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Publication Number: 2295 Date:April 2006 (01/11)
CHASSIS PARTS MANUAL
COVERING:ENVIRO 400 MODELS
XB15LBRAXB15LBRAXB45LBRAX345NBRAX345PBRAX345MBRAXB15MBRAXE15MBRAXD45LBRAXD45NBRAX346MBRAX346NBRAX346PBRAXB16LBRAXB16MBRAXE16MBRAXE16MBRE EURO 4, 4+ & 5-
Alexander Dennis Limited Alexander Dennis LimitedDennis Way, Guildford. 91 Glasgow RoadSurrey GU1 1AF Falkirk FK14JBTel: +44 (0) 1483 571271 Tel: +44 (0)1324 621672Fax: +44 (0) 1483 301696 Fax: +44 (0)1324 633120
This manual covers those Enviro 400 models listed on the front cover. It should be regarded as part of the product and retained with the vehicle.At the time of resale it should be passed on to any subsequent owner.
As the manual lists the specifications for several models, some of the items covered may not apply to your vehicle. If any doubt exists pleasedo not hesitate to contact your Alexander Dennis Parts Centre who will be pleased to offer technical assistance.
We would like to point out that non-Alexander Dennis parts have not been approved by Alexander Dennis and we cannot certify the suitabilitynor the safety of such parts. Alexander Dennis is not liable for any damage caused by the use of non-Alexander Dennis parts.
AMENDMENTS
Any amendments received should be incorporated into the text.
The amendment date appears at the top of the page.
This symbol, next to an item line, indicates that the item has been amended for the current issue of the page.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic,mechanical, photocopying, recording or otherwise without prior written permission of ALEXANDER DENNIS LIMITED .
3Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
AFTER MARKET SUPPORT LINE
0845 358 9988FOR ALL ENQUIRIES
Including : Part Number Identification
Parts Ordering
Service Support
Warranty Support
Technical Support
FAX numbers : Parts Ordering 0845 358 9992
Technical Support 01483 451458
Warranty/Service 01483 301696
SERVICE DIRECTOR
BRIAN EVANS E-MAIL : brian.evans@alexander-dennis.com
MOBILE : 07881 825840
TECHNICAL SUPPORT MANAGER
REGIONAL SERVICE MANAGER STEVE HARDY
E-MAIL : stev.hardy@alexander-dennis.com
MOBILE : 07788 717570
Service Assistance and Spare Parts Amended:
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4
ENVIRO 400
PARTS DIRECTOR
CUSTOMER MANAGEMENT ROB WILLIAMSE-MAIL : rob.williams@alexander-dennis.com
MOBILE : 07764 922274
LONDON & SOUTH EAST
REGIONAL PARTS MANAGER MARK BOWLEYE-MAIL : mark.bowley@alexander-dennis.com
MOBILE : 07770 645212
SOUTH WEST & EU
REGIONAL PARTS MANAGER KEVIN YEARDLEYE-MAIL : kevin.yeardley@alexander-dennis.com
MOBILE : 07979 705519
MIDLANDS
REGIONAL PARTS MANAGER GARY GLOVERE-MAIL : gary.glover@alexander-dennis.com
MOBILE : 07881 958463
NORTH
REGIONAL PARTS MANAGER LES RIVETTE-MAIL : les.rivett@alexander-dennis.com
MOBILE : 07843 357228
SCOTLAND & NI
REGIONAL PARTS MANAGER JIM WEBBE-MAIL : jim.webb@alexander-dennis.com
MOBILE : 07979 703605
Regional Parts Managers Amended:120111
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5
LONDON, SURREY, HAMPSHIRE AND BERKSHIRE
JOHN CHAVES E-MAIL : john.chaves@alexander-dennis.com
MOBILE : 07760 220923
LONDON, KENT AND EAST & WEST SUSSEX
STEVE EDMONDS E-MAIL : steve.edmonds@alexander-dennis.com
MOBILE : 07831 704251
CENTRAL
REGIONAL SERVICE MANAGER GLEN WILKIE
E-MAIL : glen.wilkie@alexander-dennis.com
MOBILE : 07736 615459
NORTH WEST & NORTHERN IRELAND & EIRE
REGIONAL SERVICE MANAGER BEN WAITE
E-MAIL : ben.waite@alexander-dennis.com
MOBILE : 07901 510724
NORTH EAST & NORTHERN IRELAND & EIRE
REGIONAL SERVICE MANAGER JOHN BRADLEY
E-MAIL : john.bradley@alexander-dennis.com
MOBILE : 07768 921192
SCOTLAND
REGIONAL SERVICE MANAGER DAVID ALLEN
E-MAIL : david.allen@alexander-dennis.com
MOBILE : 07770 733779
Regional Service Managers Amended:120111
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6
ENVIRO 400
BRISTOL
BRISTOL SERVICE CENTRE: Folly Lane. St Philips. Bristol. BS2 0RH
TELEPHONE: 0117 955 0444 FAX : 0117 955 0666
OUT OF HOURS CONTACT : +44 (0) 7747 760 255
HARLOW
HARLOW SERVICE CENTRE: Unit B, Barrows Road, Pinnacles Industrial Estate.Harlow. Essex. CM15 5AT
TELEPHONE: 01279 770600 FAX : 01279 419744
COMMERCIAL MANAGER ALAN REYNOLDS
E-MAIL : alan reynolds@alexander-dennis.com
MOBILE : 07799 762070
TRAINING
TRAINING MANAGER PAUL HOPWOODE-MAIL : paul.hopwood@alexander-dennis.com
MOBILE : 07831263246
Service Centres & Training Amended:
7Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Main Index Amended:120111
SERVICE ASSISTANCE AND SPARE PARTS
Section 1: GENERALHealth and Safety . . . . . . . . . . . . . . . . Page 1.2 - 4Environmental Warnings . . . . . . . . . . . Page 1.4Vehicle Identification . . . . . . . . . . . . . . Page 1.5Quick Reference Spares . . . . . . . . . . . Page 1.6 - 1.15Fastener identification . . . . . . . . . . . . . Page 1.16 - 21Miscellaneous . . . . . . . . . . . . . . . . . . . Page 1.22
Section 2: ENGINEAir Cleaner . . . . . . . . . . . . . . . . . . . . . . Page 2.2 - 3Cooling System . . . . . . . . . . . . . . . . . . Page 2.4 - 25Exhaust System . . . . . . . . . . . . . . . . . . Page 2.26 - 33Fuel System . . . . . . . . . . . . . . . . . . . . . Page 2.34 - 61Hydraulic System . . . . . . . . . . . . . . . . Page 2.62 - 71Engine & Mounting . . . . . . . . . . . . . . . Page 2.72 - 85Heater Pipework . . . . . . . . . . . . . . . . . Page 2.86 - 87Air Conditioning . . . . . . . . . . . . . . . . . Page 2.88 - 89
Section 3: TRANSMISSIONVoith Transmission . . . . . . . . . . . . . . . Page 3.2 - 3.3ZF Transmission . . . . . . . . . . . . . . . . . Page 3.4 - 3.5ZF Transmission Air Piping . . . . . . . . . Page 3.6 - 3.7Propeller Shaft . . . . . . . . . . . . . . . . . . . Page 3.8 - 3.9Rear Axle . . . . . . . . . . . . . . . . . . . . . . Page 3.10 - 23
Section 4: BRAKINGUsed on & up to Chassis No 5114 Braking System . . . . . . . . . . . . . . . . . . Page 4.2 - 5Pipe Fittings - Braking System . . . . . . . Page 4.6 - 9Used on & after Chassis No 5115 onwardsBraking System . . . . . . . . . . . . . . . . . . . Page 4.10 - 13Pipe Fittings - Braking System . . . . . . . Page 4.14 - 17Front Brake Chambers & Rear Brake Actuators . . . . . . . . . . . . . Page 4.18 - 19Footbrake Valve and Valve Assembly . Page 4.20 - 23Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . Page 4.24 - 25Handbrake Interlock . . . . . . . . . . . . . . . Page 4.26 - 27Brake Caliper & Spares . . . . . . . . . . . . Page 4.28 - 35Nylon Brake Tubing Sizes . . . . . . . . . . . Page 4.36
PARTS MANUAL
8
ENVIRO 400
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Main Index Amended:090209
Section 5: ELECTRICAL SYSTEM AND INSTRUMENTATIONUsed on & up to Chassis No 5114 excluding 4625 & 4752
Instrument binnacle assembly . . . . . . Page 5.2 - 5Electrical Distribution Centre - FEDC . Page 5.6 - 7PCB board assembly - front . . . . . . . . Page 5.8 - 9Rear Electrical Distribution Centre REDC Page 5.10 - 11Cables . . . . . . . . . . . . . . . . . . . . . . Page 5.14 - 15Harnesses . . . . . . . . . . . . . . . . . . . . . . Page 5.16 - 17Miscellaneous . . . . . . . . . . . . . . . . . . . Page 5.18 - 19
BATTERY CARRIER AREABattery Carrier . . . . . . . . . . . . . . . . . . Page 5.20 - 23Battery Boost Socket . . . . . . . . . . . . . Page 5.23
Used on & after Chassis No 4625, 4752, 5115 onwardsElectrical System
Instrument binnacle assembly . . . . . . Page 5.26 - 27Front Electrical Distribution Centre - EDC Page 5.28 - 29PCB assembly - Front EDC . . . . . . . . . Page 5.30 - 31Rear Electrical Distribution Centre - EDC Page 5.32 - 33PCB assembly - Rear EDC . . . . . . . . . Page 5.34 - 35Cables . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.36Harnesses . . . . . . . . . . . . . . . . . . . . . . Page 5.37
Battery CarrierBattery Carrier Area . . . . . . . . . . . . . . . Page 5.38 - 39
Section 6: SUSPENSION, FRAME, WHEELSSuspension . . . . . . . . . . . . . . . . . . . . . Page 6.2 - 19Frame . . . . . . . . . . . . . . . . . . . . . . Page 6.20 - 23Cab Floor . . . . . . . . . . . . . . . . . . . . . . Page 6.24 - 25Wheels . . . . . . . . . . . . . . . . . . . . . . Page 6.26 - 27
Section 7: STEERING, FRONT AXLESteering . . . . . . . . . . . . . . . . . . . . . . Page 7.2 - 9Front Axle - DANA . . . . . . . . . . . . . . . . Page 7.10 - 19Front Axle - ZF . . . . . . . . . . . . . . . . . . . Page 7.20 - 23
ALPHABETICAL INDEX
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Contents
General Amended:120111
Health and SafetyMoving the Vehicle . . . . . . . . . . . . . . . . Page 1.2Working on the Vehicle . . . . . . . . . . . . . Page 1.2Hazardous Materials . . . . . . . . . . . . . . . Page 1.3 - 4Environmental Warnings . . . . . . . . . . . . Page 1.4
Vehicle IdentificationVehicle Compliance Plate . . . . . . . . . . . Page 1.5
Quick Reference Spares . . . . . . . . . . . . . . . Page 1.6 - 15
Fastener identification . . . . . . . . . . . . . . . . Page 1.16 - 21Bolts and Screws . . . . . . . . . . . . . . . . . . Page 1.16 - 17Split Pins . . . . . . . . . . . . . . . . . . . . . . . . Page 1.17Nuts . . . . . . . . . . . . . . . . . . . . . . . . . Page 1.17Washers . . . . . . . . . . . . . . . . . . . . . . . . Page 1.18Self Tapping Screws . . . . . . . . . . . . . . . Page 1.18'P' Clips . . . . . . . . . . . . . . . . . . . . . . . . . Page 1.19Beam Clip . . . . . . . . . . . . . . . . . . . . . . Page 1.20Protective Sleeving . . . . . . . . . . . . . . . . Page 1.21Cable Ties . . . . . . . . . . . . . . . . . . . . . . . Page 1.21Hose Clips . . . . . . . . . . . . . . . . . . . . . . . Page 1.22Pipe Clamps . . . . . . . . . . . . . . . . . . . . . Page 1.23
LubricationLubrication . . . . . . . . . . . . . . . . . . . . . . Page 1.24 - 25
MiscellaneousAbbreviations . . . . . . . . . . . . . . . . . . . . Page 1.26
Section 1
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.2
ENVIRO 400
Moving the Vehicle
During movement of the vehicle chassis the hazards involved are thosenormally associated with all forms of powered transport.
Before driving the vehicle, operators should familiarise themselves with thevehicle operator’s handbook.
Working on the VehicleBefore commencing work on the vehicle, take note of all instructions relating tosafety and hazardous items.
The following potential hazards should be considered:
Stored EnergyCertain components and systems on the vehicle contain stored energy whichmust not be released in a non approved manner.
• Tyre air pressure.
• Braking system air pressure.
• Park brake spring compression.
Cooling System Pressure and TemperatureThe system will remain hot and under pressure after use. Allow to cool beforeattempting to remove the filler cap.
Chassis LiftingAdequate support required during jacking or lifting. Eye and head protectionshould be worn when working under the vehicle.
Diesel Injection PumpsSupply fuel to the engine at very high pressure, care must be taken whenworking on the injectors or injection pipes as fuel under high pressure canpenetrate the skin.
Braking SystemBrake drums or discs will remain at an extremely high temperature for aconsiderable time after use, caution must be exercised when handling suchitems to avoid burns.
Self Locking Nuts • When self locking nylon type nuts are removed, they should be
disgarded and new items used. THEY SHOULD NEVER BE RE-USED.
Health and Safety Amended:080708
�� Use Common Sense - If in Doubt Ask
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.3
Hazardous MaterialsCertain components on the vehicle contain, or can produce, material whichmust be handled cautiously. These materials are as follows:
Those which must not be taken internally or contact the eyes, skin, ormouth:
Battery acidDiluted sulphuric acid can cause skin burns, eye damage and internal damageif ingested. Vapour from the solution can also irritate the respiratory system andthe eyes.
Cooling system antifreezeBased on ethylene glycol, and has significant toxicity if ingested, but can alsobe absorbed through the skin. Causes mild eye and skin irritation. Hot fluid canalso scald.
FuelDiesel fuel is a mixture of hydrocarbons largely consisting of paraffinichydrocarbons, with blended constituents such as refined vacuum distillants andcatalytically cracked oil. Contact with the skin can cause irritation anddermatitis. Inhalation and ingestion are serious risks and can cause chemicalpneumonitis.
Hydraulic FluidsThese are generally made from polyalkylene glycol ethers and can cause mildirritation of the skin and eyes. The toxicity through ingestion is generallyregarded to be low order.
Friction Material DustMay consist of a high percentage of white asbestos bonded in a resin. Handlingand fitting lined brake shoes or clutch plates is not regarded as a health risk.The dust produced by worn linings is degraded by the brake or clutch is notbelieved to be hazardous. However it is prudent to avoid generating airbornedust concentration, therefore dust removal should be by the use of approvedvacuum cleaner or by the use of a damp cloth (for occasional exposure).
Insulation MaterialsMan made fibres which include glass, rock, slag and metal oxides. These maycause skin irritation. Inhalation of dust from the fibres should be kept below 1fibre/ml.
Mineral oil (Engine and Transmission)This type of oil contains small quantities of polycyclic aromatic hydrcarbons,which can cause irritation, dermatitis and oil acne if allowed persistent contactwith the skin. Toxicity through ingestion is of a low order, however this shouldbe avoided.
Exhaust EmissionsSubstances produced are carbon monoxide, hydrocarbons and oxides ofnitrogen. Can be highly toxic if inhaled in sufficient quantity. Emissions inenclosed spaces should be minimised unless adequate extraction facilities areavailable.
PERSONAL POINTS Remember to:Remove rings, watches before working on the vehicle, particularly necessarywhen working on the electrical system.Wear eye and head protection when working underneath the vehicle.Use barrier cream or wear gloves as necessary to protect hands.Keep loose clothing and long hair away from moving parts.
These instructions are for your own and others safety and are by no meanscomprehensive.
Each job and situation should be assessed for its Health, Safety andEnvironmental Risks as these will change and vary depending on the taskundertaken.
Health and Safety Amended:080708
�� Use Common Sense - If in Doubt Ask
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.4
ENVIRO 400
Viton ‘O’ rings and seals (fluoro-elastomers)‘Viton’ material, used in the manufacture of oil seals and ‘O’ rings, produces ahighly corrosive acid (hydroflouric) when subjected to temperatures above315°C. The resulting contamination can have extreme consequences onhuman tissue since it is almost impossible to remove after contact.
The following procedure is recommended when it is necessary to inspect anyequipment that has been subjected to a high temperature i.e. fire.
1. Visually inspect for any gaskets or seals which have suffered from heat;they will appear black and sticky.
2. If this is affirmed:- Do not touch.
3. Make enquiries to ascertain material composition.
Any fluoro-elastomer (Viton, Flourel or Tecmoflon) should be considereddangerous but natural rubber and nitrile are non-hazardous.
4. If fluoro-elastomer seals have been used, then the affected area MUSTbe decontaminated before undertaking further work.
5. Disposable heavy duty gloves (neoprene) MUST be worn and theaffected area decontaminated by washing thoroughly with limewater(calcium hydroxide solution).
6. Any cloths, residue and gloves used MUST be safely discarded afteruse.
ENVIRONMENTAL WARNINGS
Those which may cause noxious fumes if allowed to burn:Coatings (Mebon chassis protection)Generally inert in the cured state, but should be removed from areas to bewelded.
Fuel (diesel)Not classified as flammable for most purposes.
Hydraulic FluidsThese do not present a fire or explosive hazard under normal circumstances.
Mineral oil (engine and transmission)These do not present a fire or explosive hazard under normal circumstances.
Rubber and synthetic alternatives (tyres, hoses, bushes, seals,insulation)Natural and synthetic rubbers are combustible and will produce unpleasant anddangerous fumes.
Health and Safety Amended:080708
�� WARNING
Used engine oil, hydraulic fluids, transmission fluid, antifreeze, (and theircontainers) batteries and tyres can be a hazard to health and the environment.
Fluids and other substances (e.g. used oil) and surplus parts must bedisposed of in a safe and environmentally sound manner.
On no account must any of these items be placed in household refuse bins,or the fluids poured down drains.
Observe local regulations and laws on environmental protection and disposalof hazardous materials.
These should be disposed of using authorised waste disposal facilities.
Consult local authority for safe disposal facilities.
Burning of discarded items is NOT RECOMMENDED, except in anapproved incineration process where gaseous products are treatedby alkaline scrubbing.
�� Use Common Sense - If in Doubt Ask
Vehicle Identification Number Amended:
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.5
W.P.O.
VEHICLETYPE
ENGINETYPE
CABTYPE
53220
TRIDENT 2
CUMMINS ISBe4 250B
DENNIS ALEXANDER LIMITED
TA
SFD15LBRA5GXB3872V.I.N.
17800 18000
6300
11500
7500
11500
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
A
B
C
D
E
F
DESIGNWEIGHTS
PLATEDWEIGHTS
KEY TO VIN PLATE
SFD World Manufacturers Identity
1 Wheelbase
5 Engine
L Transmission
B Air ConditioningR Hand of DriveA Series / marK
5 (*) Build / Year
G Build Plant
X Model
B Frame Type
1234 Serial Number
A Type Approval Number
B Vehicle Identification Number
C Gross Weight
E Axle 1 Weight
F Axle 2 Weight
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.6
ENVIRO 400
Quick Reference Spares Amended:
1
76
432
LIFT L
EVER FULL
Y
TO UNLO
CK & R
ELEASE P
RESSURE
50KPA
11
8
129 10
5
50K
Pa
Quick Reference Spares Amended:120907
ITEM PART NO QTY DESCRIPTION REMARKS
AIR CLEANER1 651031-1 1 Element - Air cleaner - engine2 658566 1 Filter restriction indicator
AIR CONDITIONING3 7040801N01 1 Drive belt 4 7040800N01 1 Air conditioning compressor
COOLING SYSTEM5a 427381 1 Radiator insert5b 442973 1 Radiator Insert - aluminium
Supplied c/w rubber mountings and can be fitted to earlier pack 4419436 430554 1 Charge cooler7 435466 1 Fly Screen8 429792 1 Header tank assembly9 654109 1 Pressure cap
10 659659 1 Pressure cap - lever release (Option) OL1520-111 652489 1 Probe - coolant level
652490 1 Grommet - coolant level probe
12 659137 1 Mount - radiator
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.7
This section contains a list of service items, selected spares and control units to save time when identifyingthe more common service spares.This is designed to be an aid and not a comprehensive list.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.8
ENVIRO 400
Quick Reference Spares Amended:
21
201917
1514
22 23 24 FUELFUEL/WATERFUEL
13
18
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.9
Quick Reference Spares Amended:070708
ITEM PART NO QTY DESCRIPTION REMARKS
EXHAUST SYSTEM13 4931680 1 Silencer assembly - EGP14 660872-5 1 Flexible pipe15 660890 5 Mount - high temperature
FUEL SYSTEM16 658137 1 Filler cap - hinged
658137-1 1 Gasket - filler neck17 660828 1 Filter - Urea18 4936201-101 1 Nozzle - Injector EGP
4935801-101 1 Nut - EGP Injector660809-14 1 Ferrule - braided pipe660809-15 1 Nut - braided pipe
HYDRAULIC SYSTEM19 655644-1 2 Element - steering reservoir20 656730-1 1 Element - Hydraulic filter21 660344 1 Filler & breather unit c/w screw
ENGINE22 DP010206 1 Fuel filter - engine mounted - Primary23 659523-1 1 Fuel / water filter - frame mounted - secondary
659523-2 1 Sensor - water in fuel24 DP010205 1 Engine Oil Filter
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.10
ENVIRO 400
Quick Reference Spares Amended:
33
29
35
26 27
32
25
KNORR - BREMSE
VOITH
28
30 31
3634
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.11
Quick Reference Spares Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
ENGINE (continued)25 661096 1 Starter motor
26a 659717 1 Alternator AC172RA - 140A - Used on & upto Chassis No 422727a 3289001-101 1 Belt - alternator
432296 1 Pulley26b 661098 1 Alternator AC172RA - 155A - Used on & after Chassis No 422827b 4988883-101 1 Belt - alternator
3281533-101 1 Pulley
TRANSMISSION28a 660878-7 1 Oil filter kit - Voith Transmission28b 652638-1 1 Oil filter kit - ZF Transmission
29 652061-1 1 Pressure switch - Voith
PROPSHAFT30 659186 2 Joint kit
REAR AXLE31 658470-41 1 Brake pad set (axle set)32 660426-4 2 Seal - drive shaft
BRAKING SYSTEM33 658208-3 1 Replacement Cartridge - Air dryer
ELECTRICAL SYSTEM34 660879 1 Transmission electronic control unit - Voith
35a 660940 1 Transmission electronic control unit - ZF36a 659974 1 ABS ‘D’ electronic control unit36b 660811 1 ABS ‘E’ electronic control unit
662093 1 Harness - adaptor - ABS-D TO ABS-E (Needed if replacing ABS-D ECU) SL2315
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.12
ENVIRO 400
Quick Reference Spares Amended:
4645
41
37
44
CA
MU
43
3938
42
47 48
40
10
651598-
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.13
Quick Reference Spares Amended:170209
ITEM PART NO QTY DESCRIPTION REMARKS
ELECTRICAL SYSTEM (continued)
37a 651598-2 A/R Add-A-Fuse - 3 Amp - Violet37b 651598-4 A/R Add-A-Fuse - 5 Amp - Tan37c 651598-5 A/R Add-A-Fuse - 7.5 Amp - Brown37d 651598-6 A/R Add-A-Fuse - 10 Amp - Red37e 651598-7 A/R Add-A-Fuse - 15 Amp - Blue37f 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow38a 656674 A/R Fuse - “maxi” - 20 Amp - Yellow38b 660060 A/R Fuse - “maxi” - 25 Amp - Grey38c 656548 A/R Fuse - “maxi” - 30 Amp - Green38d 660061 A/R Fuse - “maxi” - 35 Amp - Brown38e 657794 A/R Fuse - “maxi” - 40 Amp - Orange39 656334 2 Battery-12v40 659973 1 Control Unit - CAMU
659972 5 Control Unit - IOU41 661828 1 Screen Control Unit - black & white
AIR SUSPENSION42 655710-1 1 Line filter43 656298-1 2 Air spring diaphragm - front axle
656299-2 4 Air spring diaphragm - rear axle44 656606 1 Solenoid valve - 3-way
656607 1 Solenoid valve - single
SUSPENSION45 657610 4 Front damper c/w mounting
657611 4 Rear damper c/w mounting657696-3 A/R Retainer657610-1 A/R Rubber mounting c/w sleeve657696-4 A/R Lock nut
46 438257 1 Bush - link plate - Front suspension Replace all47a 434216 4 Bush half- Anti roll bar - Front suspension Replace all47b 434214 4 Bush half - Anti roll bar. - drive axle48 434947 4 Mounting rubber - Anti roll bar. - upper link - drive axle
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.14
ENVIRO 400
Quick Reference Spares Amended:230409
5150 52
53
57
565554
49
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.15
Quick Reference Spares Amended:230209
ITEM PART NO QTY DESCRIPTION REMARKS
SUSPENSION49 658973 8 Mounting rubber - Anti roll bar. - ends - drive axle50 657505 1 Proximity switch
STEERING GEAR51a 658521-22 1 Socket assembly R/H 51b 658521-23 1 Socket assembly L/H 52 412555-8 1 Relay shaft53 611511 1 Universal joint assembly
FRONT AXLE54a 658470-41 1 Brake pad kit (axle set) - SB Caliper)54b 660364-7 1 Brake pad kit (axle set) - SN caliper)55a 658470-39 2 Brake Disc - Front - Dana 55b 661773-9 2 Brake Disc - Front - ZF56 657303-126 2 Brake Disc - Rear57 659334-8 1 Kit - wear indicator with cable (axle set)
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.16
ENVIRO 400
IntroductionAll attaching hardware are given a part number in a standard code which exactlyidentifies each item.
Bolts and Screws
Grade of Material
Blank . . . . . . . . . . . . . . . 8.8 metric or "S" imperial
10 . . . . . . . . . . . . . . . 10.9 metric
12 . . . . . . . . . . . . . . . 12.9 metric
R . . . . . . . . . . . . . . . R grade nut (imperial)R" grade nut is used with "V" grade bolt
T . . . . . . . . . . . . . . . T grade nut (imperial)"T" grade nut is used with "X" grade bolt
V . . . . . . . . . . . . . . . V grade bolt (imperial)
X . . . . . . . . . . . . . . . X grade (imperial)
Thread
BA . . . . . . . . . . . . . . . BABF . . . . . . . . . . . . . . . B.S.F.MC . . . . . . . . . . . . . . . Metric Coarse MF . . . . . . . . . . . . . . . Metric FineUC . . . . . . . . . . . . . . . Unified CoarseUF . . . . . . . . . . . . . . . Unified FineBC . . . . . . . . . . . . . . . B.S.W.
Type
B . . . . . . . . . . . . . . . BoltG . . . . . . . . . . . . . . . GrubscrewN . . . . . . . . . . . . . . . NutS . . . . . . . . . . . . . . . Screw
Tool
Blank . . . . . . . . . . . . . . . Spanner1 . . . . . . . . . . . . . . . Screw driver (conventional)2 . . . . . . . . . . . . . . . Pozidrive or Philips type screwdriver3 . . . . . . . . . . . . . . . Alan key (hexagonal socket head)4 . . . . . . . . . . . . . . . Coach type head
Head
Bolts and Screws1 . . . . . . . . . . . . . . . Hexagonal2 . . . . . . . . . . . . . . . Square3 . . . . . . . . . . . . . . . Flat csk4 . . . . . . . . . . . . . . . Raised csk5 . . . . . . . . . . . . . . . Round6 . . . . . . . . . . . . . . . Cheese or cap7 . . . . . . . . . . . . . . . Raised csk for instruments8 . . . . . . . . . . . . . . . Mushroom or cup9 . . . . . . . . . . . . . . . Pan
10 . . . . . . . . . . . . . . . Durlock
Grubscrews1 . . . . . . . . . . . . . . . Plain2 . . . . . . . . . . . . . . . Cup3 . . . . . . . . . . . . . . . W - point4 . . . . . . . . . . . . . . . Cone5 . . . . . . . . . . . . . . . Half dog6 . . . . . . . . . . . . . . . Full dog
Fastener Identification Amended:
Grade Thread Type Tool Head Diameter Length Finish
10 MC S 3 3 10 80 P
Diameter (two digits)BA sizes . . . . . . . . . gauge numberBSF, UNF, BSW . . . diameter in sixteenths of an inchMetric . . . . . . . . . . . diameter in millimetresBA, BSF, UNF, BSW length in eighths of an inchMetric . . . . . . . . . . . length in millimetres
Length (two or three digits)
BA, BSF, UNF, BSW length in eighths of an inchMetric . . . . . . . . . . . length in millimetres
Finish
C . . . . . . . . . . . . . . . Chrome plateP . . . . . . . . . . . . . . . Cadmium or zinc plate, sheradized or passivatedS . . . . . . . . . . . . . . . StainlessB . . . . . . . . . . . . . . . Black passivated
Split Pins
Diameter
One or two figures indicate diameter in sixty - fourths of an inch
LengthOne or two figures indicate length in sixteenths of and inch
MaterialBR . . . . . . . . . . . BrassST . . . . . . . . . . . Mild steel
Nuts
Thread
BA . . . . . . . . BABF . . . . . . . . B.S.F.MC . . . . . . . . Metric Coarse MF . . . . . . . . Metric FineUC . . . . . . . . Unified CoarseUF . . . . . . . . Unified FineBC . . . . . . . . B.S.W.
Type1 . . . . . . . . Full Plain2 . . . . . . . . Half plain (locknut)3 . . . . . . . . Castle4 . . . . . . . . Slotted5 . . . . . . . . Full, self locking6 . . . . . . . . Thin, self locking7 . . . . . . . . Full Nyloc or Simmonds8 . . . . . . . . Thin Nyloc or Simmonds9 . . . . . . . . Square
Size (two digits)Thread diameterMetric - millimetresBSF, UNF, BSW - sixteenths of an inch
FinishC . . . . . . . . Chrome plateP . . . . . . . . Cadmium or zinc plate, sheradized or passivatedS . . . . . . . . StainlessB . . . . . . . . Black passivated
Fastener Identification Amended:
Thread Nut Type Size Finish
BC N 5 20 P
Split Pin Diameter Length Material
SP 6 12 ST
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.17
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.18
ENVIRO 400
Washers
Measuring SystemWB . . . . . . . . BA sizesWG . . . . . . . . Woodscrew gauge sizesWL . . . . . . . . Inch sizeWM . . . . . . . . Metric sizes
TypeA . . . . . . . . Plain, flatB . . . . . . . . Spherical or BellevilleC . . . . . . . . Single coil springD . . . . . . . . Double coil springE . . . . . . . . External starF . . . . . . . . Countersunk internal starG . . . . . . . . Internal starH . . . . . . . . Internal and external starJ . . . . . . . . Cup
SizeOne or two figures give the internal diameter in:
Screw gauge sizeBA numberSixteenths of an inchMillimetres
MaterialA . . . . . . . . AluminiumB . . . . . . . . BrassC . . . . . . . . CopperS . . . . . . . . Steel
FinishC . . . . . . . . Chrome plateN . . . . . . . . Nickel plateO . . . . . . . . NaturalP . . . . . . . . Cadmium or zinc plate, sheradized or passivatedB . . . . . . . . Brassed
Self-Tapping Screws
ToolBlank . . . . . . . . . . . Spanner
1 . . . . . . . . . . . Screw driver (conventional)2 . . . . . . . . . . . Pozidrive or Philips type screwdriver3 . . . . . . . . . . . Allen key (hexagonal socket head)4 . . . . . . . . . . . NA5 . . . . . . . . . . . Plain, i.e. hammer drive
Head1 . . . . . . . . . . . Hexagonal2 . . . . . . . . . . . Square3 . . . . . . . . . . . Flat C'sk4 . . . . . . . . . . . Raised cheese head (fillister)5 . . . . . . . . . . . Round6 . . . . . . . . . . . Cheese or cup7 . . . . . . . . . . . Raised C'sk. (instrument)8 . . . . . . . . . . . Mushroom or cup9 . . . . . . . . . . . Pan
SizeOne or two figures give the diameter in screw gauge number.
LengthOne or two figures give the length in eighths of an inch
FinishC . . . . . . . . . . . Chrome plateN . . . . . . . . . . . Nickel plateO . . . . . . . . . . . NaturalP . . . . . . . . . . . Cadmium or zinc plate, sheradized or passivatedB . . . . . . . . . . . Brassed
Fastener Identification Amended:
Measuring System Type Size Material Finish
WM C 10 S PSelf Tap Tool Head Screw Length Finish
ST 1 3 08 5 P
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.19
'P' Clips 'P' Clips - High Temperature
Fastener Identification Amended:120111
Inside dia Part No. Inside Part No.inches (mm) diameter (mm)
4 611673-1 21 610029-5
5 611673-2 0.906” (23) 660217-6*
6 611673-3 0.953” (24) 660217-7*
7 611673-4 1.063” (27) 660217-8*
8 611673-5 31 660217-9*
9 611673-6 1.234” (38) 660217-10*
10 611673-7 39 610029-11
11 611673-8 1 3⁄4” (45) 660217-12*
12 611673-9 51 610029-13
1/2 ” (13) 660217-1* 2 1⁄4” (57) 660217-14*
- 14 610029-2 70 610029-15
5/8” (17) 660217-3* 1” (25) 660217-20*
3/4” (19) 660217-4* 2.5” 442489*
Inside dia Part No. Inside Part No.inches (mm) diameter (mm)
4 611673-1 21 610029-5
5 611673-2 0.906” (23) 660217-6*
6 611673-3 0.953” (24) 660217-7*
7 611673-4 1.063” (27) 660217-8*
8 611673-5 31 660217-9*
9 611673-6 1.234” (38) 660217-10*
10 611673-7 39 610029-11
11 611673-8 1 3⁄4” (45) 660217-12*
12 611673-9 51 610029-13
1/2 ” (13) 660217-1* 2 1⁄4” (57) 660217-14*
- 14 610029-2 70 610029-15
5/8” (17) 660217-3* 1” (25) 660217-20*
3/4” (19) 660217-4* 2.5” 442489*
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.20
ENVIRO 400
P Clips - High Temperature
Beam / Frame Clip - Cables and Pipes
Fastener Identification Amended:120111
A -Frame B - Clip Part No.Thickness (mm) Diameter (mm)
8 - 12 6-7 656880-1
A
B
A -Frame B - hole Part No.Thickness (mm) Diameter (mm)
5 - 10 6.5 611075
AB
A -Frame B - hole Part No.Thickness (mm) Diameter (mm)
4 6.5 656737
A
B
Part No: Diameter Diameter (mm) (mm)
657677-1 10 8.4
657677-2 6 6.4
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.21
Protective Sleeving Cable Ties
Fastener Identification Amended:120111
Inside diameter
Closed (mm) Max: open (mm) Part No.
6.7 25.4 610561/1
9.3 44.5 610561/2
13.2 63.5 610561/3
19.9 127.0 610561/4
26.1 178.0 610561/5
14.0 75.0 610561/6
Length (mm)
Length (mm) Part No.
115mm 607008
130 - 133mm wide 653608
190 - extra wide 610808
266mm 607007
Spacer
Diameter (mm) Part No.
25mm 656844
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.22
ENVIRO 400
Hose Clips - constant torque
Constant Torque
Fastener Identification Amended:120111
Dia Min Dia Max Part No. Torque(mm) (mm) Standard Setting
12 22 661990-3 3.0 +0.5 Nm
16 27 661990-4 5.0 +0.5 Nm
20 32 661990-5 5.0 +0.5 Nm
23 35 661990-6 5.0 +0.5 Nm
25 40 661990-7 5.0 +0.5 Nm
30 45 661990-8 5.0 +0.5 Nm
35 50 661990-9 5.0 +0.5 Nm
40 60 661990-10 5.0 +0.5 Nm
50 70 661990-11 5.0 +0.5 Nm
60 80 661990-12 5.0 +0.5 Nm
70 90 661990-13 5.0 +0.5 Nm
80 100 661990-14 5.0 +0.5 Nm
90 110 661990-15 5.0 +0.5 Nm
100 120 661990-16 5.0 +0.5 Nm
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.23
Pipe clamps
Fastener Identification Amended:120111
A - Centres B-hole Part No.(mm) Diameter (mm)
36 25 658591-1
Cover plate for above - 658592-1
B B
A
A
B
d D
6.5
Part No. a b h d D Cover PlatePart No.
653488-1 38 70 30.5 16 16 653489-1
653488-2 38 70 30.5 19 19 653489-1
653488-3 38 70 30.5 19 20 653489-1
653488-4 30 54 23.5 16 16 653489-2
Part No. a b h d D
653487-1 19 40 30.5 16 16
653487-2 19 40 30.5 19 19
653487-3 19 40 30.5 19 20
653487-4 15 33 23.5 16 12
ab
7
Ø6.5Ød
14.5
h
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.24
ENVIRO 400
Lubricants and Fluids Amended:
Unit No:FZ1510
413
6
5
2
6 8 9 7
7
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.25
Unit No:FZ1510
Lubricants and Fluids Amended:080708
* When using products other than those supplied by Texaco/Fuchs, consult your supplier to confirm compatibility.
** This Valvoline Antifreeze, to Cummins 14603, must be used for vehicles fitted with an Aluminium Radiator Insert .
Ref. Vehicle Part Capacity in General RecommendedNo. Component Number litres (approx.) Specification Brands
1 Engine Cummins ISBe4 659047-1 20.5 To a minimum of europeanclassification ACEA E5 Fuchs Titan HPE15W40. Cummins 20072
2a Transmission - Voith 657507-1 28 * Dexron III Texamatic 7045*Oil change 26
2b Transmission - ZF 657507-1 30 * Dexron III Texamatic 7045*Oil change 15
3 Drive axle 650803 19.0 API - GL5 Texaco Geartex
Oil change 18.5 85W/140 EPB 140
4 Cooling System 660252-1 55 To Cummins 14603 Valvoline HD Extended Life RTU
approx Prediluted mix - DO NOT ADD WATER
5 Steering Reservoir 657507-1 6.0 * Dexron III Texamatic 7045*Fan Drive Reservoir 657507-1 7.0 * Dexron III Texamatic 7045*
6 Rear Axle Hubs - 0.13 - 0.15kg/hub Fuchs Renolit LX PEP 2 Fuchs Renolit LX PEP 2
7 Grease Points: 603472 A/R Multi purpose Texaco Multifak EP2Steering shaftPropshaft grease pointsBattery carrier slide
8 Fuel Tank - 275 Ultra Low Sulphur Diesel City Diesel
9 Urea Tank 660683 17 Urea reagent AdBlue® www.air1.info
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.26
ENVIRO 400
Abbreviations used in this manualABS Anti-Lock Brake System
A/R As required
BSP British Standard Pipe
FEDC Front Electrical Distribution Centre
JIC Joint Industries Council
LH Left Hand
MM Millimetre
NPT National Pipe Thread
NPTF National Pipe Thread Fine
REDC Rear Electrical Distribution Centre
RH Right Hand
SAE Society of Automotive Engineers
Miscellaneous Amended:
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Contents
Engine Amended:070111
Air CleanerAir Cleaner Assembly . . . . . . . . . . . . . . . . Page 2.2 - 3
Cooling SystemCooling System - Voith Transmission . . . . Page 2.4 - 9Cooling System - ZF Transmission . . . . . . Page 2.10 - 15Cooling Pack Assembly . . . . . . . . . . . . . . Page 2.16 - 19Intercooler Assembly . . . . . . . . . . . . . . . . Page 2.20 - 21Header tank Assemblies . . . . . . . . . . . . . . Page 2.22 - 25
Exhaust SystemExhaust Gas Processor System . . . . . . . . Page 2.26 - 29Exhaust Gas Processor System Insulation Page 2.30 - 31Exhaust Gas Processor System Pipework Page 2.32 - 33
Fuel SystemUrea Tank - stainless steel . . . . . . . . . . . . Page 2.34 - 35Urea Tank - plastic . . . . . . . . . . . . . . . . . . Page 2.36 - 37Urea Tank - Identic . . . . . . . . . . . . . . . . . . Page 2.40 - 41Fuel Tank Assembly - Staircase . . . . . . . . Page 2.40 - 41Fuel Tank Assembly - Staircase - Identic . . Page 2.42 - 43Fuel Tank Assembly - Staircase - Posilock Page 2.44 - 45Fuel Tank Assembly - Wheel arch . . . . . . . Page 2.46 - 47Fuel Tank Assembly . . . . . . . . . . . . . . . . .
- Wheel arch - Identic Remote . . . . . . . . . Page 2.48 - 49
Used on & up to Chassis No 4191Fuel System Pipework - Staircase . . . . . . . Page 2.50 - 53Fuel System Pipework - Wheel arch . . . . . Page 2.54 - 57
Used on & up after Chassis No 4192Fuel System Pipework -
. . . . . . . .Wheelarch & Understair Page 2.58 - 59Fuel System Pipework - Engine Fuel Filter Page 2.60 - 61
Hydraulic SystemHydraulic System . . . . . . . . . . . . . . . . . . . Page 2.62 - 67Steering Reservoir Assembly . . . . . . . . . . Page 2.68 - 69Hydraulic Fan Reservoir Assembly . . . . . Page 2.70 - 71
Engine & MountingEngine and Mounting - Voith . . . . . . . . . . . Page 2.72 - 75Engine and Mounting - ZF . . . . . . . . . . . . Page 2.76 - 79Engine oil filler . . . . . . . . . . . . . . . . . . . . . Page 2.80 - 81Engine Service Sundries . . . . . . . . . . . . . . Page 2.82 - 83Alternator Mounting . . . . . . . . . . . . . . . . . Page 2.84 - 85
Heater pipeworkHeater Pipework . . . . . . . . . . . . . . . . . . . . Page 2.86 - 2.87
Air ConditioningAir Conditioning Compressor . . . . . . . . . . Page 2.88 - 2.89
Section 2
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.2
ENVIRO 400
Air Cleaner Amended:200112
Unit No: AC1511A
2
43
5
22
21
7
8
10
9
12
13
14
15
17
6
1
19
20
18
AR1511A
16
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.3
Unit No: AC1511A
Air Cleaner Amended:200112
ITEM PART NO QTY DESCRIPTION REMARKS
1 651031 1 Air Cleaner2 651031-1 1 Element Assembly3 650551-3 1 Nut & gasket assembly4 651031-3 1 Cover assembly5 651031-2 1 Body assembly6 651032 1 Mounting band - air cleaner
MCS 110 20P 4 SetscrewMCN 510P 4 Nut
7 611005-9 2 Clip8 651058 1 Hump hose9 611005-2 2 Clip
10 440751 1 Air intake pipe11 611005-2 2 Clip12 611605 1 Elbow-reducing13 611005-2 1 Clip14 440752 1 Air intake pipe - short15 611005-6 2 Clip16 658566 1 Restriction indicator17 660718 1 Elbow - air outlet
611005-6 2 Clip - pipe to turbo18 434249-1 1 Elbow - inlet pipe
656818-7 2 Clip19 441223 1 Pipe - inlet pipe to compressor 20 434255 1 Elbow - compressor inlet
656818-7 2 Clip21 611007-5 1 Dust valve22 651034-4 1 Clip - dust valve
417594 1 Label - air cleaner
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.4
ENVIRO 400
Cooling System - Voith Transmission Amended:120907
Unit No: R1516A&R1517A
REAR
FRONT
9
2
6
7
19 42
4529
4
3
5
17
1
10
13
37
32
22
26
14
33
28
34
23
25
38
30
8
36
21
24
AR7935V-E400
46
18
12 11
15
35
27
40
20
31
44
4347
16
41
39
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.5
Unit No: R1516A&R1517A
Cooling System - Voith Transmission Amended:260509
ITEM PART NO QTY DESCRIPTION REMARKS
1 429792 1 Header tank assembly (See Separate List)2a 437722 1 Hose - tank fill AL1538-12b 435201-6 1 Hose - tank fill - (Non Enviro 400 bodies) AL1538-3
656818-10 2 Clip3a 440909 1 Filler neck3b 442382 1 Filler neck - Coolant level Check Option OL1541-14 434248-37 1 Hose - breather - tank to neck
656818-1 2 Clip5a 654109 1 Pressure cap5b 659659 1 Pressure cap - lever release (Option - replaces item 5a) OL1520-16 654242 1.75m Hose - drain7 434238-1 1 Hose - upper - sight gauge
656818-1 1 Clip - filler neck656818-2 1 Clip - sight gauge
8 425557 1 Sight gauge assembly430896 1 Front plate - sight glassMCS 1903 16P 4 Screw424128 1 Glass tube657359 2 Grommet436304 1 Bracket - sight glassMCN 103P 2 Nut
9 434238-1 1 Hose - lower - sight gauge)656818-2 1 Clip - sight gauge656818-1 1 Clip - header tank
10 434248-10 1 Hose elbow - tank to bleed pipe656818-2 2 Clip - pipe
11 409853 1 “Y” Bleed pipe12 434248-11 1 Hose - “Y” to bleed pipe
656818-2 2 Clip
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.6
ENVIRO 400
Cooling System - Voith Transmission Amended:120907
Unit No: R1516A&R1517A
REAR
FRONT
9
2
6
7
19 42
4529
4
3
5
17
1
10
13
37
32
22
26
14
33
28
34
23
25
38
30
8
36
21
24
AR7935V-E400
46
18
12 11
15
35
27
40
20
31
44
4347
16
41
39
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.7
Unit No: R1516A&R1517A
Cooling System - Voith Transmission Amended:120907
ITEM PART NO QTY DESCRIPTION REMARKS
13 441227 1 Pipe assembly - bleed14 435198 1 Elbow - radiator
656818-1 1 Clip - pipe656818-2 1 Clip - radiator
15 434248-5 1 Hose assembly - “Y” pipe to elbow656818-2 2 Clip
16 659329-1 1 Elbow - bleed17 434248-22 1 Hose- engine
656818-1 2 Clip18 434776 1 Hose elbow - engine to pipe
656818-10 2 Clip19 440870 1 Pipe - elbow to convolute
403863 2 Bracket - “L” - pipe support20 434263 1 Hose convolute - pipe to pipe
656818-10 2 Clip402421 Bracket strip - P clip
21 440871 1 Pipe - hose to elbow22 434378 1 Hose elbow - 135°- pipe to elbow23 425498 1 Pipe assembly - hose to elbow24 5349-2 1 Plug (also see item 48)
603677 1 Bonded seal25 434375-2 1 Hose elbow - radiator inlet
656818-10 2 Clip26 435199 1 Hose “S” - radiator - Voith
656818-10 2 Clip27 441226 1 Pipe - transmission / radiator / bypass
435139 1 Bracket - pipe support - off transmission28 5349-2 1 Plug (also see item 48)
603677 1 Bonded seal
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.8
ENVIRO 400
Cooling System - Voith Transmission Amended:120907
Unit No: R1516A&R1517A
REAR
FRONT
9
2
6
7
19 42
4529
4
3
5
17
1
10
13
37
32
22
26
14
33
28
34
23
25
38
30
8
36
21
24
AR7935V-E400
46
18
12 11
15
35
27
40
20
31
44
4347
16
41
39
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.9
Unit No: R1516A&R1517A
Cooling System - Voith Transmission Amended:170209
ITEM PART NO QTY DESCRIPTION REMARKS
29 694266 1 Elbow - bypass656818-4 2 Clip
30 441225 1 Pipe - bypass 444775 2 Bracket - pipe support - bellhousing
31 434252-4 1 Hose elbow - connecting - bleed pipes656818-4 2 Clip
32 439876 1 Pipe - bypass - to engine (See page 2.15, item 32 for details of elbow)33 434375-1 1 Hose elbow - transmission cooler - inlet
656818-10 2 Clip34 434246-1 1 Hose - transmission cooler - outlet
656818-10 2 Clip35 440873 1 Pipe assembly - transmission cooler to engine 36 439643 1 Hose elbow - engine inlet
656818-10 2 Clip - pipe to elbow37 434244 1 Hose - fill pipe
656818-9 2 Clip 38 440874 1 Pipe - make up39 434260 1 Hose - reducing elbow - tank outlet
656818-9 2 Clip40 658650 1 Valve - heater supply41 429610 1 Pipe - heater return42 440329 1 “F” Pipe assembly
440977 2 Connector - “F” pipe Torque 55 Nm43 434249-2 1 Hose elbow - “F” pipe44 441165 1 Pipe - heater feed (For further details see saloon heater pipework)45 658650 1 Valve - heater supply46 441166 1 Pipe - heater feed47 660159 1 Valve - coolant test point (Option) OL1524-1&2
652542 1 Reducer - -engine block48 658455-6 1 Drain Valve (Option - replaces items 24 & 28) OL1534-1
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.10
ENVIRO 400
Cooling System - ZF Transmission Amended:030910
Unit No: R1516B&R1517B&D
REAR
FRONT
16
39
GEARBOX COOLER
22
22
9
2
6
7
19 40
38
29
4
3
5
17
1
10
13
ENGINE
HEATERRETURN
SIGHTGAUGE
COOLANT HEADER TANK
HEATERSUPPLY
RA
DIATO
R
35
32
22
26
14
33
28
23
25
36
30
8
34
21
24
AR7936ZF-E400
44
18
12 11
15
33
27
38
20
31
43
4245
39
414146
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.11
Unit No: R1516B&R1517B&D
Cooling System - ZF Transmission Amended:260509
ITEM PART NO QTY DESCRIPTION REMARKS
1 429792 1 Header tank assembly (See Separate List)2a 437722 1 Hose - tank fill AL1538-12b 435201-6 1 Hose - tank fill - (Non Enviro 400 bodies) AL1538-3
656818-10 2 Clip3 440909 1 Filler neck4 434248-37 1 Hose - breather - tank to neck
656818-1 2 Clip5a 654109 1 Pressure cap5b 659659 1 Pressure cap - lever release (Option - replaces item 5a) OL1520-16 654242 1 Hose - drain7 434238-1 1 Hose - upper - sight gauge
656818-1 1 Clip - filler neck656818-2 1 Clip - sight gauge
8 425557 1 Sight gauge assembly430896 1 Front plate - sight glassMCS 1903 16P 4 Screw424128 1 Glass tube657359 2 Grommet436304 1 Bracket - sight glassMCN 103P 2 Nut
9 434238-1 1 Hose - lower - sight gauge)656818-2 1 Clip - sight gauge656818-1 1 Clip - header tank
10 434248-10 1 Hose elbow - tank to bleed pipe656818-2 2 Clip - pipe
11 409853 1 “Y” Bleed pipe12 434248-11 1 Hose - “Y” to bleed pipe
656818-2 2 Clip 13 441227 1 Pipe assembly - radiator bleed
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.12
ENVIRO 400
Cooling System - ZF Transmission Amended:030910
Unit No: R1516B&R1517B&D
REAR
FRONT
16
39
GEARBOX COOLER
22
22
9
2
6
7
19 40
38
29
4
3
5
17
1
10
13
ENGINE
HEATERRETURN
SIGHTGAUGE
COOLANT HEADER TANK
HEATERSUPPLY
RA
DIATO
R
35
32
22
26
14
33
28
23
25
36
30
8
34
21
24
AR7936ZF-E400
44
18
12 11
15
33
27
38
20
31
43
4245
39
414146
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.13
Unit No: R1516B&R1517B&D
Cooling System - ZF Transmission Amended:030910
ITEM PART NO QTY DESCRIPTION REMARKS
14 435198 1 Elbow - radiator656818-1 1 Clip - pipe656818-2 1 Clip - radiator
15 434248-5 1 Hose assembly - “Y” pipe to elbow656818-2 2 Clip
16 659329-1 1 Elbow - bleed17 434248-22 1 Hose- engine
656818-2 2 Clip18 434776 1 Hose elbow - engine to pipe
656818-10 2 Clip 19 440870 1 Pipe - elbow to convolute
403863 2 Bracket - “L” - pipe support400463-8 2 Spacer
20 434263 1 Hose - straight - pipe to pipe656818-10 2 Clip402421 Bracket strip - P clip
21 440871 1 Pipe - hose to elbow22 434378 3 Hose - 45° elbow
656818-10 6 Clip23 425498 1 Pipe assembly - hose to elbow
401825 1 Bracket - pipe support (off fan cowl)24 5349-2 1 Plug (also see item 48)
603677 1 Bonded seal25 434375-2 1 Hose elbow - radiator inlet
656818-10 2 Clip26 434375-2 1 Hose elbow - radiator - Voith
656818-10 2 Clip27 441449 1 Pipe - transmission / radiator / bypass28 5349-2 1 Plug
603677 1 Bonded seal
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.14
ENVIRO 400
Cooling System - ZF Transmission Amended:030910
Unit No: R1516B&R1517B&D
REAR
FRONT
16
39
GEARBOX COOLER
22
22
9
2
6
7
19 40
38
29
4
3
5
17
1
10
13
ENGINE
HEATERRETURN
SIGHTGAUGE
COOLANT HEADER TANK
HEATERSUPPLY
RA
DIATO
R
35
32
22
26
14
33
28
23
25
36
30
8
34
21
24
AR7936ZF-E400
44
18
12 11
15
33
27
38
20
31
43
4245
39
414146
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.15
Unit No: R1516B&R1517B&D
Cooling System - ZF Transmission Amended:080910
ITEM PART NO QTY DESCRIPTION REMARKS
29 444316 1 Elbow - bypass656818-4 2 Clip
30 441451 1 Pipe - bypass 444775 1 Bracket - bypass pipe (off transmission housing)660217-3 1 Clip - high temperature
31 434252-4 1 Hose -connecting - bleed pipes656818-4 2 Clip
32 439876 1 Pipe - bypass - to engine 3287186-101 1 Hose elbow3287185-101 1 Connector - engine block
33 441450 1 Pipe assembly - transmission cooler to engine 440774 1 Bracket - pipe support - downpipe to bellhousing
34 439643 1 Hose elbow - engine inlet656818-10 2 Clip - pipe to elbow
35 434244 1 Hose - fill pipe656818-9 2 Clip
36 440874 1 Pipe - make up441448 1 Plate - mounting - bypass mounting
37 434260 1 Hose - reducing elbow - tank outlet656818-9 2 Clip
38 658650 1 Valve - heater supply39 429610 1 Pipe - heater return40 440329 1 “F” Pipe assembly41 440977 2 Connector - “F” pipe42 434249-2 1 Hose elbow - “F” pipe43 441165 1 Pipe - heater feed44 441166 1 Pipe - heater feed45 660159 1 Valve - coolant test point (Option) OL1524-1
652542 1 Reducer - -engine block46 658455-6 1 Drain Valve (Option - replaces items 24 & 28) OL1534-147 660159 1 Coolant test point (use Volvo Service Tool - 9996049) OL1524-4
652542 1 Reducer652782 1 Elbow - 45 °
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.16
ENVIRO 400
Cooling Pack Assembly Amended:120111
Unit No: R1516A&B. R1517A,B&D
7
9
10
11
8
2
5
18
19
1
23
25
26
440690/441943
16/17
21
20
24
1415
13
1514
12
24
22
3a
3b
27
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.17
Unit No: R1516A&B. R1517A,B&D
Cooling Pack Assembly Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
Used on and up to Chassis No 4363 including 4369 to 4374, 4387 to 4398 & 4402 to 4429. R1516A&B
441943 1 Cooling pack assembly (supercedes 440690)Used on and after Chassis No 4364 to 4368, 4375 to 4386, 4399 to4401, 44300 onwards. R1517A&C
442972 1 Cooling pack assembly - aluminium radiator
1a 427381 1 Radiator Insert1b 442973 1 Radiator Insert - aluminium Supplied c/w rubber mountings Can be fitted to earlier pack 4419432 435179-2 1 Fan cowl
MCS 106 16P 17 Setscrew - cowlWMA 6SP 17 Washer - springWMC 6SP 17 Washer - plain
3b 661142 1 Fan Blade - plastic (Used on Chassis No 4146 & after 4148 onwards)406935 1 Hub - plastic fan blade
3b 659981 1 Fan Blade - metal (Used up to Chassis No 4145 & 4147) 4 435179-4 1 Fan motor/carrier bracket - “top hat”
MCB 108 30P 4 Bolt - carrier to cowl652361 4 Washer - plainWMC 12SP 4 Washer - springMCN 508P 4 Nut
5 435179-3 2 Fan carrier arm6 661124 1 Fan motor (660051)
658086-1 1 Seal kitMCB 108 40P 4 BoltMCN 508P 4 Nut
7 659137 2 Flexible mounting - radiatorMCS 108 20P 4 Setscrew - mountingMCN 508P 4 Nut - mounting
NOTE : Valvoline Antifreeze, to Cummins 14603, must be used forvehicles fitted with an Aluminium Radiator Insert .
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.18
ENVIRO 400
Cooling Pack Assembly Amended:260609
Unit No: R1516A&B. R1517A,B&D
7
9
10
11
8
2
5
18
19
1
23
25
26
440690/441943
16/17
21
20
24
1415
13
1514
12
24
22
3a
3b
27
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.19
Unit No: R1516A&B. R1517A,B&D
Cooling Pack Assembly Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
8 190036 2 Washer - rebound 57 o/d9 409042 2 Washer clamp 30 o/d
10 MCB 112 85P 2 Bolt - mounting- radiator11 MCN 512P 2 Nut - mounting- radiator12 419390 1 Stud - straight - radiator mounting13 MCN 510P 4 Nut- self locking14 211401 8 Backing washer15 211402 4 Mounting rubber16 MCN 110P 8 Nut - plain17 MCN 210P 8 Nut - plain - half18 440690-1 1 Oil cooler
MCS 108 20P 2 SetscrewWMC 8SP 2 Spring washer
19 435466 1 Flyscreen425472-13 3 Retainer425472-14 3 Clip425472-15 3 Stud660157-4 1 Seal - rubber - flyscreen - lower660157-3 1 Seal - rubber - flyscreen - RH660157-9 1 Seal - rubber - flyscreen - LH
20 430554 1 Charge cooler Insert21 440690-5 1 Radiator frame22 659386 1 Hose adaptor - radiator top tank23 428035-4 1 Recirculating shield - RH - oil cooler24 428035-5 1 Recirculating shield - LH25 428035-6 1 Recirculating shield - top26 425472-10 1 Frame - bottom rail27 448050 1 Lower sealing plate
RADIATOR FOAM FILTER AL1550-1661333 1 Radiator filter kit661333-1 1 Filter - foam
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.20
ENVIRO 400
Intercooler Assembly Amended:120907
Unit No: R1516B&C. R1517A,B&D
3
37
11
6
3
2
3 5
3
11
R1516-E400
12
12
3
9
10
8
4
1
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.21
Unit No: R1516B&C. R1517A,B&D
Intercooler Assembly Amended:120907
ITEM PART NO QTY DESCRIPTION REMARKS
1 611005-15 1 Clip tee bolt - turbo2 415733 1 Elbow - engine outlet3 611005-3 6 Clip - tee bolt4 441236 1 Pipe assembly - engine to intercooler5 415733 1 Hose 45° - intercooler to pipe6 430554 1 Charge cooler Insert7 413894 1 Hose - convolute8 441237 1 Pipe assembly - intercooler to turbocharger9 422764 1 Hose reducer - pipe to inlet manifold
10 611005-29 1 Clip - tee bolt11 656160-17 2 U clamp - pipe to engine frame12 426681 2 Bracket - U clamp
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.22
ENVIRO 400
Header Tank Assembly Amended:130111
Unit No: R1516B&C. R1517A,B&D - 429792,444689,OL1541-1 & OL1541-2
429792/444689-E400
1
54
3
3
6
5
4
2
7
8
COOLANT
OK TOP UP
PUSH TO CHECK
11
9
12
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.23
Unit No: R1516B&C. R1517A,B&D - 429792,444689,OL1541-1 & OL1541-2
Header Tank Assembly Amended:110111
ITEM PART NO QTY DESCRIPTION REMARKS
1a 429792 1 Header tank assembly R1516B&C. R1517A&B2 428069-1 1 Insert - header tank (SL2125 - S/S replacement)3 428071-1 2 Insert - header tank 4 652489 1 Probe - coolant level5 652490 1 Grommet - coolant level probe6 658286-1 1 Insert - header tank 7 432308 2 Strap assembly - header tank 8 656768 2 Rubber strip - self adhesive - header tank brackets 0.5m
1b 444689 1 Header tank assembly - no probe R1517D443566 1 header tank and inserts
2 428069-1 2 Insert - header tank 3 428071-1 1 Insert - header tank 6 658286-1 1 Insert - header tank 9 660911 3 Plug
COOLANT LEVEL CHECK - WPO53424 OL1541-11c 442377 1 Header tank assembly - replaces 429792
442382 1 Filler neck (Replaces 440909 - no sight glass)442363 1 Kit - coolant check:
11 661230 1 Module - push button - coolant check442361 1 Harness - coolant check
COOLANT LEVEL CHECK - WPO53770 & WPO53789 OL1541-21d 442377 1 Header tank assembly - replaces 429792
442382 1 Filler neck (Replaces 440909 - no sight glass)11 661843 1 Module - push button - coolant check
446179 1 Harness - link - top up12 661850 1 Switch - coolant level
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.24
ENVIRO 400
Header Tank Assembly - Stainless Steel Amended:180310
Unit No: R1517D - 447030
447101-SS-HK
3
3
2
10
6a
4
7
9
8
5
6b
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.25
Unit No: R1521A - 447030
Header Tank Assembly - Stainless Steel Amended:130111
ITEM PART NO QTY DESCRIPTION REMARKS
Used on and after Chassis No 5419 not including 5334 & 5378447030 1 Header Tank Assembly - stainless steel
1 447031 1 Header tank2 447061 1 Insert assembly - filler / breather 95mm3 441814 2 Insert assembly - vent tube 260mm4 659329-2 1 Elbow - header tank5 606078-34 2 Plug6a 660864 1 Sensor - coolant level7 432492 2 Strap assembly - header tank 8 MCN 506P 2 Nut9 WMA 6SP 2 Washer - plain10 656768 0.5m Rubber strip - self adhesive - header tank brackets
SL2297 1 Conversion kit - plastic to stainless - 1st Gen with sight glassIncludes items 2,3,5
447269 1 Header Tank Assembly - stainless steel652370-2 2 Probe - coolant level5349-2 1 Plug603677 1 Seal - dowtySL2298 1 Conversion kit - plastic to stainless - 1st Gen with level check
Includes items 2,3,5447269 1 Header Tank Assembly - stainless steel652370-2 3 Probe - coolant level
SL2299 1 Conversion kit - plastic to stainless - 2nd Gen with sight glassIncludes items 2,3,4,5 (Sensor 660864 to be removed from original)
447031 1 Header Tank Assembly - stainless steel
SL2300 1 Conversion kit - plastic to stainless - 2nd Gen with level checkIncludes items 2,3,5 (Sensor 660864 to be removed from original)
447031 1 Header Tank Assembly - stainless steel
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.26
ENVIRO 400
EGP - Exhaust Gas Processor System Amended:080311
Unit No: EGP1510A,B,C,D,H&J
660872/661131/661262 EGP
FROM TURBO
3
5
16
17
13
4
3
6
7
8
9
10a
11
12
13
14
15
19
20
2526
2
1
22
23
13
21
1324
SOFT LAGGING HARD LAGGING
EURO 4+EURO 5-
10b
18
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.27
Unit No: EGP1510A,B,C,D,H&J
EGP - Exhaust Gas Processor System Amended:080311
ITEM PART NO QTY DESCRIPTION REMARKS
660872 1 EGP Kit - Euro 4 - jacket lagging (BEIGE engine) EGP1510A&B
661131 1 EGP kit - Euro 4+ - hard lagging (RED engine) EGP1510C
661262 1 EGP kit - Euro 5- hard lagging (RED engine) EGP1510D,H&J
1 660898 1 Clamp - Vee type - Turbocharger outlet2a 660872-4 1 Pipe assembly - turbocharger outlet - jacket lagging EGP1510A&B2b 661131-2 1 Pipe assembly - turbocharger outlet - hard lagging EGP1510C,D,H&J3 660941 2 Clamp - Vee type - Pipes to flexible4 660872-5 1 Flexible pipe5a 660872-6 1 Pipe assembly - flexible to EGP inlet - jacket lagging EGP1510A&B5b 661131-3 1 Pipe assembly - flexible to EGP inlet - hard lagging EGP1510C,D,H&J6 4936201-101 1 Nozzle - Injector EGP
4935801-101 1 Nut - EGP Injector7 660942 1 Clamp - stepped - pipe to EGP8 661148-7 1 Thermister - Inlet9 661148-7 1 Thermister - outlet10a 660872-2 1 EGP Silencer assembly - Euro 4 without NOX sensor (BEIGE engine)10b 661262-1 1 EGP Silencer assembly - Euro 4+ & Euro 5- with NOX sensor (RED engine)
661915 1 NOX sensor - Euro 4+ & Euro 5 11 660943 1 Clamp - stepped - EGP to tailpipe12 660872-7 1 Tailpipe13 660890 7 Mount -high temperature
MCN 110P 14 NutWMA 10SP 14 Washer - PlainWMC 10SP 14 Washer - Spring211401 6 Backing washer
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.28
ENVIRO 400
EGP - Exhaust Gas Processor System Amended:080311
Unit No: EGP1510A,B,C&D
660872/661131/661262 EGP
FROM TURBO
3
5
16
17
13
4
3
6
7
8
9
10a
11
12
13
14
15
19
20
2526
2
1
22
23
13
21
1324
SOFT LAGGING HARD LAGGING
EURO 4+EURO 5-
10b
18
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.29
Unit No: EGP1510A,B,C&D
EGP - Exhaust Gas Processor System Amended:080311
ITEM PART NO QTY DESCRIPTION REMARKS
14 440815 1 Bracket - tailpipe support15 657374 1 “U” Pipe clamp - tailpipe support16 660873 3 Band clamp - EGP mounting17 440649 2 Mounting Bracket - EGP18 661915 1 NOX sensor - Euro 4+ & Euro 5- (RED engine) EGP1510D,H&J19 440652 1 Heat shield assembly - EGP - side20 611005-27 2 Band clamp - heatshield to EGP21 440753 1 Bracket - pipe support - use with jacket lagging Euro 422 441951 1 Bracket - mount - use with hard lagging Euro 4+ & Euro 5-23 441952 1 Bracket - clamp - use with hard lagging Euro 4+ & Euro 5-24 611005-15 1 Clamp - tee bolt type - bracket to pipe25 440774 1 Bracket - pipe support - downpipe to bellhousing
400622-76 4 SpacerMCS 116 25P 2 SetscrewMCN 16SP 2 Nut
26 656160-18 1 “U” Pipe clamp - tailpipe support400622-76 2 Spacer
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.30
ENVIRO 400
EGP - Exhaust Gas Processor System - Insulation Amended:061112
Unit No: EGP1510A,B&C
1
4
2
3
5
660872-11 - E400/A
TURBOOUTLETEGP INLET
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.31
Unit No: EGP1510A,B&C
EGP - Exhaust Gas Processor System - Insulation Amended:080107
ITEM PART NO QTY DESCRIPTION REMARKS
660872-11 1 KIT - INSULATION JACKETS:
1 660872-12 1 Jacket - turbo pipe outlet (not required for hard lagged pipe)2 660872-13 1 Jacket - flexible pipe outlet3 660872-14 1 Jacket - decomp pipe (not required for hard lagged pipe)4 660872-15 1 Jacket - EGP inlet pipe5 660872-16 13 Clip - insulation jackets
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.32
ENVIRO 400
EGP - Exhaust Gas Processor System - Pipework Amended:070111
Unit No: EGP1510A,B,C,D,E,H&J
AirFilter
Dosing Unit
UREA Tank
1
UREA�IN
UREA�OUT
AIR�IN
MIX�OUT
AR7972
EXHAUSTGAS
PROCESSOR
9
AUXILIARY &SUSPENSIONRESERVOIR
SUPPLYFROM
AIR DRYER
OR
2
3
6
4
5
7
8
8
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.33
Unit No: EGP1510A,B,C,D,E,H&J
EGP - Exhaust Gas Processor System - Pipework Amended:070111
ITEM PART NO QTY DESCRIPTION REMARKS
660872-3 1 Urea Pipework Kit - comprising:1a 660809-12 1 Doser to Injector pipe - braided1b 660872-8 1 Doser to Injector pipe - nylon
660809-14 * 1 Ferrule - braided pipe660809-15* 1 Nut - braided pipe
2 660872-9 1 Doser to Urea tank - feed3 660872-10 1 Urea Tank to doser unit - return4 - 1 Urea Tank (See separate lists)
MCS-106-25P 4 Setscrew M6 x 16 - tank to frameMCN-506P 4 Nut - self locking
5 660681 1 Air filter660681-2 Elbow660681-1 1 CartridgeMCS-108-55P 4 Setscrew M6 x 16 - tank to frameMCN-508P 4 Nut - self locking
6 4931694 1 Dosing Unit660613-1 1 Connector - “air in”660613-2 1 Connector - “mix out”660613-3 1 Connector - “urea out”660613-4 1 Connector - “urea in”MCS-108-30P 4 Setscrew M6 x 16 - tank to frameMCN-508P 4 Nut - self locking441387 1 Protection plate - doser unit (WPO53220 only) EGP1510A441364 1 Protection plate - doser unit EGP1510B441128 1 Mounting plate - doser unit
7 4936201 1 Nozzle - Injector EGP4935801 1 Nut - EGP Injector
8 660035-2 2 Clip - urea pipe9 661915 1 Nox Sensor
NOTE:IF REPLACING THE INJECTION NOZZLE FITTED WITH ABRAIDED PIPE, A NEW NUT AND FERRULE WILL BE REQUIRED.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.34
ENVIRO 400
Fuel System - Urea Tank Assembly Amended:070111
Unit No: EGP1510A,B,C - 440724-2. EGP1510D,H - 442431-2
1
3
24
440724-2
6
9
58 10
3
2
9
5
442431-2
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.35
Unit No: EGP1510A,B,C - 440724-2. EGP1510D,H - 442431-2
Fuel System - Urea Tank Assembly Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
440724-2 1 Urea Tank assembly - 19 litres EGP1510A,B&C442431-2 1 Urea Tank assembly - 30.7 litre EGP1510D,H
1a 440725 1 Urea Tank - 19 litres1b 442432 1 Urea Tank - 30 litres
MCS 108 25P 4 SetscrewMCN 508P 4 Nut
2 660739 1 Magnet adaptor3 660751 1 Cap - tank4 660767 1 Plug - drain5 660876 1 Sender unit - urea tank
660876-1 1 “O” ring - sender unit6 660828 1 Filter - Urea7 417362 1 Breather SL21518 442375 1 Bracket - breather mounting9 651787 0.5m Tube - tank to valve
607007 1 Cable tie - tube to tank660035-5 1 Clip tube to breather
10 654242 A/R Tube
Urea Tank Mounting - Wheelarch mounted fuel tank only OL1538-1MCB 108 50P 4 Bolt400622-39 4 SpacerWMC 8SP 4 Washer -springWMA 8SP 4 Washer -Plain
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.36
ENVIRO 400
Fuel System - Urea Tank Assembly - Plastic Amended:070111
Unit No: EGP1510J - 446320-2
16
446242-1
2
3,5,6
4
137,8
9
1011
12
15
14
17
16
18
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.37
Unit No: EGP1510J - 446320-2
Fuel System - Urea Tank Assembly - Plastic Amended:070111
ITEM PART NO QTY DESCRIPTION REMARKS
1 446240 1 Urea Tank - 30 litresMCS 108 25P 4 SetscrewMCN 508P 4 Nut
2 660876 1 Sender unit - urea tank3 661037 1 Filler neck4 661036 1 Cap - urea tank5 661044 1 “O” ring - filler neck6 660739 1 Magnet adaptor7 661040 1 Plug - drain8 661041 1 “0” ring seal9 446257 1 Gasket - urea sender
10 446256 1 Mounting plate - urea sensor11 MCS 3308 16S 6 Screw - socket head12 658286-1 1 Tank insert13 660828 1 Filter - Urea14 417362 1 Breather15 442375 1 Bracket - breather mounting16 651787 0.5m Tube - tank to valve
660035-5 1 Clip tube to breather17 654242 A/R Tube
447097 1 Clamp - urea tank
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.38
ENVIRO 400
Fuel System - Urea Tank Assembly - Identic Amended:070308
Unit No: OL1536-1,OL1536-2
5/6
23
4
7
89
OL1536-1
1
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.39
Unit No: OL1536-1,OL1536-2
Fuel System - Urea Tank Assembly - Identic Amended:070308
ITEM PART NO QTY DESCRIPTION REMARKS
Used on and up to Chassis No 4306441310 1 Urea Tank assembly - Used on Euro 4 OL1536-1
1a 441308 1 Urea Tank Used on & after Chassis No 4307
442482 1 Urea Tank assembly - Used on Euro 4+ OL1536-21b 442483 1 Urea Tank
2 660739 1 Magnet adaptor3 660751 1 Cap - tank4 660767 1 Plug - drain5 660876 1 Sender unit - urea tank6 660828 1 Filter - Urea7 441784 1 Urea sensor - identic filler8 441299 1 Adaptor plate - urea sensor9 441326 1 Gasket - adaptor plate
10 MCS 3604 10 8 Capscrew
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.40
ENVIRO 400
Fuel Tank Assembly - Staircase Amended:140907
Unit No: FS1514A&D. FS1515A,E,F&J
2322 21
24
1
2
3
6,7
8
440866/442220-STD
14
16
14
10
15
17
1213
15
14
16
15
14
16
101213
15
1416
14
19
10
18
204
9
13
11
4
8
5
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.41
Unit No: FS1514A&D. FS1515A,E,F&J
Fuel Tank Assembly - Staircase Amended:140907
ITEM PART NO QTY DESCRIPTION REMARKS
440866 1 Fuel tank assembly 442220 1 Fuel tank assembly - stainless steel FS1515E
1 440367 1 Fuel tank2 603678 2 Seal3 5349-3 2 Plug 4 657829 2 Gasket5 441020 1 Filler neck assembly6 658137 1 Filler cap
650189 A/R Loctite7 658137-1 2 Washer8 MCS 106 16P 12 Setscrew9 440783 1 Bracket - tank support - “Z”10 438628 3 Rubber strip - tank isolator11a 440784 1 Angle bracket - tank support rear - 19 litre Urea Tank - Euro 411b 442414 1 Angle bracket - tank support rear - 30.7 litre Urea Tank - Euro 4+12 WMA 8SP 18 Washer - plain13 MCN 508P 15 Nut - full 14 652361 19 Washer - large15 10 MCB 108 50 D 9 Bolt - tank mounting16 432210 9 Mounting rubber17 MCS 108 25P 9 Setscrew - support brackets18 439230 1 Plate - top mounting19 439228 1 Tank mounting - top20 426083 1 Blanking plate
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.42
ENVIRO 400
Fuel Tank Assembly - Identic Filler Amended:140907
Unit No: FS1514C&F. FS1515C&H
AR7717-440766
1
2
3
6,7
8
AR7717-440766
14
16
14
10
15
17
1213
15
14
16
15
14
16
101213
15
1416
14
19
10
18204
9
13
11
23
21
4
8
23 2224
2526
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.43
Unit No: FS1514C&F. FS1515C&H
Fuel Tank Assembly - Identic Filler Amended:140907
ITEM PART NO QTY DESCRIPTION REMARKS
440766 1 Fuel tank assembly - Identic:
1 440367 1 Fuel tank2 603678 2 Seal3 5349-3 2 Plug 4 657829 2 Gasket5 441026 1 Filler neck assembly - Identic6 658137 1 Filler cap
650189 A/R Loctite7 658137-1 2 Washer8 MCS 106 16P 12 Setscrew9 440783 1 Bracket - tank support - “Z”
10 438628 3 Rubber strip - tank isolator11a 440784 1 Angle bracket - tank support rear - 19 litre Urea Tank - Euro 411b 442414 1 Angle bracket - tank support rear - 30.7 litre Urea Tank - Euro 4+
12 WMA 8SP 18 Washer - plain13 MCN 508P 15 Nut - full 14 652361 19 Washer - large15 10 MCB 108 50 D 9 Bolt - tank mounting16 432210 9 Mounting rubber17 MCS 108 25P 9 Setscrew - support brackets18 439230 1 Plate - top mounting19 439228 1 Tank mounting - top20 440789 1 Plate - sender mounting - Identic21 660708-1 1 Identic level sensor c/w cable22 656706-5 1 Coupling - spill free23 656709-9 1 Hose - re-inforced24 656706-10 1 Hose clip25 MCS 3605 16P 2 Screw26 WMC 5SP 2 Washer - spring
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.44
ENVIRO 400
Fuel Tank Assembly - Posilock Filler Amended:140907
Unit No: FS1514E. FS1515B&G
AR7717-440766
1
2
3
21
AR7717-440766
14
16
14
10
15
17
1213
15
14
16
15
14
16
101213
15
1416
14
19
10
18
204
9
13
11
4
8
5
7
6
8
22
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.45
Unit No: FS1514E. FS1515B&G
Fuel Tank Assembly - Posilock Filler Amended:260509
ITEM PART NO QTY DESCRIPTION REMARKS
441037 1 Fuel tank assembly - posilock:
1 441733 1 Fuel tank2 603678 1 Seal3 5349-3 1 Plug 4 657829 2 Gasket5 441901 1 Filler neck assembly - Posilock6 658570-1 1 Filler cap - posilock flip cap
658570-3 1 Filler cap658570-4 1 Dust seal658570-5 1 Spring clip
7 657002 1 Filler adaptor8 MCS 106 16P 12 Setscrew9 440783 1 Bracket - tank support - “Z”
10 438628 3 Rubber strip - tank isolator11a 440784 1 Angle bracket - tank support rear - 19 litre Urea Tank - Euro 411b 442414 1 Angle bracket - tank support rear - 30.7 litre Urea Tank - Euro 4+
12 WMA 8SP 18 Washer - plain13 MCN 508P 15 Nut - full 14 652361 19 Washer - large15 10 MCB 108 50 D 9 Bolt - tank mounting16 432210 9 Mounting rubber17 MCS 108 25P 9 Setscrew - support brackets18 439230 1 Plate - top mounting19 439228 1 Tank mounting - top20 439512 1 Valve mounting plate21 659405 1 Pressure relief valve assembly
659405-1 1 Gasket22 660965 1 Level control valve assembly
657059-1 1 Gasket23 661102 1 Tube - posilock filler
661130 1 Vent kit - body
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.46
ENVIRO 400
Fuel Tank Assembly - Wheelarch Amended:231008
Unit No: FS1514G. FS1515D&L. OL1521-6
FS1514G-434911
1
4,5
14
15
16
12
1718
3
6
62
37
8
910
11
13
15
14
16
19
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.47
Unit No: FS1514G. FS1515D&L. OL1521-6
Fuel Tank Assembly - Wheelarch Amended:100209
ITEM PART NO QTY DESCRIPTION REMARKS
434911 1 Fuel tank assembly - steel FS1514G/FS1515D434913 1 Fuel tank assembly - stainless steel FS1515L5349-3 1 Plug603678 1 Seal
1a 434914 1 Fuel tank - steel2a 434932 1 Filler neck assembly1b 434915 1 Fuel tank - stainless steel2b 434934 1 Filler neck assembly
3 657829 1 Gasket - blanking plate4 658137 1 Filler cap
650189 A/R Loctite5 658137-1 2 Washer6 MCS 106 20P 6 Setscrew
7a 426083 1 Plate - blanking8 431429 1 Plinth - tank support - rear9 MCS 108 25P 3 Setscrew - support brackets
10 WMA 8SP 3 Washer - plain11 MCN 508P 3 Nut - full 12 427829 1 Rubber strip - tank isolator - rear13 427827 1 Rubber strip - tank isolator - front14 10 MCB 108 50 D 6 Bolt - tank mounting15 652361 6 Washer - large16 432210 6 Mounting rubber17 WMA 8SP 6 Washer - plain18 MCN 508P 6 Nut - full
FUEL TANK SENDER UNIT OL1521-67b 439123 1 Plate - fuel sender19 660534-3 1 Fuel tank sender unit
445420 1 Harness - sender unit
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.48
ENVIRO 400
Fuel Tank Assembly - Wheelarch - Remote identic Filler Amended:100209
Unit No: FS1515P
FS1515P-445315
1
4,5
14
15
16
12
1718
3
6
62
37
8
910
11
13
15
14
16
20
21
19
22
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.49
Unit No: FS1515P
Fuel Tank Assembly - Wheelarch - Remote Identic Filler Amended:130111
ITEM PART NO QTY DESCRIPTION REMARKS
445315 1 Fuel tank assembly - identic - remote5349-3 1 Plug603678 1 Seal
1 434914 1 Fuel tank - steel2 434932 1 Filler neck assembly3 657829 1 Gasket - blanking plate4 658137 1 Filler cap
650189 A/R Loctite5 658137-1 2 Washer6 MCS 106 16P 12 Setscrew7 445316 1 Plate - Identic remote8 447259 1 Plinth - tank support - rear SL22969 MCS 108 25P 3 Setscrew - support brackets
10 WMA 8SP 3 Washer - plain11 MCN 508P 3 Nut - full 12 427829 1 Rubber strip - tank isolator - rear13 427827 1 Rubber strip - tank isolator - front14 10 MCB 108 55 D 6 Bolt - tank mounting15 652361 6 Washer - large16 432210 6 Mounting rubber17 WMA 8SP 6 Washer - plain18 MCN 508P 6 Nut - full 19 661741 1 Kit - Identic filler c/w clips20 661742 1 Filler hose21 661743 1 Breather hose22 661740 1 Kit - identic comprising:
658763-1 1 Armour hose658763-4 1 Weight658763-2 1 Level sensor656818-5 1 Hose clip
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.50
Fuel System Pipework - Staircase Amended:050407
Unit No: FS1514A,C,D,E&F
3
FS1514A-F
FUEL SHUT OFF VALVE
4
26
31
5 12
11
9
1,2
14
13
15
24
18
16
17
13
10
7
25
7
6
8
23
20
19
20
1824
FUEL SHUT OFF VALVES
WITHOUT FUELSHUT OFF VALVE
WITHOUT FUELSHUT OFF VALVE
3029
32
10 mm BLACK
21
ENGINE FUEL
DISTRIBUTIONPOINT
12 mm BLACK
41
40
37 38 39
SUPPLY
33
3334
35
36
RETURN
27,28
ENVIRO 400
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.51
Unit No: FS1514A,C,D,E&F
Fuel System Pipework - Staircase Amended:080710
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & up to Chassis No 4191
1 656181 1 Elbow - tank feed2 655832-3 1 Sleeve - 12mm3 654993 A/R Pipe - nylon - black - 12mm4 660535-8 1 Connector - feed
655832-3 1 Sleeve - 12mm5 654916-7 1 Adaptor6 441175 1 Pipe assembly 7 651936 1 Adaptor8 441176 1 Pipe assembly 9 441177 1 Pipe assembly - fuel filter inlet
10 660151 1 Adaptor pipe to valve11 658188 1 Valve12 660744 1 Adaptor13 660643-1 2 Adaptor - fuel filter inlet / outlet14 659523 1 Fuel filter
659523-1 1 Element - fuel filter659523-2 1 Harness - sensor659523-3 1 Sensor - water in fuel660975 2 Plug - blanking
15 441114-1 1 Hose assembly - 16 655443 1 Bulkhead connector17 441078 1 Bracket - bulkhead connector mounting18 441178 1 Pipe assembly - to engine fuel manifold19 654909-3 1 Connector - manifold inlet20 661099 2 Reducer21 - - “O” ring22 - - “O” ring23 654933-3 1 Elbow - manifold outlet
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.52
ENVIRO 400
Fuel System Pipework - Staircase Amended:050407
Unit No: FS1514A,C,D,E&F
3
FS1514A-F
FUEL SHUT OFF VALVE
4
26
31
5 12
11
9
1,2
14
13
15
24
18
16
17
13
10
7
25
7
6
8
23
20
19
20
1824
FUEL SHUT OFF VALVES
WITHOUT FUELSHUT OFF VALVE
WITHOUT FUELSHUT OFF VALVE
3029
32
10 mm BLACK
21
ENGINE FUEL
DISTRIBUTIONPOINT
12 mm BLACK
41
40
37 38 39
SUPPLY
33
3334
35
36
RETURN
27,28
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.53
Unit No: FS1514A,C,D,E&F
Fuel System Pipework - Staircase Amended:010708
ITEM PART NO QTY DESCRIPTION REMARKS
24 438724-2 1 Hose assembly - from engine25 660535-6 1 Connector - return26 654992 A/R Pipe - nylon - black - 10mm27 655842 1 Elbow - tank return28 655832-1 1 Sleeve - 10mm29 417362 1 Breather valve30 655164 1 Elbow - breather31 651548 A/R Pipe - nylon - black - 8mm32 654242 A/R Pipe - PVC - clear - 6mm33 603678 2 Bonded seal34 650133 1 Connector35 661076 1 Valve - non return36 655842 1 Connector
655832-1 1 Sleeve - 10mm37 660136 1 Elbow - tank supply AR790438 660854-1 1 Connector
655832-3 1 Sleeve - 12mm39 660855 1 Valve - solenoid - fuel shut off40 654927-3 1 Adaptor41 658204 1 Connector
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.54
ENVIRO 400
Fuel System Pipework - Wheelarch Amended:050407
Unit No: FS1514G
5
FS1514C
FUEL SHUT OFF VALVE
6
26
7
14
13
11
16
15
17
24
20
18
19
15
12
9
25
9
8
10
23
22
21
22
2024
3332
35
10 mm BLACK
21
ENGINE FUEL
DISTRIBUTIONPOINT
12 mm BLACK
325L
31
30
27 28 29
SUPPLY
1
12
3
4
34
RETURN
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.55
Unit No: FS1514G
Fuel System Pipework - Wheelarch Amended:231008
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & up to Chassis No 41911 603678 2 Bonded seal2 650133 1 Connector3 661076 1 Valve - non return4 655842 1 Connector
655832-1 1 Sleeve - 10mm5 654993 A/R Pipe - nylon - black - 12mm6 660535-8 1 Connector - feed
655832-3 1 Sleeve - 12mm7 654916-7 1 Adaptor8 441175 1 Pipe assembly 9 651936 1 Adaptor
10 441176 1 Pipe assembly 11 441177 1 Pipe assembly - fuel filter inlet12 660151 1 Adaptor pipe to valve13 658188 1 Valve14 660744 1 Adaptor15 660643-1 2 Adaptor - fuel filter inlet / outlet16 659523 1 Fuel filter
659523-1 1 Element - fuel filter659523-2 1 Harness - sensor659523-3 1 Sensor - water in fuel660975 2 Plug - blanking
17 441114-1 1 Hose assembly - 18 655443 1 Bulkhead connector19 445491 1 Bracket - bulkhead connector mounting20 441178 1 Pipe assembly - to engine fuel manifold21 654909-3 1 Connector - manifold inlet22 661099 2 Reducer
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.56
ENVIRO 400
Fuel System Pipework - Wheelarch Amended:120906
Unit No: FS1514G
5
FS1514C
FUEL SHUT OFF VALVE
6
26
7
14
13
11
16
15
17
24
20
18
19
15
12
9
25
9
8
10
23
22
21
22
2024
3332
35
10 mm BLACK
21
ENGINE FUEL
DISTRIBUTIONPOINT
12 mm BLACK
325L
31
30
27 28 29
SUPPLY
1
12
3
4
34
RETURN
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.57
Unit No: FS1514G
Fuel System Pipework - Wheelarch Amended:050407
ITEM PART NO QTY DESCRIPTION REMARKS
23 438724-2 1 Elbow - manifold outlet24 438724-2 1 Hose assembly - from engine25 660535-6 1 Connector - return
655832-1 1 Sleeve - 10mm26 654992 A/R Pipe - nylon - black - 10mm27 660136 1 Elbow - tank supply AR790428 660854-1 1 Connector
655832-3 1 Sleeve - 12mm29 660855 1 Valve - solenoid - fuel shut off30 654927-3 1 Adaptor31 658204 1 Connector32 417362 1 Breather valve33 655164 1 Elbow - breather34 651548 A/R Pipe - nylon - black - 8mm35 654242 A/R Pipe - PVC - clear - 6mm
441671 1 Harness - fuel cut out valve
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.58
ENVIRO 400
Fuel System Pipework - Wheelarch & Staircase Amended:060308
Unit No: FS1515A,B,C,D&L
FS1515A-C
FUEL SHUT OFF VALVE
3
1
2
4
5
TO FUEL PUMP
RETURNFROMFUELPUMP
10 mm BLACK
21
ENGINE FUEL
DISTRIBUTIONPOINT
12 mm BLACK
Used on & after Chassis No 4192
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.59
Unit No: FS1515A,B,C,D&L
Fuel System Pipework - Wheelarch & Staircase Amended:060308
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & after Chassis No 41921 441342 1 Bulkhead connector
654960 1 Locknut2 4943865-101 1 Connector - bulkhead fitting3 4941856-101 1 Hose assembly - bulkhead fitting to fuel pump4 661099 1 Reducer5 654909-3 1 Connector
All other parts as previous pages
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.60
ENVIRO 400
Fuel System Pipework - Engine Fuel Filter Amended:110111
Unit No: FS1515A,B,C,D&L
'C'
'B'
'B''C'
'A'
TYPICAL CLIPPING
FUEL PUMP
6
6
3
4
1
4
3
2
2
2
3
42
2
34
5
6
78
14
10
9
11
12
13
15
Used on & after Chassis No 4192
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.61
Unit No: FS1515A,B,C,D&L
Fuel System Pipework - Engine Fuel Filter Amended:110111
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & after Chassis No 41921 441433 1 Plate - fuel hose mounting2 661169 5 Stud - sump3 WMA 6SP 5 Washer - plain4 MCN 506P 5 Nut - self locking5 401825 1 Bracket - hose mounting6 418888 2 Bracket - hose mounting7 656844 5 Spacer8 610808-1 5 Cable tie9 442111 1 Spacer plate - filter mounting
10 400622-121 3 Spacer - filter mounting plate11 MCB 112 45P 2 Bolt12 MCB 112 35P 2 Bolt13 WMC 12SP 2 Washer - Spring14 MCN 512P 2 Nut - self locking15 4941856-101 2 Hose assembly - supply / return
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.62
ENVIRO 400
Hydraulic System Amended:110407
Unit No: HS1517A&C. HS1518A&C
OILCOOLER
1
2
32
FAN PUMP
STEER PUMPSTEERING
BOX
OIL FILTER
FAN MOTOR
TESTPOINT
TESTPOINT
STEERING
FAN
8,91013111312
2221 1323 26/2724
40 41
3637
14
5
44
20
45
6
38
15
1617
18
28
4649
50
33
28
3
35
4
4 34
7
19
2513
29/30
31
42
43
43
47 4748
52
39
39
51
53
AR7934/AR8167
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.63
Unit No: HS1517A&C. HS1518A&C
Hydraulic System Amended:140710
ITEM PART NO QTY DESCRIPTION REMARKS
1 655644 1 Steering reservoir assembly (see separate list)2 441116-1 1 Hose assembly - reservoir to pipe
656818-7 2 Clip3a 440988 1 Pipe assembly - reservoir to tandem pump elbow3b 440990 1 Pipe assembly - suction pipe - steering - drain valve type
658445-6 1 Drain valve4 656732 2 Elbow - tandem pump5 661123 1 Tandem pump
657514-1 1 Seal kit - tandem pump658063 1 Gasket - pump to compressor439972 1 Bracket - tandem pump support - for use with original pump 659674441897 1 Bracket - tandem pump support - for use with later pump 661123UFN 506AP 2 Nut - pump to bracket WLA 6SP 2 Washer - plain - pump to bracketMCS 112 25P 2 Bolt - bracket to engineWLA 12SP 2 Washer - bracket to engineWLC 12SP 2 Washer - bracket to engine
6 653810 1 Adaptor - steering pump outlet7 440234 1 Hose - tandem pump to connector
443322 1 Support plate610029-4 1 “P” clip - hose660217-1 1 “P” clip - high temperature - pipe
8 654957-1 1 Connector - hose to pipe9 654958-1 1 Locknut
10 441228 1 Pipe assembly - rear
NOTE:Tandem pump 661123 has replaced Tandem pump 659684. To fit this later Tandem pump, support bracket 439972is replaced by 441897. The fan motor return fitting, item 34, 656251-9 is replaced by 656251-10.SL2130 is available for this conversion.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.64
ENVIRO 400
Hydraulic System Amended:110407
Unit No: HS1517A&C. HS1518A&C
OILCOOLER
1
2
32
FAN PUMP
STEER PUMPSTEERING
BOX
OIL FILTER
FAN MOTOR
TESTPOINT
TESTPOINT
STEERING
FAN
8,91013111312
2221 1323 26/2724
40 41
3637
14
5
44
20
45
6
38
15
1617
18
28
4649
50
33
28
3
35
4
4 34
7
19
2513
29/30
31
42
43
43
47 4748
52
39
39
51
53
AR7934/AR8167
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.65
Unit No: HS1517A&C. HS1518A&C
Hydraulic System Amended:110111
ITEM PART NO QTY DESCRIPTION REMARKS
11a 422385 1 Pipe assembly - mid (5.25 m wheel base) HS1517A11b 426612 1 Pipe assembly - mid (5.95 m wheel base) HS1517C12 441229 1 Pipe assembly - front13 654955-1 4 Adaptor 14 659321 1 Adaptor15 440846 1 Hose assembly - pipe to test point elbow16 660934 1 Elbow17 656394 1 Test point18 659633 1 Steering Gear (See Section 7)19 658379 1 Seal20 659632 1 Adaptor21 436968 1 Hose assembly - steering box to connector22 660935 1 Adaptor - hose to return pipe23 422386 1 Pipe assembly - front
24a 422385 1 Pipe assembly - mid (5.25 m wheel base) HS1517A24b 426612 1 Pipe assembly - mid (5.95 m wheel base HS1517C
25 441230 1 Pipe assembly - rear26 654957-1 1 Adaptor - bulkhead
441053 1 Bracket - bulhead connector27 654958-1 1 Lock nut28 441231 1 Pipe assembly - rear29 654957-1 1 Adaptor - bulkhead30 654958-1 1 Lock nut31 440845 1 Hose assembly - pipe to steering reservoir
656818-3 2 Clip32 441117-1 1 Hose - reservoir to pipe
33a 440987 1 Pipe assembly - suction pipe - fan33b 440989 1 Pipe assembly - suction pipe - fan - drain valve type
658455-6 1 Drain valve - located near tandem pump
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.66
ENVIRO 400
Hydraulic System Amended:110407
Unit No: HS1517A&C. HS1518A&C
OILCOOLER
1
2
32
FAN PUMP
STEER PUMPSTEERING
BOX
OIL FILTER
FAN MOTOR
TESTPOINT
TESTPOINT
STEERING
FAN
8,91013111312
2221 1323 26/2724
40 41
3637
14
5
44
20
45
6
38
15
1617
18
28
4649
50
33
28
3
35
4
4 34
7
19
2513
29/30
31
42
43
43
47 4748
52
39
39
51
53
AR7934/AR8167
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.67
Unit No: HS1517A&C. HS1518A&C
Hydraulic System Amended:140710
ITEM PART NO QTY DESCRIPTION REMARKS
34 656251-10 1 Adaptor - outlet to fan motor Replaces 656251-935 440843 1 Hose assembly - tandem pump to fan motor36 659323 1 Tee piece37 656394 1 Test point38 659322 1 Adaptor - fan motor drain39 440842 1 Hose assembly - fan motor drain40 661124 1 Fan motor
658086-1 1 Seal kit - fan motor41 656612-2 1 Connector42 441232 1 Pipe assembly - fan motor to oil cooler43 660884-1 2 Elbow - oil cooler44 440690-1 1 Oil cooler45 441233 1 Pipe assembly - oil cooler to filter46 660645-1 1 Adaptor - oil filter47 603680 2 Seal - adaptor - oil filter48 656730 1 Oil filter
656730-1 1 Element - oil filter49 606122 1 Adaptor - oil filter50 440844 1 Hose - filter to reservoir - push on
656818-7 3 Clip51 442447 1 Hose assembly - filter to reservoir52 442100 1 Fan drive reservoir assembly (see separate list)53 603676 1 Dowty washer
Hydraulic pipe support427379 6 Bracket - 90° - Isolator bracket assembly427380 1 Bracket - 90°658135 1 Isolator
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.68
ENVIRO 400
Steering Reservoir Assembly Amended:
Unit No:655644
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.69
Unit No: 655644
Steering Reservoir Assembly Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
655644 1 Hydraulic tank assembly1 655644-2 1 Reservoir body2 655644-6 1 Dipstick3 655644-1 1 Filter element4 655644-3 1 Bolt5 655644-5 1 Filler cap6 655644-4 1 Sealing washer
440778 1 Mounting bracket - steering reservoir / fan reservoir611005-11 2 Clamp - tee bolt type - reservoir to bracket440736 1 Oil filler - drip tray
441253 1 Label - steering reservoir levels
When replacing the earlier Hydraulic tank assembly
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.70
ENVIRO 400
Hydraulic Fan Reservoir Assembly Amended:120407
Unit No:442100
2
3
1442100
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.71
Unit No: 442100
Hydraulic Fan Reservoir Assembly Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
442100 1 Hydraulic tank assembly1 442101 1 Hydraulic tank 2 660344 1 Filler cap3 661942 1 Level indicator sight gauge
441252 1 Label - sight glass - “max / min”
440778 1 Mounting bracket - steering reservoir / fan reservoir611005-16 2 Clamp - tee bolt type - reservoir to bracket440736 1 Oil filler - drip tray
441251 1 Label - fan reservoir levels
SL2142 - Hydraulic Fan Reservoir Filler extension. SK11400442095 1 Filler pipe661238 1 Gasket - filler neckST 110 5P 3 Screw 3NmWMC-5SP 3 Washer - spring
NOTEWhen replacing the earlier Hydraulic tank assembly with the latest 442100an elbow , 650441, will be required to connect the push on hose to the newthreaded boss using the existing hose clip.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.72
ENVIRO 400
Engine and Mounting - Voith Transmission Amended:210110
Unit No: EM1513A,C&E.EM1514A,EM1515A
EM1513-E400
17
6
14
11
13
12
15
16
30 31
7
15
16
6
13 2
4 5
13,14
10
9
11
Coupling to Flywheel
3233
36
38
EM1513-E400
18
24
292827
19
21
22
23
22 21 20
2625
3031
Voith Transnmission to engine bellhousing
8
3435
3637
12
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.73
Unit No: EM1513A,C&E.EM1514A,EM1515A&EM1516A
Engine and Mounting - Voith Transmission Amended:110111
ITEM PART NO QTY DESCRIPTION REMARKS
Used on and up to Chassis No 4227661241 1 Engine - ISBe 6 Cylinder - Euro 4 - BEIGE ~ Voith transmission EM1513A,C
Used on and after Chassis No 4228661476 1 Engine - ISBe 6 Cylinder - Euro 4+ - RED ~ Rationalised - Voith/ZF EM1514A
Used on and after Chassis No 4689661541 1 Engine - ISBe 6 Cylinder - Euro -5 ~ RED - Voith/ZF EM1516A
659268 1 Starter motor - Used on and up to Chassis No 4082 & 4105 - 4115 EM1513A661096 1 Starter motor - Used on and after Chassis No 4083 - 4104 & 4116 EM1513C,E,F. EM1514A &
EM1515C1 MCB 122 180P 1 Bolt - upper - engine stay - M222 425867 1 Engine stay assembly
425704 1 Engine stay3 657138 1 Bush - engine stay4 WMA 22SP 1 Washer - plain5 MCN 722P 1 Nut - self locking - M226 412711 2 Rebound washer - upper7 440364 1 Engine mounting bracket - RH - Voith8 440363 1 Engine mounting bracket - LH - Voith
9a MFB 114 50P 8 Bolt - engine mounting bracket9b MFB 114 80P 4 Bolt - engine mounting bracket10 WMC 14SP 8 Washer - spring 11 657639 2 Engine mount - transmission12 MCS 112 40P 4 Setscrew - mount to bracket13 WMA 12SP 4 Washer - spring14 MCN 512P 4 Nut - self locking15 437801 2 Rebound washer - lower16 MFN 524P 2 Nut - self locking - M2417 MFB 124 190P 1 Bolt - engine mounting18 439569 1 Bracket - engine mounting19 MCB 112 90P 2 Bolt - Bracket to engine 20 MCS 112 30P 6 Setscrew - Bracket to engine
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.74
ENVIRO 400
Engine and Mounting - Voith Transmission Amended:210110
Unit No: EM1513A,C&E.EM1514A,EM1515A
EM1513-E400
17
6
14
11
13
12
15
16
30 31
7
15
16
6
13 2
4 5
13,14
10
9
11
Coupling to Flywheel
3233
36
38
EM1513-E400
18
24
292827
19
21
22
23
22 21 20
2625
3031
Voith Transnmission to engine bellhousing
8
3435
3637
12
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.75
Unit No: EM1513A,C&E.EM1514A,EM1515A
Engine and Mounting - Voith Transmission Amended:170811
ITEM PART NO QTY DESCRIPTION REMARKS
21 WMC 12SP 8 Washer - spring22 WMA 12SP 8 Washer - Plain
606631 A/R Loctite - 27023 660743 1 Engine mount24 MCB 112 40P 4 Bolt - mount to engine bracket 40 - 45 lbs ft25 MCN 512P 4 Nut - self locking26 WMA 12SP 4 Washer - plain27 MFS 116 55P 2 Screw - mount to frame28 WMC 16SP 2 Washer - spring29 WMA 16SP 2 Washer - plain30 MCB 110 40P 11 Bolt - transmission to bellhousing 50 Nm
606152 A/R Loctite - HO 24231 659314-5 11 Washer - hardened32 660878-5 11 Bolt - flywheel adaptor to flywheel - Voith33 660281-4 11 Washer - plain 50 Nm34 439797 1 Skirt angle - RH (For further frame deatils see Page 6.22 - 6.23)35 426497 1 Plate - tapped36 MCS 110 30P 9 Setscrew - skirt37 WMC 10SP 9 Washer - spring38 MCN 510P 6 Nut - self locking
ENGINE BREATHER TUBE EXTENSION - SL2152442426 1 Tube - engine breather656818-5 1 Hose clip610029-4 1 “P”clipWMA 8SP 1 Washer
431894 1 Plug - bottom bellhousing hole
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.76
ENVIRO 400
Engine and Mounting - ZF Transmission Amended:210110
Unit No: EM1513B,D&F.EM1514A,EM1515A
17
6
14
11
13
12
15
16
30 31
7(8)
15
16
6
13 2
45
12
10
9
11
14
34
36
EM1513-E400-ZF
18
24
292827
19
21
22
23
22 21 20
2625
3233
3435
13
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.77
Unit No: EM1513B,D&F.EM1514A,EM1515A
Engine and Mounting - ZF Transmission Amended:110111
ITEM PART NO QTY DESCRIPTION REMARKS
Used on and up to Chassis No 4227660558 1 Engine - Cummins ISBe 6 cylinder - Euro 4 - BEIGE - ZF transmission EM1513B&D
Used on and after Chassis No 4228661476 1 Engine - ISBe 6 Cylinder - Euro 4+ - RED ~ Rationalised - Voith/ZF EM1514A (661261)
Used on and after Chassis No 4689661541 1 Engine - ISBe 6 Cylinder - Euro -5 ~ RED - Voith/ZF EM1516A
659268 1 Starter motor - Used on and up to Chassis No 4082 & 4105 - 4115 EM1513B661096 1 Starter motor - Used on and after Chassis No 4083 - 4104 & 4116 EM1513D,E,F. EM1514A&
EM1515C1 MCB 122 180P 1 Bolt - upper - engine stay - M222 425867 1 Engine stay assembly
425704 1 Engine stay3 657138 1 Bush - engine stay4 WMA 22SP 1 Washer - plain5 MCN 722P 1 Nut - self locking - M226 412711 2 Rebound washer - upper7 440342 1 Engine mounting bracket - RH - ZF8 440341 1 Engine mounting bracket - LH - ZF
9a MFB 114 50P 8 Bolt - engine mounting bracket9b MFB 114 80P 4 Bolt - engine mounting bracket10 WMC 14SP 8 Washer - spring 11 657639 2 Engine mount - transmission12 MCS 112 40P 4 Setscrew - mount to bracket13 WMA 12SP 4 Washer - spring14 MCN 512P 4 Nut - self locking15 437801 2 Rebound washer - lower16 MFN 524P 2 Nut - self locking - M2417 MFB 124 190P 1 Bolt - engine mounting18 439569 1 Bracket - engine mounting19 MCB 112 90P 2 Bolt - Bracket to engine 20 MCS 112 30P 6 Setscrew - Bracket to engine
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.78
ENVIRO 400
Engine and Mounting - ZF Transmission Amended:210110
Unit No: EM1513B,D&F.EM1514A,EM1515A
17
6
14
11
13
12
15
16
30 31
7(8)
15
16
6
13 2
45
12
10
9
11
14
34
36
EM1513-E400-ZF
18
24
292827
19
21
22
23
22 21 20
2625
3233
3435
13
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.79
Unit No: EM1513B,D&F.EM1514A,EM1515A
Engine and Mounting - ZF Transmission Amended:060308
ITEM PART NO QTY DESCRIPTION REMARKS
21 WMC 12SP 8 Washer - spring22 WMA 12SP 8 Washer - Plain
606631 A/R Loctite - 27023 660743 1 Engine mount24 MCB 112 40P 4 Bolt - mount to engine bracket 40 - 45 lbs ft25 MCN 512P 4 Nut - self locking26 WMA 12SP 4 Washer - plain27 MFS 116 55P 2 Bolt - mount to frame 40 - 45 lbs ft28 WMC 16SP 2 Washer - spring29 WMA 16SP 2 Washer - plain30 MCB 110 40P 12 Bolt - flywheel adaptor to flywheel - ZF
606152 A/R Loctite - HO 24231 659314-5 12 Washer - hardened32 439797 1 Skirt angle - RH (For further frame deatils see Page 6.22 - 6.23)33 426497 1 Plate - tapped34 MCS 110 30P 9 Setscrew - skirt35 WMC 10SP 9 Washer - spring36 MCN 510P 6 Nut - self locking
ENGINE BREATHER TUBE EXTENSION - SL2152442426 1 Tube - engine breather656818-5 1 Hose clip610029-4 1 “P”clipWMA 8SP 1 Washer
431894 1 Plug - bottom bellhousing hole
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.80
ENVIRO 400
Engine and Mounting - Oil Filler Amended:080708
Unit No: EM1513A&B
ENGINE OIL
ENGINE�OIL
3 6
1
4
2
5
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.81
Unit No: EM1513A&B
Engine and Mounting - Oil Filler Amended:290113
ITEM PART NO QTY DESCRIPTION REMARKS
1 68243-26 1 Cap - oil filller2 440762 1 Filler neck / dipstick support bracket
MCS 104 20P 3 Screw - neck to drip trayWMA 4SP 3 Washer - plainMCN 504P 3 NutMCS 108 50P 1 Bolt - neck to drip tray
400622-39 1 Spacer 610029-4 1 “P” clip
MCN 508P 1 Nut3 659637 1 Hose - oil filler pipe
656818-5 1 Clip - hose to engine656818-9 1 Clip - hose to filler
4 440736 1 Oil filler drip tray5 B37294 0.065M Edge trim
6 419966 1 Label - engine oil filler
FOR DIPSTICK, SEE ENGINE SUNDRIES SECTION PAGE 2.79
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.82
ENVIRO 400
Engine Service Sundries Amended:070708
Unit No:EM1513B,D&F.EM1514A,EM1515A
3
FUEL/WATERFUEL FUEL 8
9
5
1 2
7
4
6
10 11 12
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.83
Unit No: EM1513B,D&F.EM1514A,EM1515A
Engine Service Sundries Amended:110111
ITEM PART NO QTY DESCRIPTION REMARKS
1 660558-1 1 Gasket - Sump 2 660558-2 1 Sump3 658455-7 1 Drain valve - sump (option) OL1534-1
660558-3 1 Sump plug 660558-4 1 Seal - sump plug
4 660558-5 1 Thermostat c/w seal660558-6 1 Seal - thermostat
5 DP010206 1 Fuel filter - engine mounted6 659523-1 1 Fuel / water filter - frame mounted
659523-2 1 Harness - sensor659523-3 1 Sensor - water in fuel
7 DP010205 1 Engine Oil Filter8 660558-11 1 Dipstick & tube assembly - locking - yellow top* Re-use block adaptor
660558-12 1 Dipstick - locking - yellow top660558-13 1 Dip tube - locking dipstick - with block adaptor
9 3289001-101 1 Alternator Drive Belt - See Altenator Section P2.8110 4899226 1 Gasket - valve cover11 660838-1 1 Compressor12 660558-9 1 Cap - oil filller
* Replaces 445418 / 445419
For further infomation please contact parts ordering, quoting your engine serial number.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.84
ENVIRO 400
Alternator Mounting Amended:
Unit No: EM1513B,D&F.EM1514A,EM1515A
87
6
12
5
EM1513
3
4
2
1
11
7
7
10
9
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.85
Unit No: EM1513B,D&F.EM1514A,EM1515A
Alternator Mounting Amended:240209
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & upto Chassis No 42271a 659717 1 Alternator AC172RA - 140A
2a 3289001-101 1 Belt - alternator
3a 432296 1 Pulley
Used on & after Chassis No 42281b 661098 1 Alternator AC172RA - 155A
2b 4988883-101 1 Belt - alternator
3b 3281533-101 1 Pulley
4 651274-8 1 Nut - pulley
5 654863-14 1 Washer - pulley nut
6 MCB 116 190P 1 Bolt - alternator pivot
7 WMA 16SP 3 Washer - plain
8 MCN 516P 2 Nut
9 MCB 116 60P 1 Bolt - alternator pivot
10 WMC 16SP 1 Washer - spring
11 658800-2 1 Alternator duct assembly
12 656818-12 1 Clip - alternator ducting
654200 2 Rubber boot
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.86
ENVIRO 400
Saloon Heater Pipework Amended:100706
Unit No:AL1542-5
LOWER
UPPER
AR7986
ENGINE
FEED
RETURN
FEED
RETURN
GEARBOX TO WATERPUMPRETURN PIPE
REAR HEATER PIPEWORK
FRONT HEATER PIPEWORK
FEED
RETURN
2
3
2
6
54
1
2
7
8
10
1110
5 14
15
16
18
17
2
10 13
12
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.87
Unit No:AL1542-5
Saloon Heater Pipework Amended:130209
ITEM PART NO QTY DESCRIPTION REMARKS
1 439981 1 Pipe - return - front of wheel arch2 434250-2 4 Hose - straight
656818-7 8 Clip3 441170 1 Pipe - return - rear of wheel arch4 441163 1 Pipe - elbow to hose 5 434249-2 2 Hose - elbow
656818-7 4 Clip6 441161 1 Pipe - return to gate valve / elbow7 441160 1 Pipe - feed - to elbow8 434249-8 1 Elbow - heater supply9 441166 1 Pipe - elbow to valve
10 658650 1 Valve - heater supply11 441165 1 Pipe - heater feed (See cooling system for further details)12 434249-1 1 Elbow - heater supply
656818-7 2 Clip13 429610 1 Pipe - elbow to gate valve14 441162 1 Pipe - feed - elbow to hose15 441169 1 Pipe - feed - rear of wheel arch16 439980 1 Pipe - feed - front of wheel arch17 439955 1 Pipe - feed - front LH wheel arch18 439956 1 Pipe - return - front RH wheel arch
FOR FURTHER DETAILS PLEASE REFER TO E400 BODY SPARES MANUAL
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.88
ENVIRO 400
Air Conditioning Amended:
Unit No:AL1532-1
1
4
8
6
7
12
8
95,10
2 7
AL1532-1
6
14
15
8
8
3
11
10
13
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 2.89
Unit No:AL1532-1
Air Conditioning Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
1 433782 1 Pulley2 439569 1 Engine mounting bracket3 441199 1 Compressor mounting bracket assembly
439029 1 Bush - “top hat”439030 3 Bush - plain
4 MCB 112 40P 2 Setscrew5 MCB 112 35P 1 Setscrew6 MCS 3610 40 3 Cap screw7 MCN 510P 6 Nut8 WMA 10SP 12 Washer - plain9 MCS 3610 50 1 Cap screw
10 WMC 12SP 3 Washer - spring11 433505 2 Stay bracket12 MCS 3610-20P 9 Bolt - flanged13 7040800N01 1 Compressor
7040801N01 1 Belt - compressor14 445062 1 Screw15 445063 1 Screw
441103 1 Block air con supportMCS 112 100P 1 Bolt - air con bracket to blockMCS 108 40P 1 Bolt - block to bracketWMC 8SP 1 Washer - spring
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Contents
Transmission Amended:
Voith D864.5E TransmissionTransmission - Voith . . . . . . . . . . . . . . . Page 3.2 - 3
ZF Transmission - 5HP502Transmission - ZF . . . . . . . . . . . . . . . . . Page 3.4 - 5Transmission Air Piping - ZF . . . . . . . . . Page 3.6 - 7
Propeller ShaftDrive shaft . . . . . . . . . . . . . . . . . . . . . . Page 3.8 - 9
Rear AxleInput assembly . . . . . . . . . . . . . . . . . . . Page 3.10 - 11Differential assembly . . . . . . . . . . . . . . . Page 3.12 - 13Axle casing . . . . . . . . . . . . . . . . . . . . . . Page 3.14 - 15Gantry . . . . . . . . . . . . . . . . . . . . . . . . . Page 3.16 - 19Output . . . . . . . . . . . . . . . . . . . . . . . . . Page 3.20 - 23Brake . . . . . . . . . . . . . . . . . . . . . . . . . Page 3.22 - 23
Section 3
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.2
ENVIRO 400
Transmission- Voith Amended:060308
Unit No: GB1516A,B
1/6
VOITH3
RND
5
VOITH4
2
7
11
14
16
1312
15
8
9
17
1819
10
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.3
Unit No: GB1516A,B
Transmission- Voith Amended:170811
ITEM PART NO QTY DESCRIPTION REMARKS
1 660878 1 Transmission- Voith D854.5E - 4 speed2 660878-3 1 Harness - transmission to harness 0.5m3 660878-1 1 Electronic control unit
660878-2 1 Harness - ECU to transmission 6.0m4 660663 1 Selector - 3 button - “DNR”
660264-1 1 Selector button -“D” Dome Shape660264-2 1 Selector button -“R” Dome Shape660264-3 1 Selector button -“N” Dome Shape650247-12 1 Illumination bulb - selector
5 652061-1 1 Pressure switch - “gearguard”6 660878-4 1 Coupling - Hydrodamp
660878-5 12 Bolt660281-4 12 Washer
7 660878-7 1 Oil filter kit - internal8 660878-8 1 Cover - filter9 660878-9 1 “O” ring - filter cover
10 658866-4 1 Oil cooler11 660878-10 1 Sump gasket12 659927-2 1 Plug - sump13 650247-2 1 Seal - sump plug14 657042-17 1 Gasket - oil cooler elbow15 650002-552 1 Breather cap16 660244-2 1 Hose assembly - oil cooler17 660244-3 1 Hose assembly - oil cooler
425862 1 Bracket - hose support18 652002-184 1 Oil filler cap19 660878-6 1 Dipstick
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.4
ENVIRO 400
Transmission - ZF Amended:060308
Unit No: GB1517A,B
2
3
5
76
4
8
1314 15
1
9
RND
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.5
Unit No: GB1517A,B
Transmission - ZF Amended:12/04/14
ITEM PART NO QTY DESCRIPTION REMARKS
1 661019 1 Transmission - ZF5HP502C 661019-7 1 Harness - main - 8 plug 661019-8 1 Harness - sub - 5 plug2 660940 1 Electronic control unit - ZF3 660839 1 Selector - 3 button - “DNR”4 652638-1 1 Oil filter kit 5 652638-2 4 Flex plate6 659418-5 10 Screw - flex plate7 656046-122 10 Washer - flex plate screw8 659418-7 2 Capscrew - starter ring to convertor9 656626-6 1 Pressure switch - retarder
659135-3 1 Solenoid valve - accumulator658235-3 1 Speedo sensor659135-4 1 Sump655018-2 1 Gasket - sump653991-2 1 Plug - sump653991-3 1 Washer - sump plug661019-1 A/R Bolt - oil cover bolt-659418-12 1 Temperature Sensor656995-75 1 Seal - temperature sensor
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.6
ENVIRO 400
Transmission - ZF Amended:060308
Unit No: GB1517A,B
21
22
23
241
REAR LOCATION
SOLENOID VALVEFRONT SUSP’N
AU
XIL
IAR
Y &
SU
SP
EN
SIO
N
ZF ACCUMULATOR
412
10mm BLACK
12mm GREEN
12mm GREEN
36
5
GB1515A
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.7
Unit No: GB1517A,B
Transmission - ZF Amended:060308
ITEM PART NO QTY DESCRIPTION REMARKS
1 654921-1 1 Connector2 654923-2 1 Tee Piece3 654921-4 1 Connector4 654919-2 1 Elbow5 654749 A/R Green - 12 mm O.D.6 654992 A/R Black - 10 mm O.D.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.8
ENVIRO 400
Drive Shaft Amended:
Unit No: P1510D&E
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.9
Unit No: P1510D&E
Drive Shaft Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
VOITH TRANSMISSION1 659107-2 1 Drive shaft P1510D
10 MFB 112 50D 8 Bolt - transmission & axle653696-1 8 Nut - transmission & axle
659651 1 Grease nipple
659186 2 Kit - drive shaft joint
ZF TRANSMISSION2 659107-2 1 Drive shaft P1510E
10 MFB 112 50D 4 Bolt - axle10 MFN 712P 4 Nut - axle 105 Nm10MCB 112 45 4 Bolt - transmission653696-1 4 Nut - transmission
659186 2 Kit - drive shaft joint
659651 1 Grease nipple
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.10
ENVIRO 400
Drive Axle - Input Amended:
Unit No: AR1511J&K
1
2
3
4
5
6
7
8
9
10
660426-input
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.11
Unit No: AR1511J&K
Drive Axle - Input Amended:250906
ITEM PART NO QTY DESCRIPTION REMARKS
660426 1 Rear axle - drive - ABS - complete - 6.2:1 AR1511K660426-20 1 Drive head assembly - 6.2:1
660425 1 Rear axle - drive - ABS - complete - 5.74:1 AR1511J 658518-1 1 Drive head assembly - 5.74:1
1a 659922-1 1 Bevel gear set - 6.20:11b 658518-1 1 Bevel gear set - 5.74:1
2 656995-2 1 Bearing3 - A/R4 - A/R5 656995-3 1 Bearing6 656995-4 1 Seal - shaft7 656995-5 1 Dust seal8 656995-6 1 Flange - input9 656995-7 1 Washer
10 656995-8 1 Nut slotted
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.12
ENVIRO 400
Drive Axle - Differential Assembly Amended:
Unit No: AR1511K
1
2
3
3
4
4
6
6
7
7
5
8 210
9
660426-diff
SEE GANTRY DRIVE ITEMS 2 & 3
SEE AXLE CASING ITEMS 5 & 6
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.13
Unit No: AR1511K
Drive Axle - Differential Assembly Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
1 656995-10 12 Locking screw - crownwheel2 659921-2 1 Differential casing - LH & RH3 656995-12 2 Thrust washer4 656995-13 2 Axle bevel gear5 659921-4 1 Differential spider6 658517-2 4 Diff bevel gear - c/w bush7 659921-3 4 Thrust washer8 656995-17 4 Grooved pin9 656995-18 12 Setscrew - differential casing
10 656995-19 12 Washer
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.14
ENVIRO 400
Drive Axle - Axle Casing Amended:
Unit No: AR1511K
45
6
2
3 7 8 9
4
1011 12
13
11
14
660426-casing
1
15 16
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.15
Unit No: AR1511K
Drive Axle - Axle Casing Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
Voith/ZF1 659921-5 1 Axle casing - lightweight2 659921-6 1 Stub shaft - short3 659921-7 1 Stub shaft - long4 656995-23 2 “O” ring5 656995-24 1 Bearing6 - A/R Shim7 656995-25 4 Stud8 656995-26 4 Washer9 656995-27 4 Nut
10 659921-9 19/20 Capscrew11 656995-26 35/37 Washer12 659921-8 1 Bracket13 658517-8 1 Drain plug - casing
656995-133 1 “O” ring - drain plug14 656995-34 12/13 Capscrew15 656995-35 1 Type plate16 650795-8 4 Grooved stud
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.16
ENVIRO 400
Drive Axle - Gantry Drive Amended:
Unit No: AR1511K
19
2120
1922
23/24
23
29
3130
28
74 5 6
8
3534
23/24
1415
1615
1718
2526
27
2526
12
9 10 1113
3233
1a,1b
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.17
Unit No: AR1511K
Drive Axle - Gantry Drive Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
1a 660426-13 1 Gantry housing - LH1b 660426-14 1 Gantry housing - RH
2 656995-38 1 Bearing3 - A/R Shim4 658517-10 1 Cup spring5 656995-39 2 Housing disc6 656995-40 2 Roller cage7 656995-41 2 Plate8 659921-12 1 Input gear9 659921-14 2 Retaining ring
10 659921-15 2 Plate11 659921-16 2 Roller cage12 659921-17 2 Housing disc13 659921-18 2 Cup spring14 - A/R Shim15 659921-19 8 Bearing - idle gear16 656995-45 4 Idler gear17 656995-46 4 ‘O’ ring18 656995-47 4 Idle bearing pin19 656995-48 2 Bearing - output gear20 656995-49 2 Pulse disc21 656995-50 2 Output gear22 - A/R Shim23 660426-1 1 Spring carrier - LH rear & RH front24 660426-2 1 Spring carrier - LH front & RH rear25 656995-53 12 Capscrew26 656995-33 12 Washer
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.18
ENVIRO 400
Drive Axle - Gantry Amended:
Unit No: AR1511K
19
2120
1922
23/24
23
29
3130
28
74 5 6
8
3534
23/24
1415
1615
1718
2526
27
2526
12
9 10 1113
3233
1a,1b
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.19
Unit No: AR1511K
Drive Axle - Gantry Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
27a 656995-51 1 Console - LH27b 656995-52 1 Console - RH
28 659921-20 1 Breather29 656995-57 4 Setscrew30 656995-132 1 Level plug - gantry 31 656995-133 1 “O” ring - level plug32 656995-125 2 Drain plug - gantry- 33 659921-13 2 “O” ring - drain plug34 658517-13 20 Capscrew35 656995-60 20 Washer
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.20
ENVIRO 400
Drive Axle - Output Amended:
Unit No: AR1511K
1
10
58
9
119
12
13
1615
2
3
45
7
6
1416
660426-output
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.21
Unit No: AR1511K
Drive Axle - Output Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
1 656995-83 2 O ring2 660426-3 2 Hub carrier3 659921-21 2 Screen Sheet4 660426-4 2 Seal - flange shaft5 660426-23 2 Bearing - hub carrier
660426-23 2 Repair kit - c/w bearing6 660426-6 20 Wheel bolt
651043-4 20 Wheel nut - non capped245183-2 20 Cover - wheel nut
7 660426-7 2 Hub8 660426-8 2 Shaft seal9 656995-68 4 Slotted nut
10 656995-69 2 Tab washer11 658517-43 2 ‘O’ ring -shaft seal12 660426-9 2 Flange shaft13 658517-19 20 Screw14 658517-22 12 Capscrew - 70mm lg15 658517-23 20 Capscrew - 115mm lg16 656995-26 32 Washer
Hubodometer AL1527-1659385 1 Hubodometer
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.22
ENVIRO 400
Drive Axle - Brake Amended:
Unit No: AR1511K
5
6
3
2
1
4
660426-brake
7
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 3.23
Unit No: AR1511K
Drive Axle - Brake Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
1 658517-26 2 ABS sensor2 660426-15 1 “O” ring - ABS sensor3 660426-16 1 Capscrew4 660426-11 2 Fitted bolt - caliper mounting5 660426-10 10 Screw - caliper mounting6 658517-27 4 Locking nut - actuator7 660426-17 20 Screw
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Contents
Braking Amended:270509
Braking System
Used on and up to Chassis No 5115Braking System . . . . . . . . . . . . . . . . . . . . Page 4.2 - 5Pipe Fittings - Braking System . . . . . . . . . Page 4.6 - 9Used on and After Chassis No 5116Braking System - secondary coil . . . . . . . Page 4.10 - 13Pipe Fittings - Braking System . . . . . . . . . Page 4.14 - 17Front Brake Chambers & Rear Brake Actuators Page 4.18 - 19Footbrake Valve and Valve Assembly . . . Page 4.20 - 23Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . Page 4.24 - 25Handbrake Interlock . . . . . . . . . . . . . . . . Page 4.26 - 27Front & Rear Brake Caliper - SB . . . . . . . Page 4.28 - 29Front & Rear Brake Caliper Spares - SB . Page 4.30 - 31Front Brake Caliper - SN . . . . . . . . . . . . . Page 4.32 - 33Front Brake Caliper Spares - SN . . . . . . . Page 4.34 - 35Nylon Brake Tubing Sizes . . . . . . . . . . . . Page 4.36
Section 4
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.2
ENVIRO 400
Braking System Amended:080710
Unit No: FB1522A,C,D,E,F,G,H&J.
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
COMPRESSOR
PINGTANK
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
FROM AIR
CLEANER
4
L
STRGPILOTVALVE
1
23
PA
RK
L
SOLENOID VALVEFRONT SUSP’N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L1
KEY TO PIPE SIZES
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
AU
XIL
IAR
Y &
SU
SP
EN
SIO
N
SOLENOID VALVEFRONT SUSP’N T
O Z
FA
CC
UM
ULA
TO
R
SAFETYVALVE
37
FRONT KNEEL
FULL KNEEL
OR
TO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP’N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR7924 / 8308 / 8510 / 8525 - E400
TO UREA DOSER
26
28
30
2927
30
26
1215
11
14
15
7
32
33
33
35
6
9
15
4
15
29
8
32
23
16
15
31
31
31
31
16 14
16
16
24
25
2
16
18
1
15
13
8
VOITH 36or
ZF 21
22
22
20
10
3
10
17
17
16
16
19
34
18
5a/5b
36
ZF VOITH
20 or 36
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.3
Unit No: FB1522A,C,D,E,F,G,H&J.
Brake System Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
1 657516 1 Air Dryer (see separate list)656644 1 Silencer
2 430083 1 Pipe assembly - coil424133 1 Bracket - coil653488-6 6 Pipe clip assembly 653489-1 12 Plate - clip assembly - 2 per clip
3 437914 1 Pipe assembly - ping tank to coil443322 1 Plate - hose support SL2171
4 660090 1 Reservoir - ping tank - 1litre426689 1 Mounting bracket - ping tank611005-7 1 Teebolt clip - ping tank
5a 657446-8 1 Hose assembly - compressor to ping tank5b 657446-3 1 Hose assembly - compressor to ping tank - to safety valve tee piece SL2198
6 657493--X 1 Handbrake valve (not serviceable)651787 0.5M Tube - exhaust
7 656249 1 Quadruple circuit protection valve8 659372 2 Relay valve (not serviceable)9 654734 1 Double check valve (not serviceable)
10 658977-A 2 Low pressure switch659154 2 Rubber boot - low presssure switch
11 654979-4 1 Reservoir - Auxiliary & Suspension - 25 litres M2212 654979-11 1 Reservoir - Service 1- 25 litres M2213 654979-9 1 Reservoir - Service 2 - 25 litres M2214 654979-6 2 Reservoir - Auxiliary & Suspension, park - 20 litres M22
656768 A/R Self adhesive rubber - for reservoirs656616-3 2 Teebolt clip - 11 3/4” 656616-2 6 Teebolt clip - 10”656616-1 2 Teebolt clip - 8 3/8”
15 654728 5 Drain valve (not serviceable)16 655026 8 Test point - M1617 656246 2 Test point - M22
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.4
ENVIRO 400
Braking System Amended:271008
Unit No: FB1522A,C,D,E,F,G,H&J.
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
COMPRESSOR
PINGTANK
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
FROM AIR
CLEANER
4
L
STRGPILOTVALVE
1
23
PA
RK
L
SOLENOID VALVEFRONT SUSP’N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L1
KEY TO PIPE SIZES
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
AU
XIL
IAR
Y &
SU
SP
EN
SIO
N
SOLENOID VALVEFRONT SUSP’N T
O Z
FA
CC
UM
ULA
TO
R
SAFETYVALVE
37
FRONT KNEEL
FULL KNEEL
OR
TO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP’N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR7924 / 8308 / 8510 / 8525 - E400
TO UREA DOSER
26
28
30
2927
30
26
1215
11
14
15
7
32
33
33
35
6
9
15
4
15
29
8
32
23
16
15
31
31
31
31
16 14
16
16
24
25
2
16
18
1
15
13
8
VOITH 36or
ZF 21
22
22
20
10
3
10
17
17
16
16
19
34
18
5a/5b
36
ZF VOITH
20 or 36
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.5
Unit No: FB1522A,C,D,E,F,G,H&J.
Brake System Amended:230813
ITEM PART NO QTY DESCRIPTION REMARKS
18 659270 2 Pressure transducer401758 2 Washer - aluminium
19 658019 1 Charge coupling417043 1 Bracket - airline606394 1 Plug and chain
20 652061-1 1 Pressure Switch - “EK” 21 658313 1 Pressure Switch 22 659171 2 Switch - stop lamp
659154 2 Boot - rubber - stop lamp switch23 660687 1 Footbrake valve (see separate list)
656302 4 Silencer24 659387-1 1 Brake chamber - front - LH (see separate list)25 659387-2 1 Brake chamber - front - RH (see separate list)26 655025 2 Hose assembly - Front chamber27 432146 2 Pipe assembly - front chamber - LH
654960 2 Lock nut28 432147 2 Pipe assembly - front chamber - RH
654960 2 Lock nut29 659092 2 Hose assembly - connector to pipe30 657727 2 Hose assembly - valve to connector
657835-1 2 Lock nut31 658879 4 ABS modulating valve32 660314 2 Hose assembly - ABS valve to brake chamber tee
612487 2 Lock nut33 658517-38 1 Brake Actuator - LH & RH (see separate list)34 654733 1 Valve - non return35 655749 1 Hose assembly - tee to D C valve36 441224 1 Pipe assembly - compressor to elbow37 654729-1 1 Safety Valve - (Used on & after Chassis No 4596) SL219838 612747 2 Plug
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.6
ENVIRO 400
Pipe Fittings Amended:271008
Unit No: FB1522A,C,D,E,F,G,H&J.
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
COMPRESSOR
PINGTANK
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
FROM AIR
CLEANER
4
L
STRGPILOTVALVE
1
23
PAR
K
L
SOLENOID VALVEFRONT SUSP'N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L1
KEY TO PIPE SIZES
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
AU
XIL
IAR
Y &
S
US
PE
NS
ION
SOLENOID VALVEFRONT SUSP'N
TO Z
F
AC
CU
MU
LATO
R
SAFETYVALVE
FRONT KNEEL
FULL KNEEL
OR
TO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP'N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR7924 / 8308 / 8510 / 8525 - E400
TO UREA DOSER
34
34,3824
33,38,41,42
12
35
19
35
9
8,48
42
2
23
5
14
22
28
5
14
8,25
24
24
15
25
17,25,30,38,46
35
13
12
44
29,32
29
16,37,40
5
18
4
47,20 9
28,3628 19
919
199
24
26 23
42
12
19
32
12
12
22
8,48
18,25
8,25
12
8,27
1226
5
44
11
9,19,25
9,19,25
43,46
47
11
81919,25,28
49
3
327,19,9
2319
1
6
27,32,52
4,19,27,52,
37
36
36
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.7
Unit No: FB1522A,C,D,E,F,G,H&J.
Pipe Fittings Amended:271008
ITEM PART NO QTY DESCRIPTION REMARKS
1 654920-4 - Elbow2 660930 - Elbow3 654931 - Adaptor4 654919-3 - Elbow5 654919-4 - Elbow6 654919-6 - Elbow7 657240 - Elbow8 654919-2 - Elbow9 654919-3 - Elbow
10 661729* - Elbow - 45 (658017)11 654919-7 - Elbow12 654919-8 - Elbow13 661727* - Elbow (654925)14 654933-4 - Elbow15 656489 - Bulkhead connector16 654912 - Bulkhead connector17 654921-6 - Connector18 654921-2 - Connector19 654921-4 - Connector20 654921-5 - Connector21 654921-13 - Connector22 654909-7 - Connector23 654921-7 - Connector24 661726* - Tee piece (654923-1)25 661725* - Tee piece (654923-2)26 661724* - Tee piece (654923-3)27 654922 Tee piece - bracketed28 661722* - Tee piece (654924)29 661721* Tee piece (655017)
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.8
ENVIRO 400
Pipe Fittings Amended:271008
Unit No: FB1522A,C,D,E,F,G,H&J.
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
COMPRESSOR
PINGTANK
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
FROM AIR
CLEANER
4
L
STRGPILOTVALVE
1
23
PAR
K
L
SOLENOID VALVEFRONT SUSP'N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L1
KEY TO PIPE SIZES
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
AU
XIL
IAR
Y &
S
US
PE
NS
ION
SOLENOID VALVEFRONT SUSP'N
TO Z
F
AC
CU
MU
LATO
R
SAFETYVALVE
FRONT KNEEL
FULL KNEEL
OR
TO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP'N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR7924 / 8308 / 8510 / 8525 - E400
TO UREA DOSER
34
34,3824
33,38,41,42
12
35
19
35
9
8,48
42
2
23
5
14
22
28
5
14
8,25
24
24
15
25
17,25,30,38,46
35
13
12
44
29,32
29
16,37,40
5
18
4
47,20 9
28,3628 19
919
199
24
26 23
42
12
19
32
12
12
22
8,48
18,25
8,25
12
8,27
1226
5
44
11
9,19,25
9,19,25
43,46
47
11
81919,25,28
49
3
327,19,9
2319
1
6
27,32,52
4,19,27,52,
37
36
36
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.9
Unit No: FB1522A,C,D,E,F,G,H&J.
Pipe Fittings Amended:060308
ITEM PART NO QTY DESCRIPTION REMARKS
30 654927-2 - Reducer32 657950-1 - Reducer33 654927-2 - Reducer34 654927-7 - Reducer35 654910 - Plug36 612747 - Plug37 606394 - Plug38 655003 - Washer - seal39 401758 - Washer - seal40 653148 - Ring41 654938 - Adaptor42 418461 - Adaptor43 652929 - Seal - bonded44 654909-10 - Adaptor45 654909-3 - Adaptor46 654909-8 - Adaptor47 424528 - Connector48 612487 - Nut49 660908-1 - Elbow50 661410-1 - Tee piece - swivel SL219851 661406 - Adaptor SL219852 654921-9 - Connector
NOTE* CERTAIN PIPE FITTING HAVE BEEN SUPERSEDED IN DESIGN. IFA REPLACEMENT FITTING IS REQUIRED, IF ONE OF THEADJACENT FITTINGS IS MARKED WITH A * THEN THIS FITTINGNEEDS TO BE REPLACED AS WELL DUE TO DIMENSIONALCHANGES IN FITTING DESIGN.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.10
ENVIRO 400
Braking System Amended:150612
Unit No: FB1526C&D
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
4
L
STRGPILOTVALVE
1
23
PA
RK
L
SOLENOID VALVEFRONT SUSP'N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L
1
KEY TO PIPE SIZES
AU
XILI
ARY
&SU
SPEN
SIO
N
SOLENOID VALVEFRONT SUSP'N
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
TO Z
FA
CC
UM
ULA
TOR
FRONT KNEEL
FULL KNEEL
ORTO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP'N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR 8525 - E400
TO UREA DOSER
COMPRESSOR
FROM AIR
CLEANER
SAFETYVALVE
PINGTANK
26
28
30
2927
30
26
1215
11
14
15
7
32
33
33
35
6
9
154
15
29
8
32
23
16
15
31
31
31
31
16
14
16
16
24
25
2
16
18
1
15
13
8
VOITH 36or
ZF 21
22
22
20
10
10
17
17
16
16
19
34
18
5
ZF VOITH
20 or 36
39a/39b
3
40
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.11
Unit No: FB1526C&D
Brake System Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
1 657516 1 Air Dryer (see separate list)656644 1 Silencer
2 430083 1 Pipe assembly - coil424133 1 Bracket - coil653488-6 6 Pipe clip assembly 653489-1 12 Plate - clip assembly - 2 per clip
3 446336 1 Pipe assembly - compressor to ping tank4 660090 1 Reservoir - ping tank - 1litre
446330 1 Mounting bracket - ping tank611005-7 1 Teebolt clip - ping tank
5 657446-3 1 Hose assembly - compressor to ping tank - to safety valve tee piece6 657493--X 1 Handbrake valve (not serviceable)
651787 0.5M Tube - exhaust7 656249 1 Quadruple circuit protection valve8 659372 2 Relay valve (not serviceable)9 654734 1 Double check valve (not serviceable)
10 658977-A 2 Low pressure switch659154 2 Rubber boot - low presssure switch
11 654979-4 1 Reservoir - Auxiliary & Suspension - 25 litres M2212 654979-11 1 Reservoir - Service 1- 25 litres M2213 654979-9 1 Reservoir - Service 2 - 25 litres M2214 654979-6 2 Reservoir - Auxiliary & Suspension, park - 20 litres M22
656768 A/R Self adhesive rubber - for reservoirs656616-3 2 Teebolt clip - 11 3/4” 656616-2 6 Teebolt clip - 10”656616-1 2 Teebolt clip - 8 3/8”
15 654728 5 Drain valve (not serviceable)16 655026 8 Test point - M16
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.12
ENVIRO 400
Braking System Amended:150612
Unit No: FB1526C&D
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
4
L
STRGPILOTVALVE
1
23
PA
RK
L
SOLENOID VALVEFRONT SUSP'N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L
1
KEY TO PIPE SIZES
AU
XILI
ARY
&SU
SPEN
SIO
N
SOLENOID VALVEFRONT SUSP'N
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
TO Z
FA
CC
UM
ULA
TOR
FRONT KNEEL
FULL KNEEL
ORTO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP'N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR 8525 - E400
TO UREA DOSER
COMPRESSOR
FROM AIR
CLEANER
SAFETYVALVE
PINGTANK
26
28
30
2927
30
26
1215
11
14
15
7
32
33
33
35
6
9
154
15
29
8
32
23
16
15
31
31
31
31
16
14
16
16
24
25
2
16
18
1
15
13
8
VOITH 36or
ZF 21
22
22
20
10
10
17
17
16
16
19
34
18
5
ZF VOITH
20 or 36
39a/39b
3
40
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.13
Unit No: FB1526C&D
Brake System Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
16 655026 8 Test point - M1617 656246 2 Test point - M2218 659270 2 Pressure transducer
401758 2 Washer - aluminium19 658019 1 Charge coupling
417043 1 Bracket - airline606394 1 Plug and chain
20 652061-1 1 Pressure Switch - “EK” 21 658313 1 Pressure Switch 22 659171 2 Switch - stop lamp
659154 2 Boot - rubber - stop lamp switch23 660687 1 Footbrake valve (see separate list)
656302 4 Silencer24 659387-1 1 Brake chamber - front - LH (see separate list)25 659387-2 1 Brake chamber - front - RH (see separate list)26 655025 2 Hose assembly - Front chamber27 432146 2 Pipe assembly - front chamber - LH
654960 2 Lock nut28 432147 2 Pipe assembly - front chamber - RH
654960 2 Lock nut29 659092 2 Hose assembly - connector to pipe30 657727 2 Hose assembly - valve to connector
657835-1 2 Lock nut31 658879 4 ABS modulating valve32 660314 2 Hose assembly - ABS valve to brake chamber tee
612847 2 Lock nut
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.14
ENVIRO 400
Braking System Amended:150612
Unit No: FB1526C&D
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
4
L
STRGPILOTVALVE
1
23
PA
RK
L
SOLENOID VALVEFRONT SUSP'N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L
1
KEY TO PIPE SIZES
AU
XILI
ARY
&SU
SPEN
SIO
N
SOLENOID VALVEFRONT SUSP'N
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
TO Z
FA
CC
UM
ULA
TOR
FRONT KNEEL
FULL KNEEL
ORTO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP'N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR 8525 - E400
TO UREA DOSER
COMPRESSOR
FROM AIR
CLEANER
SAFETYVALVE
PINGTANK
26
28
30
2927
30
26
1215
11
14
15
7
32
33
33
35
6
9
154
15
29
8
32
23
16
15
31
31
31
31
16
14
16
16
24
25
2
16
18
1
15
13
8
VOITH 36or
ZF 21
22
22
20
10
10
17
17
16
16
19
34
18
5
ZF VOITH
20 or 36
39a/39b
3
40
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.15
Unit No: FB1526C&D
Brake System Amended:150612
ITEM PART NO QTY DESCRIPTION REMARKS
33 658517-38 1 Brake Actuator - LH & RH (see separate list)34 654733 1 Valve - non return35 655749 1 Hose assembly - tee to D C valve36 446341 1 Pipe assembly - coil to coil37 654729-1 1 Safety Valve 38 612747 2 Plug
39a 446333 1 Coil assembly - ZF transmission446342 1 Bracket cooling coil - ZF446343 1 Bracket cooling coil (slotted angle)
39b 446396 1 Coil assembly - Voith transmission446398 1 Bracket cooling coil - Voith446343 1 Bracket cooling coil (slotted angle)
40 446341 1 Pipe assembly - coil to pipe
Service List kits are available for conversion to second cooling coils:SL2236 - Compressor cooling coil - ZF variant
SL2264 - Compressor cooling coil - Voith variant REF: D24668
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.16
ENVIRO 400
Pipe Fittings Amended:140612
Unit No: FB1526C&D
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
4
L
STRGPILOTVALVE
1
23
PA
RK
L
SOLENOID VALVEFRONT SUSP'N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L
1
KEY TO PIPE SIZES
AU
XILI
ARY
&SU
SPEN
SIO
N
SOLENOID VALVEFRONT SUSP'N
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
TO Z
FA
CC
UM
ULA
TOR
FRONT KNEEL
FULL KNEEL
ORTO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP'N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR 8525 - E400
TO UREA DOSER
COMPRESSOR
FROM AIR
CLEANER
SAFETYVALVE
PINGTANK
34
34,3824
33,38,41,42
12
35
19
35
9
8,48
42
2
23
5
14
22
28
5
14
8,25
24
24
15
25
17,25,30,38,46
35
12
29,32
29
16,37,40
5
4
47,20 9
28,3628 19
919
199
24
26 23
42
12
19
32
12
12
22
8,48
18,25
8,25
12
8,27
12
26
5
44
11
9,19,25
91925
46
4347
11
81919,25,28
49
3
327,19,9
2319
1
6
27,32,52
4,19,27,52,
5051
53
15
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.17
Unit No: FB1526C&D
Pipe Fittings Amended:270509
ITEM PART NO QTY DESCRIPTION REMARKS
1 654920-4 - Elbow2 660930 - Elbow3 654931 - Adaptor4 654919-3 - Elbow5 654919-4 - Elbow6 654919-6 - Elbow7 657240 - Elbow8 654919-2 - Elbow9 654919-3 - Elbow
10 661729 - Elbow - 45°11 654919-7 - Elbow12 654919-8 - Elbow13 661727 - Elbow14 654933-4 - Elbow15 656489 - Bulkhead connector16 654912 - Bulkhead connector17 654921-6 - Connector18 654921-2 - Connector19 654921-4 - Connector20 654921-5 - Connector21 654921-13 - Connector22 654909-7 - Connector23 654921-7 - Connector24 661726 - Tee piece25 661725 - Tee piece26 661724 - Tee piece27 654922 Tee piece - bracketed28 661722 - Tee piece29 661721 Tee piece
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.18
ENVIRO 400
Pipe Fittings Amended:140612
Unit No: FB1526C&D
211
124
2
FRONT AXLEREAR AXLE
13 23
2
13
EK
121
21
22
23
24
1
s
ZF BUS STOP SWITCH ONLY
4
11 12
2221
1
14
22
2
P
S
21
22
SE
RV
ICE
2
REAR LOCATION
AUXILIARY &SUSPENSION
SERVICE 1
HANDBRAKEINTERLOCKSOLENOID
12
11
12
11
4
L
STRGPILOTVALVE
1
23
PA
RK
L
SOLENOID VALVEFRONT SUSP'N
BODYBUILDERSUPPLY
RETARDER - REFERGEARBOX SECTIONZF ONLY
FRONT LOCATION
CHARGECOUPLING
REAR LOCATION
L
1
KEY TO PIPE SIZES
AU
XILI
ARY
&SU
SPEN
SIO
N
SOLENOID VALVEFRONT SUSP'N
16mm Red
12mm Red
10mm Red
12mm Orange
10mm Orange
6 mm Orange
6mm Yellow
10mm Yellow
12mm Yellow
12mm Green
4mm Black
TO Z
FA
CC
UM
ULA
TOR
FRONT KNEEL
FULL KNEEL
ORTO UREA DOSER
TO UREA DOSER
21
SOLENOID VALVEFRONT SUSP'N
TO ZFACCUMULATOR
11,26,21
11819
25,19,4
EARLIER MODELS
AR 8525 - E400
TO UREA DOSER
COMPRESSOR
FROM AIR
CLEANER
SAFETYVALVE
PINGTANK
34
34,3824
33,38,41,42
12
35
19
35
9
8,48
42
2
23
5
14
22
28
5
14
8,25
24
24
15
25
17,25,30,38,46
35
12
29,32
29
16,37,40
5
4
47,20 9
28,3628 19
919
199
24
26 23
42
12
19
32
12
12
22
8,48
18,25
8,25
12
8,27
12
26
5
44
11
9,19,25
91925
46
4347
11
81919,25,28
49
3
327,19,9
2319
1
6
27,32,52
4,19,27,52,
5051
53
15
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.19
Unit No: FB1526C&D
Pipe Fittings Amended:130111
ITEM PART NO QTY DESCRIPTION REMARKS
30 654927-2 - Reducer32 657950-1 - Reducer33 654927-2 - Reducer34 654927-7 - Reducer35 654910 - Plug36 612747 - Plug37 606394 - Plug38 655003 - Washer - seal39 401758 - Washer - seal40 653148 - Ring41 654938 - Adaptor42 418461 - Adaptor43 652929 - Seal - bonded44 654909-10 - Adaptor45 654909-3 - Adaptor46 654909-8 - Adaptor47 424528 - Connector48 612487 - Nut49 660908-1 - Elbow50 661410-1 - Tee piece - swivel SL219851 661406 - Adaptor SL219852 654921-9 - Connector53 661974 - Elbow - 45°
12 11 24/2
4
1/2
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.20
ENVIRO 400
Front Brake Chambers & Rear Brake Actuators Amended:
Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D
2
1
FRONT BRAKE CHAMBER REAR ACTUATOR
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.21
Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D
Front Brake Chambers & Rear Brake Actuators Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
FRONT BRAKE CHAMBER - Type 221a 659387-1 1 Brake chamber - LH1b 659387-2 1 Brake chamber - RH
2 659387-8 2 Diaphragm - T22
REAR BRAKE ACTUATOR1 658517-38 2 Brake actuator2 658470-44 2 Diaphragm
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.22
ENVIRO 400
Footbrake Valve Amended:050609
Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D - 660687
659171658313656626-6ZF - "EK"
652061-1VOITH
"GEARGUARD"
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.23
Unit No: FB1522A,C,D,E,F,G,H&J. FB1526D - 660687
Valve Assembly Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
660687 1 Footbrake valve complete 651847-25 1 Repair kit - valve (see separate list)659776-2 1 Repair kit - treadle (*Comprising items: 13, 21, 22, 23,24, 26)
1 660687-1 1 Brake valve assembly2 - 1 Tappet3 658719-10 2 ‘O’ ring4 - 1 Body5 660687-2 1 Switch6 658719-11 1 Gasket/Seal7 - 2 Washer8 - 6 Screw M4x129 - 1 Cover
10 - 4 Stud11 - 4 Nut M812 - 1 Base13 1 Pin*14 - 1 Compression spring15 - 1 Nut M816 - 1 Bolt M8x2817 658719-3 1 Bush18 658719-13 1 Ring19 - 1 Pin20 - 1 Operating roller21 - 1 Lock washer*22 - 1 Pressure plate*23 - 1 Pressure plate*24 - 1 Spacer*25 658719-8 1 Treadle26 - 1 Hollow rivet 3.2 x 10*27 658719-9 1 Pedal cover
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.24
ENVIRO 400
Footbrake Valve Amended:
Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D - 660687
*
*
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.25
Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D - 660687
Valve Assembly Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
651847-25 1 Repair kit - (comprising items marked *)
1 658719-17 1 Body2 - 1 ‘O’ ring* 71.12 x 2.623 658719-15 2 Valve*4 - 2 Conical spring*5 - 2 Spacer6 - 2 ‘O’ ring* 25.07 x 2.627 - 2 ‘O’ ring* 32.0 x 2.58 - 1 C-Clip9 - 1 ‘O’ ring* 15.55 x 2.62
10 - 1 Piston11 - 1 Tappet12 - 1 Compression spring13 - 1 Applicator14 - 2 ‘O’ ring* 63.1 x 3.53
- 2 ‘O’ ring* 64.0 x 3.015 - 1 Lower body16 - 4 Bolt M6 x 5517 658719-16 1 ‘O’ ring* 40.95 x 2.6218 658719-18 1 Venting guide19 - 1 C-Clip20 - 1 Compression spring21 - 1 ‘O’ ring* 50.4 x 3.5322 - 2 Ring*23 658719-19 1 Piston24 - 1 Spacer25 - 1 Boot*26 - 1 C-Clip
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.26
ENVIRO 400
Air Dryer Amended:
Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D - 657516
1
2
3
4
5
6
7
8
9
10
1311
1214
15
16
17
23
26
27
2220
18
21
19
28
657516
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.27
Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D- 657516
Air Dryer Amended:130906
ITEM PART NO QTY DESCRIPTION REMARKS
657516 Air dryer unit - complete
1 - 25 657516-1 1 Repair kit26 658208-2 1 Heater plug27 658208-3 1 Filter cartridge
657516-2 1 Silencer assembly657186-6 A/R Lubricant
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.28
ENVIRO 400
Handbrake Interlock Amended:
Unit No: AL1511-2
4mm
BLUE 2
AR7828
8
AR7573
1,3,4
5,6,7
10
3
1
2
SUPPLY FROMAUXILIARY &SUSPENSIONRESERVOIR
HANDBRAKEVALVE
6 m
m
OR
AN
GE
6 m
m
OR
AN
GE
6 mm
ORANGE6 mm
ORANGE
31
2
21
1
SOLENOIDVALVE
FROM RELAYVALVE SIGNAL
LINE - Port 4
EXHAUST
EXHAUST
PILOTVALVE
4 mm
BLACK
4 mm
BLACK
STEERINGCOLUMN
6 mm
ORANGE
21
FROM RELAYVALVE SIGNAL
LINE - Port 1
2
31PILOT VALVE OPERATION
12
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.29
Unit No: AL1511-2
Handbrake Interlock Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
1 655776 1 Solenoid Valve2 652285 1 Connector - kostal3 MCB-108-55P 2 Bolt - M8 x 554 MCN-708P 2 Nut - full nyloc M85 654339 1 Nut - 6mm-M12 x 1.56 654340 1 Olive - 6mm7 655832-2 1 Sleeve - 6mm od x 4mm id8 654919-5 1 Connector elbow 90 deg9 654921-8 1 Connector straight
10 654748 0.1m Pipe nylon - 6mm orange
For details of Steering Column Adjustment see Page 7.9
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.30
ENVIRO 400
Front & Rear Brake Caliper - SB type Amended:
Unit No: AF1511
Assembly grease (white)
Assembly grease (white)
pre-applied adhesive
REAR
FRONT
THIS ILLUSTRATION SHOWS THE REAR CALIPER. FRONT CALIPER
COMPONENT LAYOUT IS THE SAME ONLY THE ORIENTATION OF THE CALIPER IS DIFFERENT ON THE
FRONT CALIPER.
F659332/R659334
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.31
Unit No: AF1511
Front & Rear Brake Caliper - SB type Amended:271008
ITEM PART NO QTY DESCRIPTION REMARKS
660364-9 1 Front caliper RH - rationalised. SN type
660364-10 1 Front caliper LH - rationalised. SN type
660426-24 1 Rear caliper RH - rationalised. SB type
660426-25 1 Rear caliper LH - rationalised. SB type
PLEASE NOTE : Rationalised calipers are supplied without pads,carriers or wear indicators. Spares kits for these are on Page 4.23
• The SN units are designed to be interchangeable with the replaced SB units and so there should be no installation issues whenreplacing SB disc brakes with the correct SN unit. The output (clamping force and brake torque) is the same for both SB and SN discbrakes. mixing of SB and SN units on the same axle is permitted.• The same Rationalised Caliper is offered for both SB and SN Air Disc Brakes (the Rationalised Caliper offered for the SB disc brakeshas been of the SN design for some time) and it can be mounted on either Carrier.• The Brake Pad Set and Wear Indicator Kit used in the SB disc brakes can be used in the SN units.• The Guide Pins and Bushes Kit and Tappet and Boot Kit for the SN disc brakes are different and some new tools are required forservicing the SN type.• The SN range of Air Disc Brakes covers only the ‘axial’ type and so the Air Disc Brakes on the Enviro 400 rear axles remainunchanged (they are the ‘radial’ type). (Y061650-EN-000)
NOTE : If Spares are required for the original fitment caliper, thecaliper number needs to be noted to determine weather it is an SBor SN caliper.This is can be read off the caliper Identification plate located as shown.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.32
ENVIRO 400
Front & Rear Brake Caliper Spares - SB type Amended:120907
Unit No: AF1511
11109
1 3 4
5 6 7
8
2
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.33
Unit No: AF1511
Front & Rear Brake Caliper Spares - SB type Amended:120907
ITEM PART NO QTY DESCRIPTION REMARKS
1 658470-41 1 Brake pad kit (axle set) 2 659956 1 Brake pad kit c/w wear sensor (axle set)
3a 659387-13 2 Brake carrier - front3b 660426-18 2 Brake carrier - rear - LH3c 660426-19 2 Brake carrier - rear -RH4 659332-5 2 Ceramic Tappet - with boot 5 659921-29 2 Steel cap kit6 659921-28 2 Adjuster cap kit 7 659334-2 2 Guide pin and seal kit
8a 658470-39 2 Disc - front brake8b 657303-126 2 Disc - rear brake
9 659334-8 1 Wear indicator kit - with cable (axle set) 10 659334-7 1 Wear indicator kit - no cable (axle set)11 659332-4 1 Caliper overhaul toolkit
657303-139 A/R Assembly grease - coloured657303-140 A/R Assembly grease - white
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.34
ENVIRO 400
Front Brake Caliper- SN type Amended:120907
Unit No: AF1411
pre-applied adhesive
White assembly grease
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.35
Unit No: AF1411
Front Brake Caliper- SN type Amended:271008
ITEM PART NO QTY DESCRIPTION REMARKS
660364-9 1 Front caliper RH - rationalised. SN type
660364-10 1 Front caliper LH - rationalised. SN type
PLEASE NOTE : Rationalised calipers are supplied without pads,carriers or wear indicators. Spares kits for these are on Page 4.27
• The SN units are designed to be interchangeable with the replaced SB units and so there should be no installation issues whenreplacing SB disc brakes with the correct SN unit. The output (clamping force and brake torque) is the same for both SB and SN discbrakes. mixing of SB and SN units on the same axle is permitted.• The same Rationalised Caliper is offered for both SB and SN Air Disc Brakes (the Rationalised Caliper offered for the SB disc brakeshas been of the SN design for some time) and it can be mounted on either Carrier.• The Brake Pad Set and Wear Indicator Kit used in the SB disc brakes can be used in the SN units.• The Guide Pins and Bushes Kit and Tappet and Boot Kit for the SN disc brakes are different and some new tools are required forservicing the SN type.• The SN range of Air Disc Brakes covers only the ‘axial’ type and so the Air Disc Brakes on the Enviro 400 rear axles remainunchanged (they are the ‘radial’ type). (Y061650-EN-000)
NOTE : If Spares are required for the original fitment caliper, thecaliper number needs to be noted to determine weather it is an SBor SN caliper.This is can be read off the caliper Identification plate located as shown.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.36
ENVIRO 400
Front Brake Caliper Spares - SN type Amended:080708
Unit No: AF1411
1 3 4
5 7
2
8 9 10
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.37
Unit No: AF1411
Front Brake Caliper Spares - SN type Amended:271008
ITEM PART NO QTY DESCRIPTION REMARKS
1 660364-7 1 Brake pad kit (axle set) 2 660364-5 2 Brake carrier - front3 660364-3 2 Ceramic Tappet - with boot 4 660364-6 2 Steel cap kit5 660364-8 2 Adjuster cap kit 6 660364-4 2 Guide pin and seal kit7 658470-39 2 Disc - front brake8 659334-8 1 Wear indicator kit - with cable (axle set) 9 659334-7 1 Wear indicator kit - no cable (axle set)
10 660364-11 1 SN Caliper overhaul toolkit
657303-139 A/R Assembly grease - coloured657303-140 A/R Assembly grease - white
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4.38
ENVIRO 400
Unit No:
Nylon Brake Tubing (metric) Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
Nylon Brake Tubing654991 a/r Red - 10 mm O.D. Air Feed Circuit654746 a/r Red - 12 mm O.D.654745 a/r Red - 16 mm O.D.
654744 a/r Yellow - 6 mm O.D. Service Brake656416 a/r Yellow - 10 mm O.D.654743 a/r Yellow - 12 mm O.D.
654750 a/r Green - 6 mm O.D. Auxiliary Equipment656415 a/r Green - 10 mm O.D.654749 a/r Green - 12 mm O.D.
654748 a/r Orange - 6 mm O.D Handbrake Circuit656417 a/r Orange - 10 mm O.D.654747 a/r Orange - 12 mm O.D
655022 a/r Black - 4 mm O.D. Gauge lines654994 a/r Black - 6 mm O.D. Signal lines654992 a/r Black - 10 mm O.D. Exhaust brake654993 a/r Black - 12 mm O.D. Signal lines
Inline Connector (repair)655416-8 A/R Inline connector - Ø6mm655416-1 A/R Inline connector - Ø8mm655416-2 A/R Inline connector - Ø10mm655416-3 A/R Inline connector - Ø12mm
610224 1 Brake Tubing Cutter
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Contents
Electrical System and Instrumentation Amended:
Used on & up to Chassis No 5114 excluding 4625 & 4752Electrical System
Instrument binnacle assembly . . . . . . . . Page 5.2 - 5Front Electrical Distribution Centre - EDC Page 5.6 - 7PCB assembly - Front EDC . . . . . . . . . . Page 5.8 - 9Rear Electrical Distribution Centre - EDC Page 5.10 - 11PCB assembly - Rear EDC . . . . . . . . . . Page 5.12 - 13Cables . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.14 - 15Used on and up to Chassis No 4306Harnesses - Euro 4 . . . . . . . . . . . . . . . . Page 5.16Used on and after Chassis No 4307Harnesses - Euro 4+ . . . . . . . . . . . . . . . Page 5. 17Micellaneous . . . . . . . . . . . . . . . . . . . . . Page 5.18 - 19
Battery CarrierBattery Carrier . . . . . . . . . . . . . . . . . . . . Page 5.20 - 23Battery Boost Socket . . . . . . . . . . . . . . . Page 5.23Battery Carrier Area . . . . . . . . . . . . . . . . Page 5.24 - 25
Used on & after Chassis No 4625, 4752, 5115 onwardsElectrical System
Instrument binnacle assembly . . . . . . . . Page 5.26 - 27Front Electrical Distribution Centre - EDC Page 5.28 - 29PCB assembly - Front EDC . . . . . . . . . . Page 5.30 - 31Rear Electrical Distribution Centre - EDC Page 5.32 - 33PCB assembly - Rear EDC . . . . . . . . . . Page 5.34 - 35Cables . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.36Harnesses . . . . . . . . . . . . . . . . . . . . . . Page 5.37
Battery CarrierBattery Carrier Area . . . . . . . . . . . . . . . . Page 5.38 - 39
Section 5
PARTS MANUALENVIRO 400
Electrical System - Instrument Binnacle Amended:100907
Unit No: E1519A,B,C,D,E,F&G
3
6
4
5
2
1a
STOP
WAIT�TO�
START
miles
mph
kmh
9 8
8
1011131415
16a 18
17a/17b 12
7Front
Rear 439053-1/443153-1
191415
16b
1b
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.2
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.3
Unit No: E1519A,B,C,D,E,F&G
Electrical System - Instrument Binnacle Amended:130810
ITEM PART NO QTY DESCRIPTION REMARKS
Used on Chassis No 3926 & 3941439053-6 1 Binnacle assembly - membrane panel - Speedometer S1513B
Used from and up to Chassis No 3962 - 4294441920-1 1 Binnacle assembly - membrane panel - Speedometer - LH column switch OL1537-1
Used on and after Chassis No 4295443153-1 1 Binnacle assembly - membrane panel - Speedometer S1514A443153-5 1 Binnacle assembly - membrane panel - Tachograph TG1514B443173-5 1 Binnacle assembly - membrane panel - Speedometer - LH column switch OL1537-1
INSTRUMENT BINNACLE - 2 HOLE ROCKER SWITCH PANEL1a 660909-4 1 Binnacle front panel - 2 hole rocker switch
2 660909-5 1 Bracket support internal660909-13 0.3m Grommet strip
3 660909-1 1 Binnacle rear4 660909-6 1 Bracket support external
MCS 3606 45P 4 Bolt 5 431936 1 Clamping plate
6a 660909-2 1 Front shroud cover7b 660909-3 1 Rear shroud cover6a 436510 1 Front shroud cover- LH indicator stalk OL1537-17b 436509 1 Rear shroud cover- LH indicator stalk OL1537-1
8 660696 1 Membrane panel assembly439056 1 Switch insert legends - one set
9a 658837 1 Lever switch - ignition Option660909-10 1 Decal, ignition switch658842 1 Switching element660246 1 Ring - anti twist
9b 659923 1 Key switch actuator Option76500215 1 Security key - Alexander lock
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.4
ENVIRO 400
Electrical System - Instrument Binnacle Amended:100907
Unit No: E1519A,B,C,D,E,F&G
3
6
4
5
2
1a
STOP
WAIT�TO�
START
miles
mph
kmh
9 8
8
1011131415
16a 18
17a/17b 12
7Front
Rear 439053-1/443153-1
191415
16b
1b
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.5
Unit No: E1519A,B,C,D,E,F&G
Electrical System Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
10a 660912 1 Speedometer S1514A660912-1 1 Bulb 658178-2 1 Holder - bulb
10b 661083 1 Tachograph S1514B11 660909-8 1 Warning lamp housing12 660909-9 1 Warning light decal strip - ISO
660909-7 1 Warning light PCB660909-12 1 Gasket, warning light housing to panel
13 661828 1 Screen Control Unit (SCU)660909-11 1 Gasket, SCU
14 658825 1 Rocker switch - hazard lights15 658840 1 Rocker switch - master16a 269558 1 Rotary switch assembly - headlights / cab lights
655321 1 Switch653757 1 Bulb
17a 660909-14 1 Harness - binnacle - 2 hole rocker switch18 660909-15 1 Cable - detail ribbon
INSTRUMENT BINNACLE - 3 HOLE ROCKER SWITCH PANELUsed on and up to 5114 Chassis No 4295 excluding 4625 & 4752All other parts as above
1b 661345-1 1 Binnacle front panel - 3 hole rocker switch16b 661349 1 Switch - lighting
661348 1 Label - lighting switch surround661350 1 Switching element
17b 661345-2 1 Harness - binnacle - 3 hole rocker switch19 661346 1 Rocker switch - drivers cab lights
660909-16 1 Low air buzzer1 SL2157 1 Buzzer - upgrade kit
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.6
ENVIRO 400
Electrical System - Front - EDC Amended:
Unit No: E1519A,B,C,D,E,F&G
KNORR - BREMSE
BLINKCODE
RETARDON/OFF
ENG DIAGON/OFF
439898-FRT
CA
MU
�IO
U�
IOU
�
8
9
3 4 5 6
12
7
13
8
11
1
2
2
10
10
Unit No: E1519A,B,C,D,E,F&G
Electrical System - Front - EDC Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
1 659973 1 Control unit - CAMU609009-12 4 Spacer
2 659972 2 Control unit - IOU609009-12 2 Spacer
3 660077 1 Switch - “Engine diagnostics” - Green4 657879 1 Switch - “Blink code” - Yellow5 660168 1 Switch - “Retarder” - Green
6a 657878 1 Housing - switch - centre6b 657877 2 Housing - switch - end
7 426290 1 Bracket - diagnostic switches8 660811 1 ABS ‘E’ control unit
662093 1 Harness - adaptor - ABS-D TO ABS-E (Needed if replacing ABS-D ECU) SL23159 439617 1 PCB assembly - front EDC (See separate list)
10 438003-3 2 Trunking - 25mm - 235mm lg11 438003-7 2 Trunking - 25mm - 190mm lg12 438004-1 1 Trunking - 50mm - 540mm lg13 439900 1 Bracket - diagnostic socket
440801 1 Label - FEDC - 441454 1 Label - FEDC - Identic filler vehicles441115 1 Label - FEDC - ZF Transmission
Used on & after Chassis No 4295 to 4302 & 4306 onwards443306 1 Label - FEDC - ZF Transmission 440797 1 Harness - front EDC
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.7
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.8
ENVIRO 400
Electrical System - PCB - Front - EDC Amended:180209
Unit No: E1519A,B,C,D,E,F&G
20 30 3040 35 25
F1
2
F1
3
F1
4
F1
5
F1
6
F1
7
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F1
F2
F3
F4
F5
F29
F30
F31
F32
F33
F34
F6
F7
F8
F9
F10
F11
R1
R2
torq
ue
3,9
Nm
BA
TT
+3
0
torq
ue
17
Nm
GN
D3
1torq
ue
3,9
Nm
SW
BA
TT
+3
0A
Ign
itio
n
AL
EX
AN
DE
R-D
EN
NIS
PC
B -
FR
ON
T -
ED
CP
T.
NO
43
96
17
8 10 12 10 11 9
13
1,14
10
439617
3A
10A
15A
20A
2
3
6
7
8
5A
47.5A
5
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.9
Unit No: 439617
Electrical System - PCB - Front - EDC Amended:180209
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & up to Chassis No 5114 excluding 4625 & 4752439617 1 PCB assembly - front EDC
1 439610 1 PCB board2 651598-2 A/R Add-A-Fuse - 3 Amp - Violet3 651598-4 A/R Add-A-Fuse - 5 Amp - Tan4 651598-5 A/R Add-A-Fuse - 7.5 Amp - Brown5 651598-6 A/R Add-A-Fuse - 10 Amp - Red6 651598-7 A/R Add-A-Fuse - 15 Amp - Blue7 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow8 656674 1 Fuse - “maxi” - 20 Amp - Yellow9 660060 1 Fuse - “maxi” - 25 Amp - Grey
10 656548 2 Fuse - “maxi” - 30 Amp - Green11 660061 1 Fuse - “maxi” - 35 Amp 12 657794 1 Fuse - “maxi” - 40 Amp - Orange13 657023 1 Relay - ignition14 660721 4 Stand off assembly - c/w screws
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.10
ENVIRO 400
Electrical System - Rear - EDC Amended:
Unit No: E1519A,B,C,D,E,F&G
IOU
3
IOU
4
IOU
5R
ETA
RD
O
N/O
FF
IOU
IOU
IOU
1 1 2a/2b
13 467
8
4407859 105
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.11
Unit No: E1519A,B,C,D,E,F&G
Electrical System - Rear - EDC Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & up to Chassis No 5114 excluding 4625 & 47521 659972 3 Control unit - IOU
609009-12 12 Spacer657585 1 Connector - power - IOU662227 A/R Terminal - power connector X220
2a 660878 1 Electronic control unit - Voith transmission2b 660940 1 Electronic control unit - ZF transmission3 657799 1 Switch - “hand throttle” - Green4 426897 1 Bracket - switch5 76752365 1 Dual Channel Current Monitor 6 655933 1 Relay - starter7 439616 1 PCB assembly - rear EDC (See separate list)8 438004-2 1 Trunking - 50mm - 700 mm lg9 438004-1 1 Trunking - 50mm - 540mm lg10 3451153NO1 1 Mounting bracket - REDC
443307 1 Label - REDC
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.12
ENVIRO 400
Electrical System - PCB - Rear - EDC Amended:240107
Unit No: 439616
3
102
2 2
2
4
5
6
7
30
30
F24SPARE
30
30
F23
30
30
F4
30
30
F3
30
30
F2
30
30
F1
5
3
15
15
5
7.5
20
3
20
5
20
20
20
10
5
10
5
20
torque
3,9Nm
BATT+
30
torque
17 Nm
GND
31
torque
9Nm
SW
BATT+
30A
Coolant
Module - Lower
Coolant
Module - Upper
Fuel Heater
F14
F15
F16
F19
F20
F21
F10
F11
F12
F13
F17
F18
F22
F5
F6
F7
F8
F9
IGNITION
ALEXANDER-DENNIS
PCB - REAR- EDC
PT. NO 439609
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.13
Unit No: 439616
Electrical System - PCB - Rear - EDC Amended:21.12.06
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & up to Chassis No 5114 excluding 4625 & 4752439616 1 PCB assembly - Rear EDC
1 439609 1 PCB board2a 651598-2 A/R Add-A-Fuse - 3 Amp - Violet2b 651598-4 A/R Add-A-Fuse - 5 Amp - Tan2c 651598-5 A/R Add-A-Fuse - 7.5 Amp - Brown2d 651598-6 A/R Add-A-Fuse - 10 Amp - Red2e 651598-7 A/R Add-A-Fuse - 15 Amp - Blue2f 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow3 656548 6 Fuse - “maxi” - 30 Amp - Green4 437840 1 Coolant module 5 651438 1 Relay6 657023 1 Relay7 660721 4 Stand off assembly - c/w screws
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.14
ENVIRO 400
Electrical System - Cables Amended:100407
Unit No: E1519A,B,C,D,E,F&G
150A
THIS IS A SCHEMATIC DIAGRAM ONLY FOR CABLE IDENTIFICATION ONLY AND SHOULD NOT BE USED AS A WIRING DIAGRAM
ALT
STA
RT
ER
ENGINE
FEDC
125A
++
--
BATT+30
GND31 SW
BATT+30A
REDC
40A
40AMASTERSWITCH
175A
MIDI
MIDI
MEGA
BATT+30
GND31
SWBATT+
30A
13
US
ED
ON
AN
D A
FT
ER
CH
AS
SIS
NO
416
2
40AMIDI
1
5
4
11
3
2
7
6
9
10
15 14
12
17
18
21
20
19
7
8
16
7b22
8b
-
+
23
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.15
Unit No: E1519A,B,C,D,E,F&G
Electrical System - Cables Amended:120907
ITEM PART NO QTY DESCRIPTION REMARKS
CABLESUsed on and up to Chassis No 4161
1 440699 1 Cable - Battery negative - to chassis earth (black)2a 440700 1 Cable - battery link2b 442868 1 Cable - battery link - Fusible - 600A OL1514-2
3 440701 1 Cable - battery to master switch (red)4 430056 1 Cable - master switch to fuses - 40A (brown)5 430055 1 Cable - master switch to fuse - 125A (red)6 430705 1 Link - 40A fuses
7a 439871 1 Cable - 40A fuse to REDC plug (Black connector)8 440787 2 Cable - REDC pos+ / neg - PCB (Black connector)9 439843 1 Cable - 40 A fuses to FEDC
10 439795 1 Cable - FEDC pos+ / neg- (brown)11 440709 1 Cable - Master switch to starter (5.25 M wheelbase)12 440708 1 Cable - starter to 175A fuse13 440707 1 Cable - 175A fuse to alternator (Red )14 440705 1 Cable - Alternator to chassis earth15 440704 1 Cable - starter to chassis earth 16 424991 1 Link - 175A to 150A fuses17 440703 1 Cable - 150A fuse to REDC (Red connector)18 439895 1 Cable - to grid heater 125A fuse (Red connector)19 431857 1 Braid - earth - engine20 439834 1 Cable - fuse 125A21 439784 1 Cable - fuse to front PCB
Used from 4162 & up to Chassis No 5114 excluding 4625 & 47527b 441598 1 Cable - negative - REDC (Blue connector)8b 441255 1 Cable - negative - REDC22 441599 1 Cable - positive - REDC (Blue connector)23 441257 1 Cable - Positive - REDC
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.16
ENVIRO 400
Unit No: E1519A,B,C,D,E,F&G
Electrical System - Harnesses Amended:270907
ITEM PART NO QTY DESCRIPTION REMARKS
HARNESSES - Euro 4 - Used on and up to Chassis No 4306 (Beige Engine)436149 1 Harness - CAN BUS - IOU1 to IOU2439442 1 Harness - CAN BUS - FEDC to Binnacle FEDC424614 1 Pad - neoprene - main harness run439684 1 Harness - CAN -FEDC440797 1 Harness - front EDC - Used on & up to chassis No 4082 not including 4074 E1519A&B441725 1 Harness - front EDC - Used on & after chassis No 4083 including 4074 E1519C&D442599 1 Harness - front EDC with speed limiter (WPO53367) E1519G441727 1 Link - front EDC harness - Voith441728 1 Link - front EDC harness - ZF440340 1 Harness - REDC - Voith441089 1 Harness - REDC - ZF440710 1 Harness - rear 441074 1 Harness - front - ZF Transmission440712 1 Harness - front - Voith Transmission441318 1 Harness - ABS - front440831 1 Harness - ABS - rear439684 1 Harness - CAN -FEDC - Voith Transmission440706 1 Harness - engine - auxiliary441357 1 Harness - chassis engine442598 1 Harness - chassis engine - with speed limiter WPO53367440839 1 Harness - rear kneel levelling valves SS1511J440802 1 Harness - Sub Diagnostic7680006NO3 1 Harness - wheechair arm link AL1547 -1 441060 1 Harness - Urea doser unit extension441085 1 Harness - Urea tank extension440983 1 Harness - ramp extension440916 1 Harness - external stop AL1548 -2
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.17
Unit No: E1519A,B,C,D,E,F&G
Electrical System - Harnesses Amended:130209
ITEM PART NO QTY DESCRIPTION REMARKS
HARNESSES - EURO 4+ & 5-. Used on and after Chassis No 4307 (Red Engine)442473 1 Harness - REDC - Voith EM1519E442638 1 Harness - REDC - ZF EM1519F442640 1 Harness - ABS - front442490 1 Harness - chassis engine
AUXILIARY BODY HARNESSES AL1553-1444983 1 Harness - heating and lights445032 1 Harness - air con clutch
DIAGNOSTIC SOCKET - ENGINE BAY (Located near Stop/ Start buttons)660500 1 Diagnostic connector - 9 way660831 A/R Pin - gold (0.5 - 2.4)659105 A/R Pin - gold (1.0 - 2.0)660819 A/R Pin - gold (0.5 - 1.3)660428 1 Cap - diagnostic connector
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.18
ENVIRO 400
Electrical System - Miscellaneous Amended:140906
Unit No: E1519A,B,C,D,E,F&G
1
119
5
432
12
STOP
76
START
EMERGENCY STOPPRESS TO STOP
START SWITCHPRESS TO START
10
REVERSEINTERLOCK
BUTTON
MUST BE PRESSEDWITHIN 2 SECS OF
SELECTING REVERSE
R
8
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.19
Unit No: E1519A,B,C,D,E,F&G
Electrical System - Miscellaneous Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
MISCELLANEOUS1 658755 1 Air temperature sensor (front crossmember)
429545 1 Grommet - temperature sensor2 655689 1 Horn - high tone
76270003 1 Reverse horn3a 610369 9 Rubber boot - Master switch / starter / alternator.3b 611783 3 Rubber boot - Master switch / starter
4 401919 1 Bracket - slotted “L” - Ø 12.5 hole 5 427380 1 Bracket - slotted “L” - Ø 15.0 hole6 424441 1 Bracket - slotted - angled
7a 443392 1 STOP button assembly - external stop - side - 2000mm - bus side AL1548-27b 443352 1 STOP button assembly - Rear Engine Frame - 190mm - engine bay AL1548-17c 443351 1 START button assembly - Rear Engine Frame
659812 1 START switch8 441043 1 Bracket - pressure switch mounting9 439599 1 Label - rear stop/start (yellow)
10a 658812 1 Steering column switch - RH10b 661710 1 Steering column switch - RH - (Used on & after Chassis No 5115) Multic panel10c 657886 1 Steering column switch - LH OL1537-1
661710 1 SWITCH-STRG COLUMN RH11 660358 1 Reverse interlock button assembly12 414566 1 Label - Reverse interlock
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.20
ENVIRO 400
Battery Carrier Amended:
Unit No: BC1511F
15
14
64
8
7
5
1
312
2
10
16
13
BC1410F
4
5
9
9
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.21
Unit No: BC1511F
Battery Carrier Amended:231008
ITEM PART NO QTY DESCRIPTION REMARKS
1 436624 1 Battery carrier tray assembly434275 1 Liner - carrier tray445057 1 Mat - batteries
2 426395 1 Slide - LH3 426396 1 Slide - RH
MCN 508P 20 Nut - slideMCS 108 20P 18 Screw - slideMCS 108 25P 2 Screw - slide
4 420616 4 Roller assembly comprising:656359 4 Roller420617 4 Bearing606614 A/R Loctite
5 656382 4 Circlip6 420701 4 Shaft - roller
MCN 220P 4 NutWMA 20SP 4 Washer
7 656376 2 Fastener “Antiluce”437575 2 Spacer - fastenerMCN 512P 2 Nut
8 430625 2 Retaining bracketMCS 110 25P 3 SetscrewWMA 10SP 3 WasherMCN 510P 3 Nut
9 436625 2 Battery Retainer channelMCS 106 30P 1 ScrewMCS 106 70P 2 SetscrewWMA 6SP 8 Washer- plainWMC 6SP 4 Washer - spring109400 4 Washer - flatMCN 106P 12 Nut
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.22
ENVIRO 400
Battery Carrier Amended:
Unit No: BC1511F
15
14
64
8
7
5
1
312
2
10
16
13
BC1410F
4
5
9
9
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.23
Unit No: BC1511F
Battery Carrier Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
10 437117 1 “J” bolt - battery clamp11 656334 2 Battery 12v12 426411 1 Shield - rear13 422843 1 Shield - front14 437554 1 Battery cover assembly
437553 2 Plate - cover retainer660321 6 Rivet443756 1 Bracket - cover support - lower443755 1 Bracket - cover support - upperMCS-104-16P 2 ScrewMCN-704P 2 Nut
15 437857 1 Shield - air tank656818-1 1 Clip - teebolt - air tank
16 437630 1 Stay - battery carrierMCS-108-25P 2 ScrewMCN-508P 2 Nut - self locking
BATTERY BOOST SOCKET - OPTION AL 1513-2653847 1 Battery boost socket440840 1 Harness - boost socket
GEL BATTERY OPTION OL1533-1660736 2 Battery - Gel type440699 1 Battery negative - chassis (replaces 439942)440770 1 Battery link (replaces 440204)443317 1 Cable master switch - battery (replaces 440211)
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.24
ENVIRO 400
Battery Carrier & Rear Frame Area Amended:
Unit No: BC1511F/E1516C
1
2
4
MEGA150A
1110
7
8,9
40
REAR FRAME
2
MEGA175A
MEGA125
2
5
3
12
6
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.25
Unit No: BC1511F/E1519A,B,C&D
Battery Carrier & Rear Frame Area Amended:170209
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & up to Chassis No 5114 excluding 4625 & 47521 658431 1 Master switch
400622-51 4 Spacer - master switch to bracketMCS 106 30P 4 SetscrewWMA 6SP 8 Washer - plainMCN 506P 4 Nut self-lockingMCN 212P 2 Half nut - spacer
2 656081 3 Fuse holder - “Mega” 9.5 lbs ft3 660326-2 2 Fuse - 125A - green4 660326-3 2 Fuse - 150A - white5 660326-4 2 Fuse - 175A - orange6 424991 1 Link - fuse7 658869 3 Fuse holder - “Midi”8 430705 1 Link - midi fuse 9 658870 3 Fuse - 40A - green
10 610369 2 Rubber boot - 12mm11 611783 1 Rubber boot - 6mm12 651598-4 1 Add-A-Fuse - 5 Amp - Tan
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.26
ENVIRO 400
Electrical System - Instrument Binnacle Amended:080212
Unit No: IP1510A&B
0
4
5
6
3
1
9
8
2
11
17
10
16
12
15
1314
18
7a7b
1
2
9a
9b
9c
9d
1
2 1
2 12 1
443787
446858
443788
446859
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.27
Unit No: IP1510A&B
Electrical System - Instrument Binnacle Amended:080212
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & after Chassis No 4625, 4752, 5115 onwards443782 1 Binnacle assembly - MPH - 1 door IP1510A443783 1 Binnacle assembly - MPH - 2 door IP1510B446854 1 Binnacle assembly - MPH - 1 door - open & close IP1510F446855 1 Binnacle assembly - MPH - 2 door - open & close IP1510G
1 661704 1 Instrument panel - MPH2 445042 1 Binnacle - front3 445043 1 Binnacle - rear4 MCS-3806-16 11 Screw - hex socket5 661709 11 Clip - spring steel nut6 445041 1 Panel assemby - ignition 7 661871 1 Lighting switch 8 443786 1 Panel assembly - 15 button (body)
9a 443787 1 Panel assembly - Door / kneel - 1 Door - single button open & close 9b 446858 1 Panel assembly - Door / kneel - 2 Door - two button open & close9c 443788 1 Panel assembly - Door - 2 Door - single button open & close + Full kneel9d 446859 1 Panel assembly - Door - 2 Door - two button open & close + Full kneel10 445047 1 Button assembly - start / stop11 445044 1 Column shroud assembly12 660909-2 1 Top shroud cover13 660909-3 1 Rear shroud cover14 661708 6 Screw15 445055 1 Blanking cap16 444264 1 Clamp half17 448827 1 Binnacle support bracket18 445046 1 Blanking plug
660913-2 1 OBD plug housing662241 a/r LED - switches
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.28
ENVIRO 400
Electrical System - Front - EDC Amended:
Unit No: E1523A
3
9
10
4 5 6
BLINKCODE
8
445288/445247-FRT
2
12
IOU
CA
MU
1
11
7
12
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.29
Unit No: E1523A
Electrical System - Front - EDC Amended:260509
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & after Chassis No 4625, 4752, 5115 onwards445247 1 Front EDC assembly
1 444203 1 Mounting plate2 659973 1 Control unit - CAMU3 659972 2 Control unit - IOU4 612314-6 1 Switch - “Retarder” - Green
612319-76 1 Lens - “retarder5 612314-6 1 Switch - “Blink code” - Yellow
612319-85 1 Lens - “Blinkcode”6 612317 1 Blanking plug7 612316 1 Switch housing - 3 way8 426290 1 Bracket - diagnostic switches9 660811 1 ABS ‘E’ control unit
10 445894 1 PCB assembly - front EDC- c/w fixings (See separate list)11 446546 1 Bracket - FEDC connections12 654200 3 Rubber boot13 Refer to body manual 1 Intellitec current monitor (where intellitec lighting system is fitted)
445609 1 Harness - front EDC - universal445895 1 Label - FEDC
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.30
ENVIRO 400
Electrical System - PCB - Front - EDC Amended:
Unit No:E1523A,445894
35
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F1
F2
F3
F4
F5
F29
F30
F31
F32
F33
F34
F6
F7
F8
F9
F10
F11
R1
R2
torq
ue
3,9
Nm
BA
TT
+30
torq
ue
17 N
m
GN
D31to
rque
3,9
Nm
SW
BA
TT
+30A
Ignitio
n
ALE
XA
ND
ER
-DE
NN
ISP
CB
- F
RO
NT
- E
DC
PT. N
O 4
39617
9
11
13
9
10
14
1,15
10
445894
3A
10A
15A
20A
21
3
6
7
8
1
5A 4
7.5A 5
20
30
40
35
25
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.31
Unit No:E1523A,445894
Electrical System - PCB - Front - EDC Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & after Chassis No 4625, 4752, 5115 onwards445894 1 PCB assembly - front EDC
1 439610 1 PCB board2 651598-12 A/R Add-A-Fuse - 1 Amp - Black3 651598-4 A/R Add-A-Fuse - 5 Amp - Tan4 651598-2 A/R Add-A-Fuse - 3 Amp - Violet5 651598-2 A/R Add-A-Fuse - 7.5 Amp - Brown6 651598-6 A/R Add-A-Fuse - 10 Amp - Red7 651598-7 A/R Add-A-Fuse - 15 Amp - Blue8 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow9 656674 1 Fuse - “maxi” - 20 Amp - Yellow
10 660060 1 Fuse - “maxi” - 25 Amp - Grey11 656548 2 Fuse - “maxi” - 30 Amp - Green12 660061 1 Fuse - “maxi” - 35 Amp 13 657794 1 Fuse - “maxi” - 40 Amp - Orange14 657023 1 Relay - ignition15 660721 4 Stand off assembly - c/w screws
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.32
ENVIRO 400
Electrical System - Rear - EDC Amended:
Unit No: E1523A
IOU
NOXSENSOR
8
445346/44523 2
7
1
4
GEARBOX ECU
6 5
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.33
Unit No: E1523A
Electrical System - Rear - EDC Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & after Chassis No 4625, 4752, 5115 onwards445248 1 Rear EDC assembly
1 443227 1 Mounting plate - rear EDC2 659972 1 Control unit - IOU 3 445884 1 PCB assembly - rear EDC (See separate list)4 654200 3 Rubber boot5 415701-105 1 Label - “Nox Sensor”6a 660879 1 Electronic control unit - Voith transmission6b 660940 1 Electronic control unit - ZF transmission 7 442637 1 Bracket - EDC connections8 655933 1 Relay - starter9 Refer to body manua 1 Dual Channel Current Monitor
445250 1 Harness - rear EDC445395 1 Label - fuses - REDC
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.34
ENVIRO 400
Electrical System - PCB - Rear - EDC Amended:
Unit No:E1523A,445894
10
11
12
1,13
10
5A
10A
15A
20A
8
7
3A
7.5
6
7
2
3
4
5
F2
4S
PA
RE
F2
3
F4
F3
F2
F1
torq
ue
3,9
Nm
BA
TT
+
30
torq
ue
17 N
m
GN
D
31
torq
ue
9N
m
SW
BA
TT
+
30A
Coola
nt
Module
- L
ow
er
Coola
nt
Module
- U
pperF
uel H
eate
r
F1
4
F1
5
F1
6
F1
9
F2
0
F2
1
F1
0
F11
F1
2
F1
3
F1
7
F1
8
F2
2
F5
F6
F7
F8
F9
IGNITION
ALE
XA
ND
ER
-DE
NN
IS
PC
B -
RE
AR
- E
DC
PT.
NO
439609
445884
30
20
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.35
Unit No: E1523A, 439616
Electrical System - PCB - Rear - EDC Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & after Chassis No 4625, 4752, 5115 onwards445884 1 PCB assembly - Rear EDC
1 439609 1 PCB board2 651598-2 A/R Add-A-Fuse - 3 Amp - Violet3 651598-4 A/R Add-A-Fuse - 5 Amp - Tan4 651598-5 A/R Add-A-Fuse - 7.5 Amp - Brown5 651598-6 A/R Add-A-Fuse - 10 Amp - Red6 651598-7 A/R Add-A-Fuse - 15 Amp - Blue7 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow8 656674 1 Fuse - “maxi” - 20 Amp - Yellow9 656548 6 Fuse - “maxi” - 30 Amp - Green
10 437840 1 Coolant module 11 651438 1 Relay12 657023 1 Relay13 660721 4 Stand off assembly - c/w screws
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.36
ENVIRO 400
Unit No: E1523A
Electrical System - Harnesses Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
Used on and After Chassis No 5115HARNESSES
445245 1 Harness - front - ZF Transmission443827 1 Harness - ABS - front443826 1 Harness - ABS - rear445244 1 Harness - engine - auxiliary445246 1 Harness - chassis engine445366 1 Harness - link - ZF445250 1 Harness - rear EDC
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.37
Unit No: E1521A
Electrical System - Cables Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & after Chassis No 4625, 4752, 5115 onwardsCABLES
439942 1 Cable - Battery negative - to chassis earth (black)440204 1 Cable - battery link440211 1 Cable - battery to master switch (red)430056 1 Cable - master switch to fast fuses430055 1 Cable - master switch to fuse - 125A (red)440709 1 Cable - Master switch to starter445067 1 Cable - Master switch fuse & ground443824 1 Cable - negative - REDC443825 1 Cable - Positive - REDC443816 1 Cable - positive - engine bay fuse445068 1 Cable- battery positive to FEDC440708 1 Cable - starter to 175A fuse440707 1 Cable - 175A fuse to alternator440705 1 Cable - Alternator to starter440704 1 Cable - starter to frame446179 1 Link - coolant top up431857 1 Braid - earth - engine
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.38
ENVIRO 400
Battery Carrier & Rear Frame Area Amended:
Unit No: BC1511F/E1521A/AL1513-2
1
2
3
MEGA125A
109
6
7,8
40
REAR FRAME
2
MEGA175A
MEGA125
2
4
3
11
5
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 5.39
Unit No: BC1511F/E1521A/AL1513-2
Battery Carrier & Rear Frame Area Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
1 658431 1 Master switch 400622-51 4 Spacer - master switch to bracketMCS 106 30P 4 SetscrewWMA 6SP 8 Washer - plainMCN 506P 4 Nut self-lockingMCN 212P 2 Half nut - spacer
2 656081 3 Fuse holder - “Mega” 9.5 lbs ft3 660326-2 2 Fuse - 125A - green4 660326-4 2 Fuse - 175A - white5 424991 1 Link - fuse6 658869 2 Fuse holder - “Midi”7 430705 1 Link - midi fuse 8 658870 2 Fuse - 40A - green9 610369 2 Rubber boot - 12mm
10 611783 1 Rubber boot - 6mm11 651598-4 1 Add-A-Fuse - 5 Amp - Tan
BATTERY BOOST SOCKET AL1513-2653847 1 Boost socketMCS 1306 20P 6 ScrewMCN 106P 6 NutWMC 6SP 6 Washer - spring440840 1 Cables - boost socket
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Contents
Suspension, Frame, Wheels Amended:
Suspension
Air suspension system - Full Kneel . . . . Page 6.2 - 5
Air suspension system - Front Kneel . . . Page 6.6 - 9
Used on & up to Chassis No 5114 excluding 4625 & 4752
Front air suspension - Dana . . . . . . . . . Page 6.10 - 13
Used on & after Chassis No 4625, 4752, 5115 onwards
Front air suspension - ZF . . . . . . . . . . . Page 6.13
Rear air suspension . . . . . . . . . . . . . . . . Page 6.14 - 17
Levelling valve linkage . . . . . . . . . . . . . . Page 6.18 - 19
Frame
Frame assembly . . . . . . . . . . . . . . . . . . Page 6.20 - 21
Rear Frame assembly . . . . . . . . . . . . . . Page 6.22 - 23
Cab Floor
Cab Floor/Foot Controls . . . . . . . . . . . . Page 6.24 - 25
Wheels
Wheel and Tyres . . . . . . . . . . . . . . . . . . Page 6.26 - 6.27
Section 6
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.2
ENVIRO 400
Air Suspension - Full Kneel Amended:
Unit No: SS1511J,SS1513A
43 42 4112
23 22
21
11/25
2121
21
21
6
3
1
24
3
2
12 BLACK
12 GREEN
6 GREEN6 BLACK6 BLUE
KEY TO PIPE SIZES
21
211
1
1
43
42
41
12
23
22
21
11/25
24
3
21 211
AR7794
AUXILIARY &SUSPENSIONRESERVOIR
AUXILIARY &SUSPENSIONRESERVOIR
3
1
2
FROMPORT 24
MCPV
FULL KNEEL REAR LOCATION
FRONTLOCATION
21
FRONT KNEEL
FULL KNEEL
ZF GEARBOXSUPPLY
24
TO STEERINGCOLUMN
PILOT VALVE
32
SOLENOID�VALVE
LEVELLING�VALVE
RH-FRONT
LEVELLING�VALVE
LH-FRONT
CHARGINGVALVE
REAR
FRONT
LEVELLING�VALVE
RH-REAR
LEVELLING�VALVE
LH-REAR
SOLENOID�VALVE
SOLENOID�VALVE
SOLENOID�VALVE
8
2
1221
24
13
21
24
4
13
8
89
14
11
23
2
18
2
23
8
2124
2122
9
8
8
20 1
22
17,16,15
25
13
6
8
15161711
13
11
14
11
11
10
6
7
5
7
3
1
27
28
25
27
28
29
10
19
19
226
7
3
5
27
28
29
30
30
22
31
4
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.3
Unit No: SS1511J,SS1513A
Air Suspension - Full Kneel Amended:1300710
ITEM PART NO QTY DESCRIPTION REMARKS
1 655711 1 Charging valve2 654919-4 - Elbow3 654931 - Connector
4a 656606 2 Solenoid valve - 3 way (Used on and up to Chassis No 5114) SS1511J4b 661657 2 Solenoid valve - 3 way (Used on and after Chassis No 5115) SS1513A
5 654923-2 - Tee piece6 654919-8 - Elbow7 654921-4 - Connector8 654919-5 - Elbow9 660076 2 Levelling valve - front (see separate list)
10 652582 2 Levelling valve - rear (see separate list)11 612525 - Plug - levelling valve12 656607 2 Solenoid valve - single 13 661723 - Tee piece - swivel14 654921-8 - Connector15 654339 - Nut16 654340 - Olive17 655832-2 - Sleeve18 654920-2 - Elbow assembly19 655710 1 Line filter
655710-1 1 Filter element20 657217 - Connector21 656919-3 - Elbow22 654921-4 - Connector23 659800 2 Air spring - front (see separate list)24 438935 4 Air spring - rear (see separate list)25 660222 - “F” fitting26 661727 - Elbow27 657920 - Tee piece
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.4
ENVIRO 400
Air Suspension - Full Kneel Amended:
Unit No: SS1511J
43 42 4112
23 22
21
11/25
2121
21
21
6
3
1
24
3
2
12 BLACK
12 GREEN
6 GREEN6 BLACK6 BLUE
KEY TO PIPE SIZES
21
211
1
1
43
42
41
12
23
22
21
11/25
24
3
21 211
AR7794
AUXILIARY &SUSPENSIONRESERVOIR
AUXILIARY &SUSPENSIONRESERVOIR
3
1
2
FROMPORT 24
MCPV
FULL KNEEL REAR LOCATION
FRONTLOCATION
21
FRONT KNEEL
FULL KNEEL
ZF GEARBOXSUPPLY
24
TO STEERINGCOLUMN
PILOT VALVE
32
SOLENOID�VALVE
LEVELLING�VALVE
RH-FRONT
LEVELLING�VALVE
LH-FRONT
CHARGINGVALVE
REAR
FRONT
LEVELLING�VALVE
RH-REAR
LEVELLING�VALVE
LH-REAR
SOLENOID�VALVE
SOLENOID�VALVE
SOLENOID�VALVE
8
2
1221
24
13
21
24
4
13
8
89
14
11
23
2
18
2
23
8
2124
2122
9
8
8
20 1
22
17,16,15
25
13
6
8
15161711
13
11
14
11
11
10
6
7
5
7
3
1
27
28
25
27
28
29
10
19
19
226
7
3
5
27
28
29
30
30
22
31
4
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.5
Unit No: SS1511J
Air Suspension - Full Kneel Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
28 657921-1 - Reducer29 655017 - Tee piece30 654923-1 - Tee piece31 654621-9 - Connector32 654919-8 - Elbow
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.6
ENVIRO 400
Air Suspension - Front Kneel Amended:
Unit No: SS1510H
12121
1 2121
6
3
12
12 BLACK
12 GREEN
6 GREEN6 BLACK6 BLUE
KEY TO PIPE SIZES
12121
434241 12
2322
21
11/25
24
3
CHARGING VALVE
AUXILIARY &SUSPENSIONRESERVOIR
FRONTLOCATION
12121
2 1 3
STEERING COLUMNPILOT VALVE
LEVELLING�VALVE
RH-REAR
SOLENOID�VALVE
LEVELLING�VALVE
LH-REAR
LEVELLING�VALVE
RH-FRONT
LEVELLING�VALVE
LH-FRONT
REAR
FRONT
SOLENOID�VALVE
5
5
3
21
19
14
14
21
19
11
16
17
10
16
13
1612
16
18
5
16
6
18
16
20
19
16
17
20 21
19
13
10
16 21
23
AR7795
29
30
29
8,9,10
2930
4
15
212221
17
26
25
24
2528
27
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.7
Unit No: SS1510H
Air Suspension - Front Kneel Amended:020708
ITEM PART NO QTY DESCRIPTION REMARKS
1 655711 1 Charging valve2 654919-4 - Elbow3 657217 - Connector4 656606 2 Solenoid valve - 3 way5 654919-4 - Elbow6 654920-2 - Elbow assembly7 656607 2 Solenoid valve - single8 654339 - Nut9 654340 - Olive
10 655832-2 - Sleeve11 655007 - Tee piece12 654921-8 - Connector13 660076 2 Levelling valve - front (see separate list)14 652582 2 Levelling valve - rear (see separate list)15 612525 - Plug 16 654919-5 - Elbow17 654921-8 - Connector18 659800 2 Air spring - front (see separate list)19 438935 4 Air spring - rear (see separate list)20 654919-3 - Elbow21 654921-9 - Connector22 654922 - Tee piece23 655710 1 Line filter
655710-1 1 Filter element24 655017 - Tee piece25 654921-1 - Tee piece26 6549919-8 - Elbow27 654921-4 - Connector28 654921-9 - Connector
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.8
ENVIRO 400
Air Suspension - Front Kneel Amended:
Unit No: SS1510H
12121
1 2121
6
3
12
12 BLACK
12 GREEN
6 GREEN6 BLACK6 BLUE
KEY TO PIPE SIZES
12121
434241 12
2322
21
11/25
24
3
CHARGING VALVE
AUXILIARY &SUSPENSIONRESERVOIR
FRONTLOCATION
12121
2 1 3
STEERING COLUMNPILOT VALVE
LEVELLING�VALVE
RH-REAR
SOLENOID�VALVE
LEVELLING�VALVE
LH-REAR
LEVELLING�VALVE
RH-FRONT
LEVELLING�VALVE
LH-FRONT
REAR
FRONT
SOLENOID�VALVE
5
5
3
21
19
14
14
21
19
11
16
17
10
16
13
1612
16
18
5
16
6
18
16
20
19
16
17
20 21
19
13
10
16 21
23
AR7795
29
30
29
8,9,10
2930
4
15
212221
17
26
25
24
2528
27
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.9
Unit No: SS1510H
Air Suspension - Front Kneel Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
29 657920 - Tee piece30 657921-1 - Reducer
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.10
ENVIRO 400
Front Air Suspension Amended:080212
Unit No: SF1511C, SF1512A. DF1510A
15
FRONT
18
PROXIMITY SWITCHARRANGEMENT - ZF AXLE
PROXIMITY SWITCHARRANGEMENT - DANA AXLE
33
30
34
20
19
2
ZF AXLELH
ZF AXLE
RH
DANA AXLE SHOWN
24
22
22
23
26
2728 29
25
21
31
3032
SF1511
25
24
23
23
23
FRONT
13a
14
15
14a
15
LOW
ER
LIN
K
UPPER LINK
13b
14a
13a
14b
1617
16
16
17
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.11
Unit No: SF1511C, SF1512A. DF1510A
Front Air Suspension Amended:080212
ITEM PART NO QTY DESCRIPTION REMARKS
Used on & up to Chassis No 5114 excluding 4625 & 4752 SF1511CFRONT SUSPENSION - DANA FRONT AXLE
1 419799 2 Torque arm - lower657691 2 Repair kit
2 10 MCB 118 50D 8 Bolt 309-332 lbs ft3 428111 2 Torque arm - upper
651697-1 2 Repair kit4 10 MCB 116 160D 4 Bolt 219-243 lbs ft5 10 MCB 116 55D 4 Bolt6 10 MCN 516 4 Nut special
7a 427970 1 Tower - LH - (Dana Front Axle) SF1511C8a 427971 1 Tower - RH - (Dana Front Axle) SF1511C
9 10 MCS 120 45D 4 Screw - tower to axle bed - front 427-471 lbs ft10 428107 1 Anti roll bar11 434216 4 Rubber- mounting - A.R.B - half Fit as pairs12 MCB 112 35P 8 Bolt - bush to frame 101-111Nm / 75-82Nm13a 425529 2/1 Link plate - ARB - (3 hole) Dana & ZF axle14a 425531 2/1 Link plate & spacer assembly - ARB - (3 hole) Dana & ZF axle15 438257 8 Rubber- mounting - A.R.B - link plate16 10MCB 116 90D 6 Bolt17 10 MCN 516 6 Nut 276 lbs ft
18a 433915 1 Block mounting (Dana Front Axle)19a 10MCB 120 140D 4 Bolt - (Dana Front Axle)
20 WMA 16SP 8 Shim - link-top21 657610 2 Damper- c/w mounting kit DF 1400A22 657610-1 4 Rubber mounting c/w sleeve 23 657696-3 8 Retaining washer - upper & lower24 657696-4 2 Nut
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.12
ENVIRO 400
Front Air Suspension Amended:080212
Unit No: SF1511C, SF1512A. DF1510A
15
FRONT
18
PROXIMITY SWITCHARRANGEMENT - ZF AXLE
PROXIMITY SWITCHARRANGEMENT - DANA AXLE
33
30
34
20
19
2
ZF AXLELH
ZF AXLE
RH
DANA AXLE SHOWN
24
22
22
23
26
2728 29
25
21
31
3032
SF1511
25
24
23
23
23
FRONT
13a
14
15
14a
15
LOW
ER
LIN
K
UPPER LINK
13b
14a
13a
14b
1617
16
16
17
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.13
Unit No: SF1511C, SF1512A. DF1510A
Front Air Suspension Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
21 657610 2 Damper- c/w mounting kit DF 1400A22 657610-1 4 Rubber mounting c/w sleeve 23 657696-3 8 Retaining washer - upper & lower24 657696-4 2 Nut25 659800 2 Air spring assembly
MCB 112 55P 2 Bolt - air spring piston to tower 55 lbs ftMCN 710P 4 Nut - top plate to piston 414 lbs ftWMC 12SP 2 Spring washer
26 659800-4 2 Top plate assembly650055 A/R Jointing compound - top plate sealing
27 656298-2 2 Diaphragm28 659800-2 2 Piston29 659800-3 2 Bump stop30 657505 1 Proximity switch Set gap 0.236 --0.250”
WMG 18SP 2 Washer 424998 1 Cable assembly - Proximity switch
31 434586 1 Plate - sensor flag Proximity switch32 421487 1 Bracket - proximity switch mounting Welded component
FRONT SUSPENSION - ZF FRONT AXLE - all other items as aboveUsed on & after Chassis No 4625, 4752, 5115 onwards SF1512A
7b 445209 1 Tower - LH - (ZF Front Axle)8b 445211 1 Tower - RH - (ZF Front Axle)
13b 445307 1 Link plate - ARB - 4 hole (ZF Front Axle)14b 445314 1 Link plate with spacer - ARB - 4 hole (ZF Front Axle)18b 445212 1 Block mounting (ZF Front Axle)19b 10MCB 120 160D 4 Bolt - (ZF Front Axle)
31 434586 1 Angle - sensor flag Proximity switch
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.14
ENVIRO 400
Rear Suspension Amended:
Unit No: SR1510B, DR1510A
26
27
28
25
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.15
Unit No: SR1510B, DR1510A
Rear Suspension Amended:260509
ITEM PART NO QTY DESCRIPTION REMARKS
1 422590 1 Anti roll bar2 423725 2 Link - Anti roll bar3 434214 4 Bearing - Anti roll bar4 423738 4 Spacer - bearing to link5 MCB 112 55P 8 Bolt6 MCN 512P 8 Nut7 422608 1 Mounting bracket - Anti roll bar - RH8 422607 1 Mounting bracket - Anti roll bar - LH9 425375 2 Pin 230-260Nm
10 658973 4 Mounting rubber - roll bar eye11 423615 2 Washer - inner12 WMA 16SP 2 Washer- outer13 MCN 516P 4 Nut-self locking14 MCS 3316 30P 2 Screw- countersunk15 MCS 116 25P 2 Bolt16 MCS 116 30P 4 Bolt
606152 A/R Loctite HO-242 (apply to 14, 15 & 16)17 404264-1 2 Washer - bottom18 404264-2 2 Washer - top19 434947 4 Mounting rubber - link plate20 MCN 520P 2 Nut - self locking21 659921-22 2 Control arm - upper (576mm)22 659921-23 2 Control arm - lower (664mm)23 10MCS-118-55D 8 Screw - torque arm to frame / axle casing (390Nm to axle & 353-438 Nm to frame)
WLA 12SP A/R Washer - torque arms24 657611 4 Damper- c/w mounting kit
657610-1 2 Rubber mounting c/w sleeve657696-3 3 Retainer657696-4 4 Lock nut
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.16
ENVIRO 400
Rear Suspension Amended:
Unit No: SR1510B, DR1510A
26
27
28
25
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.17
Unit No: SR1510B, DR1510A
Rear Suspension Amended:130209
ITEM PART NO QTY DESCRIPTION REMARKS
25 657130 1 Air spring assembly - LH & RHMCB 112 35P 2 Bolt - air spring piston to tower 75NmMCN 710P 4 Nut - top plate to piston 17-20NmWMC 12SP 2 Washer - spring
26 657130-1 4 Top plate assembly - L.H650055 A/R Jointing compound - top plate sealing
27 656299-2 4 Diaphragm28 651461-13 4 Piston
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.18
ENVIRO 400
Levelling Valve Linkage Amended:
Unit No: SS1511J & SS1510H
REAR - R.H REAR - L.H
FRONT - L.H FRONT - R.H
2
43
43 4
3
43
1 1
2
8
8
8
8
10
12
5
12
7
10
12
5
12
7
10
12
5
12
7
13
13
11 13
11
11
14 15
9
99
9
AR7792
10
12
5
12
7
13
13
131415
12
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.19
Unit No: SS1511J & SS1510H
Levelling Valve Linkage Amended:120111
ITEM PART NO QTY DESCRIPTION REMARKS
660076 2 Levelling valve assembly - Front 652582 2 Levelling valve assembly - Rear400622-39 4 Spacer to frame MCB 108 50P 4 Bolt - front valvesMCB 108 80P 4 Bolt - rear valvesMCN 508P 8 NutWMA 8SP Washer - plain
1 436179 1 Lever arm - front2 439280 1 Lever arm - Rear3 MCS 108 16P 4 Setscrew - lever arm4 WMC 8SP 4 Washer - spring5 419951-4 2 Connecting Rod - Front6 419951-6 2 Connecting Rod - Rear7 659694 4 Pressure plate assembly - upper - M6 - c/w clip8 MCN 506P 4 Nut9 WMA 6SP 4 Washer - Spring
10 655691-1 2 Pressure plate assembly - lower - c/w clip11 437478 2 Pin - pressure plate12 655691-2 A/R Clip - pressure plate13 MCN 108P 12 Nut14 WMC 6SP 2 Washer - Spring15 438400 1 Anchor plate - levelling valve -front
MCS 106 16P 4 Bolt - brackets to towerWMC 6SP 4 Washer - Spring
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.20
ENVIRO 400
Frame Assembly Amended:080107
Unit No: F1523A&B,F1524A&B,NS1510B&C
2
1
3 4
8
12
9105,6,7
ALEXANDER DENNIS
11
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.21
Unit No: F1523A&B,F1524A&B,NS1510B&C
Frame Assembly Amended:100209
ITEM PART NO QTY DESCRIPTION REMARKS
1a 440658 1 Frame assembly - 5.25m - Voith transmission F1523A1b 442180 1 Frame assembly - 5.25m - Voith transmission - wheelarch tank F1523B3a 440290 1 Front module4a 439212 1 Centre module - 5.25m - 2 door5a 440629 1 Rear module
1c 440917 1 Frame assembly - 5.95m - ZF transmission - F1524A1d 441852 1 Frame assembly - 5.95m - ZF transmission - wheelarch tank F1524B1e 442453 1 Frame assembly - 5.25m - ZF transmission F1523C2b 440290 1 Front module3b 439212 1 Centre module - 5.95m - 2 door4b 440629 1 Rear module
5 439234 1 Front crossbeam - “Z”6 MCS 112 35P 4 Screw7 MCN 512P 4 Nut
Used on & up to Chassis No 4164 NS 1510B8a 424293 1 Noise pad- LH9a 440670 1 Noise pad - centre
10a 424300 1 Noise pad - RH657085 16 Clip - noisepad
Used on & after to Chassis No 4165 NS1510C8b 441866 1 Noise pad- LH9b 441867 1 Noise pad - centre
10b 441868 1 Noise pad - RH11 441869 1 Noise pad - Centre - Lower
657085 16 Clip - noisepad
12 438978 1 Plate - vehicle identification number
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.22
ENVIRO 400
Frame Assembly Amended:080107
Unit No: F1523A&B,F1524A&B,NS1510B&C
1
7,85
3 4
2
1111
2
611,13,14
12,9,10 11,9,10
2
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.23
Unit No: F1523,NS1510B
Frame Assembly Amended:130907
ITEM PART NO QTY DESCRIPTION REMARKS
1 440737 1 Rear lower channel2 MCS 110 25P 18 Screw3 432842 1 Rear upright angle - LH4 424607 1 Rear upright angle - RH5 422573 1 Skirt angle - LH6 439797 1 Skirt angle - RH (For engine mount details see Pages 2.66 - 2.76)
430532-1 A/R Shim - eng mounting member - 0.8 mm430532-2 A/R Shim - eng mounting member - 1.0 mm430532-3 A/R Shim - eng mounting member - 1.2 mm
7 MCS 112 45P 3 Screw - skirt to frame8 MCN 512P 3 Nut9 426497 2 Tapping plate - 3 hole
10 WMC 10SP 6 Spring washer11 MCS 112 30P 9 Screw 12 MCS 110 45P 6 Screw13 MCS 112 35P 1 Screw 14 MCN 510P 6 Nut
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.24
ENVIRO 400
Cab Floor & Foot Controls Amended:
Unit No: EC1511C&D
3
4
1
2
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.25
Unit No: EC1511C&D
Cab Floor & Foot Controls Amended:120907
ITEM PART NO QTY DESCRIPTION REMARKS
1 660687 1 Footbrake pedal - (See braking system)MCS 108 30P 2 Setscrew655185 1 Washer - largeWMA 8SP 1 Washer - spring
2 661198 1 Thottle pedal - used on and after Chassis No 4228 (660583)661219 1 Kit - Adaptor plate
3 657404 1 Foot button valve
4 658740 1 Steering column adjustable (See Steering section)
NOTE:When a vehicle orginally fitted with obselete throttle pedal 660583 isfitted with new pedal 661198, an adaptor plate kit will be needed.
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.26
ENVIRO 400
Wheels and Tyres Amended:120907
Unit No: W1510C,F&G
23
1
MICHELIN
4/5/6
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.27
Unit No: W1510C,F,G&H
Wheels and Tyres Amended:170209
ITEM PART NO QTY DESCRIPTION REMARKS
Used on and uo to Chassis No 4423 ACN 20761a 657297-17 6 Wheel and tyre assembly - Silver W1510C2a 657296-2 6 Wheel rim `3a - 6 Tyre - 305/70R - 22.5” - Michelin XZU+
Used on and After Chassis No 4424 ACN 20761b 657297-20 6 Wheel and tyre assembly - Silver W1510F2b 657296-2 6 Wheel rim3b - 6 Tyre - 305/70R - 22.5” - Michelin Intercity XZU 3
1c 657297-21 6 Wheel and tyre assembly - blue W1510G2c 658314 6 Wheel rim - blue3c - 6 Tyre - 305/70R - 22.5” - Michelin intercity XZU 3
1c 657297-22 6 Wheel and tyre assembly W1510H2c 657296-3 6 Wheel rim - silver3c - 6 Tyre - 305/70R - 22.5” - Goodyear Metro MCS
4 650723-4 20 Wheel nut - front5 651043-4 20 Wheel nut - rear6 245183-2 20 Cover - wheel nut - black
WHEEL EMBELLISHERS AL512-1660092 2 Embellisher
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.28
ENVIRO 400
Wheels and Tyres Amended:
Unit No:OL1539-1
23
1
MICHELIN
ALCOA
ALCOA
ALCOA
ALCOA
ALCOA
ALCOA
ALCOA
ALCOA
ALCOA
ALCOA
4/5
ALCOA 6
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 6.29
Unit No: OL1539-1
Wheels and Tyres Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
1 661202-1 6 Wheel and tyre assembly2 661186 6 Alloy wheel - 22.5” x 8.25” - offset 6.7”3 - 6 Tyre - 305/70R - 22.5” - Michelin XZU+
4 660438-1 20 Wheel nut - sleeved - short - single wheel 5 660438-2 20 Wheel nut - sleeved - long - twin wheel6 661081 40 Wheel nut cover
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
Contents
Steering and Front Axle Amended:180209
SteeringSteering Column - air adjustable . . . . . . Page 7.2 - 5Steering Column - air adjustable - spares Page 7.6 - 7Steering Column adjustment - air diagram Page 7.8 - 9
Front Axle - DanaSwivel Hub assembly . . . . . . . . . Page 7.10 - 15Swivel pin kits . . . . . . . . . . . . . . Page 7.16 - 17Hub and Brake assembly . . . . . . Page 7.18 - 19
Front Axle - ZFSwivel Hub assembly . . . . . . . . . Page 7.20 - 21Axle Beam . . . . . . . . . . . . . . . . . Page 7.22 - 23
Section 7
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.2
ENVIRO 400
Steering Column Amended:
Unit No: SG1510H
1
2/9
4
3
5
6
7
8
10
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.3
Unit No: SG1510H
Steering Column Amended:29.07.09
ITEM PART NO QTY DESCRIPTION REMARKS
1 427483 1 Steering wheel427923 1 Badge - steering wheel - “DENNIS” OL1535-1440672 1 Badge - steering wheel - “ALEXANDER DENNIS”654449-12 1 Nut
2 658740 1 Steering column assembly (See separate list)3 433455 1 Shroud - steering column
MCB 112 120P 2 Setscrew - column to frameMCN 512P 2 Nut - setscrew - columnMCS 108 20P 4 Setscrew - column to cabWMC 8SP 4 Washer - spring658136 4 Washer
4 412555-8 1 Steering shaft607139 A/R Lubricator - splined shaft for spline
5 611511 1 Universal joint400546 3 Bolt - special 42 lbs ftMCN 410P 3 Nut - slotted further tightenSP5 16ST 3 Split pin to align split pin
6 659633 1 Steering gear408440-5 4 Bolt special 400-426 lbs ft421387 1 Bolt - forged 400-426 lbs ft659314-8 4 Washer - hardened
7 422673 1 Drop arm 405-446 lbs ft654660-1 1 Nut - stake type - drop arm
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.4
ENVIRO 400
Steering Column Amended:
Unit No: SG1510H
1
2/9
4
3
5
6
7
8
10
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.5
Unit No: SG1510H
Steering Column Amended:130111
ITEM PART NO QTY DESCRIPTION REMARKS
Dana Front Axle only (orientation of clamps and bolt heads is important)8a 419801 1 Drag link assembly 210-230 Nm
653910 2 Ball joint656692-4 2 Bolt 70 - 80 Nm656692-3 2 NutSP10 32 ST 2 Split pin
ZF Front Axle only (orientation of clamps and bolt heads is important)8b 446999 1 Drag link assembly 210-230 Nm
653910 2 Ball joint656692-4 2 Bolt 70 - 80 Nm656692-3 2 NutSP10 32 ST 2 Split pin
9 439734 2 Packer10a 658812 1 Steering column switch - RH10b 661710 1 Steering column switch - RH - (Used on & after Chassis No 5115) Multic panel10c 657886 1 Steering column switch - LH OL1537-1
656602 2 Limiter assembly - steering box
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.6
ENVIRO 400
Steering Column Spares Amended:
Unit No: SG1510H
13139
8
177
9
6
1010
17
12
5 16
2
14,15
1
4
3
11
18
19
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.7
Unit No: SG1510H
Steering Column Spares Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
658740 1 Steering column assembly
1 658092-1 1 Column body assembly2 658740-2 1 Column and clamp assembly3 657115-2 1 Bevel box assembly4 658740-1 1 Slider assembly5 658092-5 1 Spring support spacer6 658092-6 1 Spring - RH7 658092-7 1 Spring - LH8 658092-8 1 Bolt - M10 x 1109 658092-9 2 Bonded aluminium washer
10 657115-11 2 Nut - M1211 657115-12 1 Patched bolt - M10 x 3512 657115-13 1 Nut - M1013 657115-15 2 End bracket14 657115-17 6 Washer - M815 657115-18 6 Setscrew - M8 x 1616 657115-20 1 Nylon tube - 1m17 655078-5 2 Washer18 654449-12 1 Nut, Nyloc -
3/4 -16 UNF
19 657115-24 1 Air piston clamp assembly
439734 a/r Angle steering column packer 2mm thick - column to frame
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.8
ENVIRO 400
Steering Gear Amended:
Unit No: SG1510H
4mmBlue
2
1
3 3
4
5
6
67
3
3,8
AR7059
98
AR6684
2
31PILOT VALVE OPERATION
3
1
2
SUPPLY FROMAUXILIARY &SUSPENSIONRESERVOIR
HANDBRAKEVALVE
6 m
mO
RA
NG
E6
mm
OR
AN
GE
6 mmORANGE
6 mmORANGE
31
2
21
1
SOLENOIDVALVE
FROM RELAYVALVE SIGNAL
LINE - Port 4
FEED FROM QUAD VALVE
TO INSTRUMENT PANEL
EXHAUST
EXHAUST
PILOTVALVE
4 mmBLACK
4 mmBLACK
STEERINGCOLUMN
6 mmORANGE
4 mmBLACK
4 m
mB
LAC
K
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.9
Unit No: SG1510H
Steering Gear Amended:080910
ITEM PART NO QTY DESCRIPTION REMARKS
1 660764 1 Pilot valve AR70592 657424-1 1 Connector3 654947-7 4 Elbow4 654255 1 Exhaust filter5 657404 1 Valve - foot button6 654926 2 Adaptor7 657424-1 1 Connector8 657950-2 1 Reducer
655022 A/R Nylon pipe - 4mm Black
For details of Handbrake interlock see Page 4.19
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.10
ENVIRO 400
Front Axle - Dana - Swivel Assembly Amended:
Unit No: AF1511G,J&L
12
34
5
6
7
8
9
1011
1213
1415
16
17
1819
2021
2223
2425
2627
28
2930
31
40
32333435
36
3738
39
41
44
41
46
42
43
47
49,50
48,51
52
45
RH
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.11
Unit No: AF1511G,J&L
Front Axle - Dana - Swivel Assembly Amended:260509
ITEM PART NO QTY DESCRIPTION REMARKS
Use on & up to Chassis No 4363 inc 4369-4374, 4387-4398, 4402-4423659387 1 Front axle - complete - RHD - SB type calipers AF1511G
Used on & After Chassis No 4424 inc 4364-4368, 4375-4386, 4399-4401661335 1 Front axle - complete - RHD - SN type calipers AF1511J/AF1511L
1 607901-62 20 Brake bracket locknut2 658470-1 20 Brake bracket stud3 658470-2 1 Swivel4 658470-3 1 King pin oil seal (top)5 658470-4 1 King pin bush (top)6 657688-25 1 Top cap spacer7 658470-6 1 Top cap foam insert8 658095-20 1 Top cap9 658470-8 1 Top cap lubricator 10 658470-9 1 Top steering lever 11 658470-10 2 Top lever bolt 12a 658470-11 A/R Swivel bearing. setting shim - 0.13 mm 12b 658470-12 A/R Swivel bearing. setting shim - 0.25 mm 12c 658470-13 A/R Swivel bearing. setting shim - 0.50 mm 12d 658470-14 A/R Swivel bearing. setting shim - 0.20 mm 13 658470-15 2 King pin thrust bearing14 606624-134 2 Cotter pin nut 1/2" UNF15 659387-3 2 Cotter pin washer16 658470-16 1 Axle bed17 658470-17 2 Cotter pin 18 - - Not required on this application19 - - Not required on this application20 658470-52 2 ABS sensor kit (per axle)21 658923-24 1 Sensor bush (supplied as part of item 20)
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.12
ENVIRO 400
Front Axle - Dana - Swivel Assembly Amended:
Unit No: AF1511G,J&L
12
34
5
6
7
8
9
1011
1213
1415
16
17
1819
2021
2223
2425
2627
28
2930
31
40
32333435
36
3738
39
41
44
41
46
42
43
47
49,50
48,51
52
45
RH
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.13
Unit No: AF1511G,J&L
Front Axle - Dana - Swivel Assembly Amended:130614
ITEM PART NO QTY DESCRIPTION REMARKS
22a 659387-5 2 Lockstop screw L/H & R/H 22b 658521-12 2 Lockstop screw R/H
68256-61 1 Shim axle stop 68256-63 1 Shim axle stop68256-64 1 Shim axle stop
23 658470-20 3 Lockstop nut24 658470-21 2 Bottom lever bolt25 658470-22 2 Bottom lever bolt
26 659387-6 1 Bottom lever R/H658470-24 1 Bottom lever L/H658470-27 1 Tie rod assembly :
27 658521-16 2 Ball pin nut 28 658521-17 2 Split pin 29 659387-7 1 Tie rod 30 658521-20 2 Socket Clamp
658521-19 2 Socket clamp pinch bolt658521-21 2 Socket clamp pinch nut
31a 658521-22 1 Socket assembly R/H 31b 658521-23 1 Socket assembly L/H 32 658470-8 1 Bottom cap lubricator33 658095-20 1 Bottom cap34 658470-6 1 Bottom cap foam insert 35 657688-25 1 Bottom cap spacer 36 658470-28 1 King pin37 658470-4 1 King pin bush (bottom)38 658470-3 1 King pin oil seal (bottom)39 655387-5 1 Thrust washer (hub bearing)40 655387-4 2 Hub nut
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.14
ENVIRO 400
Front Axle - Dana - Swivel Assembly Amended:
Unit No: AF1511G,J&L
12
34
5
6
7
8
9
1011
1213
1415
16
17
1819
2021
2223
2425
2627
28
2930
31
40
32333435
36
3738
39
41
44
41
46
42
43
47
49,50
48,51
52
45
RH
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.15
Unit No: AF1511G,J&L
Front Axle - Dana - Swivel Assembly Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
41 438300 1 Plate - bracket support AL1543-142 MCS 3610 25 2 Cap screw43 431400 1 Bracket - brake pipe - upper
44a 432004 1 Bracket - brake hose - LH44b 432005 1 Bracket - brake hose - RH
45 655768-2 2 Swivel elbow - pipe to bracket46 MCN 510P 2 Nut - self locking
47a 438282 2 Brake pipe asssy - LH47b 438281 2 Brake pipe asssy - RH
48 MCS 3610 20 2 Cap screw49 MCB 108 16P 1 Bolt - bracket to backplate50 WMC 8SP 1 Washer - spring51 WMC 10SP 1 Washer - spring52 655768-4 1 Elbow - pipe to bulhead bracket
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.16
ENVIRO 400
Front Axle - Dana - Swivel Assembly Amended:
Unit No: AF1511G,J&L
4
5
6
7
8
912
13
1415
17
32333435
36
3738
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.17
Unit No: AF1511G,J&L
Front Axle - Dana - Swivel kits Amended:110907
ITEM PART NO QTY DESCRIPTION REMARKS
SWIVEL PIN SERVICE KIT
1 Comprising items: 4, 5,6, 8, 9, 12 to 15 17, 32 to 38 With cap/ lubricator658109-14 1 One hub set
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.18
ENVIRO 400
Front Axle - Dana - Hub and Brake assembly Amended:010708
Unit No: AF1511G,J&L
12
3
4 5a6a
789
10
5b
SN
SB
658470,659387,661335
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.19
Unit No: AF1511G,J&L
Front Axle - Dana - Hub and Brake assembly Amended:170209
ITEM PART NO QTY DESCRIPTION REMARKS
1 650723-4 20 Wheel nut 2 658470-31 2 Hub flange 3 658470-32 20 Wheel stud (R/H Thread)4 - 1 Brake Caliper assembly L.H & R.H (See Braking System)
5a 655387-24 12 Brake Caliper retaining washer - SB Caliper6a 658470-35 12 Brake Caliper retaining Bolt - SB Caliper5b - - Not required on this application 6b 661336-1 12 Brake Caliper retaining Bolt - SN Caliper
7 658470-36 1 Brake Bracket R/H658470-37 1 Brake Bracket L/H
8 658470-38 2 Unitised Hub Bearing Alignment tool E6609 658470-39 2 Brake Disc
10 658521-33 28 Hub Flange Bolt
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.20
ENVIRO 400
Front Axle - ZF - Swivel assembly Amended:120609
Unit No: AF1513A
4
12
5
3
68
7
9
1011
121314
15
16
17
18
19
20
17
18
19
20
21/2223
2423
25 26
27 28
661773
29
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.21
Unit No: AF1513A
Front Axle - ZF - Swivel assembly Amended:180811
ITEM PART NO QTY DESCRIPTION REMARKS
661773 1 Front axle - complete - RHD - SN type calipers
1 661773-1 2 Cover2 661773-2 2 ‘O’ ring3 661773-3 2 Hub4 661773-4 2 Hexagon screw5 661773-5 20 Screw - “torx”6 661773-6 20 Wheel bolt7 661773-7 4 Nut - slotted8 661773-8 2 Lock plate9 661773-9 2 Brake Disc10 661773-10 2 ‘O’ ring - shaft seal11 661773-11 2 Bearing Unit12 661773-12 2 ‘O’ ring 13 661773-13 2 Ring - bearing unit14 661773-14 2 ABS pulse ring15 661773-15 2 Swivel16 661773-16 2 Swivel pin17 661773-17 4 Sealing ring 18 661773-18 8 Bearing sleeve19 661773-19 4 Top cap assembly20 661773-20 4 Circlip21 661773-21 1 Steering lever - RH22 661773-22 1 Steering lever - LH23 661773-23 6 Bolt - steering levers24 661773-24 1 Steering lever - upper RH25 653877-8 2 ABS sensor26 653877-7 2 Bush - ABS sensor27 661773-28 2 Stop screw28 661773-29 2 Nut - stop screw29 651043-4 20 Wheel nut
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.22
ENVIRO 400
Front Axle - ZF - Axle Beam Amended:
Unit No: AF1513A
661773
4
17,8
2 35/6
9
13
12
1110
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 7.23
Unit No: AF1513A
Front Axle - ZF - Axle Beam Amended:
ITEM PART NO QTY DESCRIPTION REMARKS
661773 1 Front axle - complete - RHD - SN type calipers
1 661773-25 1 Tie rod2 661773-31 1 Ball joint3 661773-32 1 Theaded sleeve4 661773-33 1 Clamp5 661773-34 1 Screw - clamp6 661773-35 1 Nut - clamp7 661773-36 1 Nut - castle8 661773-37 1 Split pin9 661773-30 1 Axle Beam10 661773-40 2 Bolt - fitted - caliper securing11 661773-41 10 Screw - caliper securing12 661773-38 1 Roller Bearing13 - A/R Shims available in thicknesses in from 3.00 mm in increments of 0.05mm
down to 2.2 mm.
BRAKE PIPES AND BRACKETS432004 1 Bracket - brake hose - LH 432005 1 Bracket - brake hose - RHMCS 108 20P 4 SetscrewWMC 8SP 4 Washer - spring446199 1 Pipe assembly - brake - LH446200 1 Pipe assembly - brake - RH446201 2 Bracket - pipe support - upper - “twisted”MCB 108 16P 2 BoltWMC 8SP 2 Washer - spring
PARTS MANUAL
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
A
Abbreviations, 1.24
Air Cleaner, 2.2
Air Conditioning, 2.84
Air Dryer, 4.24
Air Suspension, 6.2
Alternator Mounting, 2.80
B
Battery Carrier, 5.20
Battery Carrier & Rear Frame Area, 5.24, 5.38
Brake Actuators & Chambers, 4.18
Brake Caliper - SB, 4.28
Brake Caliper- SN, 4.32
Brake Caliper Spares - SB type, 4.30
Brake Caliper Spares - SN, 4.34
Brake Chambers, 4.18
Brake Tubing, 4.36
Braking, 4.1
Braking System - ABS/ASR, 4.2, 4.4, 4.10, 4.12
C
Cab Floor, 6.24
Cables, 5.14, 5.37
Cooling Pack Assembly, 2.16, 2.18
Cooling System - Voith, 2.4
Cooling System - ZF, 2.10, 2.12
D
Drive Axle - Differential Assembly, 3.12
Drive Axle - Axle Casing, 3.14
Drive Axle - Brake, 3.22
Drive Axle - Gantry, 3.18
Drive Axle - Gantry Drive, 3.16
Drive Axle - Input, 3.10
Drive Axle - Output, 3.20
Drive Shaft, 3.8
E
Electrical System, 5.1
Electrical System - Miscellaneous, 5.18
Engine, 2.1
Engine and Mounting - Voith, 2.68
Engine and Mounting - ZF, 2.72, 2.74
Engine Fuel Filter, 2.56
Engine Service Sundries, 2.78
Exhaust Gas Processor, 2.24, 2.26, 2.30
Exhaust Gas Processor System - Insulation, 2.28
F
Fastener Identification, 1.16, 1.21
Foot Controls, 6.24
Footbrake Valve, 4.20
Frame Assembly, 6.20, 6.22
Front - EDC, 5.6, 5.28
Front Air Suspension, 6.10, 6.12
Front Axle, 7.1
Front Axle - Dana - Swivel Assembly, 7.10
Front Axle - ZF - Swivel assembly, 7.20
Fuel System Pipework, 2.46, 2.48, 2.50, 2.52,2.54, 2.56
Fuel Tank Assembly, 2.36
Fuel Tank Assembly - Identic, 2.38
Fuel Tank Assembly - Posilock, 2.40
Fuel Tank Assembly - Wheelarch, 2.42
G
General, 1.1
H
Handbrake Interlock, 4.26
Harnesses, 5.36
Header Tank, 2.22
Health and Safety, 1.2
Hydraulic Fan Reservoir, 2.66
Hydraulic System, 2.58, 2.60, 2.62
I
Instrument Binnacle, 5.2, 5.4, 5.26
Instrumentation, 5.1
Intercooler Assembly, 2.20
Alphabetical Index Amended:
ENVIRO 400
Enviro 400 - Parts Manual - Publication Number 2295 - January 2006
L
Levelling Valve Linkage, 6.18
Lubricants and Fluids, 1.22
M
Main Index, 7
O
Oil Filler, 2.76
P
PCB - Front - EDC, 5.8, 5.30
PCB - Rear - EDC, 5.12, 5.34
Pipe Fittings - ABS/ASR, 4.6, 4.8, 4.14, 4.16
Q
Quick Reference Spares, 1.6, 1.14
R
Rear - EDC, 5.10, 5.32
Rear Suspension, 6.14
Regional PartsManagers, 4
Regional Service Managers, 5
S
Safety, 1.2
Saloon Heater Pipework, 2.82
Service Assistance, 3
Service Centres, 6
Spare Parts, 3
Steering, 7.1
Steering Column, 7.2, 7.4
Steering Column Spares, 7.6
Steering Gear, 7.8
Steering Reservoir, 2.64
Suspension, Frame, Wheels, 6.1
T
Transmission - ZF, 3.4, 3.6
Transmission- Voith, 3.2
Tyres, 6.26, 6.28
U
Urea Tank Assembly, 2.32
Urea Tank Assembly - Identic, 2.34
V
Vehicle Identification Number, 1.5
W
Wheels, 6.26, 6.28
Alphabetical Index Amended:
Recommended