Hitachi AH500-D Articulated Dump Truck Service + Technical Manual
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Hitachi AH500-D Articulated Dump Truck Service + Technical Manual
This Manual Includes:
- Hitachi AH500-D Articulated Dump Truck Service Manual (KM8T JG-E-01)
- Hitachi AH500-D Articulated Dump Truck Technical Manual (KM-8TJ-E)
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DESCRIPTION:
Hitachi AH500-D Articulated Dump Truck Service + Technical Manual
- This manual is written for an experienced technician and are on-the-job guides containing only the vital information needed for diagnosis, analyses, testing and repair. Essential tools required in performing certain service works are identified and in this manual and are recommended for use.
- The safe operation of your HITACHI machines very important to prevent any personal injury and/ or damage.
- This manual must be read and fully understood before carrying out any tests on your HITACHI machine. Right and left hand sides are determined by facing in the direction of forward travel. This manual is divided into chapters.
- The information contained in the manual is in logical sequence, with the instructions written in step by step format. Effective maintenance on your HITACHI machine is achieved when personnel fully understand the information contained in this manual.
- Every effort has been made to ensure that the information contained in this manual was correct at the time of publication.
- HITACHI . has a policy of continuous product development, improvement, and design. HITACHI . reserves the right to change, amend and update the design of its product at any time without prior notice. With this policy, changes may have occurred that are not included in this manual.
TABLE OF CONTENTS:
Hitachi AH500-D Articulated Dump Truck Service Manual (KM8T JG-E-01)
AH500-D_KM8TJG-E-00…………………………………………………………… 1
TO THE SERVICE PERSONNEL………………………………………………………. 5
SAFETY SYMBOL………………………………………………………………… 6
IMPORTANT……………………………………………………………………. 8
ABBREVIATIONS………………………………………………………………… 9
AMENDMENT……………………………………………………………………. 11
INTRODUCTION…………………………………………………………………. 13
TABLE OF CONTENTS…………………………………………………………….. 29
SAFETY………………………………………………………………………. 15
SAFETY FEATURES…………………………………………………………… 15
GENERAL SAFETY……………………………………………………………. 16
SAFETY REGULATION…………………………………………………………. 17
SAFETY DECALS………………………………………………………………… 23
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE………………………………………. 41
OPERATIONAL CHECK-OUT……………………………………………………… 41
OPERATIONAL CHECKS – KEY SWITCH ON, ENGINE OFF……………………………….. 41
CHAPTER 2. ENGINE…………………………………………………………….. 47
SECTION 1. THEORY OF OPERATION……………………………………………… 47
ENGINE……………………………………………………………….. 47
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS……………………………………… 51
SECTION 3. ADJUSTMENTS…………………………………………………….. 53
DISPLAY MENU TACHOMETER………………………………………………… 53
SLOW AND FAST IDLE ADJUSTMENT…………………………………………… 53
VALVE CLEARANCE ADJUSTMENT……………………………………………… 53
EXHAUST BRAKE ADJUSTMENT……………………………………………….. 55
SECTION 4. TESTS………………………………………………………….. 57
CYLINDER COMPRESSION TEST………………………………………………. 57
FUEL PUMP PRESSURE TEST………………………………………………… 57
OIL PUMP PRESSURE TEST…………………………………………………. 59
CAN BUS J1939…………………………………………………………. 62
WHAT EXACTLY IS A “CAN BUS”…………………………………………….. 62
CANBUS……………………………………………………………….. 63
TESTING THE “CANBUS”…………………………………………………… 64
CHECKING THE CABLES……………………………………………………. 64
CHECKING OPENS, SHORTS BETWEEN WIRES AND SHORTS TO GROUND ON THE CAN HARNESS…. 65
MAIN “CAN” HARNESS…………………………………………………….. 65
“CAN” SHORT TO GROUND………………………………………………….. 66
“CAN “OPEN CIRCUIT…………………………………………………….. 67
“CAN” SHORT TO POSITIVE 0 -24 VOLTS……………………………………… 68
CHAPTER 3. ELECTRICAL SYSTEM…………………………………………………… 69
SECTION 1. SYSTEM INFORMATION………………………………………………. 69
ELECTRICAL SCHEMATIC SYMBOLS……………………………………………. 69
CHASSIS CONTROL UNIT (CCU & OEU)………………………………………… 70
MDU2 (MONITOR DISPLAY UNIT)…………………………………………….. 71
MDU2 LAYOUT…………………………………………………………… 72
MDU2 INPUT AND OUTPUTS…………………………………………………. 73
RELAY………………………………………………………………… 75
START-UP DISPLAY………………………………………………………. 76
DEFAULT SCREEN………………………………………………………… 76
DEFAULT SCREEN………………………………………………………… 76
DEFAULT SCREEN………………………………………………………… 76
DEFAULT SCREEN………………………………………………………… 76
DEFAULT SCREEN………………………………………………………… 77
TO GO TO MAIN MENU FROM DEFAULT SCREEN…………………………………… 77
MAIN MENU…………………………………………………………….. 77
EXPLANATION OF WIRE MARKINGS……………………………………………. 82
SECTION 2. DESCRIPTION OF CIRCUITS…………………………………………..115
SSM…………………………………………………………………..127
MDU2 WARNING LIGHTS…………………………………………………….138
MDU2 GAUGES……………………………………………………………142
CCU2 OUTPUT SPECIFICATION……………………………………………….143
OEU OUTPUT SPECIFICATION………………………………………………..147
SECTION 3. REFERENCES………………………………………………………151
ENGINE FAULT CODES (ADM)………………………………………………..151
ENGINE FAULT CODES (PLD-MR)……………………………………………..156
SSM FAULT CODES………………………………………………………..182
PART 2. DM1 FAULT CODES…………………………………………………183
SECTION 4. TESTS…………………………………………………………..201
KEY SWITCH TEST………………………………………………………..201
RELAYS………………………………………………………………..201
Diode Test…………………………………………………………….202
Pneumatic System Solenoids, Pressure Switches, and Sensor Tests……………..203
Steering Column Switch Test……………………………………………..208
CHAPTER 4. TRANSMISSION………………………………………………………..221
SECTION 1. THEORY OF OPERATION………………………………………………221
GENERAL DESCRIPTIONS……………………………………………………221
STALL SPEEDS…………………………………………………………..228
PLANETARY GEARS AND POWER FLOWS………………………………………….230
THE BASIC LAWS OF PLANETARY GEAR SETS…………………………………….231
HD TRANSMISSION PLANETARY CONFIGURATION…………………………………..232
HD TRANSMISSION CLUTCH CONFIGURATION……………………………………..233
POWER FLOW…………………………………………………………….234
HYDRAULIC SYSTEM……………………………………………………….243
SOLENOIDS……………………………………………………………..247
3000 and 4000 4th Generation Control Valve Body……………………………248
HYDRAULIC CIRCUITS……………………………………………………..250
TORQUE CONVERTER AND LUBE PRESSURE CIRCUITS – OVERVIEW……………………..258
EXHAUST BACKFILL PRESSURE……………………………………………….259
PRESSURE TABLE AND TEST POINTS…………………………………………..264
RETARDER………………………………………………………………265
APPLICATIONS AND CAPACITIES……………………………………………..265
INPUTS AND OUTPUTS……………………………………………………..267
RETARDER CONTROL HYDRAULICS……………………………………………..267
TESTING RETARDER CHARGING PRESSURE……………………………………….268
HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF………………………………269
HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON……………………………….270
ELECTRONIC CONTROL SYSTEM……………………………………………….271
PUSH BUTTON SHIFT SELECTOR………………………………………………275
SPEED SENSORS………………………………………………………….276
WIRING HARNESSES……………………………………………………….276
RANGE / SHIFT TESTS…………………………………………………….277
DO NOT SHIFT LIGHT……………………………………………………..278
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………280
DIAGNOSTIC PROCEDURE……………………………………………………280
DIAGNOSE POWER TRAIN SYSTEM MALFUNCTIONS………………………………….281
CHECK THE TRANSMISSION FLUID LEVEL……………………………………….292
TRANSMISSION CONTROL UNIT ERROR CODES…………………………………….295
TABLE OF ERROR CODES……………………………………………………….296
ALLISON HD 4560R ELECTRONIC CONTROL WTEC III………………………………302
SECTION 3. ADJUSTMENTS AND TESTS…………………………………………….303
TRANSMISSION WARM-UP PROCEDURE…………………………………………..303
TRANSMISSION OIL COOLER RESTRICTION TEST………………………………….312
CHAPTER 5. PNEUMATIC SYSTEM…………………………………………………….313
SECTION 1. THEORY OF OPERATION………………………………………………313
PNEUMATIC SYSTEM OPERATION………………………………………………313
PNEUMATIC SYSTEM SCHEMATIC………………………………………………314
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………323
DIAGNOSTIC PROCEDURE……………………………………………………323
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS……………………………………324
SECTION 3. ADJUSTMENTS AND TESTS…………………………………………….326
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT…………………………326
PARK BRAKE PRESSURE TEST………………………………………………..327
PARK BRAKE ADJUSTMENT…………………………………………………..328
GRAMMER SEAT FUNCTIONAL TEST…………………………………………….330
CHAPTER 6. HYDRAULIC SYSTEM…………………………………………………….331
SECTION 1. THEORY OF OPERATION………………………………………………331
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION………………………….331
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………361
DIAGNOSTIC PROCEDURE……………………………………………………361
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS……………………………………362
SECTION 3. TESTS…………………………………………………………..373
JT05800 DIGITAL THERMOMETER INSTALLATION………………………………….373
JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYSER INSTALLATION…………373
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY…………………373
HYDRAULIC SYSTEM WARM-UP PROCEDURE……………………………………….374
CYCLE TIME TEST………………………………………………………..375
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT………376
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST…………………378
PRIORITY VALVE TEST…………………………………………………….379
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT…………………….379
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT…………………………380
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST……………………….381
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE…………382
SERVICE BRAKE VALVE TEST………………………………………………..384
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT…………………………385
STEERING CYLINDER LEAKAGE TEST…………………………………………..385
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND
ADJUSTMENT….386
BIN LOWER CIRCUIT RELIEF VALVE TEST………………………………………387
SUSPENSION CALIBRATION PROCEDURE…………………………………………388
SUSPENSION SERVICE CHECK………………………………………………..389
Hydraulic Pressure Setting and Fault Finding Procedure……………………..392
CHAPTER 7. HEATING AND AIR CONDITIONING………………………………………….405
SECTION 1. THEORY OF OPERATION………………………………………………405
AIR CONDITIONING SYSTEM CYCLE OF OPERATION………………………………..405
HEATER CORE OPERATION…………………………………………………..406
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………407
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS……………………………..407
HEATING/AIR CONDITIONING COMPONENT LOCATION……………………………….409
SECTION 3. TESTS…………………………………………………………..411
AIR CONDITIONING OPERATIONAL CHECKS………………………………………411
R134A AIR CONDITIONING SYSTEM TEST……………………………………….412
OPERATING PRESSURE DIAGNOSTIC CHART………………………………………413
A/C FREEZE CONTROL SWITCH TEST…………………………………………..415
A/C COMPRESSOR CLUTCH TEST………………………………………………415
A/C HIGH/LOW PRESSURE SWITCH TEST………………………………………..415
A/C EXPANSION VALVE TEST………………………………………………..416
EXPANSION VALVE BENCH TEST………………………………………………417
REFRIGERANT LEAK TEST…………………………………………………..418
CHAPTER 8. MAINTENANCE SCHEDULES………………………………………………..421
NOTES:……………………………………………………………………423
CHAPTER 9. DAILY OR 10 HOURLY SERVICE CHECKS……………………………………..425
CHAPTER 10. 500 HOURS SERVICE AND CHECKS…………………………………………427
SECTION 1. DRIVE TRAIN……………………………………………………..427
INTRODUCTION…………………………………………………………..427
SERVICE INSTRUCTIONS……………………………………………………427
ENGINE………………………………………………………………..427
TRANSMISSION…………………………………………………………..430
BRAKES………………………………………………………………..433
AXLES…………………………………………………………………433
TRANSFER CASE………………………………………………………….434
SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS…………………………………435
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS……………………………435
TRANSMISSION BREATHER (LOCATED UNDER CAB)…………………………………435
REPLACE FUEL TANK BREATHER………………………………………………435
TRANSFER CASE BREATHER (LOCATED BEHIND CAB)……………………………….435
AXLE BREATHERS…………………………………………………………436
SECTION 3. CAB AND ELECTRICAL……………………………………………….437
INSPECT, CLEAN AND REPLACE CAB AIR FILTER…………………………………437
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS………………………………438
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS…………………………..438
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS……………………………….438
RECORD & DELETE FAULT CODES ON THE MDU……………………………………438
CHECK THE OPERATOR CONTROLS AND INSTRUMENTS……………………………….438
SECTION 4. LUBRICATION……………………………………………………..439
CHECK GREASE LEVEL OF AUTO GREASING SYSTEM………………………………..439
REPLACE AUTO GREASING SYSTEM FILTER………………………………………439
HYDRAULICS…………………………………………………………….440
CHAPTER 11. 500 HOURS SERVICE AND CHECKS…………………………………………443
SECTION 1. DRIVE TRAIN……………………………………………………..443
INTRODUCTION…………………………………………………………..443
SERVICE INSTRUCTIONS……………………………………………………443
ENGINE………………………………………………………………..443
TRANSMISSION…………………………………………………………..444
BRAKES………………………………………………………………..447
TRANSFER CASE………………………………………………………….447
SECTION 2. CLEAN, CHECK AND REPLACE BREATHERS…………………………………449
GENERAL CHECK DRIVE LINE & SUSPENSION FASTENERS……………………………449
TRANSFER CASE BREATHER (LOCATED UNDER THE CAB)…………………………….449
AXLE BREATHERS…………………………………………………………449
SECTION 3. CAB AND ELECTRICAL……………………………………………….451
INSPECT, CLEAN AND REPLACE CAB AIR FILTER…………………………………451
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS………………………………452
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS…………………………..452
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS……………………………….452
RECORD & DELETE FAULT CODES ON THE MDU……………………………………452
CHECK THE OPERATOR CONTROLS AND INSTRUMENTS……………………………….452
SECTION 4. LUBRICATION……………………………………………………..453
CHECK GREASE LEVEL OF AUTO GREASING SYSTEM………………………………..453
REPLACE AUTO GREASING SYSTEM FILTER………………………………………453
HYDRAULICS…………………………………………………………….454
CHAPTER 12. 1 000 HOURS SERVICE AND CHECKS……………………………………….457
SECTION 1. DRIVE TRAIN……………………………………………………..457
INTRODUCTION…………………………………………………………..457
SERVICE INSTRUCTIONS……………………………………………………457
Engine………………………………………………………………..457
SECTION 2. HYDRAULICS AND LUBRICATION………………………………………..461
REPLACE HYDRAULIC RESERVOIR BREATHER……………………………………..461
SECTION 4. AXLES AND CHASSIS & SUSPENSION…………………………………….463
CHECK AXLE OIL LEVEL……………………………………………………463
CHECK FINAL DRIVE OIL LEVELS…………………………………………….463
CHECK BIN SHOCK PAD CLEARANCE……………………………………………463
CHAPTER 13. 2 000 HOURS SERVICE AND CHECKS……………………………………….465
SECTION 1. DRIVE TRAIN……………………………………………………..465
INTRODUCTION…………………………………………………………..465
SERVICE INSTRUCTIONS……………………………………………………465
ENGINE………………………………………………………………..465
SECTION 2. HYDRAULICS AND LUBRICATION………………………………………..469
REPLACE HYDRAULIC OIL RETURN FILTER………………………………………469
SECTION 3. CAB, PNEUMATICS AND ELECTRICAL…………………………………….471
REPLACE PNEUMATIC SYSTEM DRYER FILTER…………………………………….471
DRYER FILTER…………………………………………………………..471
CHAPTER 14. 3 000 HOURS SERVICE AND CHECKS……………………………………….473
SECTION 1. DRIVE TRAIN……………………………………………………..473
INTRODUCTION…………………………………………………………..473
SERVICE INSTRUCTIONS……………………………………………………473
SECTION 2. HYDRAULICS AND PNEUMATICS…………………………………………475
CHAPTER 15. 4 000 HOURS SERVICE AND CHECKS……………………………………….477
SECTION 1. DRIVE TRAIN……………………………………………………..477
REPLACE FAN BELT……………………………………………………….477
SECTION 2. HYDRAULICS AND PNEUMATICS…………………………………………479
INTRODUCTION…………………………………………………………..479
SERVICE INSTRUCTIONS……………………………………………………479
CHAPTER 16. AS REQUIRED SERVICE…………………………………………………481
SECTION 1. ENGINE………………………………………………………….481
INTRODUCTION…………………………………………………………..481
SERVICE INSTRUCTIONS……………………………………………………481
SECTION 2. CAB AND LUBRICATION………………………………………………485
CLEAN AIR CONDITIONING FILTERS…………………………………………..485
GREASE HINGES………………………………………………………….485
CHAPTER 17. MISCELLANEOUS SERVICE AND CHECKS……………………………………..487
SECTION 1. DRIVE TRAIN……………………………………………………..487
INTRODUCTION…………………………………………………………..487
SERVICE INSTRUCTIONS……………………………………………………487
ENGINE………………………………………………………………..487
WHEELS………………………………………………………………..487
SECTION 2. ELECTRICAL………………………………………………………489
USING BATTERY CHARGER…………………………………………………..489
ADJUST HEADLIGHTS………………………………………………………491
SECTION 3. OPERATIONAL CHECKOUT……………………………………………..495
OPERATIONAL CHECK-OUT…………………………………………………..495
CHAPTER 18. TROUBLE SHOOTING……………………………………………………503
SECTION 1. SYMPTOMS AND REMEDIES…………………………………………….503
INTRODUCTION…………………………………………………………..503
CHAPTER 19. APPENDIX…………………………………………………………..515
OBW Functional Description – ADT Mk IV 001-4002-00…………………………….515
HYDRAULIC FAN COOLER FUNCTIONAL DESCRIPTION . ADT MK IV 001-4003-02……………..518
TABLE OF CONTENTS………………………………………………………518
1. INTRODUCTION………………………………………………………..518
2. CHASSIS CONTROL UNIT SOFTWARE REQUIREMENTS……………………………..518
CCU2 HEADLIGHT LOGIC AND CONTROL 001-4004-00………………………………….521
1. INTRODUCTION………………………………………………………..521
2. HEADLIGHT LOGIC AND CONTROL…………………………………………..521
CCU2 WIPER CONTROL LOGIC 001-4005-00…………………………………………523
1. INTRODUCTION………………………………………………………..523
2. WIPER CONTROL LOGIC AND TIMING………………………………………..523
AIR-CONDITIONING CONTROL LOGIC 001-4006-00……………………………………525
1. INTRODUCTION………………………………………………………..525
2. INPUTS/OUTPUTS………………………………………………………525
BIN CONTROL LOGIC 001-4007-00……………………………………………….527
1. INTRODUCTION………………………………………………………..527
2. BIN CONTROL LOGIC……………………………………………………527
PR001_PARK BRAKE FUNCTION…………………………………………………..531
INTRODUCTION…………………………………………………………..531
SERVICE MANUAL REVISION REQUEST FORM…………………………………………….533
Hitachi AH500-D Articulated Dump Truck Technical Manual (KM-8TJ-E)
COVER…………………………………………………………………………………………. 1
USER’S INFORMATINON FEEDBACK FORM………………………………………………………………… 13
SAFETY………………………………………………………………………………………… 21
Specification………………………………………………………………………………. 21
Safety Features…………………………………………………………………………….. 21
Material Safety Data Sheets (MSDS)……………………………………………………………. 22
Unauthorised Modifications of the Roll Over Protective Structure (ROPS) and the Falling Objects P……. 22
Noise Emission Levels……………………………………………………………………….. 22
General Safety……………………………………………………………………………… 22
SAFETY DECALS………………………………………………………………………………….. 29
CHAPTER 1. OPERATIONAL CHECK-OUT PROCEDURE………………………………………………………… 39
OPERATIONAL CHECK-OUT……………………………………………………………………….. 39
OPERATIONAL CHECKS – KEY SWITCH ON, ENGINE OFF…………………………………………………. 39
OPERATIONAL CHECKS – ENGINE ON……………………………………………………………….. 41
CHAPTER 2. ENGINE………………………………………………………………………………. 47
SECTION 1. THEORY OF OPERATION……………………………………………………………….. 47
ENGINE…………………………………………………………………………………. 47
SECTION 2. DIAGNOSE ENGINE MALFUNCTIONS……………………………………………………….. 51
SECTION 3. ADJUSTMENTS………………………………………………………………………. 55
DISPLAY MENU TACHOMETER………………………………………………………………….. 55
SLOW AND FAST IDLE ADJUSTMENT…………………………………………………………….. 55
VALVE CLEARANCE ADJUSTMENT……………………………………………………………….. 55
EXHAUST BRAKE ADJUSTMENT…………………………………………………………………. 56
SECTION 4. TESTS……………………………………………………………………………. 59
CYLINDER COMPRESSION TEST………………………………………………………………… 59
FUEL PUMP PRESSURE TEST………………………………………………………………….. 59
OIL PUMP PRESSURE TEST…………………………………………………………………… 60
CHAPTER 3. ELECTRICAL SYSTEM…………………………………………………………………….. 63
SECTION 1. SYSTEM INFORMATION………………………………………………………………… 63
HARNESSES AND COMPONENT LOCATION………………………………………………………….. 64
EXPLANATION OF WIRE MARKINGS……………………………………………………………… 94
PLUGS AND CONNECTORS……………………………………………………………………..119
SECTION 2. DESCRIPTION OF CIRCUITS…………………………………………………………….247
ISOLATOR SWITCH………………………………………………………………………….247
IGNITION SWITCH ON……………………………………………………………………….249
IGNITION SWITCH IN START POSITION………………………………………………………….250
MENU D………………………………………………………………………………….272
SECTION 3. REFERENCES………………………………………………………………………..275
SERVICE CODE DIAGNOSTICS – AFTER MACHINE REPAIR……………………………………………..275
SECTION 4. TESTS…………………………………………………………………………….365
KEY SWITCH TEST………………………………………………………………………….365
RELAYS………………………………………………………………………………….365
CHAPTER 4. TRANSMISSION HD4560……………………………………………………………………389
SECTION 1. THEORY OF OPERATION………………………………………………………………..389
GENERAL DESCRIPTIONS……………………………………………………………………..389
TRANSMISSION IDENTIFICATION……………………………………………………………….390
TORQUE CONVERTER…………………………………………………………………………391
TORQUE CONVERTER OPERATION………………………………………………………………..392
LOCK-UP CLUTCH OPERATION………………………………………………………………….396
B50D STALL SPEEDS………………………………………………………………………..398
PLANETARY GEARS AND POWER FLOWS……………………………………………………………399
THE BASIC LAWS OF PLANETARY GEAR SETS………………………………………………………400
CLUTCHES………………………………………………………………………………..400
HD TRANSMISSION PLANETARY CONFIGURATION…………………………………………………….401
HD TRANSMISSION CLUTCH CONFIGURATION……………………………………………………….402
POWER FLOW………………………………………………………………………………406
HYDRAULIC SYSTEM…………………………………………………………………………415
MAIN-PRESSURE CIRCUIT…………………………………………………………………….415
CONTROL MAIN CIRCUIT……………………………………………………………………..417
TORQUE CONVERTER CIRCUIT………………………………………………………………….417
CONVERTER-IN PRESSURE CIRCUIT……………………………………………………………..418
HYDRAULICS (OPERATION)……………………………………………………………………419
SOLENOIDS……………………………………………………………………………….419
NORMALLY OPEN SOLENOIDS…………………………………………………………………..420
NORMALLY CLOSED SOLENOIDS…………………………………………………………………421
HYDRAULIC CIRCUITS……………………………………………………………………….423
TORQUE CONVERTER AND LUBE PRESSURE CIRCUITS – OVERVIEW……………………………………….431
CONVERTER FLOW VALVE OPERATION…………………………………………………………….431
OVERDRIVE KNOCKDOWN VALVE…………………………………………………………………431
EXHAUST BACKFILL PRESSURE…………………………………………………………………432
PRESSURE TABLE AND TEST PIONTS…………………………………………………………….433
RETARDER………………………………………………………………………………..435
APPLICATIONS AND CAPACITIES……………………………………………………………….435
Retarder Control – Overview……………………………………………………………….436
Apply Controls…………………………………………………………………………..436
INPUTS AND OUTPUTS……………………………………………………………………….437
RETARDER CONTROL HYDRAULICS……………………………………………………………….437
TESTING RETARDER CHARGING PRESSURE…………………………………………………………438
Retarder Off…………………………………………………………………………….438
HD RETARDER HYDRAULIC SCHEMATIC RETARDER OFF………………………………………………..439
HD RETARDER HYDRAULIC SCHEMATIC RETARDER ON…………………………………………………440
ELECTRONIC CONTROL SYSTEM…………………………………………………………………441
TRANSMISSION CONTROL UNIT (T C U)………………………………………………………….441
PULSE WIDTH MODULATION (P W M)…………………………………………………………….441
PUSH BUTTON SHIFT SELECTOR………………………………………………………………..445
SPEED SENSORS……………………………………………………………………………446
WIRING HARNESSES…………………………………………………………………………446
RANGE / SHIFT TESTS………………………………………………………………………447
DO NOT SHIFT LIGHT……………………………………………………………………….448
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………………………..457
DIAGNOSTIC PROCEDURE……………………………………………………………………..457
DIAGNOSE POWER TRAIN SYSTEM MALFUNTIONS…………………………………………………….458
CHAPTER 5. PNEUMATIC SYSTEM………………………………………………………………………475
SECTION 1. THEORY OF OPERATION………………………………………………………………..475
PNEUMATIC SYSTEM OPERATION………………………………………………………………..475
PNEUMATIC SYSTEM SCHEMATIC………………………………………………………………..476
CHAPTER 5. PNEUMATIC SYSTEM………………………………………………………………………487
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………………………..487
DIAGNOSTIC PROCEDURE……………………………………………………………………..487
DIAGNOSE PNEUMATIC SYSTEM MALFUNCTIONS……………………………………………………..488
SECTION 3. TESTS…………………………………………………………………………….497
PNEUMATIC SYSTEM MAIN PRESSURE TEST AND ADJUSTMENT…………………………………………..497
PARK BRAKE PRESSURE TEST………………………………………………………………….498
CHAPTER 6. HYDRAULIC SYSTEM………………………………………………………………………499
SECTION 1. THEORY OF OPERATION………………………………………………………………..499
ARTICULATED DUMP TRUCK HYDRAULIC SYSTEM OPERATION……………………………………………499
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………………………..537
DIAGNOSTIC PROCEDURE……………………………………………………………………..537
DIAGNOSE HYDRAULIC SYSTEM MALFUNCTIONS……………………………………………………..538
HYDRAULIC SYSTEM COMPONENT LOCATION………………………………………………………..546
SECTION 3. TESTS…………………………………………………………………………….559
JT05800 DIGITAL THERMOMETER INSTALLATION……………………………………………………559
JT02156A DIGITAL ANALOGUE PRESSURE/TEMPERATURE ANALYZER INSTALLATION…………………………..559
HYDRAULIC OIL CLEANUP PROCEDURE USING PORTABLE FILTER CADDY…………………………………..559
HYDRAULIC SYSTEM WARM-UP PROCEDURE…………………………………………………………560
CYCLE TIME TEST………………………………………………………………………….561
MAIN HYDRAULIC PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT………………………..562
SYSTEM RELIEF VALVE AND BIN RAISE CIRCUIT RELIEF VALVE TEST…………………………………..563
PRIORITY VALVE TEST………………………………………………………………………564
ACCUMULATOR PRESSURE REDUCING VALVE TEST AND ADJUSTMENT………………………………………564
BRAKE ACCUMULATOR CHARGE VALVE TEST AND ADJUSTMENT…………………………………………..565
BRAKE LOW PRESSURE SWITCH AND BRAKE ACCUMULATOR TEST…………………………………………566
FRONT AND REAR BRAKE ACCUMULATORS PRESSURE TEST AND CHARGE PROCEDURE…………………………..567
SERVICE BRAKE VALVE TEST………………………………………………………………….567
STEERING RELIEF VALVE PRESSURE TEST AND ADJUSTMENT…………………………………………..568
STEERING CYLINDER LEAKAGE TEST…………………………………………………………….569
SECONDARY STEERING PUMP RESIDUAL AND COMPENSATOR VALVES TEST AND ADJUSTMENT…………………….569
BIN LOWER CIRCUIT RELIEF VALVE TEST………………………………………………………..570
FAN DRIVE CONTROLLER TEST AND ADJUSTMENT……………………………………………………571
CHAPTER 7. HEATING AND AIR CONDITIONING……………………………………………………………575
SECTION 1. THEORY OF OPERATION………………………………………………………………..575
AIR CONDITIONING SYSTEM CYCLE OF OPERATION………………………………………………….575
HEATER CORE OPERATION…………………………………………………………………….576
SECTION 2. DIAGNOSTIC INFORMATION……………………………………………………………..577
DIAGNOSE AIR CONDITIONING SYSTEM MALFUNCTIONS……………………………………………….577
DIAGNOSE HEATER SYSTEM MALFUNCTIONS………………………………………………………..579
HEATING/AIR CONDITIONING COMPONENT LOCATION…………………………………………………580
SECTION 3. TESTS…………………………………………………………………………….583
AIR CONDITIONING OPERATIONAL CHECKS………………………………………………………..583
R134A AIR CONDITIONING SYSTEM TEST…………………………………………………………584
OPERATING PRESSURE DIAGNOSTIC CHART………………………………………………………..585
A/C FREEZE CONTROL SWITCH TEST…………………………………………………………….587
A/C COMPRESSOR CLUTCH TEST………………………………………………………………..587
A/C HIGH/LOW PRESSURE SWITCH TEST………………………………………………………….587
A/C EXPANSION VALVE TEST………………………………………………………………….588
EXPANSION VALVE BENCH TEST………………………………………………………………..589
REFRIGERANT LEAK TEST…………………………………………………………………….590
CHAPTER 8. MENU DISPLAY UNIT AND ALPHA NUMERICAL DISPLAY…………………………………………….591
START-UP DISPLAY…………………………………………………………………………….591
DEFAULT SCREEN………………………………………………………………………………592
TO SELECT BETWEEN MENUS………………………………………………………………………592
CHAPTER 9. MAINTENANCE SCHEDULES………………………………………………………………….603
CHAPTER 10. DAILY OR 10 HOURLY SERVICE CHECKS………………………………………………………607
CHAPTER 11. 500 HOURS SERVICE AND CHECKS…………………………………………………………..609
SECTION 1. DRIVE TRAIN……………………………………………………………………….609
INTRODUCTION…………………………………………………………………………….609
SERVICE INSTRUCTIONS……………………………………………………………………..609
ENGINE………………………………………………………………………………….609
TRANSMISSION…………………………………………………………………………….611
BRAKES………………………………………………………………………………….612
AXLES…………………………………………………………………………………..613
TRANFER CASE…………………………………………………………………………….614
SECTION 2. CLEAN, CHECK AND REPALCE BREATHERS…………………………………………………..615
GENERAL CHECK DRIVELINE & SUSPENSION FASTENERS………………………………………………615
REPLACE CRANKCASE BREATHER………………………………………………………………..615
TRANSMISSION BREATHER (LOCATED UNDER CAB)…………………………………………………..616
REPLACE FUEL TANK BREATHER………………………………………………………………..616
TRANSFER CASE BREATHER (LOCATED BEHIND CAB)…………………………………………………616
AXLE BREATHERS…………………………………………………………………………..616
SECTION 3. CAB AND ELECTRICAL…………………………………………………………………618
INSPECT, CLEAN AND REPLACE CAB AIR FILTER…………………………………………………..618
CHECK BATTERIES, CLEAN AND TIGHTEN TERMINALS………………………………………………..619
CHECK ELECTRICAL CONNECTORS, HARNESSES AND LOOMS…………………………………………….619
CHECK WORK LIGHTS, REVERSE BUZZER AND HORNS…………………………………………………619
RECORD & DELETE FAULT CODES ON THE MDU……………………………………………………..619
CHECK THE OPERATOR CONTROLS AND INSTUMENTS………………………………………………….619
SECTION 4. LUBRICATION……………………………………………………………………….621
CHECK GREASE LEVEL OF AUTO GREASING SYSTEM………………………………………………….621
REPLACE AUTO GREASING SYSTEM FILTER………………………………………………………..621
HYDRAULICS………………………………………………………………………………622
CHAPTER 12. 1 000 HOURS SERVICE AND CHECKS…………………………………………………………625
SECTION 1. ENGINE……………………………………………………………………………625
INTRODUCTION…………………………………………………………………………….625
SERVICE INSTRUCTIONS……………………………………………………………………..625
REPLACE TRANSMISSION OIL FILTERS…………………………………………………………..631
Check oil level. (See Chapter 12 – Check Transmission Oil Level)………………………………631
CHANGE THE TRANSFER CASE FILTER……………………………………………………………631
SECTION 3. HYDRAULICS AND LUBRICATION………………………………………………………….633
REPLACE HYDRAULIC RESERVOIR BREATHER……………………………………………………….633
SECTION 3. AXLES AND CHASSIS & SUSPENSION………………………………………………………635
CHANGE AXLE OIL………………………………………………………………………….635
CHANGE FINAL DRIVE OIL……………………………………………………………………636
CHAPTER 13. 2 000 HOURS SERVICE AND CHECKS…………………………………………………………637
SECTION 1. DRIVE TRAIN……………………………………………………………………….637
INTRODUCTION…………………………………………………………………………….637
SERVICE INSTRUCTIONS……………………………………………………………………..637
SECTION 2. HYDRAULICS AND LUBRICATION………………………………………………………….639
REPLACE HYDRAULIC SYSTEM OIL RETURN FILTER………………………………………………….640
SECTION 3. CAB, PNEUMATICS AND ELECTRICAL………………………………………………………643
REPLACE PNEUMATIC SYSTEM DRYER FILTER………………………………………………………643
CHAPTER 14. 4 000 HOURS SERVICE AND CHECKS…………………………………………………………645
SECTION 1. HYDRAULICS AND PNEUMATICS…………………………………………………………..645
INTRODUCTION…………………………………………………………………………….645
SERVICE INSTUCTIONS………………………………………………………………………645
CHAPTER 15. AS REQUIRED SERVICE…………………………………………………………………..647
CHAPTER 16. MISCELLANEOUS SERVICE AND CHECKS……………………………………………………….649
SECTION 1. ENGINE……………………………………………………………………………649
INTRODUCTION…………………………………………………………………………….649
SERVICE INSTRUCTIONS……………………………………………………………………..649
SECTION 2. ELECTRICAL………………………………………………………………………..651
USING BATTERY CHARGER…………………………………………………………………….651
ADJUST HEADLIGHTS………………………………………………………………………..653
SECTION 3. OPERATIONAL CHECKOUT……………………………………………………………….657
OPERATIONAL CHECK-OUT…………………………………………………………………….657
CHAPTER 17. TROUBLE SHOOTING……………………………………………………………………..667
SECTION 1. SYMPTOMS AND REMEDIES………………………………………………………………667
INTRODUCTION…………………………………………………………………………….667
SECTION 2. FAULT CODES……………………………………………………………………….681
Table of Error Codes For Machine and Engine………………………………………………………..681
TRANSMISSION CONTROL UNIT ERROR CODES………………………………………………………….695
TABLE OF ERROR CODES…………………………………………………………………………….696
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