessary.

5. Check that the drain hole in base of

sedimenter bowl is clean and unobstructed.

6. Check/clean the sedimenter head filter

mesh.

E9703 4–1–25
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

To Reassemble To Refit
1. Lightly smear the sedimenter bowl sealing 1. Refit the sedimenter to the fuel tank.
ring with grease and then locate in position
within the sedimenter filter head. 2. Connect fuel pipes at sedimenter.

1 2. Refit the drain plug and then fill the 3. Small amounts of air introduced into the
sedimenter bowl with clean, filtered diesel fuel system when refitting the sedimenter
fuel. Locate the sedimenter bowl and bowl, will be vented automatically providing
secure in position with the retaining bolt. the sedimenter bowl has been filled with
diesel fuel prior to refitment. However in
isolated instances the fuel system may
require manually bleeding as instructed in
this Section.

9
1

7
8
040612

FIG.13. FUEL SEDIMENTER

1. Retaining bolt 4. Sealing ring 7. Sealing ring

2. Sealing ring 5. Filter mesh 8. Drain plug
3. Filter head 6. Bowl 9. Fuel pipes

E9703
4–1–26
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

Fuel Tank

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’. 1

3. Note connections, then disconnect electrical
leads from fuel tank sender unit and release
leads from clips at fuel tank and mounting
bracket.

4. Position a suitable container below the fuel

tank, then remove the drain plug and allow
the fuel to drain into the container.

5. Disconnect fuel supply and return pipes

from tank.

6. Release fuel sedimenter from fuel tank.

7. Release the fuel tank mounting straps and

remove the fuel tank.

8. If necessary remove the sender unit from

fuel tank.

E9703 4–1–27
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

To Refit
Reverse removal procedure, noting:

1. Ensure the rubber anti–squeak strips are

correctly positioned on both mounting
1 straps and brackets.

2. Bleed the fuel system as instructed in this

Section.

7 1

2
9
1

4
6
040613
5

FIG.14. FUEL TANK

1. Fuel pipes 4. Mounting bracket 7. Sender unit

2. Sedimenter 5. Nut 8. Gasket
3. Mounting strap 6. Anti–squeak strip 9. Electrical lead

E9703
4–1–28
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

Bleeding the Fuel System (Fig.15)

NOTE: Small amounts of air introduced into the
fuel system during routine maintenance will be
vented automatically. However, in isolated
instances the fuel system may require bleeding
as follows: 1
WARNING:

— Do NOT bleed a hot engine; fuel

spillages are highly inflammable and
must not be exposed to a naked flame,
spark or any intense heat source.

— Do NOT attempt to bleed the fuel system

by towing the vehicle in gear as this
would result in serious damage to the
fuel injection pump.

— The engine may suddenly start when

using the starter motor to bleed the fuel
system, therefore, it is essential that the
correct start procedure is observed.

1. Ensure that there is an adequate supply of

fuel in the fuel tank.

2. Use a suitable container to collect any

expelled fuel.

E9703 4–1–29
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

3. Attach a bleed tube to the bleed screw

connection, open the filter head bleed
screw and operate the lift pump hand
lever/primer until air–free fuel flows from the

1 bleed tube; tighten the bleed screw whilst

operating the lift pump hand lever/primer.
Remove the bleed tube.

4. The fuel injection pump is self–bleeding and

will automatically bleed through the vent
pipe by operating the starter motor.

5. Commencing at No.1 cylinder, individually

bleed each fuel injection pipe as follows:
— Slacken the injector union nut at the
injector and, using the starter motor,
crank the engine until air–free fuel
flows from the union. Tighten the union
nut to the torque figure quoted in
DATA.
— Continue to bleed the fuel injection
pipes until the engine is capable of
firing on all cylinders.

E9703
4–1–30
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

2
A

1
3

3
3

2
040949

FIG.15. BLEEDING THE FUEL SYSTEM

A — Lift pump and filter arrangement Bosch P–7100 in–line injection pump
B — Lift pump and filter arrangement Bosch VP 14 rotary injection pump

1. Bleed screw 2. Lift pump primer 3. Injection pipes

E9703 4–1–31
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

Road Speed Limiter (R.S.L.) Control Cables

R.S.L. Accelerator Control Cable

To Remove
1 1. Isolate the batteries.

2. Remove the screws securing the

accelerator pedal and cable assembly to
the cab floor.
1 2
3. Remove the screws, then carefully separate
the accelerator pedal assembly.

4. Position the accelerator pedal in the idle

position and withdraw the cam/cable from
the pedal assembly.

5. Release the inner cable from the cam.

3
6. Tilt the cab, see ‘Drivers Handbook’.

7. Remove setscrews securing the accelerator

cable slide block to the R.S.L. bracket;
remove the safety clip and retaining nut and
release the inner cable from the R.S.L.
actuator lever.

8. Release the cable from all cable clips, then

remove cable.

To Refit
Reverse removal procedure, noting:

1. Do not secure the cable clips until the cable

adjustment is carried out. 4

2. Adjust the control cable, as instructed in

this Section.

5
1 040951

FIG.16. R.S.L. ACCELERATOR CONTROL

CABLE

1. R.S.L. Accelerator cable

2. Accelerator pedal cam
3. Accelerator pedal assembly
4. R.S.L. Actuator lever
5. Slide block

E9703
4–1–32
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

R.S.L Fuel Injection Pump Control Lever

Cable—Bosch VP 14 Injection Pump

To Remove 2
1
1. Isolate the batteries.
1
2. Tilt the cab, see ‘Drivers Handbook’.

3. Remove the safety clips and retaining nuts 3

and release the inner cable from the R.S.L.
actuator lever and injection pump control
lever.

4. Remove the ‘C’ clip securing the outer

cable to the R.S.L. bracket.
4
5. Remove setscrews securing the outer cable
slide block to the injection pump bracket. 2

6. Withdraw cable from R.S.L. bracket.

To Refit
Reverse removal procedure, noting:

1. Adjust the control cable, as instructed in 5

this Section.

040952

FIG.17. R.S.L. FUEL INJECTION PUMP

CONTROL LEVER CABLE

1. Accelerator return spring

2. R.S.L. injection pump control cable
3. Cable slide block
4. ‘C’ clip
5. R.S.L. actuator lever

E9703 4–1–33
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

ADJUSTMENT

Road Speed Limiter (R.S.L.) Control

Cables—Bosch VP 14 Fuel Injection Pump

To Adjust
1. With the aid of an assistant, hold the
1 accelerator pedal down, against the fixed
stop, at full throttle position.

2. Position the accelerator cable slide block at

its mid–adjustment position (‘A’ Fig.18) on
the R.S.L. mounting bracket.
3
3. Slacken the setscrews securing the control
cable slide block to the fuel pump bracket.
A 1 2
4. Switch on the ignition to energise the
engine control unit (E.C.U.).

5. With the accelerator pedal held down, 4

against the fixed stop, at full throttle
position, adjust the position of the control
cable slide block so that the injection pump
control lever is in contact with the maximum
fuel stop screw. Allowing for approximately 7 6 5
1 to 2 mm further travel of the injection
pump control lever spring, and ensuring that
the cable slide block is in line with the
cable, secure the cable slide block in this
040956
position.

6. Check the operation of the accelerator, to FIG.18. CONTROL CABLE

ensure that both full throttle and idle ADJUSTMENT—BOSCH VP 14 FUEL
positions are achieved. INJECTION PUMP

7. Secure all plastic cable ties and clips. 1. Slide block

2. R.S.L. accelerator cable
3. R.S.L. actuator lever
4. Maximum fuel screw
5. Cable slide block
6. R.S.L. injection pump control cable
7. Injection pump control lever
A = 145 mm

E9703
4–1–34
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Fuel system

Road Speed Limiter (R.S.L.) Control Rod

and Accelerator Cable—Bosch P–7100 Fuel
Injection Pump

To Adjust
1. Adjust the R.S.L. control rod to an initial 1
length of 284 mm, see Fig.19.
NOTE: The control rod ball–ends are LH
and RH threaded; the control rod can be
lengthened or shortened by releasing the
ball–end locknuts and turning the control
rod in the appropriate direction.

2. With the aid of an assistant, hold the

accelerator pedal down against the fixed
stop (full throttle position).

3. Tighten the accelerator inner cable by

positioning the slide block on the R.S.L
mounting bracket with approximately two
thirds movement (‘b’, Fig.19) still available.

4. Switch on the ignition to energise the

engine control unit (E.C.U.).

5. With the accelerator pedal held down

against the fixed stop (full throttle position),
adjust the length of the control rod so that
the injection pump control lever is in contact
with the injection pump maximum fuel stop.
Reposition the slide block to give a further 1
to 2 mm movement of the accelerator
cable.

6. Check the operation of the accelerator, to

ensure that both full throttle and idle
positions are achieved.

7. Secure all plastic cable ties and clips.

E9703 4–1–35
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Fuel system 55 Series

2 A

3
5
a b 4 040957

FIG.19. CONTROL ROD AND ACCELERATOR CABLE ADJUSTMENT

BOSCH P–7100 FUEL INJECTION PUMP
1. Control Lever 3. R.S.L. Actuator lever 5. Slide block
2. R.S.L. Control rod 4. R.S.L. Accelerator cable

A = Initial setting of 282 to 286 mm

a = 1/3 movement b = 2/3 movement

E9703
4–1–36
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Contents

CONTENTS Page Date

SECTION 2—INDUCTION AND EXHAUST SYSTEMS

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2—1 . . . . . . . . . 9703
Overhaul:
Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2—12 . . . . . . . . 9703
Removal and Refitment:
Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2—10 . . . . . . . . 9703
Exhaust Brake Actuating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2—11 . . . . . . . . 9703
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Induction Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4—2—4 . . . . . . . . .
4—2—2 . . . . . . . . .
9703
9703 2
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2—6 . . . . . . . . . 9703
Turbocharger Wastegate Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2—8 . . . . . . . . . 9703
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2—1 . . . . . . . . . 9703

SECTION 2C—TURBOCHARGER (HOLSET H1)

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2C—1 . . . . . . . . 9703
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—2C—2 . . . . . . . . 9703

E9703 1
2

E9703
2
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Induction and exhaust system

2. INDUCTION AND EXHAUST SYSTEMS

DATA

Special Compounds
Induction manifold bolt sealing compound . . . . . Loctite RTV superflex clear
Exhaust brake bolts and cross–shaft . . . . . . . . . . ‘Rocol J 166’ anti–seize grease

Torque Tightening Figures Nm lbf ft

Induction manifold bolts * . . . . . . . . . . . . . . . . . . . . 24 18
Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . 43 32
2
* Refer to Fig.2. for correct torque tightening sequence

WARNINGS:

1. BEFORE ANY WORK IS ATTEMPTED ON THE ENGINE WHILST INSTALLED IN THE

VEHICLE, BOTH BATTERY LEADS MUST BE DISCONNECTED TO PREVENT ACCIDENTAL
OR INADVERTENT STARTING OF THE ENGINE.

2. DO NOT RUN THE ENGINE IN A CONFINED SPACE OR UNVENTILATED AREA. EXHAUST

FUMES CONTAIN TOXIC GASES WHICH, IF INHALED, MAY PROVE FATAL.

3. FUEL SPILLAGES ARE HIGHLY INFLAMMABLE AND MUST NOT BE EXPOSED TO A

NAKED FLAME, SPARK OR INTENSE HEAT SOURCE.

CAUTION: To prevent the ingress of foreign matter, always thoroughly clean the exterior of
induction/exhaust system components prior to dismantling and ensure that all open ports and pipework
are suitably blanked.

NOTE: Before disconnecting the vehicle battery supply, ensure that, if applicable, the radio security
code is available to enable the radio to be re–activated upon completion of all work.

E9703 4–2–1
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Induction and exhaust systems 55 Series

REMOVAL AND REFITMENT

IMPORTANT: The ingress of unfiltered air can

seriously damage the engine. All joints and
piping from the air cleaner must be inspected as
a routine precaution, whenever the induction
system has been disturbed.

Induction Manifold

2 To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. L.H.D. Vehicles only: Remove the radiator

stabiliser and release the steady bracket
from the induction manifold.
Release the gear lever assembly from the
engine, then raise and support gear lever
assembly clear of induction manifold.

4. Remove air intake pipe, intercooler to

induction manifold.

5. Vehicles fitted with a Bosch VP 14 fuel

injection pump: Disconnect electrical lead
from the KSB thermal sensor at induction
manifold. Release the cable clip from the
rear fuel injector pipe clamp bracket.

6. Vehicles fitted with a Bosch P–7100 fuel

injection pump:
— Remove fuel feed pipe, fuel filter head
to injection pump.
— Disconnect leak–off pipe from fuel filter
head and release pipe clip from
induction manifold.
— Remove fuel filter assembly.
— Disconnect turbocharger wastegate
hose from injection pump and position
clear of manifold.

7. Remove rear engine lifting bracket.

E9703
4–2–2
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Induction and exhaust systems

8. Remove the three rear fuel injection pipes. To Refit

Blank the fuel ports of injectors and Reverse removal procedure, noting:
injection pump to prevent the ingress of dirt.
1. Fit a new induction manifold gasket.
9. Release fuel injection pipe support brackets
from induction manifold. 2. Apply sealant quoted in DATA to the
threads of the induction manifold bolts.
10. Remove the bolts securing the induction
manifold to the cylinder head. 3. Tighten the induction manifold bolts to the
torque figure quoted in DATA. 2
11. Manoeuvre the induction manifold
rearwards and remove; discard gasket. 4. Bleed the fuel system as detailed in
Section 1.
12. Clean gasket faces.

1 2 3 4 5

040953

FIG.1. INDUCTION MANIFOLD

1. Air intake pipe 4. Induction manifold

2. Fuel injection pipes 5. Lifting bracket
3. KSB Thermal sensor

E9703 4–2–3
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Induction and exhaust systems 55 Series

Exhaust Manifold

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. R.H.D. Vehicles only: Detach the steady

2 bracket from the gear–change lever bracket
and heat shield/exhaust manifold.

4. Remove turbocharger/exhaust manifold

heat shield.

5. Remove air intake pipe, turbocharger to

intercooler.

6. Release turbocharger oil feed pipe from

exhaust manifold.

7. Vehicles fitted with a wastegate

turbocharger: Release wastegate pipe clip
from exhaust manifold.

8. Remove nuts securing turbocharger to

exhaust manifold.

9. Remove bolts securing exhaust manifold to

cylinder head; withdraw manifold and
discard gaskets.

To Refit
Reverse removal procedure, noting:

1. Renew exhaust manifold gaskets.

2. Tighten exhaust manifold bolts in the

sequence shown in Fig.2., to the torque
figure quoted in DATA.

E9703
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4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Induction and exhaust systems

12 8 4 1 5 9

2
11 7 3 2 6 10

4
6

040954

FIG.2. EXHAUST MANIFOLD

1. Heat shield (if fitted) 4. Air intake pipe turbocharger to intercooler

2. Torque tightening sequence 5. Turbocharger oil feed pipe
3. Bracket 6. Exhaust manifold

E9703 4–2–5
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Induction and exhaust systems 55 Series

Turbocharger

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Remove the rear noise suppression panel.

2 4. Deplete the air system.

5. Remove the turbocharger/exhaust manifold

heat shield.

6. Disconnect air pipe from exhaust brake

actuating cylinder.

7. Remove air pipe, turbocharger to

intercooler.

8. Remove the compressor air intake hose/air

restrictor indicator pipe from the air filter
elbow. Release retaining clips and remove
the air intake elbow.

9. Remove the bolts securing the turbocharger

exhaust elbow/exhaust brake to the
exhaust down–pipe, then remove
bolts/clamp band securing exhaust elbow to
turbocharger; withdraw exhaust elbow and
exhaust brake assembly.

10. Vehicles fitted with a wastegate

turbocharger: Disconnect pipe from
turbocharger wastegate actuator cylinder.

11. Disconnect oil feed pipe from turbocharger.

E9703
4–2–6
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Induction and exhaust systems

12. Remove turbocharger oil return pipe and

discard gasket.

13. Remove nuts securing turbocharger to

exhaust manifold; withdraw turbocharger
and discard gasket.

14. Clean all gasket faces.

2
To Refit
Reverse removal procedure, noting:

1. Fit new gaskets.

2. Prime turbocharger with clean engine oil

before connecting the oil feed pipe.
Manually turn the impeller to ensure oil is
distributed to the turbocharger bearings.

E9703 4–2–7
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Induction and exhaust systems 55 Series

Turbocharger Wastegate Actuator

CAUTION: New turbochargers are supplied with
the wastegate actuator fitted and pre–set by the
manufacturer; no adjustment is required.

To Remove
1. Isolate the batteries.

2 2. Tilt the cab, see ‘Drivers Handbook’.

3. Prior to removing the actuator, measure the

length of the actuator control rod from the
actuator cylinder to the wastegate lever.

4. Disconnect the boost pipe hose from the

actuator cylinder.

5. Disconnect the actuator control rod from the

turbocharger wastegate lever; if necessary,
apply regulated air pressure to the cylinder,
sufficiently to activate control rod
movement.

6. Remove nuts securing actuator cylinder to

mounting bracket, then withdraw actuator.

7. Remove the rod–end and locknut from the

actuator rod and assemble to new actuator
to the dimension previously identified.

E9703
4–2–8
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Induction and exhaust systems

To Refit
Reverse removal procedure, noting:

1. Calibrate the new actuator as follows:

CAUTION: The calibration of the actuator is
critical to engine performance.
— Refit the actuator to the mounting 1
bracket.
— Connect a regulated air supply to the
2
2
actuator cylinder and apply a pressure
of 198 kPa (28.72 lbf/in2).
— Position the wastegate lever in the
closed position (lever towards actuator
cylinder) and adjust the length of the
actuator rod–end until the clevis pin
hole aligns with the wastegate lever; 4
connect actuator rod, refit clip and 3
secure actuator rod–end locknut.
— Disconnect air supply and connect
boost pipe hose.

040620

FIG.3. WASTEGATE ACTUATOR

1. Wastegate boost pipe hose

2. Actuator control rod
3. Mounting bracket
4. Cylinder

E9703 4–2–9
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Induction and exhaust systems 55 Series

Exhaust Brake

To Remove
1. Isolate the batteries.

2. Tilt the cab, see ‘Drivers Handbook’.

3. Deplete the air system.

2 4. Remove the bottom noise suppression
panel.

5. Disconnect air pipe from exhaust brake

actuating cylinder.

6. Release exhaust down–pipe support 3

bracket from crankcase.

7. Release the exhaust down pipe support 1 2

clamp from the clutch housing bracket.

8. Remove bolts securing exhaust

down–pipe/exhaust brake to turbocharger
exhaust elbow; swivel the down–pipe away
from the turbocharger and withdraw the
040955
exhaust brake assembly. Retain the
down–pipe support bracket.
FIG.4. EXHAUST BRAKE ASSEMBLY

To Refit 1. Down–pipe support bracket

Reverse removal procedure, noting: 2. Exhaust brake assembly
3. Air pipe
1. Apply ‘Rocol J 166’ or a suitable high
temperature anti–seize grease to the
threads of the down–pipe/exhaust brake
bolts.

E9703
4–2–10
4 FUEL, INDUCTION and EXHAUST SYSTEMS
55 Series Induction and exhaust systems

Exhaust Brake Actuating Cylinder

1
To Remove
1. Isolate the batteries.

2. Deplete the air system.

3. Remove the bottom noise suppression

2
panel.
2
4. Disconnect the air pipe from the actuating
5
cylinder.

5. Remove ball–joint retaining clip, cylinder

retaining nut and washer, then withdraw
cylinder from actuating lever and pivot pin.

6. If necessary, extract rubber pivot bush from

cylinder.
3
To Refit
Reverse removal procedure, noting:

1. The slot in the end of the cross–shaft

indicates the position of the butterfly valve,
ensure the slot is in the vertical position
when connecting the actuating cylinder 4
ball–joint, if necessary, adjust the length of 040968

the cylinder rod to attain this condition.

FIG.5. EXHAUST BRAKE CYLINDER

1. Cross–shaft slot
2. Clip
3. Actuating cylinder
4. Pivot bush
5. Cross–shaft lever

E9703 4–2–11
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Induction and exhaust systems 55 Series

OVERHAUL

Exhaust Brake

To Dismantle
1. Remove the exhaust brake assembly, as
instructed in this Section.

2. Remove the rivets securing butterfly valve

to cross–shaft.
2 3. Remove the roll–pins securing cross–shaft
lever in butterfly housing, withdraw
cross–shaft lever and spring and remove
butterfly valve from housing.

4. Remove bolts securing actuating cylinder

mounting bracket to housing.

5. Replace any worn or damaged parts.

To Reassemble
Reverse the dismantling procedure, noting:

1. Apply ‘Rocol J 166’ or a suitable high

temperature anti–seize grease to
cross–shaft contact faces.

E9703
4–2–12
4 FUEL, INDUCTION and EXHAUST SYSTEMS
Turbocharger – Holset H1

2C. TURBOCHARGER (HOLSET H1)

DATA

Bearing housing bores . . . . . . . . . . . . . . . . . . . . . . 15,875 to 15,885 mm (0.6250 to 0.6254 in)

Seal bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,305 to 19,330 mm (0.7600 to 0.7610 in)
Shaft bearing diameter . . . . . . . . . . . . . . . . . . . . . . 10,97 to 10,98 mm (0.4320 to 0.4323 in)
Shaft run–out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,008 mm (0.0003 in)
Shaft end–play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,077 mm (0.001 to 0.003 in)
Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . 0,31 to 0,46 mm (0.012 to 0.018 in)
2
Torque Tightening Figures Nm lbf in
Clamp band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 120
Diffuser setscrews . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 75
Impeller shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 120
Thrust bearing retaining screws . . . . . . . . . . . . . . 4,5 40
Turbine housing setscrews . . . . . . . . . . . . . . . . . . 14 120

E9703 4–2C–1
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Turbocharger – Holset H1

OVERHAUL

Service tools: TX20 and 2801 adapter

To Dismantle (See Fig.1.)

1. Isolate the batteries.

2. Remove turbocharger, as instructed in this

Group.

2 3. Suitably reference mark the housings to aid

reassembly.

4. Release compressor housing clamp band

(2), withdraw compressor housing (1) and
remove O–ring (4).

5. Bend back tabs of lockplates (if fitted) (17)

and remove setscrews (16), lockplates (17)
and clamping plates (18); separate bearing
housing (21) from turbine housing (25).

6. Remove impeller nut (3) and withdraw

impeller (5) from shaft (24).
NOTE: Impeller nut and shaft have
left–hand threads.

7. Remove diffuser setscrews (19) and

lockplates (if fitted) (20) and withdraw
diffuser (6); remove and discard the seal
(7).

8. Remove the oil slinger (9); remove split ring

seal (8) from oil slinger.

9. Remove oil baffle (10).

E9703
4–2C–2
4 FUEL, INDUCTION and EXHAUST SYSTEMS
Turbocharger – Holset H1

10. Remove and discard thrust bearing

retaining screws (11) using tool TX20,
withdraw and discard thrust bearing (12).

11. Remove the thrust collar (13).

12. Withdraw shaft and turbine wheel assembly

(24) from bearing housing.

13. Remove heat shield (22). 2

14. Remove and discard split ring seal (23)
from shaft.

15. Remove and discard outer retaining circlips

(14).

16. Remove and discard the turbocharger shaft

bearings (15).

17. Remove and discard inner retaining circlips

(14).

E9703 4–2C–3
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Turbocharger – Holset H1

FIG.1. EXPLODED VIEW OF TURBOCHARGER (Typical)

1. Compressor housing 10. Oil baffle 19. Setscrew

2. Clamp band 11. Retaining screw 20. Lockplate (when fitted)
3. Impeller nut 12. Thrust bearing 21. Bearing housing
4. O–ring 13. Thrust collar 22. Heat shield
5. Impeller 14. Retaining circlip 23. Split ring seal
6. Diffuser 15. Shaft bearing 24. Shaft
7. Sealing ring 16. Setscrew 25. Turbine housing
8. Split ring seal 17. Lockplate (when fitted) 26. Gasket
9. Oil slinger 18. Clamp plate

E9703
4–2C–4
4 FUEL, INDUCTION and EXHAUST SYSTEMS
Turbocharger – Holset H1

Inspection
1. Using a stiff brush clean all items in a
suitable solvent, then dry thoroughly.

2. Remove any carbon build–up in the

compressor housing with a scraper or
medium grit emery cloth.

3. Do not use a wire brush on the compressor

wheel. 2
4. Do not attempt to straighten bent or
damaged blades. The wheel and shaft
assembly is balanced as a unit; if the
turbine blades, compressor blades or shaft
are damaged, the complete assembly must
be replaced.

5. Check shaft bearing journal diameter, see

DATA.
NOTE: The bearing journals may be
polished using a fine grade carborundum
paper.

6. Check shaft for straightness, see DATA.

7. If bearing housing bores are scratched or

damaged the housing must be replaced.
Check bearing housing bore diameter, see
DATA and replace if necessary.

8. Inspect all other parts for cracks, wear,

scoring, damage and distortion, replace as
necessary.

9. Check all the oil ways are clear.

E9703 4–2C–5
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Turbocharger – Holset H1

To Reassemble
NOTE: On assembly ensure to align balance
marks on compressor wheel, shaft, thrust collar
and oil slinger.

1. Fit inner retaining circlips with bevelled face

towards bearing.

2 2. Lubricate with clean engine oil and install

the turbocharger bearings.

3. Fit outer retaining circlips with bevelled face

towards bearings.

4. Fit heat shield on bearing housing.

5. Fit split ring seal to shaft and lubricate with

clean engine oil.

6. Assemble turbine shaft in the bearing

housing; rotating the housing as it is
pressed downward will assist to correctly
seat the split ring seal.

7. Fit thrust collar to shaft, aligning balance

marks.

8. Lubricate and fit thrust bearing, using tool

TX20 tighten retaining screws to the torque
figure quoted in DATA.

9. Refit oil baffle.

10. Assemble split ring seal onto oil slinger and

suitably mark the top surface of the oil
slinger in line with the balance mark to aid
assembly when fitted to the diffuser.

11. Lubricate and install the oil slinger and

O–ring seal into the diffuser.

E9703
4–2C–6
4 FUEL, INDUCTION and EXHAUST SYSTEMS
Turbocharger – Holset H1

12. Fit the diffuser aligning balance marks on oil

slinger and shaft.

13. Ensure reference marks on housing align,

then fit lockplates (if fitted) and tighten
diffuser retaining setscrews to the torque
figure quoted in DATA. Bend over tabs of
lockplates.

14. Align the balance marks and fit the 2

compressor impeller, tightening the nut to
the torque figure quoted in DATA.
NOTE: The impeller nut has a left–hand
thread. Do not allow the impeller to turn
when tightening the nut.

15. Locate the bearing housing assembly in the

turbine housing, aligning reference marks.
Apply an anti–seize compound to the
setscrew threads, fit clamping plates and
lockplates (if fitted), then tighten setscrews
to the torque figure quoted in DATA. Bend
over tabs of lockplates. Check blades rotate
freely in turbine housing.

16. Check shaft end–play and radial clearance,

see DATA.

17. Ensure housing reference marks align, fit

compressor wheel housing and O–ring and
tighten clamp band to the torque figure
quoted in DATA.
NOTE: To aid fitment apply anti–seize
compound to the clamp band screw
threads, lightly tap in four places around the
clamp bands circumference to aid location
then re–torque clamp band to the same
torque value. Check impeller blades rotate
freely in compressor housing.

E9703 4–2C–7
 FUEL, INDUCTION and EXHAUST SYSTEMS 4
Turbocharger – Holset H1

E9703
4–2C–8
3 SUB DIVISION
55 Series

TRANSMISSION COMPONENTS
1
CLUTCH HYDRAULIC CYLINDERS
2
GEARBOX—ZF S6–36 & S6–36 + GV36
3
GEARBOX—EATON 6109
4

E9706
3 TRANSMISSION
55 Series Contents

CONTENTS Page Date

SECTION 1—TRANSMISSION COMPONENTS

Removal and Refitment:
Bleeding The Clutch Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—55 . . . . . . . . 9706
Centre Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—29 . . . . . . . . 9706
Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—42 . . . . . . . . 9706
Clutch Servo Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3—1—45 . . . . . . . .
3—1—39 . . . . . . . .
9706
9706
1
Clutch Withdrawal Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—41 . . . . . . . . 9706
Eaton 6109 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—11 . . . . . . . . 9706
Gear–Change Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—33 . . . . . . . . 9706
Gearbox Input Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—22 . . . . . . . . 9706
Gearbox Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—16 . . . . . . . . 9706
Operating Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—46 . . . . . . . . 9706
Operating Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—53 . . . . . . . . 9706
Propeller Shaft—Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—26 . . . . . . . . 9706
Propeller Shaft—Intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—27 . . . . . . . . 9706
Propeller Shaft—Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—28 . . . . . . . . 9706
Propeller Shaft Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—30 . . . . . . . . 9706
Propeller Shaft grease procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—32 . . . . . . . . 9706
Rear Engine/Gearbox Mounting Rubbers . . . . . . . . . . . . . . . . . . . . . . . 3—1—25 . . . . . . . . 9706
ZF S6–36 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—1 . . . . . . . . . 9706
ZF 9S–75 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—1—7 . . . . . . . . . 9706
NOTE: For the ZF 9S–75 Gearbox overhaul procedure refer to Component Manual, DW032002

E9706 1
1

E9706
2
3 TRANSMISSION
55 Series Transmission components

1. TRANSMISSION COMPONENTS
REMOVAL AND REFITMENT

ZF S6–36 Gearbox

To Remove
1. Isolate the batteries.

2. Drain oil from gearbox. 1

3. Release the exhaust down pipe clamp from
the clutch housing bracket.

4. Remove clamp securing the exhaust

intermediate pipe to the down pipe.

5. Support the exhaust system, release the

exhaust silencer support straps from the
chassis brackets and withdraw the exhaust
silencer/intermediate pipe from the vehicle.

6. Remove nuts and bolts securing the

propeller shaft centre bearing to the chassis
cross–member. Disconnect the propeller
shaft from the gearbox coupling flange and
support the shafts from a convenient point
on the chassis frame.

7. Unscrew the cap and disconnect the cable

from the reversing light switch.

8. If the gearbox is being replaced or removed

for overhaul, break the seal and disconnect
the tachograph cable coupling from the
speedometer transducer. Remove the
transducer.
If the gearbox is being removed for a
replacement clutch, input oil seal or clutch
withdrawal gear; do not disconnect the
cable, but release the clips securing the
cable to the chassis cross–member and the
pipe loom adjacent to the gearbox.

E9706 3–1–1
 TRANSMISSION 3
Transmission components 55 Series

9. Detach the cover plate from the servo slave

cylinder mounting bracket. Remove
retaining nuts and bolts and withdraw the
cylinder from the mounting bracket;

1 suspend the cylinder clear of the gearbox,

taking care not to strain the hydraulic pipe.
CAUTION: Do NOT press the clutch pedal
with the air and hydraulic pipes still
connected to the servo slave cylinder.

10. Release the compressor air delivery pipe

support bracket from the clutch housing.

11. Separate the reaction rod from the control

tube. Release the control tube ball joint
from the gearbox selector lever and position
the control tube assembly clear of the
gearbox.

12. Position a suitable lifting trolley beneath the

gearbox and support the weight of the unit.

13. Remove the clutch housing bolts and retain

the exhaust support bracket. Manoeuvre
the gearbox rearwards until the input shaft
is clear of the clutch unit, then lower and
withdraw the gearbox from the vehicle.

E9706
3–1–2
3 TRANSMISSION
55 Series Transmission components

1
2 3

5
1 4

6
2

8
9

7
050477

FIG.1. ZF S6–36 GEARBOX REMOVAL DETAILS

(L.H. Drive vehicle illustrated)

1. Compressor air delivery pipe support bracket 6. Reaction rod

2. Control tube 7. Propeller shaft
3. Clutch servo slave cylinder 8. Speedometer transducer
4. Cover plate 9. Reversing light switch
5. Exhaust clamp

E9706 3–1–3
 TRANSMISSION 3
Transmission components 55 Series

To Refit
1. Engage top gear to enable the input shaft
splines to be aligned with the driven plate.

2. Position the gearbox in the vehicle and

1 align the input shaft with the clutch driven
plate. Apply high melting point grease
sparingly to the input shaft.

3. Introduce the input shaft into the clutch and

rotate the coupling flange to align the
splines. Secure the gearbox to the engine
with four bolts diagonally opposed.

4. Secure the compressor air delivery pipe

and exhaust pipe support brackets to the
clutch housing. Fit the remaining clutch
housing bolts and then tighten all the bolts
to a torque of 80 to 110 Nm.

5. Locate the servo slave cylinder push–rod in

the jaw–end and assemble the cylinder to
the mounting bracket; tighten the nuts and
bolts to a torque of 30 Nm. Refit the cover
plate to the mounting bracket.

6. Reconnect the reversing light switch.

7. Refit the speedometer transducer, if

previously removed.

8. Re–coil the tachograph cable and clip to the

chassis cross–member and pipe loom
adjacent to the gearbox.
NOTE: If the tachograph cable has been
disconnected from the gearbox, the unit
must be calibrated and resealed by
qualified personnel at an approved
Tachograph Calibration Centre.

E9706
3–1–4
3 TRANSMISSION
55 Series Transmission components

9. Reconnect the propeller shaft to the

gearbox coupling flange, then secure the
centre bearing assembly to the chassis
cross–member.
Tighten the coupling flange bolts and the
centre bearing retaining bolts to a torque of
1
100 to 110 Nm.

10. Refit the exhaust silencer/intermediate pipe

assembly and secure the down pipe to the
clutch housing bracket.

11. Assemble the control tube to the gearbox

selector lever and tighten the ball joint nut
to a torque of 40 to 50 Nm.

12. Connect the reaction rod to the control tube

and tighten the ball joint nut to a torque of
58 to 64 Nm.

13. Refill gearbox with correct grade of oil, refer

to the ‘Maintenance Manual’.

14. Reconnect the batteries.

E9706 3–1–5
 TRANSMISSION 3
Transmission components 55 Series

1 2

5
1 6

11 7

13 12 10
14

15

11

10
16
9
050744

FIG.2. ZF 9S–75 GEARBOX REMOVAL DETAILS

(L.H. Drive vehicle illustrated)

1. Main air delivery pipe 9. Propeller shaft

2. Compressor air delivery pipe support bracket 10. Speedometer transducer
3. ‘Lo’ Range splitter pipe 11. Gate interlock air pipe
4. Servo slave cylinder 12. Gate interlock solenoid
5. Cover plate 13. Range–change protection valve
6. Exhaust clamp 14. Reversing light switch
7. Reaction rod 15. ‘Lo’ Range splitter pipe
8. Control tube 16. Range–change switch (Hi/Lo)
E9706
3–1–6
3 TRANSMISSION
55 Series Transmission components

ZF 9S–75 Gearbox

To Remove
1. Isolate the batteries.

2. Drain oil from gearbox. 1

3. Release the exhaust down pipe clamp from
the clutch housing bracket.

4. Remove clamp securing the exhaust

intermediate pipe to the down pipe.

5. Support the exhaust system, release the

exhaust silencer support straps from the
chassis brackets and withdraw the exhaust
silencer/intermediate pipe from the vehicle.

6. Remove nuts and bolts securing the

propeller shaft centre bearing to the chassis
cross–member. Disconnect the propeller
shaft from the gearbox coupling flange and
support the shafts from a convenient point
on the chassis frame.

7. Note cable positions, then unscrew the

caps and disconnect the cables from the
gate interlock solenoid, range–change
protection valve, reversing light and
range–change switches.

8. If the gearbox is being replaced or removed

for overhaul, break the seal and disconnect
the tachograph cable coupling from the
speedometer transducer. Remove the
transducer.

If the gearbox is being removed for a

replacement clutch, input oil seal or clutch
withdrawal gear; do not disconnect the
cable, but release the clips securing the
cable to the chassis cross–member and the
pipe loom adjacent to the gearbox.

E9706 3–1–7
 TRANSMISSION 3
Transmission components 55 Series

9. Detach the cover plate from the servo slave

cylinder mounting bracket. Remove
retaining nuts and bolts and withdraw the
cylinder from the mounting bracket;

1 suspend the cylinder clear of the gearbox,

taking care not to strain the hydraulic pipe.
CAUTION: Do NOT press the clutch pedal
with the air and hydraulic pipes still
connected to the servo slave cylinder.

10. Release the compressor air delivery pipe

support bracket from the clutch housing.

11. Depress the quick release sleeve and

disconnect the air delivery pipe from the
selector mechanism Tee piece (upper).

12. Depress the quick release sleeves and

disconnect the gate interlock air pipe from
the selector mechanism Tee piece (lower)
and interlock valve.

13. Disconnect the Hi/Lo splitter pipes from the

selector mechanism Tee piece and the
range–change protection valve. Release
the clips retaining the splitter pipes to the
gate interlock air pipe.

14. Separate the reaction rod from the control

tube. Release the control tube ball joint
from the gearbox selector lever and position
the control tube assembly clear of the
gearbox; if necessary, release the air pipes
from the control tube.

15. Position a suitable lifting trolley beneath the

gearbox and support the weight of the unit.

16. Remove the clutch housing bolts and retain

the exhaust support bracket. Manoeuvre
the gearbox rearwards until the input shaft
is clear of the clutch unit, then lower and
withdraw the gearbox from the vehicle.

E9706
3–1–8
3 TRANSMISSION
55 Series Transmission components

To Refit
1. Engage top gear to enable the input shaft
splines to be aligned with the driven plate.

2. Position the gearbox in the vehicle and

align the input shaft with the clutch driven 1
plate. Apply high melting point grease
sparingly to the input shaft.

3. Introduce the input shaft into the clutch and

rotate the coupling flange to align the
splines. Secure the gearbox to the engine
with four bolts diagonally opposed.

4. Secure the compressor air delivery pipe

and exhaust pipe support brackets to the
clutch housing. Fit the remaining clutch
housing bolts and then tighten all the bolts
to a torque of 80 to 110 Nm.

5. Locate the servo slave cylinder push–rod in

the jaw–end and assemble the cylinder to
the mounting bracket; tighten the nuts and
bolts to a torque of 30 Nm. Refit the cover
plate to the mounting bracket.

6. Reconnect cables to the gate interlock

solenoid, range–change protection valve,
reversing light switch and range–change
switch.

7. Refit the speedometer transducer, if

previously removed.

8. Re–coil the tachograph cable and clip to the

chassis cross–member and pipe loom
adjacent to the gearbox.
NOTE: If the tachograph cable has been
disconnected from the gearbox, the unit
must be calibrated and resealed by
qualified personnel at an approved
Tachograph Calibration Centre.

E9706 3–1–9
 TRANSMISSION 3
Transmission components 55 Series

9. Reconnect the propeller shaft to the

gearbox coupling flange, then secure the
centre bearing assembly to the chassis
cross–member.

1 Tighten the coupling flange bolts and the

centre bearing retaining bolts to a torque of
100 to 110 Nm.

10. Refit the exhaust silencer/intermediate pipe

assembly and secure the down pipe to the
clutch housing bracket.

11. Assemble the control tube to the gearbox

selector lever and tighten the ball joint nut
to a torque of 40 to 50 Nm.

12. Connect the reaction rod to the control tube

and tighten the ball joint nut to a torque of
58 to 64 Nm.

13. Reconnect the Hi/Lo splitter pipes to the

selector mechanism Tee piece (upper) and
the range–change protection valve.

14. Connect the air delivery pipe to the selector

mechanism Tee piece (upper).

15. Connect the gate interlock air pipe to the

selector mechanism Tee piece (lower) and
interlock valve.

16. Refill gearbox with correct grade of oil, refer

to the ‘Maintenance Manual’.

17. Reconnect the batteries.

E9706
3–1–10
3 TRANSMISSION
55 Series Transmission components

Eaton 6109 Gearbox

To Remove
1. Isolate the batteries.

2. Drain oil from gearbox. 1

3. Release the exhaust down pipe clamp from
the clutch housing bracket.

4. Remove clamp securing the exhaust

intermediate pipe to the down pipe.

5. Support the exhaust system, release the

exhaust silencer support straps from the
chassis brackets and withdraw the exhaust
silencer/intermediate pipe from the vehicle.

6. Remove nuts and bolts securing the

propeller shaft centre bearing to the chassis
cross–member. Disconnect the propeller
shaft from the gearbox coupling flange and
support the shafts from a convenient point
on the chassis frame.

7. Note cable positions, then unscrew the

caps and disconnect the cables from the
range–change protection valve, reversing
light and the range–change switches.

8. If the gearbox is being replaced or removed

for overhaul, break the seal and disconnect
the tachograph cable coupling from the
speedometer transducer. Remove the
transducer.

If the gearbox is being removed for a

replacement clutch, input oil seal or clutch
withdrawal gear; do not disconnect the
cable, but release the clips securing the
cable to the chassis cross–member and the
pipe loom adjacent to the gearbox.

E9706 3–1–11
 TRANSMISSION 3
Transmission components 55 Series

9. Detach the cover plate from the servo slave

cylinder mounting bracket. Remove
retaining nuts and bolts and withdraw the
cylinder from the mounting bracket;

1 suspend the cylinder clear of the gearbox,

taking care not to strain the hydraulic pipe.
CAUTION: Do NOT press the clutch pedal
with the air and hydraulic pipes still
connected to the servo slave cylinder.

10. Release the compressor air delivery pipe

support bracket from the clutch housing.

11. Depress the quick release sleeves and

disconnect the air delivery pipe and the
‘Hi’ range splitter pipe from the air
filter/regulator valve.

12. Depress the quick release sleeve and

disconnect the ‘Lo’ range splitter pipe from
the range–change protection valve.

13. Separate the reaction rod from the control

tube. Release the control tube ball joint
from the gearbox selector lever and position
the control tube assembly clear of the
gearbox; if necessary, release the air pipes
from the control tube.

14. Position a suitable lifting trolley beneath the

gearbox and support the weight of the unit.

15. Remove the clutch housing bolts and retain

the exhaust support bracket. Manoeuvre
the gearbox rearwards until the input shaft
is clear of the clutch unit, then lower and
withdraw the gearbox from the vehicle.

E9706
3–1–12
3 TRANSMISSION
55 Series Transmission components

3
1
6
4

7
1
2

15
3
13 12

14

11

10
050745

FIG.3. EATON 6109 GEARBOX REMOVAL DETAILS

1. ‘Lo’ Range splitter pipe 9. Control tube

2. Range–change protection valve switch 10. Propeller shaft
3. Reversing light switch 11. Speedometer transducer
4. Compressor air delivery pipe support bracket 12. ‘Hi’ Range splitter pipe
5. Clutch servo slave cylinder 13. Main air delivery pipe
6. Cover plate 14. Air filter/regulator valve
7. Splitter pipes 15. Range–change switch (Hi/Lo)
8. Reaction rod

E9706 3–1–13
 TRANSMISSION 3
Transmission components 55 Series

To Refit
1. Engage top gear to enable the input shaft
splines to be aligned with the driven plate.

2. Position the gearbox in the vehicle and

1 align the input shaft with the clutch driven
plate. Apply high melting point grease
sparingly to the input shaft.

3. Introduce the input shaft into the clutch and

rotate the coupling flange to align the
splines. Secure the gearbox to the engine
with four bolts diagonally opposed.

4. Secure the compressor air delivery pipe

and exhaust pipe support brackets to the
clutch housing. Fit the remaining clutch
housing bolts and then tighten all the bolts
to a torque of 80 to 110 Nm.

5. Locate the servo slave cylinder push–rod in

the jaw–end and assemble the cylinder to
the mounting bracket; tighten the nuts and
bolts to a torque of 30 Nm. Refit the cover
plate to the mounting bracket.

6. Reconnect cables to the range–change

protection valve, reversing light and
range–change switches.

7. Refit the speedometer transducer, if

previously removed.

8. Re–coil the tachograph cable and clip to the

chassis cross–member and pipe loom
adjacent to the gearbox.
NOTE: If the tachograph cable has been
disconnected from the gearbox, the unit
must be calibrated and resealed by
qualified personnel at an approved
Tachograph Calibration Centre.

E9706
3–1–14
3 TRANSMISSION
55 Series Transmission components

9. Reconnect the propeller shaft to the

gearbox coupling flange, then secure the
centre bearing assembly to the chassis
cross–member.

Tighten the coupling flange bolts and the 1

centre bearing retaining bolts to a torque of
100 to 110 Nm.

10. Refit the exhaust silencer/intermediate pipe

assembly and secure the down pipe to the
clutch housing bracket.

11. Assemble the control tube to the gearbox

selector lever and tighten the ball joint nut
to a torque of 40 to 50 Nm.

12. Connect the reaction rod to the control tube

and tighten the ball joint nut to a torque of
58 to 64 Nm.

13. Connect the ‘Hi’ range splitter pipe and air

delivery pipe to the air filter/regulator valve.

14. Connect the ‘Lo’ range splitter pipe to the

range–change protection valve

15. Refill gearbox with correct grade of oil, refer

to the ‘Maintenance Manual’.

16. Reconnect the batteries.

E9706 3–1–15
 TRANSMISSION 3
Transmission components 55 Series

Gearbox Rear Oil Seal (ZF S6–36)

Service tools: 0484977 and 0485063

To Remove
1. Isolate the batteries
1
2. Reference mark the propeller shaft in
relation to the gearbox coupling flange.
Remove nuts and bolts securing the
propeller shaft centre bearing to the chassis
cross–member. Disconnect the propeller
shaft from the gearbox coupling flange and
support the shafts from a convenient point
on the chassis frame.

3. Release the lockwasher from the hole in the

coupling flange, then withdraw the
lockwasher.

4. Assemble tool 0484977 to the coupling

flange and remove the retaining nut.
Dismantle the service tool from the flange.

5. Using a suitable three legged puller,

withdraw the coupling flange.

6. Extract the oil seal from the gearbox casing.

E9706
3–1–16
3 TRANSMISSION
55 Series Transmission components

To Refit
1. Using tool 0485063 drift the oil seal into the
gearbox casing; the tool positions the seal
at the correct depth in the casing.

2. Heat the coupling flange to a temperature 1

of 100 to 120°C and locate on the
mainshaft.

3. Assemble service tool 0484977 to the

coupling flange; refit and tighten the
retaining nut to a torque of 360 Nm.
Remove the service tool.

4. Locate the lockwasher on the nut; stake the

washer into the hole in the coupling flange
to secure the nut.

5. Connect the propeller shaft to the gearbox

coupling flange, aligning the reference
marks, then secure the centre bearing
assembly to the chassis cross–member.

6. Top–up gearbox oil as necessary, see

‘Maintenance Manual’.

7. Reconnect the batteries.

E9706 3–1–17
 TRANSMISSION 3
Transmission components 55 Series

Gearbox Rear Oil Seal (ZF 9S–75)

Service tools: 0484977, 0535928 and 1240426

To Remove
1 1. Isolate the batteries

2. Reference mark the propeller shaft in

relation to the gearbox coupling flange.
Remove nuts and bolts securing the
propeller shaft centre bearing to the chassis
cross–member. Disconnect the propeller
shaft from the gearbox coupling flange and
support the shafts from a convenient point
on the chassis frame.

3. Assemble tool 0484977 to the coupling

flange; release the locking washer and
remove the coupling flange retaining bolts.
Dismantle the service tool from the flange.

4. Using a suitable three legged puller,

withdraw the coupling flange.

5. Extract the oil seal from the rear housing.

E9706
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3 TRANSMISSION
55 Series Transmission components

To Refit
1. Using tool 1240426 drift the oil seal into the
rear housing; the tool positions the seal at
the correct depth in the housing.
NOTE: Ensure the snap ring is fitted into
the first groove of the tool. 1
2. Heat the coupling flange to a temperature
of 60°C and locate on the mainshaft.

3. Assemble service tool 0484977 to the

coupling flange; refit and tighten the
retaining bolts to a torque of 60 Nm.
Remove the service tool.

4. Locate the locking washer on the retaining

bolts and, using tool 0535928 secure the
washer to the bolt heads.

5. Connect the propeller shaft to the gearbox

coupling flange, aligning the reference
marks, then secure the centre bearing
assembly to the chassis cross–member.

Tighten the coupling flange bolts and the

centre bearing retaining bolts to a torque of
100 to 110 Nm.

6. Top–up gearbox oil as necessary, see

‘Maintenance Manual’.

7. Reconnect the batteries.

E9706 3–1–19
 TRANSMISSION 3
Transmission components 55 Series

Gearbox Rear Oil Seal (Eaton 6109)

Service tools: 0484977, 0485173 and 1329358

To Remove
1. Isolate the batteries
1
2. Reference mark the propeller shaft in
relation to the gearbox coupling flange.
Remove nuts and bolts securing the
propeller shaft centre bearing to the chassis
cross–member. Disconnect the propeller
shaft from the gearbox coupling flange and
support the shafts from a convenient point
on the chassis frame.

3. Assemble tool 0484977 to the coupling

flange and remove the retaining nut.
Dismantle the service tool from the flange.

4. Using a suitable puller, withdraw the

coupling flange.

5. Remove retaining bolts and separate the oil

seal housing from the bearing housing.
Extract the seal and clean the joint faces of
the oil and bearing housing.

E9706
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3 TRANSMISSION
55 Series Transmission components

To Refit
1. Using tool 0485173 with adapter 1329358
drift the oil seal into the oil seal housing.

2. Apply ‘Loctite 518’ to the joint face of the oil

seal housing, refit the housing and tighten 1
the retaining bolts to 35 to 39 Nm.

3. Smear the sealing lip of the seal with

grease and locate the output flange on the
output shaft. Place a spacer on the flange,
fit and tighten the flange nut to press the
flange into the bearing. Remove the flange
nut and spacer.

4. Fit tool 0484977 to the output flange, fit and

tighten a new flange nut to 490 to 588 Nm.
Remove the service tool.

5. Connect the propeller shaft to the gearbox

coupling flange, aligning the reference
marks, then secure the centre bearing
assembly to the chassis cross–member.

Tighten the coupling flange bolts and the

centre bearing retaining bolts to a torque of
100 to 110 Nm.

6. Top–up gearbox oil as necessary, see

‘Maintenance Manual’.

7. Reconnect the batteries.

E9706 3–1–21
 TRANSMISSION 3
Transmission components 55 Series

Gearbox Input Oil Seal (ZF S6–36)

Service tools: 0499809 and 0484924

To Remove
1. Remove the gearbox as detailed in this
1 Section.

2. Detach the clutch housing/clutch withdrawal

gear assembly.

3. Remove the connection plate from the

gearbox; retain the input shaft and layshaft
adjustment shims and discard the joint.

4. Press the oil seal from the connection plate.

A
050750
To Refit
1. Using tool 0499809 with adapter 0484924,
press the oil seal into the connection plate. FIG.4. CLUTCH HOUSING FIXING
BOLT PATTERN
2. Position a new joint on the gearbox casing, (Viewed from engine flywheel)
refit the connection plate and tighten the
setscrews to a torque of 25 Nm. A — Non fixing bolt hole

3. Assemble the clutch housing/clutch

withdrawal gear assembly to the gearbox;
tighten the clutch housing bolts to a torque
of 69 Nm.
NOTE: On early vehicles the clutch housing
has a nine bolt fixing pattern of which only
eight are used, see Fig.4. If all the bolt hole
fixings are used to secure the clutch
housing to the gearbox, a foul condition will
occur between the head of the extra bolt
and the clutch withdrawal lever, causing
reduced clutch life.

4. Refit the gearbox as detailed in this

Section.

E9706
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3 TRANSMISSION
55 Series Transmission components

Gearbox Input Oil Seal (ZF 9S–75)

Service tools: 0535423 and 1240099

To Remove
1. Remove the gearbox as detailed in this
Section. 1
2. Detach the clutch housing/clutch withdrawal
gear assembly.

3. Remove the input adapter plate from the

gearbox; retain the input shaft adjustment
shim(s) and baffle plate and discard the
joint.

4. Lever the oil ring and oil seal from the input
adapter plate.

To Refit
1. Using tool 0535423 press the oil seal into
the connection plate. Insert the oil ring into
the adapter plate, with the star shaped face
of the ring uppermost (facing the gearbox
when fitted).

2. Locate guide sleeve 1240099 on the input

sleeve. Position a new joint on the gearbox
casing, refit the input adapter plate and
tighten the setscrews to a torque of 23 Nm.

3. Assemble the clutch housing/clutch

withdrawal gear assembly to the gearbox;
tighten the clutch housing bolts to a torque
of 69 Nm.

4. Refit the gearbox as detailed in this

Section.

E9706 3–1–23
 TRANSMISSION 3
Transmission components 55 Series

Gearbox Input Oil Seal (Eaton 6109)

Service tools: 0485173 and 1329354

To Remove
1. Remove the gearbox as detailed in this
1 Section.

2. Detach the clutch housing/clutch withdrawal

gear assembly.

3. Remove retaining bolts and withdraw the

input shaft cover; clean the joint faces of
the cover and gearbox casing.

4. Press the oil seal from the input shaft cover.

To Refit
1. Using tool 0485173 with adapter 1329354,
press the oil seal into the input shaft cover.

2. Apply ‘Loctite 518’ sealing compound to the

joint face of the input cover, refit the cover
and tighten the setscrews to 35 to 39 Nm.

3. Assemble the clutch housing/clutch

withdrawal gear assembly to the gearbox;
tighten the clutch housing bolts to a torque
of 69 Nm.

4. Refit the gearbox as detailed in this

Section.

E9706
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3 TRANSMISSION
55 Series Transmission components

Rear Engine/gearbox Mounting Rubbers

To Remove
1. Isolate the batteries.

2. Release the fuel pipe clamp from the L.H. 1

mounting bracket and the cable loom from
the R.H. bracket.

3. Remove the rear engine/gearbox centre

mounting bolts, nuts and washers.

4. Jack rear of engine until a minimal

clearance exists between the rear
engine/gearbox mounting brackets and the
mounting rubbers; place suitable packing
beneath rear of engine.

5. Remove the retaining nuts and bolts and

manoeuvre the mounting brackets from the
chassis frame.

6. Detach the mounting rubbers from the

chassis mounting brackets.

To Refit
Reverse the removal procedure, noting the
following torque figures:

Mounting rubber bolts:

119 to 131 Nm

Chassis mounting bracket bolts:

119 to 131 Nm

Centre mounting bolts:

190 to 210 Nm

E9706 3–1–25
 TRANSMISSION 3
Transmission components 55 Series

Propeller Shaft—Front

To Remove
1. Isolate the batteries.

1 2. Remove bolts securing the rear propeller

shaft to the front shaft coupling yoke/flange.
11 to 15 tonne vehicles: Use rubber bands
to retain the bearing assemblies in position.

3. Support the rear propeller shaft from a

convenient point on the chassis frame.

4. Suitably support the weight of the front

propeller shaft.

5. Remove bolts securing the propeller shaft

to the gearbox coupling flange.

6. Remove nuts and bolts securing the centre

bearing assembly to chassis cross–member
and withdraw the propeller shaft from the
vehicle.

To Refit
Reverse the removal procedure, noting:
1. Tighten the propeller shaft coupling flange
bolts and the centre bearing retaining bolts
to a torque of 100 to 110 Nm.
Tighten the strap bolts to a torque of 61 to
81 Nm.

2. Lubricate the bearings and sliding joint/slip

yoke splines as detailed in this Section.

E9706
3–1–26
3 TRANSMISSION
55 Series Transmission components

Propeller Shaft—Intermediate

To Remove
1. Isolate the batteries.

2. Suitable support the intermediate propeller 1

shaft.

3. Remove bolts securing the rear propeller

shaft to the intermediate shaft coupling
yoke/flange; support the rear propeller shaft
from a convenient point on the chassis
frame.
11 to 15 tonne vehicles: Use rubber bands
to retain the bearing assemblies in position.

4. Remove bolts securing the propeller shaft

to the front shaft coupling yoke/flange.
Remove nuts and bolts securing the centre
bearing assembly to chassis cross–member
and withdraw the propeller shaft from the
vehicle.
11 to 15 tonne vehicles: Use rubber bands
to retain the bearing assemblies in position.

To Refit
Reverse the removal procedure, noting:

1. Tighten the propeller shaft coupling flange

bolts to a torque of 100 to 110 Nm.
Tighten the strap bolts to a torque of 61 to
81 Nm.

2. Lubricate the bearings and sliding joint/slip

yoke splines as detailed in this Section.

E9706 3–1–27
 TRANSMISSION 3
Transmission components 55 Series

Propeller Shaft—Rear

To Remove
1. Isolate the batteries.

1 2. Remove bolts securing the rear propeller

shaft to the front shaft coupling yoke/flange.

3. Remove bolts and disconnect the propeller

shaft from the rear axle coupling flange.
Withdraw the propeller shaft from the
vehicle.

To Refit
Reverse the removal procedure, noting:

1. Tighten the propeller shaft coupling flange

bolts to a torque of 100 to 110 Nm.
Tighten the strap bolts to a torque of 61 to
81 Nm.

2. Lubricate the bearings and sliding joint/slip

yoke splines as detailed in this Section.

E9706
3–1–28
3 TRANSMISSION
55 Series Transmission components

Centre Bearing Assembly

To Remove
1. Remove the appropriate propeller shaft as
previously described.
1
2. Secure the propeller shaft in a vice.

3. Suitably reference mark the coupling yoke

in relation to the propeller shaft. Remove
retaining nut and withdraw the coupling
yoke/flange.

4. Using a suitable puller, withdraw the centre

bearing assembly from the shaft.

To Refit
Reverse the removal procedure, noting:

1. Fill the cavity around the centre bearing

with waterproof ‘calcium based’ grease to
protect the bearing from water and
contaminants. Sufficient grease must be
used to fill the cavity to the extreme edge of
the retainer surrounding the bearing.

E9706 3–1–29
 TRANSMISSION 3
Transmission components 55 Series

Propeller Shaft Universal Joint (circlip design) 3

4
To Remove
1. Remove the appropriate propeller shaft as 2 5 7
previously described.
1 1
6

2. Reference mark the coupling flange in

relation to the shaft.

3. Remove the bearing circlips and the

lubricator from the bearing journal.

4. Support the propeller shaft on a suitable

diameter bush, with the shaft yoke in the
vertical position. Press the upper
bearing/journal assembly downward to
partially release the lower bearing from the
shaft. Invert the shaft and withdraw the
bearing. 050487

5. Repeat the above operation for the opposite FIG.5. PROPELLER SHAFT
bearing and separate the journal/coupling UNIVERSAL JOINT
flange from the shaft yoke.
1. Coupling flange
6. Repeat operation 3 for the removal of the 2. Lubricator
flange yoke bearings. Separate the journal 3. Circlip
from the flange. 4. Bearing assembly
5. Bearing seal
7. Examine components for wear or damage, 6. Journal
renew as necessary. 7. Shaft yoke

To Refit
Reverse the removal procedure, noting:

1. Ensure the journal lubricator is facing the

propeller shaft.

2. Inject the journal and smear the bearings

with lithium grease (N.L.G.I. Grade 2).

3. Refit the propeller shaft and lubricate the

bearings and sliding joint/slip yoke splines
as detailed in this Section.

E9706
3–1–30
3 TRANSMISSION
55 Series Transmission components

Propeller Shaft Universal Joint

(bearing plate design)
3
To Remove
4 5
1. Remove the appropriate propeller shaft as
previously described.
2
1
1
2. Unscrew the seal cap and separate the slip
yoke from the propeller shaft.
NOTE: The slip yoke and propeller shaft
are reference marked (arrows) on initial
build; if necessary, re–stamp the slip yoke
and shaft prior to dismantling.

3. Reference mark the coupling flange in

6
relation to the slip yoke/propeller shaft.

4. Remove the bearing cap setscrews.

050751
5. Support the slip yoke/propeller shaft with
the fixed yoke uppermost, then lever the
bearing cap assembly from the yoke. FIG.6. PROPELLER SHAFT
UNIVERSAL JOINT
6. Invert the slip yoke/propeller shaft and
repeat the above operation for the opposite 1. Coupling flange
bearing assembly; separate the 2. Lubricator
journal/coupling flange from the shaft. 3. Bearing plate assembly
4. Bearing seal
7. Secure the coupling flange/journal in a vice. 5. Shaft yoke
Lever the bearing cap assemblies from the 6. Journal
flange and withdraw the journal.

8. Examine components for wear or damage,

renew as necessary.

To Refit
Reverse the removal procedure, noting:

1. Ensure the journal lubricator is facing the

propeller shaft.

2. Inject the journal and smear the bearings

with lithium grease (N.L.G.I. Grade 2).

3. Refit the propeller shaft and lubricate the

bearings as detailed in this Section.

E9706 3–1–31
 TRANSMISSION 3
Transmission components 55 Series

Propeller Shaft Grease Procedure

1. Using a hand operated grease gun, inject
each grease nipple and ensure that the
grease exudes from all the trunnion seals

1 on each universal joint.

2. Universal joint (Bearing plate design):

If grease does not exude from any of the
seals, slacken the relevant bearing
setscrews and release the bearing
assembly approximately 1,6 mm to allow
the grease to penetrate the bearing/seal.
Tighten the bearing setscrews to 38 to
65 Nm.

3. Sliding joint/slip yoke splines: Inject the

grease nipple until grease is seen to exude
from the sliding joint seal.
If a vent plug is fitted to the yoke end of the
sliding joint/slip yoke, inject the grease
nipple until grease is seen to exude from
the vent hole. Cover the vent hole and
continue to inject the grease nipple until
grease exudes from the sliding joint/slip
yoke seal.

NOTE: In cold temperatures drive the vehicle

immediately after lubricating the propeller shafts;
this will force excessive grease from the sliding
joint/slip yoke splines.
Failure to carry out this procedure in cold
temperatures could cause the excess lubricant to
harden and force the plug out of the sliding joint.

E9706
3–1–32
3 TRANSMISSION
55 Series Transmission components

Gear–change Lever Assembly

To Remove (Figs. 7 and 8)

1. Isolate the batteries.

2. Tilt the cab, refer to the ‘Drivers Handbook’. 1

3. Remove retaining nut and separate the
reaction rod from the gearbox bracket.

4. Disconnect the control tube ball joint from

the gearbox selector lever.

5. ZF 9S–75 and Eaton 6109 Gearboxes

Only: Release the gaiter from the splitter
valve.
Prise out the gear–change motif and
remove the gear knob retaining nut and
washer; withdraw the gear knob.

6. ZF S6–36 Gearbox Only: Unscrew the gear

knob from the gear–change lever.

7. Release the rubber gaiter and inner gaiter

from the gaiter bracket and withdraw the
gaiters from the gear–change lever.

8. Remove screws and separate the gaiter

bracket from the springs.

9. Detach the steady bracket from the support

bracket and the air induction manifold.

E9706 3–1–33
 TRANSMISSION 3
Transmission components 55 Series

10. Remove nuts and bolts securing the

mounting plate/gear–change lever to the
support bracket. Withdraw the gear–change
lever/control tube assembly from the

1 vehicle.

11. Remove retaining nut and separate the ball

joint from the mounting plate.

12. Press the ball joint from the gear–change

lever.

13. Dismantle the ball joint and reaction rod

from the control tube.

14. Drift the swivel pin and bearings from the

control tube and gear–change lever.

E9706
3–1–34
3 TRANSMISSION
55 Series Transmission components

23 24

22
1
20
19 21
1

3
15

5
17 16

18
14

15

8
9
12
10 11
11 10
12 6
13 7
6
050746

FIG.7. GEAR–CHANGE LEVER ASSEMBLY — ZF GEARBOXES

(R.H. Drive application illustrated)
1. Gear knob 13. Swivel pin
2. Gaiter 14. Steady bracket
3. Inner gaiter 15. Control tube
4. Gaiter bracket 16. Spring
5. Gear–change lever 17. Ball joint
6. Rubber bush 18. Reaction rod
7. Sleeve 19. Ball joint
8. Mounting plate 20. Locknut
9. Ball joint 21. Splitter valve *
10. Bearing 22. Gear knob *
11. Seal 23. Gear knob nut and washer *
12. Washer 24. Gear–change motif *

* ZF 9S–75 Gearbox L.H. Drive Application

E9706 3–1–35
 TRANSMISSION 3
Transmission components 55 Series

To Refit
1. Position the gear–change lever in the
control tube fork. Insert the washers and
seals between the lever and fork, then

1 press the swivel pin through the fork,

washers, seals and into the gear–change
lever. Install the bearings into the control
tube fork and locate on the swivel pin; stake
the fork to retain the bearings.

2. Degrease the splined spigot and plain

shank of the ball joint.

3. Apply ‘Loctite 601’ to the splined spigot and

then press the ball joint into the
gear–change lever.

4. Smear the ball joint shank with ‘Loctite 601’,

locate the mounting plate on the ball joint
and secure with retaining nut to a torque of
80 to 90 Nm.

5. Fit the ball joint to the control tube.

6. Position the gear–change lever/control tube

assembly in the vehicle. Assemble the
mounting plate to the support bracket,
tightening the nuts and bolts to a torque of
25 to 30 Nm.
Secure the steady bracket to the air
induction manifold and support bracket.

7. Connect the control tube ball joint to the

gearbox selector lever, do not fit the
retaining nut at this stage.

8. Fit the reaction rod to the gearbox bracket

and control tube; tighten the ball joint nuts to
a torque of 58 to 64 Nm.

9. Locate the gaiter bracket on the springs and

secure in position with the two retaining
screws.

E9706
3–1–36
3 TRANSMISSION
55 Series Transmission components

2 1

3 1
21
4
20
23
5

6
22 18
7

8
20 19

21
17

18

11
12

13 15 14
14 13
15 9
16
10
9
050747

FIG.8. GEAR–CHANGE LEVER ASSEMBLY — EATON GEARBOX

1. Gear–change motif 13. Bearing
2. Gear knob nut and washer 14. Seal
3. Gear knob 15. Washer
4. Splitter valve 16. Swivel pin
5. Gaiter 17. Steady bracket
6. Inner gaiter 18. Control tube
7. Gaiter bracket 19. Spring
8. Gear–change lever 20. Ball joint
9. Rubber bush 21. Reaction rod
10. Sleeve 22. Ball joint
11. Mounting plate 23. Locknut
12. Ball joint

E9706 3–1–37
 TRANSMISSION 3
Transmission components 55 Series

10. Slide the inner gaiter on the gear–change

lever and secure to the gaiter plate with the
fasteners.

11. Slide the rubber gaiter/support pad onto the

1 gear–change lever and re–seat the gaiter on
the bracket.

12. ZF S6–36 Gearbox Only: Apply ‘Loctite 601’

to the gear–change lever threads and refit the A
gear knob.

13. ZF 9S–75 and Eaton 6109 Gearboxes Only:

Locate the splitter valve on the gear–change
lever and reconnect the air pipes.
Position the gear knob on the splitter valve
and secure with retaining nut and washer;
refit the gear–change motif.
Re–seat the gaiter on the splitter valve

14. Place the gear–change lever in neutral

position adjacent to the 3rd/4th speed
selector gate. Check that the gear–change
lever is vertical to the support bracket, when
viewed from the rear, Fig.9. If necessary,
90°
adjust the length of the reaction rod to
achieve this condition.

15. Adjust the length of the control tube, as

necessary, to give dimension ‘A’. Fit and
tighten the control tube ball joint nut to a
torque of 40 to 50 Nm. 1
050748
16. Check gear–change lever is in the neutral
3rd/4th position, then lower the cab.
FIG.9. GEAR–CHANGE LEVER SETTING
17. Reconnect the batteries. 1. Support bracket
Dimension A:
ZF S6–36 Gearbox — 27 " 2 mm
ZF 9S–75 and Eaton 6109
Gearboxes — 46 " 2 mm

E9706
3–1–38
3 TRANSMISSION
55 Series Transmission components

Clutch Unit

Borg and Beck—330, 350 and 380 mm

Diaphragm Spring

WARNING: Do NOT inhale the dust from the 1

clutch lining or blow the dust from the clutch
assembly and housing; remove the dust
using a damp cloth or a recommended
vacuum cleaner. Deposit used cloths, whilst
damp, in a plastic waste disposal bag.

Service tool: 0484966

To Remove
1. Remove the gearbox as detailed in this
Section.

2. Assemble the alignment tool as shown in

Fig.10. and then locate the tool in the driven
plate and flywheel spigot bearing.

3. Remove the clutch cover bolts; carefully

release the cover plate from its dowel
location and withdraw the clutch assembly.

4. Remove the clutch driven plate and the

alignment tool.

E9706 3–1–39
 TRANSMISSION 3
Transmission components 55 Series

To Refit
1. Apply high melting point grease sparingly to
the driven plate splined hub, slide the driven
plate along the gearbox input shaft several

1 times; this will ensure correct lubrication of

the hub splines. Remove excess grease from
the hub.

2. Position the driven plate on the flywheel,

splined hub facing outward, then locate the
alignment tool in the driven plate and flywheel
spigot bearing.

NOTE: The 380 and 350mm clutch cover location 1 2

dowels fitted in the flywheel are of different
diameters, the size of dowels are as follows:
— 330 mm clutch unit
7,95 mm and 9,55 mm 3 4

— 350 mm clutch unit A 4 2

9,55 and 11,14 mm.

The dowels fitted to the 380mm clutch unit are the

same diameter (10,07mm) 8 6

It is essential that the location holes in the clutch

cover are aligned with the correct size dowel. 5 7

3. Locate the cover assembly on the dowels, fit

and evenly tighten the cover bolts in the 1 3
sequence shown in Fig.10. and to a torque of
45 to 55 Nm. Remove the alignment tool. B 4 2

6 11
4. Refit the gearbox as detailed in this Section.

8 9

10 7

12 5
1 3

050749

FIG.10. CLUTCH ALIGNMENT TOOL

1. Spindle
2. Collar
3. Locator
4. Spigot

A—8 Bolt torque tightening sequence

B—12 Bolt torque tightening sequence

E9706
3–1–40
3 TRANSMISSION
55 Series Transmission components

Clutch Withdrawal Mechanism

To Remove 1
2
1. Remove the gearbox as detailed in this
3
Section.
1
2. Withdraw the release bearing from the clutch
release lever and connection plate. 4
3. Unscrew the ball joint/release lever from the
clutch housing and then press the socket
assembly from the release lever.

4. Separate the ball joint from the threaded

adapter.

5. Dismantle the servo slave cylinder jaw–end 8 7 6 5 050767

from the release lever.

FIG.11. CLUTCH WITHDRAWAL MECHANISM
6. Press the jaw–end bush from the release
lever. 1. Threaded adapter
2. Ball joint
3. Clutch release lever
To Refit 4. Clutch release bearing
1. Press the jaw–end bush into the release lever 5. Split pin
6. Washer
2. Assemble the servo slave cylinder jaw–end to
7. Jaw–end
the release lever.
8. Clevis pin
3. Apply ‘Loctite 270’ to the splined spigot of the
ball joint and press the ball joint into the
release lever.

4. Screw the threaded adapter into the clutch

housing to a torque of 95 to 108 Nm.

5. Apply ‘Loctite 242’ to the ball joint spigot, then

press the ball joint/release lever assembly
into the threaded adapter.

6. Slide the release bearing onto the connection

plate and engage with the release lever.

7. Refit the gearbox as detailed in this Section.

E9706 3–1–41
 TRANSMISSION 3
Transmission components 55 Series

Clutch Master Cylinder

WARNING: Hydraulic fluid is a toxic

substance which must not be consumed or
allowed to come into skin contact. In the
1 event of slight skin contact, thoroughly rinse
the affected area with water. If there is
excessive skin contact or ingestion/inhalation
seek medical attention immediately.

To Remove
1. Isolate the batteries.

2. Raise the front panel.

3. Remove the protective cap and attach a

rubber bleed tube to the servo slave cylinder
bleed screw, immerse the free end of the
tube into a clean container. Slacken the bleed
screw sufficiently to allow the hydraulic fluid
to be expelled. Depress the clutch several
times to expel the fluid from the system.

4. Remove the instrument panel as detailed in

Group 5, ‘Electrical System’.

5. Release the heater controls from the

instrument panel shroud, then detach the
shroud from the corner trim panel, main trim
panel and steering column bracket.

6. L.H Drive Vehicles: Remove screws and bolt

securing the corner trim panel to the
windscreen trim panel and cab door pillar.
Release the door seal and partially withdraw
the trim panel, disconnect the air ducting from
the air vent and withdraw the panel from the
cab.

R.H Drive Vehicles: Refer to Fig.14. for the

following operations.
Carefully lever the air vents from the main
trim panel and heater box.
Withdraw the diagnostic socket cover and
release the socket/bracket assembly from the
trim panel.

E9706
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3 TRANSMISSION
55 Series Transmission components

2
1
1

7
5

6
050755

FIG.12. CLUTCH MASTER CYLINDER REMOVAL DETAILS

1. Instrument panel shroud 5. Steering column adjustment control handle
2. Heater controls 6. Air pressure switches
3. Corner trim panel 7. Clutch master cylinder
4. Pedal cover
E9706 3–1–43
 TRANSMISSION 3
Transmission components 55 Series

Remove retaining screws, nut and washer

securing the trim panel to the windscreen
trim panel, heater box and cab. Release the
door seal and partially withdraw the trim

1 panel, disconnect the air ducting from the

air vents and, if applicable, the electrical
connector from the cigar lighter; withdraw
the trim panel from the cab.

7. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle, depress the clutch and
brake pedals and withdraw the cover.

8. Early Vehicles only: Release the air

pressure switches/bracket assembly from
the bulkhead bracket and position clear of
the cylinder.

9. Disconnect the hydraulic pipes from the

master cylinder.

10. Depress the clutch pedal and disconnect

the push–rod jaw–end from the clutch
operating pedal.

11. Remove retaining nuts and withdraw the

master cylinder.

To Refit
Reverse the removal procedure, noting:

1. Bleed the hydraulic system as detailed in

this Section.

E9706
3–1–44
3 TRANSMISSION
55 Series Transmission components

Clutch Servo Slave Cylinder

1
WARNING: Hydraulic fluid is a toxic
substance which must not be consumed or
allowed to come into skin contact. In the
event of slight skin contact, thoroughly rinse 1
the affected area with water. If there is
excessive skin contact or ingestion/inhalation
seek medical attention immediately.

To Remove 2
1. Isolate the batteries.

2. Deplete the air system; depress the quick

release sleeve and disconnect the air pipe
from the cylinder.

3. Disconnect the hydraulic pipe from the servo

cylinder and insert the free end of the pipe 4
into a suitable container. Depress the clutch 3
pedal several times to expel the fluid from the 050482
system.

4. Detach the cover plate from the cylinder FIG.13. CLUTCH SERVO SLAVE CYLINDER
mounting bracket.
1. Hydraulic pipe
5. Remove the retaining nuts and bolts and 2. Servo slave cylinder
withdraw the cylinder from the mounting 3. Cover plate
bracket. 4. Air pipe

To Refit
1. Locate the cylinder push–rod in the release
lever jaw–end and assemble the cylinder to
the mounting bracket; tighten the nuts and
bolts to a torque of 30 Nm.

2. Refit the cover plate to the mounting bracket.

3. Reconnect the air and hydraulic pipes to the

cylinder.

4. Bleed the hydraulic system as detailed in this

Section.

5. Reconnect the batteries.

E9706 3–1–45
 TRANSMISSION 3
Transmission components 55 Series

Operating Pedal Assembly

WARNING: Hydraulic fluid is a toxic

substance which must not be consumed or
allowed to come into skin contact. In the
1 event of slight skin contact, thoroughly rinse
the affected area with water. If there is
excessive skin contact or ingestion/inhalation
seek medical attention immediately.

To Remove
1. Isolate the batteries.

2. Raise the front panel.

3. Deplete the air system.

4. Remove the protective cap and attach a

rubber bleed tube to the servo slave cylinder
bleed screw, immerse the free end of the
tube into a clean container. Slacken the bleed
screw sufficiently to allow the hydraulic fluid
to be expelled. Depress the clutch pedal
several times to expel the fluid from the
system.

5. Remove the instrument panel as detailed in

Group 5, ‘Electrical System’.

NOTE: Refer to Fig.12. for operations 6, 7 and 8

and Fig.14. for operations 9, 10 and 11.

6. Release the heater controls from the

instrument panel shroud, then detach the
shroud from the corner trim panel, main trim
panel and steering column bracket.

7. Remove retaining screws and bolt securing

the corner trim panel to the windscreen trim
panel and cab door pillar. Release the door
seal and partially withdraw the trim panel,
disconnect the air ducting from the air vent
and withdraw the panel from the cab.

E9706
3–1–46
3 TRANSMISSION
55 Series Transmission components

8. Remove the pedal cover retaining screws.

Unscrew the steering column adjustment
control handle, depress the clutch and brake
pedals and withdraw the cover.

9. Carefully lever the air vents from the main 1

trim panel and heater box.

10. Withdraw the diagnostic socket cover and

release the socket/bracket assembly from the
trim panel.

11. Remove retaining screws, nut and washer

securing the trim panel to the windscreen trim
panel, heater box and cab. Release the door
seal and partially withdraw the trim panel,
disconnect the air ducting from the air vents
and, if applicable, disconnect the electrical
connector from the cigar lighter; withdraw the
trim panel from the cab.

12. Remove the front grille and lower panels and

detach the corner panel from the bulkhead
and windscreen finisher rail.

13. Release the windscreen washer reservoir

filler tube from the bulkhead pedal bracket.

14. Remove the cover plate from the bulkhead

pedal bracket to gain access to the footbrake
mounting nuts.

15. Note connections, then disconnect the air

pipes from the footbrake valve. Remove the
retaining nuts and withdraw the footbrake
valve.

16. Note connections, then disconnect the

electrical leads from the stop–light
micro–switch.

17. Release the air pressure switches/bracket

assembly from the bulkhead bracket.

E9706 3–1–47
 TRANSMISSION 3
Transmission components 55 Series

18. Disconnect the hydraulic pipe from the

master cylinder.

19. Remove bolts securing the pedal bracket to

the steering column bracket.
1
20. Remove the bulkhead pedal bracket
setscrews and manoeuvre the pedal
assembly from the cab.

21. Disconnect the hydraulic hose from the

clutch fluid reservoir.

22. Detach the pedal bracket assembly from

the bulkhead bracket. Clean the joint faces.

E9706
3–1–48
3 TRANSMISSION
55 Series Transmission components

060780

FIG.14. MAIN CAB TRIM PANEL R.H.D. Application

1. Trim panel 5. Diagnostic socket/bracket assembly

2. Air vent 6. Ash tray
3. Diagnostic socket cover 7. Cigar lighter electrical connector
4. Air vent

E9706 3–1–49
 TRANSMISSION 3
Transmission components 55 Series

To Refit
1. Apply ‘Kelseal Glasticon 238’ adhesive to the
joint face of the pedal bracket. Fit the bracket
assembly to the bulkhead bracket; tighten

1 nuts and bolts to a torque of 22 Nm.

2. Reconnect the clutch master cylinder

hydraulic hose to the reservoir.

3. Apply ‘Kelseal Glasticon 238’ adhesive to the 1

bulkhead pedal bracket and cab joint faces.
Manoeuvre the pedal bracket assembly into 2
the cab and secure the bulkhead pedal
bracket to the cab.

4. Secure the windscreen washer reservoir filler

tube to the bulkhead bracket.

5. Fit bolts securing the pedal bracket to the

steering column bracket and tighten to a
torque of 22 Nm.

6. Secure the air pressure switches/bracket

assembly to the bulkhead bracket. 3
050756

7. Connect the hydraulic pipe to the clutch

master cylinder. FIG.15. BULKHEAD PEDAL BRACKET
8. Connect the electrical leads to the stop–light 1. Cover plate
micro–switch. 2. Bulkhead bracket
3. Footbrake valve retaining nuts
9. Assemble the footbrake valve to the pedal
bracket, then reconnect the air pipes to the
valve.

10. Fit blanks to the air pressure gauge pipes,

then using a workshop air line fitted to the
vehicle full flow I.S.O. connection, fully
charge the air system.

11. Check the footbrake connections for leaks;

no leakage is permissible. After carrying out
the leakage test, fully deplete the air system
and remove the blanks from the air pressure
gauge pipes.

E9706
3–1–50
3 TRANSMISSION
55 Series Transmission components

12. Fit the cover plate to the bulkhead bracket,

using ‘Kelseal Glasticon 238’ to seal the joint
faces.

13. Position the main trim panel in the cab,

reconnect the air ducting to the air vents and, 1
if applicable, the electrical connector to the
cigar lighter. Secure the trim panel to the
windscreen trim panel, heater box and cab;
refit the air vents.

14. Secure the diagnostic socket/bracket

assembly to the trim panel and refit the
cover.

15. Fit the pedal cover to the steering column

bracket, refit and tighten the steering column
adjustment control handle.

16. Position the corner trim panel in the cab,

reconnect the air ducting to the air vent and
then secure the panel to the door pillar and
windscreen trim panel.

17. Assemble the instrument panel shroud to the

trim panels and steering column bracket and
secure the heater controls to the shroud.

18. Refit the instrument panel, see Group 5,

‘Electrical System’.

19. Fit the corner panel, front grille and lower

panels.

20. Bleed the clutch hydraulic system as detailed

in this Section.

21. Check the stop–light micro–switch setting,

see Group 6, ‘Brakes’.

22. Reconnect the batteries.

E9706 3–1–51
 TRANSMISSION 3
Transmission components 55 Series

21

1 20
1

19
7
18 2
6 3
17 11 5 4
16 7

13
14 12
15 10
13 9

050485

FIG.16. EXPLODED VIEW OF THE OPERATING PEDALS

1. Pedal bracket 12. Split pin

2. Support shaft 13. Clips
3. Micro–switch bracket 14. Hose
4. Locknuts 15. Clutch pedal
5. Micro–switch 16. Clutch master cylinder
6. Spring 17. Clevis pin
7. Needle roller bearing 18. Split pin
8. Brake pedal 19. Washer
9. Clevis pin 20. Spring
10. Roller 21. Spring pin
11. Washer

E9706
3–1–52
3 TRANSMISSION
55 Series Transmission components

Operating Pedals

To Remove
1. Remove the operating pedal assembly as
previously described.
1
2. Remove the clutch and brake pedal return
springs.

3. Detach the stop–light micro–switch from the

pedal bracket.

4. Disconnect the master cylinder push–rod

from the clutch pedal, remove nuts and
bolts and withdraw the master cylinder.

5. Secure the pedal bracket assembly in a

vice.

6. Drift out the spring pin retaining the support

shaft, slide the shaft from the pedal bracket
and withdraw the clutch and brake pedals.

7. Remove the split pin, washer, clevis pin and

roller from the brake pedal.

To Inspect
1. Inspect all components for wear or damage,
with particular attention to the roller bearing
assemblies and support shaft.

E9706 3–1–53
 TRANSMISSION 3
Transmission components 55 Series

To Refit
1. Assemble the roller to the brake pedal.

2. Lubricate all bearings and working surfaces

with lithium grease (N.L.G.I. Grade 2)
1
3. Position the clutch and brake pedals on the
pedal bracket. Refit the support shaft and
retain in position with spring pin.

4. Assemble the clutch master cylinder to the

pedal bracket and reconnect the push–rod
to the clutch pedal.

5. Refit the clutch and brake pedal return

springs.

6. Assemble the stop–light micro–switch to the

pedal bracket.

7. Refit the operating pedal assembly.

E9706
3–1–54
3 TRANSMISSION
55 Series Transmission components

Bleeding The Clutch Hydraulic System

WARNING:

i. Hydraulic fluid is a toxic substance

which must not be consumed or allowed 1
to come into skin contact. In the event
of slight skin contact, thoroughly rinse
the affected area with water. If there is
excessive skin contact or
ingestion/inhalation seek medical
attention immediately.

ii. Use clean new hydraulic fluid of the

correct specification from a sealed
container and ensure that no dirt enters
the clutch reservoir. Absorbed water or
dirt in the hydraulic system can result in
spongy pedal operation/clutch failure.
Do not shake the container or aerate the
fluid in any way. Keep hydraulic fluid
away from all paintwork.

iii Do NOT use hydraulic fluid that has

been exposed to atmosphere for a
period of time.

It is recommended that either vacuum or

pressure bleed equipment is used to
evacuate the hydraulic system. In the
absence of such equipment, the system
can be bled as follows:

1. Open the cab front panel, remove the

reservoir cap and extract the diaphragm.
Ensure that the hydraulic fluid is maintained
at the level indicated in the illustration
throughout the evacuation procedure.

E9706 3–1–55
 TRANSMISSION 3
Transmission components 55 Series

2. Remove the protective cap, attach a clear

plastic bleed tube to the servo slave
cylinder bleed screw and immerse the free
1
end of the tube into a clean transparent jar
2
1 containing a small amount of clean
hydraulic fluid.
3
3. Slacken the bleed screw sufficiently to allow
the hydraulic fluid to be expelled. Depress 4
the clutch pedal slowly and return the clutch
pedal, by hand, at the end of each stroke.
Repeat this procedure until a flow of clean
hydraulic fluid, free of air bubbles, is

LEVEL
FLUID
5
obtained then tighten the bleed screw
immediately after the last downward stroke
of the clutch pedal.
6
4. Check the fluid level in the reservoir and top
up as necessary.
7
5. Remove the bleed tube from the bleed
screw and refit the protective cap.

6. Insert the diaphragm into the clutch

reservoir and, to prevent leakage from the
reservoir, ensure that the seal in the
reservoir cap is in good condition and that
the reservoir cap is correctly and securely
fitted.

050486

FIG.17. BLEEDING THE CLUTCH

HYDRAULIC SYSTEM

1. Reservoir cap
2. Seal
3. Diaphragm
4. Reservoir
5. Level indicator
6. Bleed screw
7. Protective cap

E9706
3–1–56
3 TRANSMISSION
55 Series Contents

CONTENTS Page Date

SECTION 2—CLUTCH HYDRAULIC CYLINDERS

Overhaul:
Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—2—1 . . . . . . . . . 9706
Clutch Servo Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—2—2 . . . . . . . . . 9706

E9706 –1
2

E9706
–2
3 TRANSMISSION
Clutch hydraulic cylinders

2. CLUTCH HYDRAULIC CYLINDERS

OVERHAUL

Clutch Master Cylinder (Kongsberg)

1
To Dismantle
1. Release the dust cover from cylinder.

2. Remove the internal circlip and extract the

washer, piston and spring from the cylinder.

3. Remove the hose connection and bush

from the cylinder. 2 3
2
4
To Inspect
1. Clean the cylinder and internal components
with clean hydraulic fluid.

2. Examine the cylinder bore and piston for

ridges or score marks. Renew the unit if the
bore is scored or ridged.
5

To Reassemble 8
6
1. During assembly, lubricate all components
with the grease supplied with the repair kit. 7
2. Insert the spring and piston into the cylinder
bore, compress the piston into the cylinder
and refit the washer and circlip.

3. Locate the dust cover on the cylinder.

9
4. Refit the hose connection and bush to the 8 050488
cylinder.
FIG.1. EXPLODED VIEW OF
MASTER CYLINDER

1. Master cylinder
2. Hose connection
3. Bush
4. Spring
5. Piston assembly
6. Washer
7. Circlip
8. Dust cover
9. Push–rod

E9706 3–2–1
 TRANSMISSION 3
Clutch hydraulic cylinders

Clutch Servo Slave Cylinder (Kongsberg)

To Dismantle
1. Remove socket head screws securing
connector housing and valve seat to
cylinder housing; withdraw housing noting
O–ring. Remove the air filter from the
housing.
2 2. Withdraw valve return spring, spring seat
and inlet valve.

3. Withdraw valve seat housing, noting

O–ring, then remove pressure spring,
piston and seal assembly.

4. Release the end–plate tabs and withdraw

the push–rod and piston assembly.
Separate push–rod from piston assembly,
noting retainer insert.

5. Remove O–ring and conical spring from

servo housing.

6. Remove split wiper seal and piston seal

from piston assembly.

7. Remove internal front circlip, washer, front

hydraulic seal and washer.

8. Remove inner rear circlip, washer, and rear

hydraulic seal.

9. If necessary, remove split bearing from

servo housing.

10. Remove exhaust diaphragm.

E9706
3–2–2
3 TRANSMISSION
Clutch hydraulic cylinders

16

17
5
4 18
2
19
3 20
21
14 22
13 15
2 11
10
11
1 12 23
11
10 24

25

9
26
27
8
28
7 29
6
30
31
32
050476

FIG.2. EXPLODED VIEW OF CLUTCH SERVO SLAVE CYLINDER

1. Rubber gaiter 12. Front hydraulic seal 23. Pressure spring

2. End–plate 13. Rear hydraulic seal 24. O–ring
3. O–ring 14. Split bearing 25. Valve seat housing
4. Push–rod 15. Servo housing 26. Inlet valve
5. Push–rod retainer 16. Bleed nipple 27. Spring seat
6. Split wiper seal 17. Breather 28. Return spring
7. Piston assembly 18. Exhaust diaphragm 29. O–ring
8. Piston seal 19. Piston seal 30. Connector housing
9. Conical spring 20. O–ring 31. Socket head screw
10. Circlip 21. O–ring 32. Air filter
11. Washer 22. Piston

E9706 3–2–3
 TRANSMISSION 3
Clutch hydraulic cylinders

Inspection
1. Clean all items with a suitable
solvent/detergent and dry thoroughly.

2. Examine all parts for wear or damage and

the bores for signs of scoring; renew as
necessary.

2 To Reassemble
Reverse the dismantling procedure, noting:

1. Renew all items contained in the repair kit.

2. Prior to fitting components; lightly smear the

cylinder bores, piston seals and hydraulic
seals with the silicone grease supplied in
the repair kit.

3. Tighten the connector housing screws to a

torque of 6 to 10 Nm.

E9706
3–2–4
3 TRANSMISSION
55 Series Contents

CONTENTS Page Date

SECTION 3—GEARBOX—ZF S6–36 & S6–36 + GV36

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—1 . . . . . . . . . 9706
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—6 . . . . . . . . . 9706
To Dismantle:
Connection and splitter housing assembly—GV36 . . . . . . . . . . 3—3—7 . . . . . . . . . 9706
Input shaft—GV36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—10 . . . . . . . . 9706
Connection housing assembly S6—36 and S6—36/2 . . . . . . . . 3—3—11 . . . . . . . . 9706
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—12 . . . . . . . . 9706
Layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—16 . . . . . . . . 9706
Mainshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—14 . . . . . . . . 9706
Selector housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—43 . . . . . . . . 9706 3
Splitter piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—48 . . . . . . . . 9706

To Reassemble:
Connection and splitter housing assembly—GV36 . . . . . . . . . . 3—3—29 ........ 9706
Input shaft—GV36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—28 ........ 9706
Connection housing assembly S6—36 and S6—36/2 . . . . . . . . 3—3—37 ........ 9706
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—25 ........ 9706
Layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—17 ........ 9706
Mainshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—20 ........ 9706
Selector housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—43 ........ 9706
Splitter piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—48 ........ 9706

E9706 1
3

E9706
2
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

3. GEARBOX, ZF–SIX AND TWELVE SPEED SYNCHROMESH

DATA

Type
6–Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S6–36 & S6–36/2 Direct and Overdrive
12–Speed Splitter . . . . . . . . . . . . . . . . . . . . . . . . . . S6–36 + GV36 Overdrive
Input torque:
S6–36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650 Nm (maximum)
S6–36/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 Nm (maximum)
Gear ratios
S6–36 (/2) S6–36 (/2) S6–36
(Direct) (Overdrive) +GV36
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.97:1 6.93:1 8.97:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.22:1
3.10:1
3.79:1
2.22:1
7.43:1
5.22:1
3
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.96:1 1.40:1 4.32:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33:1 1.00:1 3.10:1
6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 0.80:1 2.57:1
7th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1.96:1
8th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1.62:1
9th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1.33:1
10th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1.10:1
11th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1.00:1
12th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 0.83:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.05:1 6.22:1 —
Reverse (Low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 8.05:1
Reverse (High) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 6.67:1
End–float
Input shaft/layshaft bearing . . . . . . . . . . . . . . 0 to 0,1 mm
Shims/circlips available:
Connection plate/input bearing shims
S6–36 (/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 to 2,0 mm in steps of 0,05 mm

S6–36 + GV36 . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 to 1,55 mm in steps of 0,05 mm

Input and intermediate shaft/mainshaft distance
washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,2 mm, 4,9 mm, 4,6 mm, 4,3 mm, 4,0 mm,
3,7 mm, 3,5 mm, 3,3 mm, 3,0 mm
Input shaft split rings . . . . . . . . . . . . . . . . . . . . . . . . 3,40 mm 3,50 mm 3,60 mm

E9706 3–3–1
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

Input bearing spacer rings GV36 . . . . . . . . . . . . . 1,40 mm to 2,30 mm in steps of 0,1 mm

Input shaft circlips . . . . . . . . . . . . . . . . . . . . . . . . . . 2,00 mm and 1,7 to 1,9 mm in steps of
0,05 mm
Intermediate shaft split rings . . . . . . . . . . . . . . . . . 3,40 mm 3,50 mm 3,60 mm
Layshaft adjustment shims . . . . . . . . . . . . . . . . . . 2.00 mm 2,2 mm and 1,35 to 1,75 mm in steps
of 0,05 mm
Layshaft circlips S6–36 (/2) . . . . . . . . . . . . . . . . . . 1,3 to 1,75 mm in steps of 0,05 mm
Layshaft circlips S6–36 + GV36
Splitter gear circlip . . . . . . . . . . . . . . . . . . . . . . 1,3 to 1,75 mm in steps of 0,05 mm
3 6th speed gear circlip . . . . . . . . . . . . . . . . . . .
Mainshaft output bearing circlips . . . . . . . . . . . . .
1,5 to 2,00 mm in steps of 0,1 mm
2,7 to 3,0 mm in steps of 0,1 mm
1st and 2nd speed synchronizer circlips . . . . . . . 2,3 to 2,5 mm in steps of 0,05 mm
4th speed gear bearing circlips . . . . . . . . . . . . . . . 1,9 mm, 2,0 mm, 2,1 mm
5th and 6th speed synchronizer circlips . . . . . . . 2,2 mm and 2,30 to 2,50 mm in steps of
0,05 mm

Torque tightening figures Nm

Connection housing bolts . . . . . . . . . . . . . . . . . . . . 50
Connection plate bolts . . . . . . . . . . . . . . . . . . . . . . 25
Coupling flange nut . . . . . . . . . . . . . . . . . . . . . . . . . 360
Intermediate bearing clamp bolts . . . . . . . . . . . . . 25
Pawl limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Pivot bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Reverse gear access plate bolts . . . . . . . . . . . . . . 25
Reversing light switch . . . . . . . . . . . . . . . . . . . . . . . 45
Selector housing bolts . . . . . . . . . . . . . . . . . . . . . . 25
Selector lever pinch bolt . . . . . . . . . . . . . . . . . . . . . 49
Speedometer connection piece . . . . . . . . . . . . . . 100
Stop bolt retaining plug . . . . . . . . . . . . . . . . . . . . . . 50
Splitter housing bolts . . . . . . . . . . . . . . . . . . . . . . . 50
Splitter piston housing bolts . . . . . . . . . . . . . . . . . . 25
Splitter piston housing end–cover bolts . . . . . . . . 25

3–3–2 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

050448

FIG.1. SECTION VIEW OF THE GEARBOX

E9706 3–3–3
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

050449

FIG.2. SECTION VIEW OF THE SPLITTER ASSEMBLY

3–3–4 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

4
2

5
3
1

14
8

10
13
11

12

050450

FIG.3. EXPLODED VIEW OF THE GEARBOX

1. Input shaft assembly 8. Oil seal

2. Layshaft assembly 9. Gearbox casing
3. Mainshaft assembly 10. Reverse/idler gear cover and joint
4. Reverse/idler gear assembly 11. Connection housing and joint
5. Speedometer connection 12. P.T.O. cover and joint
6. Pawl limit 13. Oil seal
7. Layshaft rear cover and joint 14. Connection plate and joint

E9706 3–3–5
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

OVERHAUL

Service tools: 0484880, 0484887, 0484901, 1

0484924, 0484977, 0484978, 0485034,
0485035, 0485037, 0485039, 0485062,
0485063, 0485064, 0485099, 0499809,
0694928, 0535662, 0694858

To Dismantle
1. Remove retaining bolts and withdraw the
clutch housing.
1 2 3 4
2. Release the lockwasher from the hole in
the coupling flange, then withdraw the
3 lockwasher.

3. Assemble tool 0484977 to the coupling

flange or yoke coupling then remove the
retaining nut. Dismantle the tool from the
coupling flange/yoke coupling.
7
4. Using tool 0484978 withdraw the coupling
flange.

5. On gearboxes fitted with a coupling yoke,

use tool 0485099 to withdraw the yoke. 5
6 050656
6. Unscrew the pawl limit, reverse light switch
and speedometer connection from the
casing. FIG.4. COUPLING FLANGE/YOKE PULLERS

1. Coupling flange 5. Coupling yoke

7. Suitably support the gearbox in the vertical 2. Nut 6. Flange nut
position with the input shaft uppermost. 3. Lockwasher 7. Tool 0485099
4. Tool 0484978

3–3–6 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

Connection and Splitter Housing

Assembly—GV36
1. Remove setscrews and separate the
connection plate from the connection
housing. Retain the input shaft and layshaft 1
adjustment shims and discard the joint.

2. Press the oil seal from the connection

plate.

3. Release the locking ring and withdraw the

split rings from the input shaft.

4. Remove the spacer ring and snap ring from 3

the input bearing. Using tool 0485037 with
adapter 0485039, withdraw the input 2
bearing. 2

050452

FIG.5. REMOVING THE INPUT BEARING

1. Tool 0485037
2. Adapter 0485039

E9706 3–3–7
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

5. Remove the connection/splitter housing

bolts.

6. Drift the two dowels from the connection

housing, separate the housing from the 2
splitter housing and discard the joint.

7. Remove circlip from front of layshaft. Using 1

tool 0484880 with adapter 0484887
withdraw the bearing.

8. Detach the splitter piston assembly from

3 the splitter housing.

9. Remove the plug from the splitter housing.

Using tool 0694928 with adapter 0484901
withdraw the splitter selector fork shaft.
050453
10. Withdraw the splitter gear, input shaft
assembly and selector fork as a complete
unit; note the position of the selector fork FIG.6. REMOVING THE LAYSHAFT
for subsequent refitment. Remove the BEARING
clutch body, synchronizer ring and needle
roller bearing race from the intermediate 1. Tool 0484880
shaft. 2. Adapter 0484887

11. Remove setscrews and withdraw the oil

pump.

3–3–8 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

12. Using tool 0535662 with adapter 0694858

withdraw the oil pump drive cam from the
layshaft.

13. Drift the two dowels from the splitter

housing, withdraw the housing from the
gearbox casing and discard the joint. 1
Withdraw the spigot bearing from the
mainshaft.

14. Release the lockwashers and remove the

setscrews, lockwashers and the
intermediate gear bearing clamp plates. 2
3
15. Press the intermediate shaft assembly
from the housing.
3
16. Release the locking ring and remove the
050454
split rings from the intermediate shaft.

17. Withdraw the bearing washer and roller FIG.7. REMOVING THE OIL PUMP
race, then press the intermediate shaft DRIVE CAM
from the bearing inner race.
1. Tool 0535662
18. Using a suitable two legged puller, 2. Adapter 0694858
withdraw the roller bearing inner race from 3. Oil pump drive cam
the layshaft.

19. Press the roller bearing race from the

splitter housing.

E9706 3–3–9
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

Input Shaft—GV36
1. Withdraw the sliding sleeve, taking care not
to lose the pressure springs, ball pins and
pressure pieces.

2. Remove the circlip, then press the input

shaft from the synchronizer body.

3. Separate the clutch body, synchronizer

body and ring.

4. Slide the gear from the input shaft and

3 withdraw the needle bearing races from the
gear.

3–3–10 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

Connection Housing Assembly S6–36 &

S6–36/2
1. Remove setscrews and separate the
connection plate from the connection
housing. Retain the input shaft and layshaft
adjustment shims and discard the joint.

2. Press the oil seal from the connection

plate.

3. Drift the two dowels from the connection

housing, separate the housing from the
gearbox casing and discard the joint.
3
4. Press the input shaft assembly from the
housing.

5. Release the locking ring and remove the

split rings from the input shaft.

6. Remove the bearing washer and outer

race.

7. Press the bearing inner race from the input

shaft.

8. Press the layshaft bearing outer race from

the connection housing.

E9706 3–3–11
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

Gearbox
1. Remove retaining bolts and withdraw the
selector housing from the gearbox casing;
discard the joint.

2. Detach the reverse gear access plate and

discard the joint. 2 3
3. Remove the reverse idler gear shaft 1
retaining screw and washer.

4. Using a soft metal drift, drive out the idler

3 gear shaft. Withdraw the idler gear,
complete with needle roller bearings from
casing.

5. Unscrew the 3rd/4th and 5th/6th speed

selector fork pivot bolts from the gearbox
casing, then withdraw the 3rd/4th and
5th/6th speed selector forks.

6. Assemble lifting tool 0485062 to the

mainshaft and layshaft. Place the
connecting rods in neutral position and fit
the clip block to the rods.

7. Unscrew the 1st/2nd speed pivot bolts from

the gearbox casing. 050455

FIG.8. LIFTING TOOL 0485062

1. Main tool
2. Clip block
3. Sleeve

3–3–12 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

8. Using suitable lifting equipment, withdraw

the mainshaft/layshaft assembly from the
gearbox casing.
NOTE: The speedometer worm gear and
bearing washer will become dislodged
during this operation.

9. Dismantle the lifting tool and remove the

selector forks, connecting rods and
selector bar.

10. Drive out the spring pins and separate the

reverse speed selector fork from the rod.
3
11. Remove circlip and withdraw the roller
bearing race from the gearbox casing.

12. Remove the layshaft rear cover and drift

the outer bearing race from the casing.

13. Drift the rear oil seal from the gearbox

casing

E9706 3–3–13
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

Mainshaft
1. Support the mainshaft vertically with the
5th/6th speed synchronizer uppermost.

2. Withdraw the 5th/6th speed synchronizer

ring and clutch body. Remove the spacer
ring from the clutch body.

3. Remove circlip, then using a suitable

extractor tool, withdraw the 5th/6th speed
synchronizer assembly.

3 4. Separate the clutch body and synchronizer

ring from the sliding sleeve and
synchronizer body. Press the synchronizer
body from the sliding sleeve, taking care
not to lose the pressure springs, ball pins
and pressure pieces.

5. Withdraw the 5th speed gear and needle

roller bearing.

6. Invert the mainshaft assembly.

7. Draw off the reverse gear, needle roller

bearing inner race and the output bearing
inner race. Withdraw the needle bearing
race from the mainshaft.

8. Draw off the 1st speed gear and reverse

gear clutch body. Withdraw the needle
bearing race from the mainshaft.

3–3–14 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

9. Remove the 1st/2nd speed synchronizer

body retaining circlip.

10. Draw off the 2nd speed gear and

synchronizer assembly. Separate the
clutch body and synchronizer rings from
the sliding sleeve and synchronizer body.
Press the synchronizer body from the
sliding sleeve, taking care not to lose the
pressure springs and ball pins.

11. Invert the mainshaft.

12. Remove the 4th speed gear retaining 3

circlip, then draw off the 3rd speed gear,
synchronizer assembly and 4th speed
gear.

13. Withdraw the bearing race from the 4th

speed gear and separate the 3rd speed
gear from the synchronizer assembly.

14. Separate the synchronizer rings and clutch

bodies from the sliding sleeve and
synchronizer body. Press the synchronizer
body from the sliding sleeve, taking care
not to lose the pressure springs, ball pins
and pressure pieces.

15. Remove the needle bearing race from the

mainshaft.

E9706 3–3–15
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

Layshaft
1. Drift the rear bearing inner race from the
layshaft.

2. Position the layshaft under a press with the

6th speed gear uppermost.
NOTE: Due to the tight fit of the helical
gears on the layshaft, it is recommended
that the gears are pressed off individually.

3. Remove circlip and press off the 6th speed

gear and bearing inner race (S6–36 only);
3 retain circlip for reassembly purposes.

4. Press off remaining gears.

Inspection
1. Clean all parts in a suitable solvent.

2. Examine all parts for wear or damage;

renew as necessary.

3. Renew oil seals.

4. Ensure all joint faces are clean and free

from burrs and traces of jointing
compound. Renew all joints when
reassembling.

3–3–16 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

2
1
To Reassemble

Layshaft
1. Position the layshaft vertically in a suitable
fixture.
NOTE: It is recommended that the gears
are heated to a temperature of
approximately 160° to 180°C to assist
refitment.
3
2. Heat the gears and fit individually onto the 4
layshaft. 5

3. Remove the layshaft assembly from the 9 8 7

6
A
3
press.
2
4. S6–36 (/2) Only. Heat the front bearing
race to a temperature of 85°C and position
on layshaft. 1
5. Fit original circlip and, using feeler gauges
check that a clearance of 0 to 0,05 mm
exists between circlip and bearing
race/gear. If excessive clearance is
apparent, replace the circlip with one of
appropriate thickness, see DATA for size of
circlips available.
3
6. Invert the layshaft assembly. Heat the rear 4
bearing inner race to a temperature of 9 5
85°C and position on the layshaft. B
6 050456

FIG.9. EXPLODED VIEW OF THE LAYSHAFT

A. S6–36 (/2) B. S6–36 + GV36

1. Layshaft
2. Taper roller bearing
3. 3rd speed gear
4. 4th speed gear
5. 5th speed gear
6. 6th speed gear
7. Taper roller bearing
8. Shim
9. Circlip
NOTE: On S6–36 (/2) overdrive gearboxes the
5th and 6th speed gear are reversed.

E9706 3–3–17
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

9 20
14
10 12 13 19
7 8 15 16 17 18
6 11
5
4
1 2 3

31
3 30
29
9 10 24 25 26 27
23 28
21 22 11

46 47
43
41 45
42 44
35 37 38
32 33 34 36 39 40

050457

FIG.10. EXPLODED VIEW OF THE MAINSHAFT

3–3–18 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

Key to Fig.10
1. Circlip 25. Sliding sleeve
2. Roller bearing race 26. Clutch body
3. Bearing inner race 27. 3rd speed gear
4. Circlip 28. Needle roller bearing
5. Distance washer 29. Mainshaft
6. Clutch body 30. Needle–roller bearing
7. Synchronizer ring 31. 2nd speed gear
8. Synchronizer body 32. Clutch body
9. Pressure piece 33. Synchronizer ring 3
10. Ball pin 34. Synchronizer body
11. Pressure spring 35. Ball pin
12. Synchronizer ring 36. Pressure spring
13. Sliding sleeve 37. Synchronizer ring
14. Clutch body 38. Sliding sleeve
15. 5th speed gear 39. Circlip
16. Needle–roller bearing 40. Needle–roller bearing
17. Circlip 41. 1st speed gear
18. Bearing sleeve 42. Clutch body
19. Needle–roller bearing 43. Reverse speed gear
20. 4th speed gear 44. Needle–roller bearing
21. Clutch body 45. Bearing inner race
22. Synchronizer ring 46. Circlip
23. Synchronizer body 47. Roller bearing
24. Synchronizer ring

E9706 3–3–19
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

Mainshaft
NOTE: To assist refitment, heat the
synchronizer bodies, output bearing inner A
race and reverse speed clutch body to a
temperature of 85°C. Heat the needle roller 050458

bearing inner races to 120°C.

FIG.11. SYNCHRONIZER WEAR LIMITS
1. Insert the needle roller bearing race into
the 2nd speed gear and place the gear on A—0,8 mm minimum
the mainshaft.

2. Locate the clutch body on the 2nd speed

3 gear and place the synchronizer ring on the
clutch body.
NOTE: Before assembling the
synchronizers, check the clearance
between the synchronizer ring and clutch
body, see Fig.11. Place the synchronizer
ring onto the corresponding clutch body;
measure the distance ‘A’ between the
clutch body and synchronizer ring. If the
measurement is less than 0,8 mm, renew
the synchronizer ring and/or body.

3. Heat the 1st/2nd speed synchronizer body

to the recommended temperature and
position on the mainshaft, aligning the slots
in the synchronizer body with the lugs on
the synchronizer ring.

4. Fit the original circlip and check that a

clearance of 0 to 0,1 mm exists between
the circlip and synchronizer body. If
excessive clearance is apparent, replace
the circlip with one of appropriate
thickness, see DATA for size of circlips
available.

3–3–20 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

5. Position the pressure springs and ball pins

in the synchronizer body. Locate the sliding
sleeve on the synchronizer body,
compressing each ball pin and pressure
spring in turn, carefully slide the sleeve into
position.

6. Locate the synchronizer ring in the

synchronizer body.

7. Insert the needle roller bearing race into

the 1st speed gear and place the gear on
the mainshaft.
3
8. Heat the reverse speed clutch body to the
recommended temperature and position on
the mainshaft.

9. Insert the needle roller bearing race into

the reverse speed gear and place the gear
on the mainshaft. Heat the bearing inner
race to the recommended temperature and
position on the mainshaft.

10. Heat the output bearing inner race to the

recommended temperature and position on
mainshaft.

11. Invert the mainshaft assembly.

E9706 3–3–21
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

12. Insert the needle roller bearing race into

the 3rd speed gear and place on the
mainshaft.

13. Locate the clutch body on the 3rd speed

gear and place the synchronizer ring on the
clutch body.

14. Heat the 3rd/4th speed synchronizer body

to the recommended temperature and
position on the mainshaft, aligning the slots
in the synchronizer body with the lugs on
3 the synchronizer ring.

15. Position the pressure springs, ball pins and

pressure pieces in the synchronizer body.
Locate the sliding sleeve on the
synchronizer body, compressing each
pressure piece, ball pin and pressure
spring in turn, carefully slide the sleeve into
position.

16. Locate the synchronizer ring on the

synchronizer body and place the clutch
body on the synchronizer ring.

17. Insert the needle roller bearing race into

the 4th speed gear and place the gear on
the mainshaft.

18. Heat the 4th speed gear bearing inner race

to the recommended temperature and
position on the mainshaft.

3–3–22 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

19. Fit the original circlip and check that a

clearance of 0 to 0,1 mm exists between
the circlip and bearing race. If excess
clearance is apparent, replace the circlip
with one of appropriate thickness, see
DATA for size of circlips available.

20. Insert the needle roller bearing in the 5th

speed gear and place the gear on the
mainshaft.

21. Locate the clutch body on the 5th speed

gear and place the synchronizer ring on the
clutch body.
3
22. Heat the 5th/6th speed synchronizer body
to the recommended temperature and
position on the mainshaft.

23. Fit the original circlip and check that a

clearance of 0 to 0,1 mm exists between
the circlip and synchronizer body. If
excessive clearance is apparent, replace
the circlip with one of appropriate
thickness, see DATA for size of circlips
available.

24. Position the pressure springs, ball pins and

pressure pieces in the synchronizer body.
Locate the sliding sleeve on the
synchronizer body, compressing each
pressure piece, ball pin and pressure
spring in turn, carefully slide the sleeve into
position.

25. Locate the synchronizer ring on the

synchronizer body and place the clutch
body on the synchronizer ring.

E9706 3–3–23
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

3 6
6 1

2
5 7
1
B
3
2 A
15 4
17 14
13
3 2
8 12 9
10
6

16
2
11
1

3
18

050459

FIG.12. EXPLODED VIEW OF THE SELECTION FORK/CONNECTING ROD ASSEMBLY

1. Pivot bolt 10. Spring pin

2. Washer 11. Reverse speed selector fork
3. Pivot bolt 12. Reverse speed selector bar
4. 3rd/4th speed selector fork 13. 3rd/4th speed connecting rod
5. Sliding pads 14. 5th/6th speed connecting rod
6. Pivot bolt 15. Sliding pads
7. 1st/2nd speed selector fork 16. 5th/6th speed selector fork
8. 1st/2nd speed connecting rod 17. Sliding pads
9. Spring pin 18. 5th/6th speed connecting rod (Overdrive models)

A—Overdrive Gearbox B—Direct Top Speed Gearbox

3–3–24 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

Gearbox Assembly
1. Press the layshaft and mainshaft rear
bearing outer races into the gearbox
casing.

2. Refit the original circlip in the roller bearing

bore and check that a clearance of 0 to
0,1 mm exists between the bearing race
and circlip. If excessive clearance is
apparent, replace the circlip with one of
appropriate thickness, see DATA for size of
circlips available.

3. Position the reverse speed selector fork on

3
the selector bar and secure with spring
pins.

4. Position the layshaft and mainshaft

together with the gears in mesh.

5. Locate the selector bar/reverse speed and

1st/2nd speed selector forks with their
respective sliding sleeves.

6. Engage the 1st/2nd speed connection rod

with the selector fork and selector bar. Fit
lifting tool 0485062 to the assembly and
locate guide sleeve 0485064 on the
mainshaft, see Fig.8

7. Locate the 3rd/4th and 5th/6th speed

connecting rods in the selector bar and
retain in position with the clip block.

E9706 3–3–25
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

8. Using suitable lifting equipment carefully

insert the mainshaft/layshaft assembly into
the gearbox casing.

9. Lightly smear the pivot bolt threads with a

suitable sealing compound, refit and locate
the pivot bolts into the 1st/2nd speed
selector fork. Tighten the bolts to the
torque figure quoted in DATA.

10. Remove the lifting tool and guide sleeve.

3 11. Engage the 3rd/4th speed selector fork

with the sliding sleeve and connecting rod.

12. Lightly smear the pivot bolt threads with a

suitable sealing compound, refit the pivot
bolts and tighten to the torque figure
quoted in DATA.

13. Repeat operations 11 and 12 for the

refitment of the 5th/6th speed selector fork.
Remove the clip block from the connecting
rods.

3–3–26 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

8
7

6
5
4
3
2
1

3
18
16 17
15
13
11 12 14
10
9

050460

FIG.13. EXPLODED VIEW OF THE INPUT SHAFT—GV36

1. Locking ring 7. Needle roller bearings 13. Ball pin

2. Split rings 8. Input gear 14. Pressure spring
3. Snap ring 9. Clutch body 15. Sliding sleeve
4. Spacer ring 10. Synchronizer ring 16. Synchronizer ring
5. Input bearing 11. Synchronizer body 17. Circlip
6. Input shaft 12. Pressure piece 18. Clutch body

E9706 3–3–27
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

Input Shaft—GV36
1. Slide the gear, complete with needle roller
bearings, onto the input shaft.

2. Locate the clutch body on the shaft and

place the synchronizer ring on the body.

3. Press the synchronizer body onto the input

shaft, ensuring the lugs on the
synchronizer ring are correctly located in
the three slots in the synchronizer body.

3 4. Fit the original circlip to the input shaft and

check that a clearance of 0 to 0,1 mm
exists between the circlip and synchronizer
body. If excessive clearance is apparent,
replace the circlip with one of appropriate
thickness, see DATA.

5. Position the pressure springs, ball pins and

pressure pieces in the synchronizer body.
Locate the sliding sleeve on the
synchronizer body, compressing each
pressure piece, ball pin and pressure
spring in turn, carefully slide the sleeve into
position.

6. Heat the input bearing to 85°C and position

on the shaft.

7. Measure the split ring groove and select

split rings to give a bearing pre–load of 0 to
0,05 mm. Refer to DATA for size of split
rings available.

8. Fit the correct size of split rings and retain

in position with the locking ring.

3–3–28 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

Connection and Splitter Housing

Assembly—GV36
1. Heat the bearing inner race to a
temperature of 85°C and position on the
intermediate shaft, shouldered face to the
gear.

2. Place the roller bearing race and washer

on the inner race.

3. Measure the split ring groove, then select

split rings to give a bearing pre–load of 0 to
0,05 mm. Refer to DATA for size of split
rings available.
3
4. Fit the correct size split rings and retain in
position with the locking ring.

5. Press the layshaft roller bearing race into

the splitter housing.

6. Press the intermediate shaft/bearing

assembly into the housing.

7. Fit the bearing clamp plates, lockwashers

and setscrews. Tighten the setscrews to
the torque figure quoted in DATA, and
secure with lockwashers.

E9706 3–3–29
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

8. To obtain correct size of distance washer to

be fitted between intermediate shaft gear
A
and 5th/6th speed synchronizer body,
proceed as follows:

See Fig.14.

a. Measure distance ‘A’ from the joint

face of splitter housing to intermediate
shaft gear face.
b. Position a new joint on the gearbox
casing and locate the original distance
3 washer in the 5th/6th speed clutch
body.
c. Measure distance ‘B’ from the distance
washer to the joint.
d. Subtract reading ‘B’ from ‘A’ and check B
the reading obtained is within a
clearance of 0,8 to 1,2 mm.
e. If the measurement obtained is outside
the limits quoted above, a distance
washer of appropriate size must be 050461
fitted; see DATA for sizes of distance
washers available.
FIG.14. INTERMEDIATE SHAFT/MAINSHAFT
DISTANCE WASHER MEASUREMENTS

3–3–30 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

8
7 10 12
11
6
3 5
4
2
1
3
13
14
15

16
18 17 050462

FIG.15. EXPLODED VIEW OF THE SPLITTER HOUSING—GV36

1. Circlip 7. Splitter housing 13. Intermediate gear

2. Taper roller bearing 8. Joint 14. Roller bearing
3. Splitter gear 9. Plug 15. Needle roller bearing
4. Oil pump drive cam 10. Selector shaft 16. Selector fork
5. Oil pump 11. Clamp plate 17. Sliding pads
6. Roller bearing 12. Lockwasher 18. Input shaft assembly

E9706 3–3–31
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

9. Locate the spigot bearing on the mainshaft.

10. Heat the layshaft roller bearing inner race

to a temperature of 85°C and position on
the shaft, shouldered face to the gear.

11. Locate the splitter housing assembly on the

gearbox casing and retain in position with
the two dowels.

12. Heat the oil pump drive cam to a

temperature of approximately 100°C and
3 position on the layshaft, shouldered face to
the bearing.

13. Assemble the oil pump to the splitter

housing.

14. Locate the clutch body on the intermediate

shaft, then place the synchronizer ring on
the body.

15. Place the needle roller bearing race on the

intermediate shaft.

16. Mesh the layshaft splitter gear with the

input shaft gear.

17. Engage the splitter selector fork with the

sliding sleeve.

18. Lift the input shaft/selector fork and the

splitter gear and position above the splitter
housing. Locate the selector fork in the
housing aperture, then lower the input shaft
and splitter gear onto the intermediate
shaft and layshaft respectively.

19. Rotate the input shaft to correctly engage

the lugs on the synchronizer ring with the
slots in the synchronizer body.

3–3–32 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

20. Heat the taper roller bearing race to a

temperature 85°C and position on the 2 1
layshaft.

21. Refit original circlip and, using feeler

gauges check that a clearance of 0 to
0,05 mm, exists between the circlip and
bearing race. If excessive clearance is
apparent, replace the circlip.

22. Locate the selector shaft in the casing.

Using tool 0694928 with adapter 0484901,
drift the shaft into the selector fork and
housing. Refit the plug.
3
23. Position a new joint on the splitter housing. 050463

24. Press the taper bearing outer race into the

connection housing until it is flush with the FIG.16. REFITTING THE SPLITTER
joint face. SELECTOR FORK SHAFT

1. Tool 0694928
25. To assist refitment, heat the connection
2. Adapter 0484901
housing around the input bearing bore and
then locate the housing on the bearing and
splitter housing.

26. Lift the input shaft and tap the connection

housing downwards, fully into position.
Refit the two dowels and housing bolts,
tighten the bolts to the torque figure quoted
in DATA.

E9706 3–3–33
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

27. An end–float of 0,8 mm must exist between

the synchronizer and clutch bodies (A)
Fig.17. To obtain this clearance setting,
proceed as follows: B
a. Fit the snap ring to the bearing, then
drift the input shaft downward to
eliminate the clearance (C) between
the clutch and synchronizer bodies.
b. Lever the snap ring upward into the
annular groove. Using feeler gauges C
measure the clearance (B) between
3 c.
the snap ring and housing.
Add the end–float clearance of 0,8 mm
to the clearance (B); this will give the
size of spacer ring to be fitted between
the snap ring and housing.

Example: mm
Clearance (B) 1,3
End–float 0,8
2,1
Spacer ring required 2,1 mm

28. Remove snap ring from the bearing. Lever

the input shaft upward sufficiently to enable A
the selective spacer ring to be fitted.

29. Fit the spacer ring to the bearing and

050464
locate the snap ring in the annular groove.

30. Drift the input shaft downward until the FIG.17. INPUT BEARING SPACER RING
snap ring rests against the spacer ring. MEASUREMENTS

3–3–34 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

31. To obtain the correct size of shim to be

fitted between the layshaft bearing and
connection plate, proceed as follows:
a. Drift the bearing outer race into
position until the bearing is free of
end–play.
b. Position a new joint on the connection
housing.
c. Using a dial test indicator, (D.T.I.),
locate the plunger on the joint and set
the gauge at zero. Carefully lower the
plunger until it rests against the
bearing outer race. Note the reading.
3
d. Subtract the thickness of the joint
(compressed condition) and the
average end–float clearance of 0 to
0,1 mm.

Example: mm
D.T.I. reading 1,55
minus joint 0,03
minus clearance 0,05
total 1,47
Shim required 1,47 " 0,05 mm

E9706 3–3–35
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

32. To obtain the correct size of shim to be

fitted between the input bearing and
connection plate, proceed as follows:
B

See Fig.18.

a. Measure distance ‘A’ from the joint

face of connection plate to the bearing
seat.
b. Measure distance ‘B’ from the input
bearing to the joint on the connection
housing.
3 c. Subtract the thickness of the joint
(compressed condition) and the average
end–float clearance of 0 to 0,1 mm and
dimension ‘B’. A

Example: mm
Distance ‘A’ 6,50
minus distance ‘B’ 4,80
minus clearance 0,05
minus joint 0,03
total 1,62
Shim required 1,62 " 0,05 mm

33. Using tool 0499809 and adapter 0484924,

press the oil seal into the connection plate. 050465

34. Place the required shims on the input shaft

and layshaft bearing races. Assemble the FIG.18. INPUT BEARING/CONNECTION
connection plate to the connection housing PLATE MEASUREMENTS
and tighten the bolts to the torque figure
quoted in DATA.

3–3–36 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

Connection Housing Assembly S6–36 & 1

S6–36/2 2
3
1. Heat the input bearing inner race to a 4
5
temperature of 85°C and position on the 6
shaft, shouldered face to the gear.

2. Place the roller bearing race and washer

on the inner race.
050466

3. Measure the split ring groove and select

split rings to give an input bearing pre–load FIG.19. EXPLODED VIEW OF THE INPUT
of 0,05 mm. Refer to DATA for size of split SHAFT (S6–36 & S6–36/2)
rings available.
1. Input shaft 3
4. Fit the selected split rings and retain in 2. Input bearing
position with the locking ring. 3. Snap–ring
4. Split ring
5. Fit the snap ring to the input bearing. 5. Lock ring
6. Shim
6. Press the input shaft into the connection
housing.

7. Press the taper bearing outer race into the

connection housing until it is flush with the
joint face.

8. Temporarily clamp the input bearing to

retain the snap ring flush against the
housing.

E9706 3–3–37
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

9. To obtain the correct size of distance

washer to be fitted between the input shaft
gear and the 5th/6th speed synchronizer
A
body, proceed as follows:

See Fig.20.

a. Measure distance ‘A’ from the joint

face of the connection housing to the
input shaft gear face.
b. Position a new joint on the gearbox
casing and locate the original distance
3 washer in the 5th/6th speed clutch
body.
c. Measure distance ‘B’ from the distance
washer to the joint.
d. Subtract reading ‘B’ from ‘A’ and check
the reading obtained is within a B
clearance of 0,8 to 1,2 mm.
e. If the measurement obtained is outside
the limits quoted above, a distance
washer of appropriate size must be 050467

fitted; see DATA for sizes of distance

washers available. FIG.20. INPUT SHAFT/MAINSHAFT
DISTANCE WASHER MEASUREMENTS
10. Locate the spigot bearing on the mainshaft.

3–3–38 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

11. Assemble the connection housing to the

gearbox casing. Tighten the housing bolts
to the torque figure quoted in DATA.

12. To obtain the correct size of shim to be

fitted between the layshaft bearing and
connection plate, proceed as follows:
a. Drift the bearing outer race into
position until the bearing is free of
end–play.
b. Position a new joint on the connection

c.
housing.
Using a dial test indicator, (D.T.I.),
3
locate the plunger on the joint and set
the gauge at zero. Carefully lower the
plunger until it rests against the
bearing outer race. Note the reading.
d. Subtract the thickness of the joint
(compressed condition) and the
average end–float clearance of 0 to
0,1 mm.

Example: mm
D.T.I. reading 1,55
minus joint 0,03
minus clearance 0,05
total 1,47
Shim required 1,47 " 0,05 mm

E9706 3–3–39
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

13. To obtain the correct size of shim to be

fitted between the input bearing and
connection plate, proceed as follows:
B

See Fig.21.

a. Measure distance ‘A’ from the joint

face of the connection plate to the
bearing seat.
b. Measure distance ‘B’ from the input
bearing to the joint on the connection
housing.
3 c. Subtract the thickness of the joint
(compressed condition) and the average
end–float clearance of 0 to 0,1 mm and
dimension ‘B’. A

Example: mm
Distance ‘A’ 6,50
minus distance ‘B’ 4,80
minus tolerance 0,05
minus joint 0,03
total 1,62
Shim required 1,62 " 0,05 mm

050465

FIG.21. INPUT BEARING/CONNECTION

PLATE MEASUREMENTS

3–3–40 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

14. Using tool 0499809 and adapter 0484924, 1

press oil seal into the connection plate. 3 2

15. Place the required shims on the input shaft

and layshaft bearing races. Assemble the 4
connection plate to the connection housing
and tighten the bolts to the torque figure
quoted in DATA.

16. Insert the needle roller bearing into the

050468
reverse/idler gear and position the gear in
the gearbox casing.

17. Insert O–ring into the inner groove on the

FIG.22. EXPLODED VIEW OF THE
REVERSE/IDLER GEAR 3
idler gear shaft.
1. Idler gear shaft
18. Install the idler gear shaft through the 2. O–ring
casing and into the gear until the lower 3. Idler gear
edge of the outer groove is flush with the 4. Needle–roller bearings
recess in the gearbox casing.

19. Check the reverse/idler gear end–play is

within a tolerance of 0,3 to 1,3 mm.

20. Secure the idler gear shaft in position with

lockwasher and setscrew, tighten the
setscrew to the torque figure quoted in
DATA.

E9706 3–3–41
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

21. Assemble the reverse gear access plate,

complete with a new joint, to the gearbox
casing. Tighten the bolts to the torque
figure quoted in DATA.

22. Place the bearing washer and the

speedometer worm gear on the mainshaft.

23. Using tool 0485063 press the oil seal into

the gearbox casing.
NOTE: This tool positions the oil seal at the
correct depth in the casing.
3 24. Heat the coupling flange/yoke coupling to a
temperature of 100° to 120°C and locate
on the mainshaft.

25. Assemble tool 0484977 to the coupling

flange/yoke coupling; refit and tighten the
retaining nut to the figure quoted in DATA.

26. On gearboxes fitted with a coupling flange. 050469

Locate the lockwasher on the nut; stake

the washer into the hole in the flange to FIG.23. FITTING THE REAR OIL SEAL
secure.

27. Refit and tighten the speedometer

connection to the torque figure quoted in
DATA.

28. Refit and tighten the reversing light switch

and pawl limit to the torque figure quoted in
DATA. Secure pawl limit with tab washer.

3–3–42 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

Selector Housing Assembly

To Dismantle (Figs 25 & 26)

1. Reference mark the selector lever in
relation to the selector shaft. Remove the
pinch bolt and withdraw the selector lever
and protective cap.

2. Release the tab washer and unscrew the

pawl limit from the selector housing.

3. Remove plug, then withdraw the spring and

stop bolt from the housing.
3
4. Position the selector finger with one set of
spring pins facing the blind hole in the
casing (Fig.24.); drive out the spring pins.
Reposition the finger and drive out the
remaining set of spring pins.

5. Detach the end–cover/reaction rod bracket

from the housing.
Type ‘B’ selector housing: Remove circlip
and drift the shaft from the lever end to
dislodge the cup washer and bush.

6. Remove circlip and withdraw the sleeve,

compression springs and washer.

7. Extract the selector shaft and withdraw the

selector finger, block plate and 050470

intermediate tube or driver finger from the

housing. FIG.24. REMOVING THE SELECTOR
FINGER SPRING PINS
8. Remove the scraper ring and oil seal from
the housing.

9. Extract the bearing bush(es) from the

selector housing.

E9706 3–3–43
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

11
1 12
13 14
15 16 17
4
5

2
3 6 9 10

3 19 18

7
8
29 20
28
27
26

24
21

25
22

23 050657

FIG.25. EXPLODED VIEW OF THE SELECTOR HOUSING ASSEMBLY (TYPE A)

1. Selector lever 11. Washer 20. Selector shaft

2. Protective cap 12. Compression spring (outer) 21. Joint
3. Scraper ring 13. Compression spring (inner) 22. Spring pins
4. Oil seal 14. Sleeve 23. Block plate/selector finger
5. Bush 15. Circlip 24. Intermediate tube {
6. Selector housing 16. Joint 25. Driver finger*
7. Seal ring 17. End cover/reaction 26. Plug
8. Bush rod bracket 27. Seal
9. Tabwasher 18. Plug 28. Spring
10. Pawl limit 19. Seal 29. Stop bolt

* Overdrive models only { Direct models only

3–3–44 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

1
2
3
4 5
6
7
8

11
A
11
3
9 10

25
24
23 12
22

20 13
14
26 15
16
21 19 17

18
050658

FIG.26. EXPLODED VIEW OF THE SELECTOR HOUSING ASSEMBLY (TYPE B)

1. Circlip 10. Tab washer 19. Spring pins

2. Cup washer 11. Pawl limit 20. Intermediate tube {
3. Bush 12. Bush 21. Driver finger*
4. Circlip 13. Selector shaft 22. Plug
5. Sleeve 14. Oil seal 23. Seal
6. Compression spring (outer) 15. Scraper ring 24. Spring
7. Compression spring (inner) 16. Protective cap 25. Stop bolt
8. Washer 17. Selector lever 26. Joint
9. Selector housing 18. Block plate/selector finger

* Overdrive models only { Direct models only A = 2 mm (0.080 in)

E9706 3–3–45
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

To Reassemble
1. Using tool 0485035, drift the bearing
bush(es) into the housing.
Type ‘B’ selector housing: Press the outer
bush into the housing to the dimension
shown in Fig.26.

2. Using tool 0485034, drift the oil seal and

scraper ring into the housing.
NOTE: Service tool 0485034 is a dual
purpose tool. One end is for fitting the
scraper seal and the opposite end is for
3 fitment of the oil seal, see Fig.28.

3. Position the selector finger, block plate,

intermediate tube or the driver finger in the
selector housing. Install the selector shaft
with the detent groove facing the pawl limit
bore.

4. Align the pin holes in the selector finger

with the pin holes in the selector shaft.
Using a suitable drift, drive in new spring
pins.
050473

5. Place the washer and compression springs

on the selector shaft, compress the springs FIG.27. SERVICE TOOL 0485035
with the sleeve and refit circlip.
Type ‘B’ selector housing: Locate the bush
in the housing. Apply suitable sealant to
the cup washer, then drift the washer into
the housing until the circlip groove is 1
visible; refit circlip.

2
050474

FIG.28. REFITTING THE OIL SEAL AND

SCRAPER RING

1. Oil seal 2. Scraper ring

3–3–46 E9706
3 TRANSMISSION
55 Series Gearbox ZF S6–36 & S6–36+GV36

6. Refit reaction rod bracket/end–cover.

7. Lightly smear the pawl limit threads with a

suitable sealing compound. Screw the pawl
limit into the housing and tighten to the
torque figure quoted in DATA; secure with
tab washer.

8. Insert the stop bolt and spring, refit plug

and tighten to the torque figure quoted in
DATA.

9. Refit the protection cap and operating

lever, aligning the reference marks. Fit and 3
tighten the pinch bolt to the torque figure
quoted in DATA.

10. Assemble the selector housing to the

gearbox casing, tighten retaining bolts to
the torque figure quoted in DATA.

E9706 3–3–47
 TRANSMISSION 3
Gearbox ZF S6–36 & S6–36+GV36 55 Series

Splitter Piston Assembly 2 3

To Dismantle
1. Detach the end–cover and discard the
O–ring. 1

2. Release the tabwasher and remove the

pawl limit.
4
3. Remove the splitter switch.
5
4. Withdraw the piston and packing seal from
3 the cylinder housing.
7 6
5. Remove the ‘V’ seals and the split seal 9 8
from the piston; discard the seals. 8
10
11 050475
To Reassemble
1. Lubricate the ‘V’ seals, split seal and the
packing seal with ‘Shell Aero Grease 22A’. FIG.29. EXPLODED VIEW OF THE
SPLITTER PISTON ASSEMBLY
2. Locate the split seal and the ‘V’ seals on
1. Splitter switch 7. O–ring
the piston.
2. Joint 8. ‘V’ seals
3. Position the packing seal in the cylinder 3. Cylinder housing 9. Split seal
housing. 4. Tabwasher 10. Piston
5. Pawl limit 11. Packing seal
4. Insert the piston into the cylinder housing, 6. End–cover
taking care not to damage the seals.

5. Refit the end–cover, complete with new

O–ring,to the cylinder housing. Tighten the
setscrews to the torque figure quoted in
DATA.

6. Refit the pawl limit and tighten to the

torque figure quoted in DATA; secure with
tabwasher.

7. Refit the splitter switch.

3–3–48 E9706
3 TRANSMISSION
55 Series Contents

CONTENTS Page Date

SECTION 4—GEARBOX—Eaton 6109

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—1 . . . . . . . . . 9706
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—3—3 . . . . . . . . . 9706
To Dismantle:
Gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—3 . . . . . . . . . 9706
Input shaft/front casing assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—7 . . . . . . . . . 9706
Layshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—19 . . . . . . . . 9706
Mainshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—20 . . . . . . . . 9706
Rear casing/planet carrier assembly . . . . . . . . . . . . . . . . . . . . . . . 3—4—9 . . . . . . . . . 9706
Remote control housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—35 . . . . . . . . 9706
Selector shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—28 . . . . . . . . 9706

To Reassemble: 4
Gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—29 . . . . . . . . 9706
Input shaft/front casing assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—8 . . . . . . . . . 9706
Layshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—19 . . . . . . . . 9706
Mainshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—24 . . . . . . . . 9706
Rear casing/planet carrier assembly . . . . . . . . . . . . . . . . . . . . . . . 3—4—14 . . . . . . . . 9706
Remote control housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—36 . . . . . . . . 9706
Selector shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4—28 . . . . . . . . 9706

E9706 –1
4

E9706
–2
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

4. GEARBOX, EATON NINE SPEED SYNCHROMESH

DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton 6109 Direct drive

Maximum input torque . . . . . . . . . . . . . . . . . . . . . . 912 Nm
Gear ratios
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.64:1
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.81:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.55:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.77:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48:1
6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.85:1
7th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34:1
8th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21:1

Mainshaft gear end–float (mm):

Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max
0,48
Min
0,35 4
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 0,35
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 0,35
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,53 0,31
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,44 0,27

Synchroniser ring/flange clearance . . . . . . . . . . . 0,5 to 1,9 mm

Layshaft bearing pre–load:
New bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 0,075 to 0,125 mm
Original bearings . . . . . . . . . . . . . . . . . . . . . . . 0,00 to 0,05 mm

3rd/4th speed synchroniser ring circlips . . . 2,02 to 2,12 mm in steps of 0,05 mm

Reverse/low speed synchroniser ring circlips 2,00 to 2,15 mm in steps of 0,05 mm
Layshaft circlips . . . . . . . . . . . . . . . . . . . . . . . . 1,77 to 2,12 mm in steps of 0,05 mm
Layshaft pre–load shims . . . . . . . . . . . . . . . . 0,051 mm, 0,127 mm, 0,254 mm,
Input shaft bearing spacers: . . . . . . . . . . . . . . . . . Colour code
3.70 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red, green, white
3.75 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow, green, blue
3.80 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue, green, white
3.85 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red, green, yellow
3.90 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green, green, white
3.95 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red, green, red
Oil muff sealing ring clearance . . . . . . . . . . . . . . . 0,178 mm (min)
Oil pump rotor clearance:
Outer rotor to pump body . . . . . . . . . . . . . . . . 0,5 mm (max)
Inner to outer pump lobes . . . . . . . . . . . . . . . 0,5 mm (max)
Air filter/regulator operating pressure . . . . . . . . . 5,34 to 5,69 bar

E9706 3–4–1
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

Torque tightening figures Nm

Front casing nuts/bolts . . . . . . . . . . . . . . . . . . . . . . 51 to 58
Rear casing nuts/bolts . . . . . . . . . . . . . . . . . . . . . . 51 to 58
Coupling flange nut:
M39 Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 to 700
M33 Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 to 588
Input shaft cover setscrews . . . . . . . . . . . . . . . . . . 35 to 39
Layshaft front and rear bearing covers . . . . . . . . 69 to 78
Range–change cylinder setscrews . . . . . . . . . . . 20 to 24
Range–change piston nut . . . . . . . . . . . . . . . . . . . 95 to 115
Range–change indicator switch . . . . . . . . . . . . . . 16 to 22
Range–change reaction plate screws . . . . . . . . . 24 to 27
Reversing light switch . . . . . . . . . . . . . . . . . . . . . . . 16 to 22
Remote control housing bolts . . . . . . . . . . . . . . . . 35 to 39
Remote control housing detent cover setscrews 20 to 24
4 Remote control housing end cover setscrews . .
Selector shaft detent cover setscrews . . . . . . . . .
20 to 24
20 to 24
Speedometer/rear oil seal housing bolts . . . . . . . 35 to 39
Speedometer drive pinion adapter . . . . . . . . . . . . 20 to 27
Sun gear retaining setscrew . . . . . . . . . . . . . . . . . 135 to 163
Oil drain/Oil strainer . . . . . . . . . . . . . . . . . . . . . . . . 40 to 47
Oil filler and level plug . . . . . . . . . . . . . . . . . . . . . . 32 to 37
Oil pump setscrews . . . . . . . . . . . . . . . . . . . . . . . . . 35 to 40
Planet gear shaft retaining setscrews . . . . . . . . . 5 to 8
P.T.O./reverse idler gear cover setscrews . . . . . . 35 to 39

3–4–2 E9706
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55 Series Gearbox−Eaton 6109

OVERHAUL

Service tools: 0484880, 0484977, 0485167,

0485172, 0485173, 0694928, 1329351,
1329352, 1329353, 1329354, 1329355,
1329356, 1329357, 1329358, 1329359,
1329360, 1329361, 1329362, 1329363,
1329365, 1329366,

Gearbox Assembly

To Dismantle
1. Suitably support the gearbox assembly in
the vertical position with the output
coupling flange uppermost.

2. Reference mark the air pipes for

subsequent refitment, disconnect the air
pipes from the air filter/regulator valve,
remote control housing and the
4
range–change cylinder.

3. Detach the range–change control valve/air

pipe and the air filter/regulator mounting
bracket assemblies from the gearbox
casing.

4. Remove retaining bolts and separate the

remote control housing from the
intermediate casing.

5. Remove the speedometer adapter and

pinion .

6. Assemble tool 0484977 to the coupling

flange, slacken but DO NOT remove the
coupling flange nut at this stage.
CAUTION: To prevent the range–change
synchroniser separating, do not allow the
output shaft to slide in the bearing.

7. Remove the oil strainer and discard the

O–ring and washer.

E9706 3–4–3
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

8. Unscrew the reversing light and 6

range–change indicator switches from the
casing; retain the detent balls and the 5
interlock pin from the range–change switch 4 7
bore.

9. Remove nuts and bolts securing the rear

casing to the intermediate casing. Attach
2
suitable lifting equipment to the coupling
flange and separate the rear casing
assembly from the intermediate casing. Do
Not use levers between the joint faces of
the casings to aid separation.
3
10. Lock the sun gear using tool 1329363,
remove the retaining bolt and special
4 washer. Remove the service tool and
withdraw the sun gear from the mainshaft.
1 050760

11. Withdraw the oil muff from the mainshaft, FIG.1. REVERSE IDLER GEAR
taking care not to damage the two sealing
1. Thrust washer
rings.
2. Needle roller bearings
12. Remove the oil pump setscrews, locate 3. Spacer
suitable levers beneath the lugs provided 4. Reverse idler gear
and prise the oil pump from the dowels. 5. Thrust washer
6. Idler gear shaft
7. Retaining pin

3–4–4 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

13. Remove the rear P.T.O. cover. Drift the

reverse idler gear shaft retaining pin into
the shaft until the pin is approximately 12
mm from the casing face. Do Not allow the
pin to ‘bottom’ in the shaft bore.
1 2 3
14. Using slide hammer 0694928 with adapter 4
1329365 withdraw the idler gear shaft from
the casing. Remove retaining pin from the
shaft.

15. Withdraw the reverse idler gear, complete

with bearings and washers from the casing.

16. Remove the mainshaft rear bearing thrust

washer and invert the gearbox assembly.

17. Remove the selector shaft detent cover,

4
spring and plunger from the front casing.

18. Rotate the selector shaft 90° to the left

(vertically mounted) or right (horizontally 050762

mounted) to prevent the casing fouling the

selector block on removal.
FIG.2. SELECTOR SHAFT DETENT

1. Detent cover
2. Gasket
3. Spring
4. Detent plunger

E9706 3–4–5
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

19. Remove nuts and bolts and separate the

front casing from the intermediate casing. Do
Not use levers between the joint faces of the
casings to aid separation.
NOTE: If difficulty is experienced separating
the casings the input shaft synchroniser ring
may have become fixed to the shaft. To
separate the casings, remove the input shaft
cover and the bearing outer snap ring and,
while lifting the casing, drive the input shaft
assembly through the casing bore.

20. Withdraw the spigot bearing from the

mainshaft.

21. Assemble tool 1329360 and 1329361 under

4 the 3rd/4th speed synchroniser hub
assembly. Using suitable lifting equipment, lift
the mainshaft approximately 10 to 20 mm;
this will allow the layshaft to tilt clear of the
mainshaft. Tilt and withdraw the layshaft.

22. Lift the mainshaft from the casing and lower

onto a suitable work bench; dismantle the
service tool from the mainshaft.

23. Separate the selector shaft assembly from

the mainshaft.

24. Press the mainshaft and layshaft rear

bearing races from the intermediate casing.

25. Using a suitable internal puller remove the

gear selector shaft and range–change
selector shaft bushes from the intermediate
casing.

3–4–6 E9706
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55 Series Gearbox−Eaton 6109

Input Shaft/Front Casing Assembly

3 4
To Dismantle 2
1. Remove setscrews and detach the input 1
shaft cover from the front casing.

2. Withdraw the input shaft/bearing assembly

from the casing.
5
3. Remove the layshaft front bearing cover
and retain the spacer ring and shim. Press 6
the bearing race from the casing.
7
4. Using a suitable internal puller remove the
8
selector shaft bush from the casing.

5. Press the blanking cup plug from the

casing.
4
6. Remove snap ring and withdraw the spacer
from the shaft.

7. Press the input shaft from the bearing and 9

retain the bearing spacer ring. 10 050761

FIG.3. EXPLODED VIEW OF THE INPUT

SHAFT/FRONT CASING ASSEMBLY

1. Snap ring
2. Spacer
3. Bearing
4. Input shaft
5. Front casing
6. Blanking cup plug
7. Oil seal
8. Input shaft cover
9. Layshaft front bearing cover
10. Cover plate

E9706 3–4–7
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

To Reassemble
1. Place the input shaft on a press. Heat the
input bearing to a temperature of 85°C and
position on the mainshaft; press the
bearing fully onto the shaft using tool
0485167 with adapter 0485172.

2. Place the original spacer on the bearing

and check that the snap ring will fit into the
groove without free play. If excessive
clearance is apparent or the snap ring does
not fit into the groove, replace the spacer
with one of appropriate thickness. See
DATA for size of spacers available.

3. Fit a new snap ring when the correct

4 spacer has been selected.

4. Using tool 0485173 with adapter 1329356,

press a new blanking cup plug into the
casing.

5. Using tool 0485173 with adapter 1329355,

press a new selector shaft bush into the
casing.

6. Press the input shaft into the front casing

until the bearing snap ring abuts the casing
face.

7. Using tool 0485173 with adapter 1329353,

drift the front layshaft bearing race into the
casing.

8. Using tool 0485173 with adapter 1329354,

press a new oil seal into the input cover.

9. Apply ‘Loctite 518’ sealing compound to

the joint face of the input cover, refit the
cover and tighten the setscrews to the
torque figure quoted in DATA.

3–4–8 E9706
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55 Series Gearbox−Eaton 6109

Rear Casing/Planet Carrier Assembly

To Dismantle, see Fig.4.

1. Support the rear casing assembly on a
suitable block/spacer positioned beneath
the planet gear assembly.

2. Detach the range–change cylinder cover.

Remove retaining nut and withdraw the
piston from the selector shaft.

3. Remove the output flange retaining nut.

Using a suitable puller withdraw the output
flange.

4. Carefully lift the rear casing from the output

shaft assembly. Separate the selector
fork/shaft from the sliding sleeve.
4
5. Remove the retaining pin and separate the
selector fork from the selector shaft.

6. Withdraw the speedometer drive gear and

spacer from the output shaft.

7. Remove the synchroniser ring. Reference

mark the sliding sleeve in relation to the
synchroniser plungers; carefully lift the
sliding sleeve and annulus from the output
shaft assembly.
NOTE: The synchroniser rollers, plungers
and springs will be released during this
operation.

8. Remove the synchroniser hub snap ring.

E9706 3–4–9
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

9. Invert the assembly and, while restraining

the hub, shock the end of the shaft on a
block of wood to separate the hub/bearing
assembly from the shaft.

10. Remove snap rings and bearing from the

synchroniser hub.

11. Remove snap ring securing the synchroniser

flange to the planet carrier; withdraw the
synchroniser flange.

12. Remove the four socket headed screws and

special washers retaining the ‘Low’
synchroniser flange and reaction plate to the
rear casing.
4 13. Withdraw the reaction plate, synchroniser
flange and spacer plate from the rear casing.
If necessary, remove the special snap ring
from the synchroniser flange.

14. Press the range–change selector shaft bush

from the rear casing; discard the O–rings.

15. To separate the sliding sleeve from the

annulus, insert a steel pin, approximately
2 to 2,3 mm dia. x 10 mm long, into three of
the holes in the annulus.

3–4–10 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

16. Locate a suitable hose clip around the steel

pins, tighten the clip to compress the
internal snap ring into the sliding sleeve.
Withdraw the sliding sleeve from the
annulus.

17. Remove setscrews and separate the oil

seal and rear bearing housings from the
rear casing.

18. Discard the oil seal and press the bearing

from the rear bearing housing.

19. Remove the planet gear shaft retaining

screws from the planet gear carrier.

20. Support the planet carrier with the output

shaft uppermost.
4
21. Drive out the planet shafts using a soft
metal drift.

22. Withdraw the planet gears, bearing rollers,

spacers and thrust washers.

E9706 3–4–11
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

16 19
15 26
14
12 13 20 25
11 24
10
21 23
9 22

8 18
17
7

6
5
4
3
2
1

4 31
32
33

44

43 28 27
29
30

34
35
36
37
38
39
40
41
42 050754

FIG.4. EXPLODED VIEW OF THE REAR CASING/PLANET CARRIER

3–4–12 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

4
Key to fig.4.

1. Socket headed screw 23. Bearing

2. Special washer 24. Oil seal housing
3. Reaction plate 25. Oil seal
4. Synchroniser flange 26. Output flange
5. Snap ring 27. Synchroniser ring
6. Spacer plate 28. Snap ring
7. Dowel 29. Snap ring
8. Rear casing 30 Bearing
9. O–ring 31 Roller
10. Selector shaft bush 32. Plunger
11. O–ring 33. Spring
12. Piston 34. Synchroniser hub
13. O–ring 35. Snap ring
14. O–ring 36. Sliding sleeve
15. O–ring 37. Snap ring
16. Range–change cylinder cover 38. Annulus
17. Speedometer drive gear 39. Synchroniser ring
18. Spacer 40. Snap ring
19. Adapter 41. Synchroniser
20. Speedometer pinion 42 Planet carrier assembly
21. Bush 43. Selector fork/shaft assembly
22. Bearing housing

E9706 3–4–13
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

To Reassemble
1. Assemble the original planet gears as
follows:
A
(a) Locally manufacture a dummy
spindle to the dimensions shown in
Fig.5.

(b) Place the thrust washer, grooved

face upwards, on the shaft and then
place an intermediate spacer on the
thrust washer.
B
(c) Position 18 rollers around the
spindle, smear the rollers with 050759
grease to retain them in position;
4 place a second intermediate spacer
on the rollers. FIG.5. DUMMY SPINDLE DIMENSIONS

(d) Position the remaining 18 rollers A — 35 mm

around the spindle. B — 23,75 mm

(e) Carefully locate the planet gear over

the spindle/rollers, refit the third
intermediate spacer and thrust
washer, grooved face to the rollers,
on the spindle.

3–4–14 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

2. Assemble a new roller pack into the planet

gears as follows:

(a) Slide the rollers and plastic centre

tube from the outer tube sufficiently 1
to enable the rollers to be guided
into the planet gear. Push the rollers 7 2
and centre tube into the gear.
(b) Carefully prise out one of the centre
tube end caps and then position an
intermediate spacer and thrust
washer, grooved face to the rollers,
on the centre tube. Repeat the
operation at the opposite end of the 3
gear. 4
6 3
3. Suitably support the planet carrier with the
output shaft lowermost.
5 4
4
3
4. Insert the planet gear into the planet carrier, 2 050758

aligning the dummy spindle/plastic tube with

the holes in the carrier.
FIG.6. PLANET CARRIER ASSEMBLY
5. Insert the gear shaft, shouldered end 1. Planet carrier
uppermost, in the carrier and withdraw the 2. Thrust washer
dummy spindle/plastic tube. 3. Intermediate washer
4. Rollers
6. Align the locating hole in the shaft with the 5. Planet gear
hole in the carrier; drive the shaft into
6. Planet gear shaft
position,using a soft faced hammer.
7. Retaining screw

E9706 3–4–15
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

7. Secure the planet gear shaft in position with

a new retaining screw. Apply ‘Loctite 270’ to
the screw prior to fitting and tighten to the A
torque figure quoted in DATA.
050458

8. Repeat operations 4, 5, 6 and 7 for fitment

of the remaining gears. FIG.7. SYNCHRONISER WEAR LIMITS

9. Fit and secure the bearing in the A — 0,5 to 1,9 mm

synchroniser hub with the two snap rings.

10. Locate the synchroniser flange on the output

shaft/planet carrier and retain with snap ring.

11. Place the synchroniser ring on the flange.

Check the clearance between the
4 synchroniser ring and flange, see Fig.7.
Place the synchroniser ring on the
synchroniser flange; measure the distance
‘A’ between the synchroniser flange and ring.
If the measurement is not within the
tolerances quoted in DATA, renew the
synchroniser flange and ring.

12. Place the synchroniser hub on the output

shaft, aligning the slots in the hub with the
lugs on the synchroniser ring. Press the hub
fully onto the shaft and refit snap ring.

13. Locate the retaining snap ring in the

synchroniser sleeve, place the sleeve in the
annulus with the ends of the snap ring
positioned between any two holes in the
annulus.

3–4–16 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

14. Compress the snap ring and press the

sliding sleeve into the annulus until the snap
ring engages in the annulus groove.

15. Insert the springs and plungers into the

synchroniser body. Engage the
annulus/sliding sleeve assembly with the
planet gears, aligning the reference marks
previously scribed.

16. Slightly raise the sliding sleeve and fit the

rollers. Press the rollers against the plungers
and guide into the sleeve.

17. Push the sleeve downwards into neutral

position.

18. Locate the ‘Low’ synchroniser ring in the

4
synchroniser hub.

19. Place the spacer ring in the rear casing. Fit

the special snap ring in the outer groove of
the ‘Low’ synchroniser ring and position the
ring on the synchroniser flange.

20. Engage the reaction plate with the

synchroniser ring, aligning the cut out with
the rear P.T.O. aperture.

21. Secure the reaction plate to the casing with

the four special washers and screws; refer to
DATA for the correct torque figure.

22. Assemble the selector fork to the selector

shaft, with the plain side of the fork to the
threaded end of the shaft.

E9706 3–4–17
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

23. Engage the selector fork/shaft assembly with

the synchroniser sleeve, threaded end of the
shaft uppermost.

24. Fit a new O–ring in the outer groove of the

selector shaft bush; lubricate the O–ring with
silicone grease.

25. Partially insert the bush until the O–ring has

just entered the casing bore. Clean off
excess grease and apply ‘Loctite 641’ to the
exposed part of the bush and, using tool
1329366 press the bush into the casing.

26. Fit a new O–ring into the inner groove of the

bush and lubricate with silicone grease.
4 27. Lower the casing onto the output shaft and
selector shaft.

28. Position the speedometer drive gear and

spacer on the output shaft.

29. Press a new bearing into the rear bearing

housing.

30. Using tool 0485173 with adapter 1329358,

press a new oil seal into the rear oil seal
housing.

31 Apply ‘Loctite 518’ sealing compound to the

joint faces of the rear bearing housing.

32. Position the bearing housing on the casing

and the oil seal housing on the bearing
housing. Refit and tighten retaining bolts to
the torque figure quoted in DATA.

33. Smear the sealing lip of the seal with grease

and locate the output flange on the output
shaft. Place a spacer on the flange, fit and
tighten the flange nut to press the flange into
the bearing.

3–4–18 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

Layshaft Assembly 6

To Dismantle
NOTE: The layshaft is a non serviceable item
and must be renewed as an assembly.
5
1. Remove the front bearing circlip and retain
for subsequent refitment.

2. Using puller 0484880 with adapter

1329351, remove the bearing cone.
Repeat the operation for the removal of the
rear bearing.

To Reassemble
1. Position the layshaft vertically in a suitable
fixture.
4 4
3
2. Heat the front bearing cone to a 2
temperature of 85°C and position on the 1
layshaft, using tool 0485173 with adapter
1329357 press the bearing fully onto the
shaft. 050752

3. Using feeler gauges, measure the snap

ring groove and select a snap ring of FIG.8. EXPLODED VIEW OF THE LAYSHAFT
appropriate size, see DATA, to give a
1. Spacer
minimum clearance when fitted. Fit the
selected snap ring into the groove. 2. Shim(s)
3. Circlip
4. Invert the layshaft and fit the rear bearing 4. Front bearing
cone as detailed in operation 2. 5. Layshaft
6. Rear bearing

E9706 3–4–19
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

Mainshaft Assembly

To Dismantle
NOTE: Prior to dismantling the mainshaft,
check the gear end float as follows:

(a) Mount the mainshaft vertically, input

end uppermost.

(b) Locate a dial test indicator (D.T.I.) as

shown in Fig.9.

(c) Raise the gear and check end–float

reading is within the tolerances
quoted in DATA.

4 If end–float is greater than the specified

tolerances, check the condition of the
050763

gears, synchroniser assemblies and FIG.9. CHECKING GEAR END–FLOAT

bearing sleeves after dismantling the
mainshaft. Renew the parts as necessary.

1. Support the mainshaft with the 3rd/4th

speed synchroniser assembly uppermost.
Remove the dowel pin from the mainshaft.

2. Carefully withdraw the sliding sleeve,

taking care not to lose the rollers, plungers
and springs.

3. Remove the 3rd/4th speed synchroniser

hub circlip.

4. Assemble a universal puller, with the puller

plates positioned under the 3rd speed
synchroniser ring (Fig.10). Carefully
remove the synchroniser ring, flange and
hub, taking care not to damage the ring
teeth.
050764

5. Withdraw the 3rd speed gear, needle roller

bearing and spacer ring; note position of
spacer ring.
FIG.10. REMOVING THE 3RD SPEED
SYNCHRONISER HUB

3–4–20 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

6. Invert the mainshaft.

7. Assemble the universal puller, with the puller A

plates positioned under the reverse speed
gear, remove the gear, thrust washer and 050458

bearing sleeve. Withdraw the needle roller

bearing from the mainshaft. FIG.11. SYNCHRONISER WEAR LIMITS

8. Remove the reverse synchroniser flange A — 0,5 to 1,9 mm

from the synchroniser hub.

9. Remove the internal snap ring from inside

the reverse/low speed synchroniser hub.

10. Carefully withdraw the sliding sleeve, taking

care not to lose the rollers, plungers and
springs. 4
11. Remove the reverse/low speed synchroniser
hub snap ring.

12. Assemble the universal puller, with the puller

plates positioned under the low speed gear.
Remove the gear, flange and hub; withdraw
the needle roller bearing from the mainshaft.

13. Invert the mainshaft assembly and remove

the 2nd speed gear bearing sleeve snap
ring.

14. Position the mainshaft on a press and

support under the 1st speed gear. Press the
mainshaft from the 2nd speed gear bearing
sleeve, 1st/2nd speed synchroniser hub and
1st speed gear.

15. Withdraw the 1st speed gear needle roller

bearing and spacer ring from the mainshaft.

16. Check the clearance between the

synchroniser ring and flange, see Fig.11.
Place the synchroniser ring onto the
corresponding synchroniser flange; measure
the distance ‘A’ between the synchroniser
flange and ring. If the measurement is not
with in the tolerances quoted in DATA, renew
the synchroniser flange and ring.

E9706 3–4–21
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

9
8 10 11
5 7 12 13 14
6
4
3

1 2

9 25
8 23 24
21 26 27
22 7
20
19
18
4 16 17
15

28

29 39
38
9 36 37
8 40
34 7
32 33 35
31

30

45 46 47
43 44
42
41

050757

FIG.12. EXPLODED VIEW OF THE MAINSHAFT

3–4–22 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

4
Key to Fig.12.

1. Needle roller bearing 25. 2nd Speed gear

2. Snap ring 26. Spacer
3. Synchroniser flange, 4th speed 27. Needle roller bearing
4. Synchroniser ring, 4th speed 28. Mainshaft
5. Sliding sleeve, 3rd/4th speed 29. Hollow dowel
6. Synchroniser hub, 3rd/4th 30. Needle roller bearing
7. Spring 31. Low speed gear
8. Synchroniser plunger 32. Synchroniser flange, low speed
9. Synchroniser roller 33. Synchroniser ring, low speed
10. Synchroniser ring, 3rd speed 34. Synchroniser hub, 1st/2nd speed
11. Synchroniser flange, 3rd speed 35. Snap ring
12. 3rd Speed gear 36. Sliding sleeve, low/reverse speed
13. Spacer 37. Snap ring
14. Needle roller bearing 38. Synchroniser flange, reverse speed
15. Snap ring 39. Reverse speed gear
16. Bearing sleeve, 2nd speed 40. Needle roller bearing
17. Needle roller bearing 41. Thrust washer
18. 2nd Speed gear 42. Output bearing
19. Synchroniser flange, 2nd speed 43. Sealing rings
20. Synchroniser ring, 2nd speed 44. Oil muff
21. Sliding sleeve, 1st/2nd speed 45. Sun gear
22. Synchroniser hub, 1st/2nd speed 46. Washer
23. Synchroniser ring, 1st speed 47. Sun gear setscrew
24. Synchroniser flange, 1st speed

E9706 3–4–23
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

To Reassemble
NOTE: To assist refitment, heat the synchroniser
hubs, 2nd speed gear bearing sleeve and rear
bearing sleeve to a temperature of 85°C.

1. Support the mainshaft, output end

uppermost.
NOTE: Prior to reassembling the mainshaft,
lubricate all needle roller bearings with clean
gear oil.

2. Place the low speed gear, complete with

needle roller bearing, on the mainshaft.
Locate the synchroniser flange on the gear
and the synchroniser ring on the flange.

4 3. Heat the low/reverse speed synchroniser

hub to the recommended temperature and 050766

position on the mainshaft, aligning the slots

in the synchroniser hub with the lugs on the
synchroniser ring. FIG.13. POSITIONING THE
SYNCHRONISER ROLLERS
4. Using feeler gauges, measure the snap ring
groove and select a snap ring of appropriate
size, see DATA, to give a minimum
clearance when fitted. Fit the snap ring into
the groove taking care not to damage the
mainshaft bearing surfaces.

5. Check the gear end–float is within the

tolerances quoted in DATA.

6. Position the springs and plungers in the

synchroniser hub. Locate the sliding sleeve,
pointed teeth lowermost, on the synchroniser
body and support the sleeve with the internal
groove just above the hub. Position the
rollers as shown in Fig.13, resting on the
heads of the plungers, then carefully press
the sleeve downwards to compress the
springs allowing the sleeve to centralise in
neutral position.

3–4–24 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

7. Fit the special snap ring into the

synchroniser hub, ensuring the tongues are
correctly located in the hub slots.

8. Locate the reverse gear flange into the

synchroniser hub.
NOTE: No synchroniser ring is fitted to the
reverse gear.

9. Place the reverse gear, complete with needle

roller bearing, on the mainshaft and into the
reverse synchroniser flange.

10. Place the reverse gear thrust washer,

chamfered face uppermost, on the gear.

11. Heat the rear bearing sleeve to the

recommended temperature and position on
4
the mainshaft.
NOTE: When cooled, the bearing sleeve
should be sufficiently tight on the shaft to
retain the reverse gear on the shaft.

12. Invert the mainshaft and place the 1st speed

gear, complete with needle roller bearing, on
the shaft.

13. Position the bearing spacer ring on the

bearing.

14. Place the synchroniser flange on the 1st

speed gear and the synchroniser ring on the
flange.

15. Support the mainshaft on a press. Heat the

1st/2nd speed synchroniser hub to the
recommended temperature and position on
the mainshaft, aligning the slots in the
synchroniser hub with the lugs on the
synchroniser ring; press the hub fully onto
the shaft.

E9706 3–4–25
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

16. Check the 1st speed gear end–float is within

the tolerances quoted in DATA.

17. Position the springs and plungers in the

synchroniser hub. Locate the sliding sleeve,
pointed teeth lowermost, on the synchroniser
body and support the sleeve with the internal
groove just above the hub. Position the
rollers as shown in Fig.13, resting on the
heads of the plungers, then carefully press
the sleeve downwards to compress the
springs allowing the sleeve to centralise in
neutral position.

18. Locate the synchroniser ring in the hub and

the synchroniser flange on the ring.
4 19. Locate the 2nd speed gear, complete with
needle roller bearing, in the synchroniser
ring.

20. Heat the rear bearing sleeve to the

recommended temperature and press the
sleeve onto the shaft, ensuring the bearing
sleeve flange abuts the bearing.

21. Using feeler gauges, measure the snap ring

groove and select a snap ring of appropriate
size, see DATA, to give a minimum
clearance when fitted. Fit the snap ring into
the groove taking care not to damage the
mainshaft bearing surfaces.

22. Check the 2nd speed gear end–float is within

the tolerances quoted in DATA.

23. Place the 3rd speed gear, complete with

needle roller bearing, on the mainshaft and
position the spacer ring against the bearing.

3–4–26 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

24. Place the synchroniser flange on the 3rd

speed gear and the synchroniser ring on the
flange.

25. Support the mainshaft on a press. Heat the

3rd/4th speed synchroniser hub to the
recommended temperature and position on
the mainshaft, aligning the slots in the
synchroniser hub with the lugs on the
synchroniser ring; press the hub fully onto
the shaft.

26. Using feeler gauges, measure the snap ring

groove and select a snap ring of appropriate
size, see DATA, to give a minimum
clearance when fitted. Fit the snap ring into
the groove taking care not to damage the
mainshaft bearing surfaces.
4
27. Using feeler gauges, check the gear
end–float is within the tolerances quoted in
DATA.

28. Position the springs and plungers in the

synchroniser hub. Locate the sliding sleeve,
pointed teeth lowermost, on the synchroniser
body and support the sleeve with the internal
groove just above the hub. Position the
rollers as shown in Fig.13, resting on the
heads of the plungers, then carefully press
the sleeve downwards to compress the
springs allowing the sleeve to centralise in
neutral position.

29. Fit the hollow dowel into the front end of the
mainshaft.

E9706 3–4–27
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

Selector Shaft Assembly 1

To Dismantle
1. Place the selector shaft assembly on a 2
work bench with the selector block to the 3
left. Reference mark the front of the
selector shaft in relation to the keys. 4

2. Hold the selector block and withdraw the

interlock key from the rear.
8
3. Withdraw the selector forks from the
selector shaft.

4. Remove setscrew and slide the selector

block from the shaft. 6
4 5
To Reassemble 7
1. Locate the selector key in the selector
shaft slot, with the three small lugs to the
front. 050765

2. Position the selector block on the shaft and FIG.14. EXPLODED VIEW OF SELECTOR
tighten the setscrew to the torque figure SHAFT ASSEMBLY
quoted in DATA.
NOTE: If re–using the selector block 1. Selector key
setscrew, apply ‘Loctite 270’ to the threads 2. Selector shaft
prior to fitting. 3. Interlock key
4. Selector fork, low/reverse
3. Place the selector forks in their respective 5. Selector fork, 1st/2nd
positions on the shaft; refit the interlock key 6. Selector block
from the rear. 7. Selector fork, 3rd/4th
8. Rotation pin

3–4–28 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

Gearbox Assembly
NOTE: When re–using patch lock bolts or fitting
bolts to through holes apply thread locking
sealant to the threads.

To Reassemble
1. Using tool 0485173 with adapter 1329355,
press a new selector shaft bush into the
intermediate casing.

2. Using tool 1329366 press a new

range–change selector bush into the
intermediate casing, until flush with the
casing bore.

3. Support the intermediate casing, rear face

uppermost.
4
4. Using tool 0485173 with adapter 1329353,
press the layshaft rear bearing race into the
casing until slightly proud of the bearing
bore.

5. Press the mainshaft roller bearing race, snap

ring uppermost, into the casing.

6. Invert the casing.

7. Assemble guide sleeve 1329359 to the rear

of the mainshaft. Retain in position with a
large washer and the sun gear retaining bolt.

8. Locate the selector shaft/fork assembly on

the mainshaft.

9. Using lifting tool 1329360 with adapter

1329361, lower the mainshaft assembly into
the casing, ensuring the selector shaft
correctly enters the rear bush. Support the
mainshaft assembly approximately 20 mm
above the normal installed position.

10. Locate the 4th speed synchroniser ring in the

synchroniser hub and place the synchroniser
flange on the ring.

E9706 3–4–29
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

11. Position the layshaft in the casing and in

mesh with the mainshaft. Lower the
mainshaft and layshaft assemblies into the
casing. Dismantle the service tool from the
mainshaft.

12. Lubricate and fit the spigot bearing on the

mainshaft.

13. Apply ‘Loctite 518’ sealing compound to the

joint face of the intermediate casing.
NOTE: Ensure the selector block is
positioned so it does not foul the front
casing.

14. Locate the front casing on the intermediate

4 casing, ensuring the selector shaft enters the
front bush and that the synchroniser teeth
on the input gear engage with the
synchroniser flange teeth. If necessary,
rotate the input shaft to ensure correct
engagement.

15. Fit and tighten the casing nuts and bolts to

the torque figure quoted in DATA.

16. Invert the gearbox assembly and remove the

guide sleeve from the rear of the mainshaft.

17. Refit the mainshaft rear bearing thrust

washer.

18. Remove the two retaining screws and

separate the oil pump casings. Check the
rotor clearances are within the tolerances
quoted in DATA; renew the pump if the
clearances exceed the recommended limits.

19. Ensure the joint faces of the pump are clean

and reassemble the pump. DO NOT apply
sealing compound to the joint faces.
NOTE: Pumps fitted to gearboxes without an
oil cooler are identified by a notch on the
edge of the pump casing.

3–4–30 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

20. Assemble the pump to the intermediate

casing, tightening the setscrews to the
torque figure quoted in DATA.

21. If removed, refit the sealing rings on the oil

muff collar. Check the clearance between
the sealing rings and collar, see DATA.

22. Lubricate and fit the oil muff on the

mainshaft, carefully compress the sealing
rings and press the oil muff into the pump.

23. Locate the sun gear on the mainshaft and

refit the special washer and a NEW patch
lock bolt.

24. Using tool 1329363 to lock the sun gear,

tighten the sun gear bolt to the torque figure
4
quoted in DATA. Remove the service tool.

25. Invert the gearbox assembly and set the

layshaft bearing pre–load as follows:

(a) Select the thickest shim available,

see DATA, and position on the
bearing, then place the spacer on
the shim.
NOTE: The spacer must stand proud
of the casing face when the bearing
race is fully seated against the bearing
cone.
(b) Fit the layshaft front bearing cover
and setscrews without washers.
Carefully and evenly tighten the
setscrews while rotating the input
shaft to settle the bearings; tighten
the setscrews until resistance is felt
on the input shaft.
(c) Back off the setscrews and then
retighten the setscrews sufficiently to
trap the cover against the washer.
(d) Using feeler gauges, measure the
gap between the cover and casing at
several points and note the average
reading. Select the appropriate shim
to give the required bearing pre–load
of 0,075 to 0,125 mm
(new bearings), 0,00 to 0,05 mm
(old bearings)

E9706 3–4–31
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

Example:
Spacer thickness 2,40 mm
add thickest shim 0,508 mm
2,908 mm
minus clearance 0,30 mm
2,608 mm
add pre–load 0,05 mm
2,658 mm
minus spacer 2,40 mm
0,258 mm
Shim required 0,254 mm

26. Place the selected shim and spacer on the

bearing race.

27. Apply ‘Loctite 518’ sealing compound to

4 the joint face of the bearing cover. Fit the
bearing cover and tighten the setscrews to
the torque figure quoted in DATA.

28. Invert the gearbox assembly.

29. Apply grease to the reverse idler gear

thrust washers and locate them in position
in the intermediate casing.

30. Insert the reverse idler gear, complete with

bearings and spacer into the casing.

31. Locate the idler gear shaft in the casing,

aligning the retaining pin in the shaft with
the pin hole in the casing.

32. Using 0694928 with adapter 1329365, drift

the shaft into the gear until the pin holes
align. Secure the shaft in position with a
new retaining pin.

3–4–32 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

33. Refit the reverse idler gear/P.T.O. cover plate

and tighten the setscrews to the torque
figure quoted in DATA.

34. Insert the selector interlock pin, rounded end

innermost, into the range–change switch
bore until it engages in the selector shaft
indent groove.
NOTE: The interlock must be fitted at this
stage before the rear casing assembly is
fitted.

35. Apply ‘Loctite 518’ sealing compound to the

joint face of the intermediate casing.

36. Using suitable lifting equipment, position the

rear casing above the intermediate casing.
Align the range–change selector shaft with
4
the rear bush and carefully lower the casing
into position; rotate the output flange to
correctly engage the planet carrier with the
sun gear.

37. Fit and tighten the casing nuts and bolts to

the torque figure quoted in DATA.

38. Refit the oil strainer, complete with a new

O–ring and washer and tighten to the torque
figure quoted in DATA.

39. Fit new O–rings to the range–change piston;

smear the O–rings with silicone grease prior
to fitting.

40. Fit the piston to the selector shaft and

tighten the retaining nut to the torque figure
quoted in DATA.

41. Fit a new O–ring to the range–change

cylinder; smear the O–ring with silicone
grease prior to fitting.

E9706 3–4–33
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

42. Carefully slide the cylinder onto the piston, fit

and tighten the cylinder setscrews to the
torque figure quoted in DATA.

43. Refit the speedometer pinion and adapter;

tighten the adapter to the torque figure
quoted in DATA.

44. Support the gearbox in the horizontal

position.

45. Fit tool 0484977 to the output flange, remove

the spacer and flange nut. Fit and tighten a
new flange nut to the torque figure quoted in
DATA. Remove the service tool.

4 46. Rotate the selector block to position the pin

uppermost. Locate the detent and spring in
the casing, fit the cover plate, complete with
gasket, and tighten the setscrews to the
torque figure quoted in DATA.

47. Apply ‘Loctite 518’ sealing compound to the

joint face of the remote control housing.
Assemble the housing to the gearbox casing,
tightening the setscrews to the torque figure
quoted in DATA.

48. Refit and tighten the reversing light switch to

the torque figure quoted in DATA.

49. Refit the range–change switch and ball;

tighten the switch to the torque figure quoted
in DATA.

50. Fit the range–change control valve and the

air filter/regulator assemblies and reconnect
all air pipes.

3–4–34 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

Remote Control Housing

To Dismantle, see Fig.15.

1. Remove the poppet valve and actuator pin
from the housing.

2. Reference mark the selector lever in relation

to the selector shaft. Slacken the retaining
bolt and withdraw the selector lever and dust
cover.

3. Remove the reverse detent cover, spring

and detent plunger; discard the gasket.

4. Remove the end cover and discard the

gasket. Remove the circlip and withdraw the
outer spring retainer and spring(s). 4
5. Withdraw the inner spring retainer and
remove the circlip from the selector shaft.

6. Invert the housing, slide the selector shaft to

the left hand side of the housing and drive
out the expansion plug from the housing.

7. Invert the housing and align the inner lever

retaining pin with the expansion plug hole in
the housing. Using a suitable drift, drive out
the retaining pin and withdraw the inner lever
and selector shaft.

8. Using a universal internal puller, remove the

bushes from the housing.

E9706 3–4–35
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

To Reassemble
1. Using tool 0485173 with adapter 1329352,
press new bushes and oil seal into the
housing.

2. Position the inner lever in the housing, with

the long groove side to the poppet valve
aperture.

3. Slide the selector shaft into the housing and

inner lever, align the inner lever and selector
shaft pin holes and fit a new retaining pin.

4. Fit the inner circlip and position the inner

spring retainer on the selector shaft.

4 5. Place the spring(s) on the selector shaft,

compress the spring(s) with the outer
retainer and fit the circlip.

6. Fit the end cover, complete with new gasket

and tighten the setscrews to the torque
figure quoted in DATA.

7. Locate the detent plunger and spring in the

housing, refit the cover, complete with new
gasket and tighten the setscrews to the
torque figure quoted in DATA.

8. Refit the dust cover and selector lever,

aligning the reference marks previously
scribed.

9. Refit the actuator pin and poppet valve.

10. Press a new blanking plug into the housing.

3–4–36 E9706
3 TRANSMISSION
55 Series Gearbox−Eaton 6109

2
3
4

1 9
8
7
5 6

10
25 11
12
13
24
23
14 4
21
22
20
15
18 16

19 17

050743

FIG.15. EXPLODED VIEW OF THE REMOTE CONTROL HOUSING

1. Selector lever 14. Spring (inner)

2. Dust cover 15. Spring retainer (outer)
3. Oil seal 16. Circlip
4. Bush 17. End cover
5. Expansion plug 18. Gasket
6. Detent plunger 19. Selector shaft
7. Spring 20. Remote control housing
8. Gasket 21. Actuator pin
9. Detent cover 22. Poppet valve
10. Bush 23. Inner lever
11. Circlip 24. Retaining pin
12. Spring retainer (inner) 25. Breather
13. Spring (outer)

E9706 3–4–37
 TRANSMISSION 3
Gearbox−Eaton 6109 55 Series

3–4–38 E9706