Service Manual 344 & 384

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Leyland Service Manual 344 & 384 Service Manual THIS IS A MANUAL

WITHOUT THE AUTHORIZATION OF LEYLAND OR IT S SUCCESSORS.

1 Leyland Service Manual 344 & 384 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF LEYLAND OR IT S SUCCESSORS. LEYLAND AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. LEY-S-344,384

2 TRACTOR 255 (344) 270 (384) INDEX Group ~ody Brakes Clutch Cooling system.. Eleetrical.. Engine Final drive and reduction gears Front axle and steering gear Fuel system Gearbox.-power take-off and belt pulley unit General Data Hydraulic units (early type) Hydraulic units (with position and draught control) Lubrication Maintenance Service tools Front of book 37 37a Front of book Front of book End of book

3 MAINTENANCE LUBRICATION The correct oil and grease recommendations for the individual components are given on Page 'Lubrication 2'. I~.., \) _. -_._---- I) u ENGINE. Check the sump oil level by removing the dipstick (1). The level should show at the 'MAX' position on the dipstick. To drain the sump oil remove the plug (2). Clean the plug before replacing it. Turn the oil filler cap (3) anticlockwise to remove. Fill the sump with new oil until the correct level is shown on the dipstick. The sump is best drained when the engine is warm. FUEL INJECTION PUMP. To drain the pump, remove the drain plug (1). Remove the level plug (2) and the filler plug (3). Fill the pump with new oil till it just runs from the level plug hol~.. DYNAMO. Remove the rubber plug (1), insert two drops of oil to the central hole (arrowed) in the end plate. \ TRANSMISSION. Check the transmission case oil level by removing the dipstick (1). The level should show at the'h' mark on the dipstick. To drain the transmission remove. both plugs, one at each side, from the axle case (2). Remove the; filler plug (3). Fill the transmission case with new oil until the correct level is shown on the dipstick. The transmission is best drai.ned after several hours' work while the case is warm. Maintenance 1

4 25 ENGINE B REMOVING AND REFITTING COMPONENTS Page Section Big-ends.. '. 25/B7 B5 "" Camshaft.. 25/B8 B6 Connecting rods ".. 25/B14 B9 Crankshaft.; 25/B14 B9 Crankshaft balancer.. 25/B14 B9 Crankshaft rear 011 seal 25/B17 B10 Cylinder head 25/B3 B2 Engine 25/B10 B7 Flywheel 25/B17 B10 Oil pump 25/B14 B9 Pistons 25/B14 B9 Sump 25/B7 B4 Tappets 25/B2 B1 Timing c~ver 25/B4 B3 Timing cover oil seal 25/B13 B8 Timing gear case /B4 B3 Timing gears 25/B4 B3 Valve rocker shaft 25/B2 B1 C OVERHAULING Balancer support bracket 25/C9 C10 Camshaft bearing liner 25/C3 C4 Connecting rods " 25/C8 C9 Crankshaft 25/C3 C3 Cylinder head 25/C4 C5 Cylinder liners 25/C3 C2 Flywheel 25/C5 C6 Fuel injector sleeves 25/C4 C5 011 pressure relief valve.. 25/C6 C7 Oil pump.. 25/C6 C7 Pistons 25jC8 C9 Tappets 25/C2 C1 Timing gears 25fC7 C8 Valve guides 25fC4 C5 Valve rockers 25/C2 C1 Valve rocker shaft 011 relief valve 25fC2 C1 Valve seat inserts 25/C4 C5 Valves 25fC4 C5 25/81

5 26 J B FUEL SYSTEM REMOVING AND REFITTING COMPONENTS Page Section Bleeding the system 26/B2 B1 >~ Fuel filter.. 26/B2 B2 Fuel tank.. 26/B2 B Injection pump 26/8-(' B6 Injectors 26/B3.&4 lift pump.. 26/B3 'BS C OVERHAULING Injection pump 26/C6 C3 Injectors 26/C2 C1 lift pump.. 26/C3 C2 26/~1.,.:;. -~

6 28 COOLING SYSTEM B REMOVING AND REFITTING COMPONENTS Fan blades.. Overflow tank Pulley Radiator Radiator and frame Thermostat Water pump Page 28/B4 28/B4 28/B4 28/B2 28/B3 28/B5 28/84 Section B4 B3 B4 B1 B2 B5 84 C OVERHAULING Thermostat Water pump.. 28/C2 28/C2 Cl C1 28/81

7 29 CLUTCH B REMOVING AND REFITTING COMPONENTS Carrier bracket and transmission assembly (LP.T.O.) Clutch and brake controls Clutch cover Double clutch Single clutch Page 29{B3 29{B7 29/B? 29{~4 29{B6 Section B2 B5 B1 B3 B4 C OVERHAULING Carrier bracket and transmission assembly (I.P.T.O.) Clutch and brake controls Double clutch Single clutch 29/C3 29{C6 29/C4 29{C2 C2 C4 C3 C1 29/81

8 30 GEARBOX AND POWER TAKE-OFF B REMOVING AND REFITTING COMPONENTS Page Section Belt pulley unit.. 30/B8 B8 Centre bearing assembly 30/B4 B3 Gearbox top cover. 30/B3 B2 Layshaft assembly 30/BS B4 Malnshaft assembly 30/B4 B3 Power take-off driving tube assembly.. 30/B7 B6 Power take-off shaft and bearing housing assembly 30/B7 B7 Primary shaft (Basic) 30/B6 BS Primary shaft (!'P.T.O.).. 30/B2 B1 Reverse gear 30/BS B4 Stub shaft (Basic).. 30/B6 BS Stub shaft (!.P.T.O.) 30/B2 B1 C OVERHAULING. Belt pulley unit.. 30/C7 C10 Centre bearing assembly.. 30/CS C6 Gearbox top cover 30/C3 C1 Layshaft 30/CS C7 Malnshaft.. 30/C3 C2 Power take-off driving gear 3OfC4 CS Power take-off shaft and bearing housing 30/C6 C9 Primary shaft 30/C4 C4 Reverse gear 30/C6 C8 Stub shaft.. 30/C4 C4 Transfer gear case and cover 30/C4 C3 30/81

9 31 FINAL DRIVE AND REDUCTION GEAR B REMOVING AND REFITTING COMPONENTS Differential assembly Differential lock.. Rear axle assemblies Page 31/B4 31/B3 31/B2 Section B3 B2 B1 C OVERHAULING Differential assembly Rear axle assemblies 31/C3 31/C2 C2 C1 31/B1

10 32 FRONT AXLE AND STEERING GEAR A ADJUSTING Front wheel alignment.. Page 32/A2 Section A1 B REMOVING AND REFITTING COMPONENTS Front axle.. Front hubs.. Power steering cylinder.. Power steering pump Steering cranked arm Steering gear 32/B3 32/B2 32/B6 32/B2 32/B5 32/B4 B3 B1 B6 B2 B5 B4 C OVERHAULING Front axle.. Front hubs.. Power steering cylinder.. Power steering pump Steering cranked arm Steering gear 32/CS 32/C3 32/C4 32/C6 32/C3 32/C2 C6 C2 C4 C5 C3 C1 32{A1

11 BRAKES 33 BRAKES B REMOVING AND REFITTING COMPONENTS Disc brakes Independent brakes Page 33/B2 33/B2 Section B1 B2 C OVERHAULING Disc brake actuator 33/C2 C1 33/81

12 ELECTRICAL 35 ELECTRICAL A DESCRIPTION Wiring Diagram-D.C. Generator. Positive Earth.. Wiring Diagram-D.C. Generator. Negative Earth.. Wiring Diagram-A.C. Generator. Negative Earth.. Page 35/A2 35/A4 35/A6 Section TESTING AND ADJUSTING Control box Charging circuit (Alternator) 35/A8 35/A10 B REMOVING AND REFITTING COMPONENTS Generator.. Starter Service precautions Windscreen wiper motor 35/82 35/82 35/83 35/ B4 C OVERHAULING Generator Dynamo.. Alternator Starter Windscreen wiper motor 35/C4 35/C8 35/C2 35/C6 C2 C4 C1 C3 35/A1

13 37,HYDRAULICS (EARLY TYPE) A DESCRIPTION Hydraulic power unit and P.T.O. with depth control "" Power take-off selector positions Valve assembly h"ydraulic flow TESTING Depth control hydraulic circuit.. High pressure spring High pressure valve" Page 37/A6 37/AS 37/A2 37/A8 37/A8 37/A8 Section B REMOVING AND REFITTING COMPONENTS Cross-shaft assembly 37/B2 B2 Depth control valve Draught control Belleville washer pack mechanism Hydraulic cylinder assembly Hydraulic lift pump " " 37/B4 37/B5 37/B8 37/B7 B4 B5 B8 B7 Hydraulic lift control quadrant "" 37/B2 B1 Hydraulic power unit Quadrant linkage. "" 37/B6 37/B2 B6 B1 Relief valve housing 37/B3 B3 Relief valves 37/B3 B3 Valve body and cylinder assembly 37/B8 B8 C OVERHAULING Cross-shaft assembly Dep~h control valve Draught control Belleville washer pack 371C3 371C4 371C5 C2 C3 C4 Hydraulic cylinder assembly 371C8 C6 HydrauliC lift control quadrant "" 371C2 C1 Hydraulic lift pump 371C6 C5 Valve body and cylinder assembly 371C8 C6 371M

14 37a HYDRAULICS (WITH POSITION AND DRAUGHT CONTROL) A DESCRIPTION Page Section Valve assembly hydraulic flow 37a/A2 Power take-off selector positions 37a/A10 ADJUSTING Hydraulic unit controls FAULT FINDING Charts 37a/A8 37a/A11 B REMOVING AND REFITTING COMPONENTS Belleville washer pack mechanism 37a/B-4 B3 Control levers assembly. 37a/B3 B2 Cross-shaft assembly 37a/B-4 B4 Draught sensing control. 37a/B6 B7 Hydraulic power unit 37a/B5 B5 Hydraulic pump 37a/B6 B6 Relief valves and housing (In position).. 37a/B2 B1 Valve body and cylinder assembly 37a/B7 B8 C OVERHAULING Belleville washer pack mechanism 37a/C9 C6 Control levers assembly. 37a/C5 C3 Cross-shaft assembly 37a/C4 C2 Draught sensing control. 37a/C8 C5 Hydraulic pump 37a/C6 C4 Valve body and cylinder assembly 37a/C2 C1 37a/A1

15 64 BODY B REMOVING AND REFITTING COMPONENTS Page Section Safety cab 64/82 81 Windscreen, door and front panel glass 64/82 82 Cab side windows 64/ /81

16 INDEX Group Clutch 29 Cooling System 28 Diesel Engine 25 Diesel Fuel System 26 Electrical.. 35 General Data lubrication Maintenance.Front of Supplement Front of Supplement Front of Supplement Power Steering.. 32 Service Tools End of Supplement NOTE.-The dismantling and assembly procedures in this Supplement are presented assuming the engine has been removed from the vehicle. 98 mm ENGINE 3

17 25 DIESEL ENGINE C OVERHAULING Page Section Balancer support bracket.. 2S/C10 C13 Bearing housing (D.P.A. Injection pump drive).. 2S/C9 C12 Camshaft 2S/C7 C9 Connecting rods 25jC3 C2 Crankshaft 25/C7 C8 Cylinder head 2SjC4 C4 Cylinder liner 25/C4 C3 Flywheel.. 2S/C6 C7 Main Idler gear 2S/C6 C6 011 pump 2S/C8 C10 Pistons 25jC3 C2 Tappets 2S/C6 CS.Valve guides 25/C4 C4 Valve rocker shaft.. 2SjC2 C1 Valve rocker shaft 011 pressure relief valve 25/C9 C11 Valve seat Inserts 25/C4 C4 Valves.. 25/C4 C4 25/A2 98 mm ENGINE

18 25 DIESEL ENGINE 12. Remove the timing cover securing bolts. detach the front lifting bracket. and pull the timing cover off the two dowels locating it to the timing case. NOTE.-The main idler gear thrust washer may stick to the timing cover. 13. Remove the oil thrower from the crankshaft. and the thrust washer from the main idler gear shaft. 14. Refit the crankshaft nut and rotate the crankshaft until the timing marks on the timing gears are in the positions shown in Fig. 2. Remove the nut. 15. Remove the bolts securing the injection pump drive gear and remove the gear from its hub. 16. Remove the circlip from the hub inside the rear end of the bearing housing. 17. Withdraw the gear hub forward. from the hub bearings. using tools'18g 284 and 18G 284 AAB. 18. Remove the securing bolts and nuts. and withdraw the bearing housing rearwards from the timing case. Refitting 19. Reverse the procedure 1 to 18. noting: a. Refer to Data for torque wrench settings. b. Disengage the main idler gear. fit the injection pump drive gear to its hub with the hub and gear timing marks aligned as shown in Fig. 3. Engage the main idler gear so that the timing gears are positioned as shown in Fig. 2. c. Fit the main idler gear thrust washer with its grooved side towards the gear. d. Fit the crankshaft oil thrower with its chamfered face towards the gear.. e. Apply sealing compound to both sides of the sump gasket. (. Position the alternator (or dynamo) to give the correct drive belt tension (refer to 'MAIN TENANCE'). g. Check the position of the injection pump timing pointer as follows: I. With No. 1 piston at the beginning of its compression stroke. insert timing pin AMK 9990 through the hole in the flywheel housing and into the hole in the flywheel. il. If necessary. maintain alight pressure on the timing pin and turn the crankshaft in its normal direction of rotation until the timing pin engages the hole in the flywheel. iii. Using tool 18G 1206 check and. if necessary. adj~st the position of the injection pump timing pointer (refer to Fig. 4). Remove the timing pin and timing tool.. Procedure using timing gauge MS 67. Carry out Instructions i and Ii above, then proceed as follows: I. Remove the scribing arm from timing gauge MS 67 and locate the hexagonal handle through the gauge body so that the corner marked '0' is in line with the 240 position marked on the gauge body spigot (refer to Fig. 5). Insert the splined end of the gauge into the injection pump drive gear hub and slide the gauge body forward until it abuts the Fig. 2 Fig. 3 Fig. 4 25/ mm ENGINE

19 26 DIESEL FUEL SYSTEM A TESTING Page Section Testing the lift pump 26/A2 A1 B REMOVING AND REFITTING COMPONENTS Bleeding the system (D.P.A. injection pump) 26/B2 B1 Bleeding the system (Simms in-line injection pump) 26/B2 B2 D.P.A. injection pump 26/B2 B3 Injectors 26/B5 B5 Simms in-line injection pump 26/B4 B4 C OVERHAULING lift pump 26/C2 C1 98 mm ENGINE 26/A1

20 28 COOLING SYSTEM B REMOVING AND REFITTING COMPONENTS Page Section Thermostat.. 28/82 81 Fan blades. pulley. and water pump 28/82 82 C OVERHAULING Water pump.. 28/C2 C1 98mm ENGINE 28/81

1180, 1180DT, 1280, 1280DT, 1380, 1380DT, 1580, 1580DT, 1880 & 1880DT

Fiat Service Manual 1180, 1180DT, 1280, 1280DT, 1380, 1380DT, 1580, 1580DT, 1880 & 1880DT Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF FIAT OR IT S SUCCESSORS.