Ultraflex EMEI, Electrical And Mechanical Engineering Instructions

Page 1: ...ue 1 May 92 FIELD AND BASE REPAIR This EMEI is authorised for issue by the CGS It provides direction mandatory con trols and procedures for the operation maintenance and support of equipment Per sonne...

Page 2: ...ed Amendment Lists have been incorporated in this COPYof the Publication Amendment List Topic Section Amendment Effect Amended By Date No Date of Issue Affected Print Name 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 3: ...ued Amendment List Topic Section Amendment Effect Amended By Date 10 Date of Issue Affected Print Name 26 27 28 39 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Note ii Insert EMEI ca...

Page 4: ...and Inspection Field and Base Repair Reassembly Field and Base Repair ELECTRICAL GROUP 15 Wiring Harness General Precautions Replacement Field and Base Repair FRAME GROUP 16 Frame Inspection Base Repa...

Page 5: ...b Winch MC2 Air Compressor Exploded View Crank pin Removal Crankshaft Removal Connecting Rod Bush Removal Crankshaft Inner Bearing Installation Crankshaft Installation Connecting Rod Installation Mani...

Page 6: ...CTIONS Table No VEHICLE G 264 l Issue 1 May 92 LIST OF TABLES Title Page No 1 Location of Identification Numbers on Maintenance Supply Items vii 2 List of Lubricants VIII 3 Compressor Wear Limits 2 4...

Page 7: ...Agreement Policy Instruction 8 9 10 11 12 13 14 EMEI VEH G 202 Technical Description Truck Cargo Light MC2 EMEI VEH G 203 Unit Repair Truck Cargo Light MC2 EMEI VEH G 204 Field Repair Truck Cargo Lig...

Page 8: ...Left hand seat box in the cab Engine No Left hand side of the engine block Injection pump identification Side of the pump Transmission and transfer case Rear of the transfer case Torque limiter On rea...

Page 9: ...el Bearings Winch Cable Radiator Inhibitor Clutch Pedal Trunnion Speedometer Cable Propeller Shaft Winch Drive Line Parking Brake Adjuster Windscreen Wiper Drive Cable Winch Air Compressor OMD 115 OMD...

Page 10: ...required to gain slack and avoid damage to connectors and fittings components disconnect the battery leads 4 Discard all used gaskets seals cotter pins tab washers lock pins key washers and lock washe...

Page 11: ...r heads valve plates and gaskets Separate the cylinder heads from the outlet manifold and discard the O rings i6 IE 1 20 19 18 17 1 I I i L 1 Cylinder head 9 Air line connector 2 Gasket 10 Outlet valv...

Page 12: ...ankshaft i Using a suitable arbor press the outer bearing from the crankcase j Using a suitable arbor press out the bush from the connecting rod see Fig 5 BUSH PRESS ARBOR CONNECTING f Figure 5 Connec...

Page 13: ...necting rods gudgeon pins and Teflon pads in the pis tons see Fig 8 O RING PISTON PISTON TEFLON PAD GUDGEON PIN w CONNECTING ROD Figure 8 Connecting Rod Installation d Lightly smear the cylinder bores...

Page 14: ...ylinder heads complete with the manifold bridge g Install the eight cylinder head screws and tighten them securely ELECTRICAL AND MECHANICAL ENGINEERING INSTRUCTIONS h Fill the crankcase to approximat...

Page 15: ...Base Repair a Disconnect the battery negative terminal first then disconnect the positive terminal NOTE All electrical wiring in the vehicle is co lour coded for identification and refer ence If neces...

Page 16: ...mmer switch 14 Map reading light 15 Blackout switch 16 Fuse and relay panel 17 Heater blower motor 18 Windscreen wrper motor 8 1 PTO warnmg light switch 2 Fuel tank 3 Reverse light switch 4 Fuse and r...

Page 17: ...lour coded Using the old har ness and tags as a guide connect the wires to the appropriate terminals VEHICLE G 264 l Issue 1 May 92 d Install and tighten the zip clamps and brackets then connect the b...

Page 18: ...Each dimension must be within 9 5 mm c Using a suitable measuring device mea sure the distance between the front axle centre line and the spring equalizer centre line dimension Y NOTE When checking th...

Page 19: ...MB LINE POSITION PLUMB LINE POSITION I AB 1 4 Z JjJ REAR 1CROSSMEMBER FRONT AXLE CENTPE LINE _ K _ CE TRE LINE 1 FRAME DATUM LINE PLUMB LINE POSITION _ l_ L Y SPRING EQUALIZER PLUMB LINE POSITION PLUM...

Page 20: ...harness at the connectors on the firewall j Disconnect the wiring from the alternator the starter motor the temperature sensor the oil pressure sensor and the glow plugs and secure the ends to the cab...

Page 21: ...n attach the slings to suitable overhead lifting equipment b Using the overhead lifting equipment raise the cab above the chassis mounting points ensuring that wiring piping hoses and link ages are cl...

Page 22: ...body f Lift the cargo body from the vehicle then place the body on suitable stands and re move the lifting equipment 12 Inspection Field and Base Repair a Inspect the cargo body for corrosion dents c...