SECTION 1
SECTION 1 INTRODUCTION This training manual Section 1 contains 14 topics, these topics refer to the 14 sections in the work shop manual. The gross vehicle mass of the OKA is 5500kg, this requires a B Class licence. The OKA bus configuration with TC rego. plates requires an F class licence. (These licence classes only apply to Australia). When information is required for a vehicle, parts needed, or warranty claims, the last 6 numbers of the chassis number is required to be given to OKA Dealers for the vehicle build information. - Ref. Section 2 Page 2 for chassis number location. Topic 1 ENGINE Topic 2 Engine (COOLING) Topic 3 Fuel, Air & Exhaust Perkins Phaser 110MT, Direct Injection, 3.99 litre.( Military Spec.) Toque 354 Nm @ 1600 RPM. Max. eng. speed 3150 RPM Engine oil CRF 30 (Castrol) This oil helps to prevent excessive oil consumption. Service schedules - Ref Section 2 Pages 19-22 Formula for calculating oil consumption - Ref Section 2 Page 33 The cooling system is a coolant recovery type with the recovery bottle in the engine compartment at the rear. The engine fan is a 7 blade Viscous Clutch type. Fuel type is Diesel, supplied to the engine from a 105 Litre tank with a fine mesh filter, to a sediment / water trap, through the lift pump, up to the main disposable fuel filter / water trap, and then through the injector pump (a Bosch rotary with boost control) to the injectors. If the fuel system has a auxiliary tank, there will be a fuel change over valve between the tank and sediment / water trap. The air filter is a 2 stage Fleet Guard filter with the second stage being a safety filter. Page 1
Topic 4 ELECTRICAL & INSTRUMENTATION Topic 5 CLUTCH The electrical system is 12 volts. All wiring exposed to the weather is water proof with sealed Weatherpack plug connecters. The starter motor is a water proof type and is sealed at the bellhousing. The bellhousing is sealed and should never be left unsealed. The instrumentation, lighting, a/c fan and ignition fuses and relays are located in a compartment accessible by opening the glove box. The fusible links, starter and accessory fuses and relays are located in a compartment behind the passengers seat. The clutch is a ceramic type and it should not be slipped, if slipped it will wear the flywheel excessively and a possible shudder will occur. The clutch housing is sealed and should never left unsealed. The throwout bearing is a greaseable type and should be greased every 10,000km, the inspection cover should be removed at the same service interval to reveal any contaminates, rectify any problems and replace cover making certain the area is sealed. The clutch master cylinder access is under instrument housing. Topic 6 TRANSMISSION Topic 7 DRIVE SHAFTS & AXLES The gear box is a Dana Spicer 5 speed all alloy transmission, gear ratios - first gear ( 5.36-1 ), second gear ( 2.62-1), third gear ( 1.51-1), forth gear (1.0-1), reverse ( 4.73-1), fifth gear O/drive (.79). Gear shift adjustment procedure - Ref Section 2 Pages 34 The transfer case is a Rockwell T223 with a park brake mounted on the rear. The transfer case gear selection is via a U shape selector, through 2 morse cables. It is very important to abjust the cables correctly - Ref Section 2 Page 35-36. The axles are supplied by Dana, the rear axle is a 70 series, and the front axle is a 60 series.( Diff. ratio 4.88-1 ). It is important the front wheel bearings are packed with water proof grease and should be repacked every 20,000km, hub seals and half shaft seals to be replaced at the same time if there is water present. It is important that all grease points ie. uni joints, king pin bushes, ball joints and spring bushes are greased weekly in severe conditions with water proof grease. Page 2
The steering box is a TRW recirculating ball type, hydraulically assisted, with a variable ratio. The TRW Steering Box should not be turned from centre position at any time whilst disconnected from axle or draglink.(caution: damage may occur if not adhered to). The steering alignment spec. - caster 3deg. to 5deg. / camber 0.4deg to 0.75deg. positive and toe in adjustment 1.0mm to 1.6mm. Turning circle 14.5 meters, 3 turns of the steering wheel lock to lock. Brake components are Bendix, the master cylinder is accessed under the instrument housing and the booster is hydraulically assisted. All four wheels have 325mm. disc brakes and park brake is a drum 254mm. dia. with 38mm. width shoes, mechanically actuated. It is very important when replacing disc brake pads, that the out side pad is clamped firmly to the caliper. (Caution: damage may occur if this procedure is not carried out). Front springs are single stage semi-elliptical leaf and the rear springs dual stage semi-elliptical leaf. Both front and rear springs have second stage Aeon rubber springs. The suspension travel is approximately 300mm, and when vehicles are constantly used in off road conditions all the 'U' bolts will have to be checked for tension regularly due to the twisting affect of the long travel suspension on the 'U' bolts. Ref. Section 2 page 22 for 'U' bolt torque. The rear springs are height adjustable ie. If carrying heavy loads all the time, the rear springs, aeon spacers and load sensor bracket are to be adjusted to the 'F' setting, so the vehicle will sit higher at the rear. - Ref. Section 2 Page 39. (There is a setting procedure on a decal on the inside the drivers door). Single cab / dual & multi cab configurations, the rear springs are set at the low setting T from the factory, the full body vehicles are set at the high setting 'F from the factory. All vehicles have dual shock absorber positions to each wheel, the only vehicles that are equipped with dual shocks from the factory are the full body configurations. - Ref Section 2 Page 38 Page 3
Topic 11 WHEELS & TYRES Topic 12 BODY The rim size is 6.5" x 16" fitted with 8.25 R 16 tyre as standard with an option of a 900 R 16 tyre. Both tyres can be run at a pressure of 20 psi. for short periods, in off road conditions when needing extra flotation. The 8.25 R 16 tyre (Dunlop Super Gripper) Supplied as standard equipment, should be changed from front to rear every 10,000km. The 900 R 16 tyre (Michlin XZL) Supplied as an option, should be changed from front to rear every 5,000km unless being used predominantly on unsealed roads. The cab is built to a ROPS safety standard for roll over protection and the cab and modules are built with Duragal RHS tubbing, Zinc Annealed steel paneling for corrosion resistance. The modules are designed for ease of removal with lifting points at the top of the cab and modules. Cab seats are easily removed to access engine compartment removable covers, for ease of maintenance. All door hinges have grease nipples and should be greased every 10,000 kms. The bus module is fitted with an air operated step, the adjustment for this is behind the removable disc cover on the L/H side of the cab. Topic 13 AIR / CON & HEATING Air/con and heating operation is explained in Section 2 Page 12. The air/con gas is R134A, the amount gas for each configuration is 1.2kg for a single cab, 1.6kg for a multi or dual cab and 1.8kg for a full body vehicle. The rear air/con is designed as a modular unit, this is so it can be removed and serviced easily. Topic 14 OPTIONS Listed hear are some of the options available. Free-wheeling hubs, Tow bar, bull bar, hub step, sump/transmission guard, sunvisor, trip meter, auxiliary fuel tank, auxiliary battery, winch 12,000 LB electric, water tank, recovery kit, comprehensive tool kit, roof rack system. c :\ms wor ks^servicc l\trainp ro Page 4