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aimler SERVICE MANUAL for THE ‘FLEETLINE’ CHASSIS ISSUED BY DAIMLER TRANSPORT VEHICLES LIMITED COVENTRY ENGLAND Telephone Bus Service Department, Telegraphic Address COVENTRY 27626 KINGFIELD ROAD, COVENTRY “paimLer PHONE COVENTRY” TEL. COVENTRY 89423 Publication No E/1003/4 Published June 1969 INDEX TO SECTIONS OPERATION AND MAINTENANCE LUBRICATION COOLING SYSTEM ENGINE UNIT FUEL SYSTEM EXHAUST SYSTEM FLUID FLYWHEEL AND TRAILING LINK COUPLING GEARBOX AND TRANSFER BOX CARDAN SHAFT REAR AXLE AND HUS ASSEMBLIES BRAKING SYSTEM WHEELS AND TYRES PRONT AXLE AND HUB ASSEMBLIES STEERING FRONT AND REAR SUSPENSION AND HYDRAULIC DAMPERS CHASSIS FRAME ENGINE COMPARTMENT COVERS ‘ELECTRICAL SYSTEM MISCELLANEOUS EQUIPMENT OPERATION AND MAINTENANCE SECTION A INDEX Prior to Starting Starting — Cold ‘Starting — Hot ‘Stopping the Engine Driving Away To Engage Reverse Sear ‘Stopping the Vehicle Gear Change Speeds "ie Maintonance Schedu'e ‘The reversing light yill_sutomatieally: be dluminated when the reverse gear 1s selected ‘Stopping the Vehicle Release the accelerator pedal and apply ire footarske, Select neutes) and apply the handbrake. During wate hats, it is possible because of the Daimler fluid: Flywheel, o_wait in alow geor rather than in neutral and apalying te brake ‘Gear Change Speeds It is recommenced sat gear changes are effected at the following speeds: Witold SSMPH. © (96 ~ 18K PH) Qnd to 3rd = 4 MPH (225 KPH) Ged to ath = 20.23MPH. (237 KPH) ‘according to passenger load or gradient. THE MAINTENANCE SCHEDULE ‘The maintenance Schedule hes been complied to show at glance the essential service requirements of the CRGS ‘chassis vice to the details mentioned vel maintsin the vehicle in good coneftion and ensure economical and trouble free ‘usage. ‘The Maintenance operations are detsled below together with the’ Section feference in which wil be found the recommended sequence of the maintenance work to be tffected, For all Routine Maintenance on the engine refer to the manufacturers ‘Service Manual. Daly Check radiator coolant level Check engine oll level Check contents” of fuel tank Drain and refil Antsreezer (when fited) Check build up of air pressure zanool WEEKLY ‘Cheek level of hydraulic fluid accelerator reservoir e ‘Check condition of flexible hydraulse reservoir hose Pomp” gear box gears hace condition of brake flexible hoses Drain 2° pressure reservoir Chex all tyre pressures heck security: of road whoel nuts heck electrolyte level in battery Check specific gra.iry of battery eteeteolyte K x FIRST 250 MILES (200 KM) (Check all ehassis frame ruts and bolts P FIRST 500 MILES 1800 KM) Chede centrifuga. 225 0! eluteh ‘land seal when fited 6 OPERATION AND MAINTENANCE FIRST 1,000 MILES (1,600 KM) Drain and cefil gearbox’ and clean oil filter element ‘and refill wansfer box ‘and refill ear axie Lar FIRST 2,500 MILES (4,000 KM) ‘Gheck the olf evel in te fluid flywhee! Check end flost af rear wheel hubs Check condition af brake Knings Check end! float of front whee! hubs =ata EVERY 2,500 MILES (4,000 KM) Top up automatic chassis lubrioator ail resarvoir (it firred) Check tension ef fan and compressor belts Lubricate all engine controls, Check First are second fu oil Filters Gheck the gearbox 01 level Check transfar 80% oil (e021 Lubricate cardan short universal joints Chock rear axle oil lovel CGhack foot brake gontral vaWe for leaks Lubricate single brake valve push rod pivot pin Clean antisfreezer gauze filter (ahen fitted) hack air pressure regulator for leeks LLubdicate brake pedal linkage Lubricate handbrake linkago Chuck unloader velve for leaks Ghece orake chamoers for leaks Lubricate romt nee: snivels not if auto-lubrication syste is fitted) Cubricate steering balr joints (not if auto-lubrication is fitted Lubricate ail read spring shackles (not if auto-lubrication svstem is feted} ® 2 2 ARRARAARE-rEMOCe FIRST 5,000 MILES (8,000 KM) Check all springéaxle mounciygs ° EVERY 5,000 MILES (8,000 KMI Check automatic chassis fubricaror Pipe unions for laaks iwhea fisted! Giean the engine ait cleaner eiement Drain oi from gearbox aw cylinders Clean transfer box air breatrer fiter element Brain ofl from electro pneumatic valve Block Clean gearbox air breatior ‘iltcr element Spray all road springs heck the fluid lavel of the front dampers Lubricate the electricat generator Check air limiting yaive for leaks (Check alt chassis frame mounvngs wrncorzrrog FIRST-¥0,000 MILES (16000 KM) Check and tighten the lock-up flywheel gland seal securing nuts (when fitted) EVERY 10,000 MILES (16,000 KM) Examine engine mountings for signs Of deterioration and security of meunting ots Lubricate fanepulley bearings jon ofall enaine water hoses ono OPERATION AND MAINTENANCE Check che fluid flywhe! oil level Cheek the “ink coupling setscrews Clean cil filter element (replace if in bad condition) Gheck cardan shaft flange nut and bolts Check the rear axle mountings Check the pressure setting — air regulator valve Chock footbrake linkage Giean unloader valve inlet filtere Check the front whee! alignment Check stooring lever and tie rods Steering box ail ievel ‘Cheek all road spring shackles fer end float EVERY 20,000 MILES (32,000 KM) ‘Cheek rear hub beatings for end float and adjust 25 necessary. Check front hub bearings fer end float and adjust a5 necessary EVERY 25,000 MILES (40,000 KM) Drain sediment from fuel oil tank Lubricate relay levar Brain and refill wanster box Drain snc refill gearbox and replace oil falter alerent Renew gearbox air breather filter eiemant Renew transfer box air breavier filter element AnACT ZOO ozey EVERY 40,000 MILES (64,000 KM) Drain and refill tne rear axle unit Remove, ciean and relubricate rear wheel pubs Remove, clean anc relubricate front wheel hubs EVERY 50,000 MILES (80,000 KM} Check magnetic fan coupling us «ition fitted) Overhaul th air pressure requiatcr vs = Overhaul sre tootbrake contral valve ‘Qvertau! she unloader valve Overhaul she brake chambers Check sll wiring connections EVERY 75,000 MILES (120,000 KM) Overnsul gear selectar syazch (Overha2) 2 sctro-preumnatie valve block EVERY 250,000 MILES (400,000 KM) Reves. “agnetie fan coupling unit (when f Over 2.1 gearbox (Cisrraul transfer box gieit BARRRO LUBRICATION SECTION B INDEX Lubrication Recommendec Lubricants ‘Automatic Chassis Lubricator Specification and data Routine maintenance ‘The Lubricator Remove Retitting Priming Priming ~ plate method Priming ~ Delivery union method ‘Adjustment LUBRICATION LUBRICATION It is important that ll oils and greases used in the ‘maintenance of the vebicie should conform to those listed in the RECOMMENDED LUBRICANTS chart. Ht it is desired to make any departure from those recommended, approval of the brand and viscosity should first be obtained trom Daimler Transport Vehicles Led, 10 avoid attecting the quarantes. In respect 2° ene Gardner engine reference should be race direct x0 viesrs, Gardner Engine ales) Ld. Since of of sifferent brands may at mix satisfactorily, raining ars ratiling is preferable to topping up if the brand of 011» ane unit is unknown, RECO*'SENDED LUBRICANTS we Fee nea | Rear Ate Sweering 2ox | Hubs 8 Gurwen Teter | GerBoe | Avwmiue™” [exe Sun |e a ee tiboation long = leo” Tew Gew on | Enwgraasd | Sotonedie 1200 om. Energol_ SA. ‘Transmission A sacsoer | pera | abep e Fac SnergoiDst TAS igre £550 [emoreet | Eosocear tego Gear oso 5.0.86] Eo Automate /HOX20 coll Esso Fleet GP90/140 or ‘Transmission oPeon4e sical Esso. Multi- Fluid Farote Gree i wort. | devacon | abtube | Dehac om “obilube C.140| Mobilyrease ¥P} Mobiluia 200 oo a REGENT [gupernem | matareae | Seperne | tiger lwatax “Toa mate Caltex? [Selegeeam | tuorcant | elo Specit | Luorieanc | AllPuraose | Hus ‘Texaco SAE20 EP90 ‘SAE20 180 SHELL [pote T [Spirax fowat | Senax 40 Retin (| stel 1 Soto, (SCP san | Stam. | Donne 6 — | faire “CASTROL | Castrol CR20 ‘Sonteed Castrol Castrol D Castro! ase Casivo] T.0. Hypoy cR.20 cM. HD.20/1 or id At x! © -matic puckHant #620 9 | Hypo 0201 eno [Lea amen oo ' LUBRICATION AUTOMATIC CHASSIS LUBRICATION ‘The Clayton Dewandre R.P. Automatic chassis lubrication system is fitted 3s 21 alternative if required anc reolaces the ‘ease gun and nipple system fitted as standard equipment. SPECIFICATION AND DATA Clayton Devsnee RP, Air pressure operate Type No. of points lubricated Capacity of Reservoir DESCRIPTION ‘The air pressure operated lubricator automatically delivers 2 measured independant supply of oil to each selected bearing point irrespective of any variation in resistence, with each application of the foot brakes. If excess resistance is encountered at any point pressure is accumulated in the individual feed line until the resistance is overcome without effecting any of the other feeds Should 2 feed line be broken or disconnected, only the ‘one particular point is effected The supply tank is mounted on brackets attached to the righthand side of the main frame. Access to the filer is provided for by the Coachbuilder. ‘The pump is mounted on an outrigger bracket on the right-hend side of the main frame beneath the driver's compartment. The oil feed supply pipes are of heavy gauge nylon, ‘rouped together in P.V.C. tubing and securely clipped t6 the frame end the various units. Twenty-srree chassis, Points are lubricated, the twenty-fourth connection being for the lubrication of the actuating cylinder and piston, ROUTINE MAINTENANCE EVERY 2,500 MILES (4,000 KM Top up the oil reservoir with the recomended lubricant EVERY 5,000 MILES (8,000 KM) Inspect delivery pipe unions for any possible leaks and re-tighten if necessary. LUBRICATOR, ‘The lubricator can be expected to outlast te fife of the vehicle without requiring any roplacements but service nits are available if required from the manufacturers Removal 1, Disconnect the main oil feed pipe By removing the banjo union bolt. Note the two s2eling washers anc drain the oll into a suitable clean containe 2, Digconnect the air pressure pipe from the lubricator cylinder 3, Bisconnect the unetion. 4, Remove the six bolts, nuts and washers securing the lubricator pipe from cylinder 24 4 gallon 14 Fis 1 Locetion of the chassis luprcaton pump mearr delivery plate to the main body. Remove the main body taking care to retain the joint, Refitting Refitting is the reverse of the removal procedure. Replace the joint between the delivery plate and bocy + camaged. NOTE: Before refitting the unit the picing must be primed, Priming Since there is only a very small quantity of oll delivered to the feed pipes at each impulse o* tne 'voricator unit. it would take some considerabie time to initially fill all the feed pipes by this method. Priming \= therefore necessery to charge the pipes to ensure that tre oll reaches each of the lubrication points without delay at the commencement of service LUBRICATION (10285) Fa 5 Pring pate in gosain, Priming can be effected by either of the two = given below. ‘The special priming plate required by the first method has twenty-three nipples which coincide with the feed pines The feed line leading from theremaining distributor plate lunion is disconnected from the operating cylinder union and can be primed separately Priming — Plate Mechos Remove the lubricator body after withdrawing the six bolts, nuts and washers securng the body to the delivery ' plate 2s describes under “Removal Disconnect the cil fead supply pipe and. the lubricator pump connection (number 24 on the location chart) and blank off the unions Bolt the priming plate to the delivery plate Using an oil gun, pump oi! into each of the priming nipples in'turn until the corresponding pipe line is full, as determined by observation. of the bearing point to which is is attached 4. When.the system is completely charged, remove the Driming plate, remount the lubricator body onto the Selvery plate. Refit the feed pipe to the operating cylinder “and reconnect the pines from the oil supply tank and air pressure system 5. Fill the oil reservoir tank with the recommended Fig. 4 End wiew of lubreetor pump showing connections apace at fake umbaring Sequenes. LUBRICATION Priming — Delivery Union Method ‘The feed pioes feom the 23 bearing points are connected 10 the distributor place in accordance with the fellaw..rg table, Number 1 being the first union following te 132 ‘centre fixing bolt in a clockwise «+ are arranged on the outer ring anc inner ring, + numbers +See on the CHassiS POINT LOCATION Distributor Point No 1. Steering Relay Lever 2. Front Steering Side Rod — Front Right-Hand Side 3. Front Steering Side Rod — Rear Right-Hand Side 4. Front Spring — Front Spring Pin Right-Hand Sice 5. Rear Stoering Side Rod — Front Right Hand Sve & Rear Staering Side Rod ~ Rear Right-Hand Side 7 Pin ~ Top Right-Hand Side 8 | Pin — Bottom Right-Hand Side 9. Track Rod ~ Right-Hand Side 10. Front Spring Rear Shackle - Top Pin Right-Hand Sice 1. Front Spring Rear Shackle. — Bottom Pin Right-Hand Side 12, Rear Spring — Front Spring Pin Right-Hand Sice 13. Rear Spring Rear Shackle — Top Pin Right Hand Side 1. Disconnect No. 1 union trom the delivery plate, 2, Release the feed pipe union from the bearing point. 3. Using a pressure gun or other suitable means, charge the pipe with oil from the lubricator end Until al air ts expelled and fl seeps from the connection point 4, Tighten the esting point Union and reconnect the delivery plate union 5. Repeat the operation to the remaining 22 tesa pipes. Testing 1. Check all connections and ensure that they are *Check that the oil reservoir is full and that the vent hole in the filer is clea, 3, Slacken off the inlet pipe banjo union until the oil is seen to flow from the joint and re-tighten. 4, Withdraw the three set bolts and remove the circular top cover plate to expose the operating 14, Resr Soring Rear Shackle — Bottom Pin Rignt Hand, Rear Soring Rear Shackle — Bottom Pin Li Sice ear Spring Rear Shackle — Top Pin Left Hand Side Rear Spring ~ Front Spring Pin Left-Hand Sice Front Spring Rear Shackle — Bottom Pin Let rand Side Front St Side 20. Track Rod — Left-Hand Side 21. Swivel Pin — Bottom Left 22. Swivel Pin — Top Lett=ano 23. Front Spring — Frort Seems 24. Lubricator Pump Hand Rear Shackle — Top Pir LeftHand Side LeftHand Si lever chamber of the lubricator. Fill the chamber wth ov! of the specified grade, to the 'ew! of the ‘euze breather in the side of the chambe" Release one pipe at the distributor plate and operate the brake pedal Ontil oll is celivered at the Sisconnected union, Restighten the amon. Suing is operation it will be necessary to maintain the pressure in the braking syste” ‘Test the vehicle on the Toad anc acolyte brakes frequently. Check all unions for leaks an tighten if necessary. Adjustment The lubricator is set initially quantity of lubricant pero) piston stroke; after 2 perioc showing at each lubrication po°' When service conditions are suct that the chassis requires ‘es lubrication adjustment snould be made as follows: Release the locknut and screw in the stop screw, located 2 the bottom of the operating cylinder. give the maximum Imeulse at the maximum service oil should be COOLING SYSTEM SECTION C INDEX Specification anc Data General Routine WM Fan and Compressor Selts: Fan Belts Remove Refitting Compressor Betts Removal Refitting Fan Removal Dismas Assembii Refitting High Speed Radiator Fan Description Routine Maintenance Removat Dismantting Reassembling Refitting Radiator Removal - Refitting Thermostat Poge oa cs c3 cs cs cs co ce ce ce C8 os cs ce or o7 c? COOLING SYSTEM Magnetic Fan Coupting Date . : Description Routine Maintenance ‘Thermal Switch . Relay . = Fan Coupling a Fault Diagnosis Radolarm Water Level Warning System: Description : Data : Operation Routine Maintenance Test Procadure Page ca ca ca cg co cs 10 cat ent eat cu cat COOLING SYSTEM COOLING SYSTEM SPECIFICATION AND DATA “Type of cooling system No. of fan blades Type of drive ‘Speed of fan — GLX Engine GLXB Engine Cooling systern capacity ‘Thermostat opens at fully open at ‘Type of radiator Normal running temperature Pressurized to Drive belt tension — Fan Compressor Coolant level GENERAL DESCRIPTION The cooling system, pressurized and thermostatically controlied, consists of the following components. (A vertical flow radiator unit resiliently mounted on ‘steel and rubber bonded bushes at the right hand side of the engine compartment. A pressure relief valve incorporated in the overflow pipe connection and a hhinged flap type radiator cap, the latter held closed by spring catch pressurizes the system tp 4 lbs per 53, inch, Radiators may aso be fitted wth an expansion chamber ‘to suit operator's requirements and have a pressure release incorporated én the radiator cap, The pressure % released by tuming the small knurled knob anti-clockwise before ‘opening the radiator cap. i) A 21.0" (833.4 me} diameter cight bladed cooling fan runs in special housing which is attached 10 the inside face of the radiator by its two vertical sides. fncluded in the fan housing assembly is a large pulley to a pulley at the: top of the timing cnest situated (on the left hand side of the engine unit. (iv) An impelior type coolant pump situated a the rear ‘bottom left hand comer of the engine unit. (V) A thermostat mounted in a housing situated on the front top left hand side of the engine. Before the engine reaches its normal working temperature the coolant Dy-passes the radiamor through an external pipe to the water pump. vi) A temperature warning device operating a warming light on the instrument panel and’or a buzzer in the If the radiator cap Pressurized, thermostatically controlled impeller pump assisted thermo-syphon 8 Vee belt and jack shaft 24 times engine speed 6 gallons 6 pints (30.5 Litres) 136°F (57°C) 68°F (75°C) Vertical flow, fixed or removable tube type block 165° — 170°F (73.9° — 767°C} 4 tbs per sq. in (0.28 kg/em?) %"— 13 com) at 4 Ib, tension Y" = (13 mm) at 6 Ib. tension To bottom edge of filler neck switch panei is fitted gs standard equipment. No routine maintenance or adjustment, with the exception of ‘occasional contact adjustment of the buzzer, és necessary € provided for. ROUTINE MAINTENANCE DAILY ‘Checking the Radiator Coolant Level. ‘Check the level of the coolant in the radiator daily, and if ‘necessary top up to the bottom of the filier neck. Use water that is as soft as procurable, hard water Produces scale which in time will impair the cooling ‘efficiency of the system. NOTE: It is dangerous to open the radiator cop while the engine is HOT as the escaping pressurised steam may cause scalding of the hands, fitwed with the prasure rewsse ‘control. turn the small kaurled knob -anti-clockwise 10 release the steam pressure generated in the system before releasing the radiator cap spring catch. Fully close when cefilling, Rapid lowering of the water level should be investigated and the whole system checked for leaks. EVERY 2,500 MILES (4,000 KM) (Checking the Fan Belt Tension Check the fan and compressor drive belts. When correctly adjusted the deflection of the belts, should moré COOLING SYSTEM thant" (13 mm) with a pressure of 4.0 Ibs (1.8 kg) applied between the pulleys. Adjustment Fan Belts Release the two self-locking nuts securing the dive pulley ‘bearing block to the mounting bracket. Release the tocknut locking the adjustor serew, and turn the screw in a clockwise direction to tighten the fan belts Rectighten the locknut and the two self-locking nuts, SB iy, Fig, 2 Location of compressor belt auster NOTE: Do not tighten the belts bayond the limits spe- ified. Any undue load will create wear in the pulleys bearings. ‘Compressor Belts Release the large nut securing the jockey pulley bearing bblock to the mounting bracket. Tum the adjuster screw located in the centre of the mounting bracket in a clockwise direction to tighten the belts. Re-tighten the large nut. NOTE: Do not tighten the belt beyond the li in “Fan Belt — Adjasment.”” its specified EVERY 10,000 MILES (16,000 KM Lubrication ‘Apply the grease gua to the grease nipples located in the fan pulley bearing and che crne pulley boss and inject a small quantity of grease Warning: Do not pack the bearing with Inbricant. Any ‘excess grease will be thrown out of the bearings by centrifugal sction and may contaminate the fen belts. PERIODICALLY. Gare of the Cooling System The entire cooling system should occasionally be flushed Out to remove sediment, Remove the plug situsted in the Fadiator bottom water pipe and open the taps in the ‘oylinder inlet pipe and water pump. Insert 2 water hose in ‘the radiator filler neck and sliow the water to flow freety with the engine running at a fast Idle speed (1,000 «.p.m.) 10 cause circulation until the water runs clear. COOLING SYSTEM Fi, 4 A Roinae valve Sectioned view of radiator expansion chamber B Gover retaining sere € Gorket 8 Cover joine E Expansion chamber tube F Gasket Drain plug Since deposits in me water wall in time cause fouling of the surface of the cooling system with consequent impaired efficiency, +t 15 desirable to retard this action a5 ‘much as possible by using water as nearty soft as possible, If the eooting system incorporates an expansion chamber remove the large brass plug in addition 10 the items previously noted when flushing. Water Pump — Lubrication Refer to the Gardner Handbook for all details concerning the lubrication of the water pump. deck Shafts — Lubrication ‘The jack shaft assembly driving the fan drive pulley is comprised of two shafts connected by @ tlexible coupling. For the lubrication of the main shaft bearings refer to tne Gardner Service Manual. The sliding joint on the coupling shaft. should only requi period of service, FROST PRECAUTIONS During the winter months it is strongly recommended that an an-freeze compound with an inhibited ethylene lycol bese % wsed in the proportions laid down by the ‘anti-freeze manufacturers. Before aiding the anti-freeze solution the cooling system should be cleaned by flushing. ‘The cylinder head gaskets must be in good conditions and the cylinder head nuts pulled down to the corract torqu refer to the Gardner Service Manual for correct torque igures. Check all water noses and connections, water pump and manifold joints. : To ensure satisfactory mixing measure the recommended, proportion of water and anti-freeze solution in a seperato container and fill the system from this receptacle rather than add the anti-freeze direct to the system. COOLING SYSTEM FAN ANO COMPRESSOR BELTS Worn or damaged Yen or compressor belts should always be replaced as soon as possible Fan Batts — Removal Release the two self-locking nuts securing the drive pulley bearing block to the mounting bracket. Release the Jocknut locking the adjust screw and turn the screw in an anticlockwise direction until the fan belts can be withdrawn clear of the pulley, Remove the two screws securing the jack shaft flexible coupling to the fan drive pullay and slide hack the sliding Joint ta allow the belts to be withdrawn, Retirting Refitting is the reverse of the removal procedure. Adjust the belts to the correct tension as derailed in the 2,500 miles rraintenance service, Compressor Belts Removal Release the large nut securing the jockey pulley bearing block to. the mounting bracket. Turn the adjuster screw, ocated in the centre of the mounting bracket in en anti-clockwise direction until the jockey pulley is clear of the belts. Remove the belts. Refitting FRefitting is the reverse of the remaval procedure, Adjust the belts to the correct tension as detailed in the 2,500 “piles maintenance service. FAN Removal Remove the fen belts as detailed under “Fan Belt — Removal” Remove the eight bolts securing the fen carrier bracket to the radiator. Withdraw the two bolts and nuts securing the radiator stays to the fan carrier. Remove the fan and carrier 23 a complete unit. Dismantling Remove the nut securing the fan tp the fan spindle and extect the woodruff key. Remove the nut sacuring the pulley to the spindle and extrect the key from the keyway. Flemove the four bolts and stocking nuts securing the bearing and caps. Remove he cops taking oare not to damage the oil seale, Extract the two bearing housings and withdraw the spindte: To remove the fan blades from the contre boss oxtract ‘the six bolts and nuts, OTE: The holes in the fan end contre boss are offset t0 senecave correct reassembly dooms fe 8 ‘Sectionad view of ove fan assembly ‘Amernotiog Assembling is the reverse of the dismantling procedure. Renew the two oil seals if worn or damaged. Referring Refitting is the reverse of the removal procedure. HIGH SPEED RADIATOR FAN. High speed (gear driven} radistor fans are available as altermative equipment for "FLEETLINE” vehicles, ‘operating in countries with a normal nigh ambrent temperature, ‘The fan is belt driven through a shaft and two bevel .2°5, the shafts being supported on ball bearings, Routine Niaintenance Routine maintenance is confined to periodically checking the oil fevel in the unit and drive Belt adjustment, Removal Femove the fan, drive belt and carrier as an assembly as, detailed on this page. Dismantling Remove the plug and drain the oil from the unit. Remove the self-locking nut and washer securing the fan 10 the spindle, withdeaw the fan and extract the key, Withdraw the sloeve from the shaft. Remove the spfir pin, nut and washer securing the pulley to the drive shaft, withdraw the pulley and extract the key Withdraw four bolts and lockwashers and detach the fan spindle bearing housing from the drive shaft housing, Remove four bolts and lockwashers and detach the bearing 2p from the fan spindle housing. COOLING SYSTEM Fig, 6 Withdraw 12 ovter bearing and housing With a soft —2 e: drift the pinion shaft through the inner bearing and ex=sce che inner bearing Remove the bes -¢ e rve pinion may be removed from the shaft after removing =e nut Renew the oil seals and gaskets Reassembling Reassembling is the reverse of the ismariing procedure, ‘Add oF subtract shims until all end fhoat « removed from the bearings Refill the unit wit me recommenose grace of lubricant GAE140), ‘The capacity is approumatety © Imo: pints. 42 Litres). RADIATOR Removal Raise the engine cover to the oper oostion. Remove the engine compartment fight hand mare. as detalled under Section Q “Engine Compartment Covers Drain away the coolant by removing the drain plug focated in the bottom water pipe, conserving the coolant ‘€ am anti-freeze is in use. Disconnect the bottom water tunk hose and the air filter rose from the bracket attached to the top tank. Remove the two bolts and nuts securing the radiator ‘Sectioned view ofthe high sped fa sssembly Fa? aciator lower mounting pointe bottom mountings, Disconnect the jatk shaft flexible ‘coupling from the fan drive pulley by removing the two setscrovs, Remove the two bolts and nuts securing the radiator stays to the radiator top mounting and Wit, away the radiator ‘complete with the fan assembly. [Note the two rubber pads fitted between radigial upper mountings and the two rubber pads and cup washers fitted between bottom mounting and bolt heed. Refitting Refitting Is the reverse of the removal progrdure. ‘THERMOSTAT For alt information and data concerning the thermostat rofer to the Gardner Service Mansal. COOLING SYSTEM MAGNETIC FAN COUPLING Vehicles may be equipped with a magnetic fan coupling to operator's requirements. ‘The following is 9 brief description ef the operation and maintenance Recemary to the coupling and associate ports. For fuller detaits, parts list and guarantee details, operators are advised to apply to the components manufacturers {address below) for a copy of their Service Manual covering the Datrmier "Fleetline” vehicle, ‘SMITHS MOTOR ACCESSORY DIVISION Service Departmént, 55, Oxgete Lan Londen, N.W.2. DATA DESCRIPTION ‘OPERATION Coupling Unit Nominal voltage 24av ~ DC, Coil resistance 19 ohms: oil insutation 10 Meg ohms at 500V Torque Inst. (min:) Relay Nominal voltage av -De, Contact current rating (Max) 1A at 24V non-conductive Pullin voltage 18V (max) Dropout voltage 38V {min} Contact gap oA" Thermal Switch Primary Operating temperature 60% — 70¢ (140° — 158°) ‘Secondary Operating temperature 70°C ~ 80°C (168° — 178°F) DESCRIPTION ‘switch (second), marked with a blue spot, being the ‘The Magnetic Fan Coupling provides 2 means of ‘automatically regulating the operation of the cooling fan by accurately sensing the engine coolant temperature through a thermal switch as shown in the electrical control circuit diagram. ‘The switch contacts close and the fan coupling engages ‘drive by being energised through the relay, only when ‘operating conditions demand extra cooling beyond the thermal dissipation of the radiator under ram air ‘conditions. As the thermal switch permits the fen ‘coupling to remain disengaged until such additional ‘cooling is necessary, the circuit is in-operative with a cool ‘engine. The fan coupling installation has a sefety control irouit incorporated as shown by the dotted line in the Circuit diagram. The principle of operation is similar 12 that already described in that the primary thermal switch fnGfstes control of the normal running circuit but in the event of failure of this circuit, control is taken over by ‘the secondary switch and relay. ‘The two switches are set at slightly different operating ‘temperatures. to avoid simultaneous control; the safety higher. Failure of the normal primary running circuit will be indicated by a warning lamp installed in the cab and if a failure is indicated the defective circuit must be serviced 25 s00n as possible, ROUTINE MAINTENANCE ‘The magnetic fan coupling components are seated units, ‘therefore no routine maintenance is necessary. NOTE: It is advisable, when carrying out 2 major engine ‘overhaul, oF at 250,000 miles, 10 obtain a replacement far, coupling, IMPORTANT ‘Anhough thete couplings are sealed units it is important that they are not allowed to become excessively covered with grease or lubricating ol H Ft is necessary to clean an ‘extort part of @ unit only Trichlorethylene must be used and this sparingly tm avoid leakage through the joints. UNITS MUST NEVER BE UNPACKED FROM THEIR CARTONS UNTIL THEY ARE ACTUALLY REQUIRED FOR USE, EVERY 50,000 MILES Carry out operational tess on tne units incorporated in the fan coupling inezallasor 2s detailed under their respective headings. Thermal Switch Disconnect the sarcery supply. Drain sufficient coolant from the system to enable the switch to oe removed, Conserve the coolant -f an anti freeze vs in use. Loosen tne clip and slide the rubber cover clear of the terinals, Disconnect the two cables. Wate a spanner on the hexagon of te switch body lunserew (righthand thread) the sia:ch from the adaptor. NOTE: If the thread i tight due 10 corrosion work the switch backwards and forwarcs 10 clear and so avoid ‘unnecessary damage. Connect the switch to 2 2.5 volt battery with a 2.5 volt Dbulb wired in series. Immarsa the lower sat its thinnest, when the vehicle nas ;. a3 trom service. * ‘Abby air pressure to ex cylinoe cy seiseting 2a~ sear fin turn whitst tne comresponcing drain plug is remove Etectro‘pneumatic Valve Unit~Draining Remove the drain plugs in the base of the EP. rit ane rain away any contaminated oth and moisture when “a+ have accumulated in the high pressure gallery. To ensure maximum discharge for ce EP ort wren the grain plags are removed ar orenure OUc oe soo: bpselecting any position on ze gear corte! sw Perform this routine maintenance service “ore ecuer+ if the vehicle is operating under very nur cmate conditions. "Transfer Box Weaning the Air Breather Fitter Element Wash the air filter element in the transfer box filler pug Jp petrol and dry in lean air. Cary out this service mere ‘pquently if the vehicle 's operating in dusty territones. Limiting Valve ~ Checking Apply a soap solution 10 the cover saint and unions ant heck for leaks. Gheck that the breather hole in tre cover is not ritricted, EVERY 10,000 MILES (16,000 KM) Geirbox — Cleaning the Oil Filter Element Remove, clean and relit the oil filter element as de Under “First 1,000 miles (1,600 ken} Servies”. Agnew if in bad condition, EVERY 25,000 MILES (40,000 KM) Gearbox Changing the Oa Drain ars r=} with the recommended grade of lubricart 4 detailee ~ Te “Fest 1,000 miles (1,800 km) Service”. Changing the Air Brasher Fiter Element Renew the er “rma sement an the gearbox filler plug. ‘Transfer Box cangaymece and (2° wt ce “eeomwnended grade of lubricant mackie! roe Son aor mee (1,600 km) Service”. (Changing the Air Breather Feuer Eimment Renew the sir “Haar eenert me sanster plug. EVERY 50,000 MILES 180,000 KM Limiting Valve — Owwtcast Westinghouse System Exhaust all 3 oremre arc remove the valve unit. Remove the setscmes arc masrers and detach the main spring cover anc “> aut se skzonragm assembly. Extract the securing sree arc ease away the end cover. Withdeaw the water soe ow exaosed, Clean all meta narct e cearsing solvent and wash the diaphragm asse“c'.. 2 "ng and valve disc in soap and, water. Dry ali cars * § Sean ale jet and inspect the diaphragm and << -ng or agns of hardening or era Check the valve cs ia Stung, renew as necessary. Check the condz2r co me valve spring for sufficient tension to seat = vse oe. Lightly smear tne sse~ 2f me diaphragm assembly with a good grade grease as John Ethorington's Paragon Antic, Reasemble the save ane instal in the vehicle. Pressurize the system and es: = cover joint and unions for leaks With a soap solution Insert a pressure gave w the delivery line and check fo correct delivery cressure, 80 Ibs. per (5.8 kg/om?). Adjust by releas~¢ we locknut and twening the adjuster clockwise to increase and anti-clockwise to decrease the pressure Clayton-Dewandre System Exhaust all ai aremure and remove the valve unit Remove the for sesscrews and washers and detach the main spring cover NOTE: Wher revoving, the cover will be under the pressure of the sonng. Withdraw the too spring guide and spring. Carefully Sift off te diaphragm assembly. Remove the carelip and withdraw the guide plate Unscrew the pug from the base of the valve ane remove ‘the grommet from the plug, Fig. 4 Sectioned stew of the Westinghouse Hnveng va Unscrew the retaining nut and lift off the release vaive, NOTE: The joint beneath the valve must be retained. Withdraw the valve guide and vive return spring Remove the inlet valve and stem. Clean all metal parts in cleansing solvent and wipe clean ‘the rubber faces of the valves. flenew the valves if ‘damaged or indented Examine the diaphragm assembly for damage, or, deterioration, renewing as necessary, ‘Gheck that the base clug and guide plate grommets are in perfect condition, renew as necessary. GEARBOX AND TRANSFER BOX’ iiimvang) vate 16 Vow woe 17 Grommet 187h9 Ensure that the metered hole in the guioe piewe 35 ‘unobstructed. ‘Check the bearing surfaces of the diaphragm assembly and ide plate for wear. Reassemble the valve and install in the vohicie, Prassurize the system and test the cover joint and unions: for lecks with a soap solution. Insort a pressure gauge in the delivery line and check for correct delivery pressure, 80 fbs. per sain. (6.6 kg/em2) Adjust by releasing the locknut and turning the adjustan- screw clockwise to increase and anti-clockwise to decrease the pressure, EVERY 75,000 MILES (120,000 KM} Goar Change Selector Switch ~- Overhaul Flemove, overhaul and refit as detailed on page H.24

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