KOMATSU HD785-5LC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10316 & UP) KOMATSU HD785-5LC – PDF DOWNLOAD

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KOMATSU HD785-5LC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10316 & UP) KOMATSU HD785-5LC

KOMATSU HD785-5LC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10316 & UP) KOMATSU HD785-5LC – PDF DOWNLOAD:

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KOMATSU HD785-5LC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10316 & UP) KOMATSU HD785-5LC

• This manual is written for use by the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service, and reassembly. Each major serviceable component has a section in the shop manual. Disassembly of any component should only be done as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning in metric units and in U.S. English units. All references to Right, Left, Front, or Rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements for common fasteners are shown in torque charts in the general information section.
• Special torque requirtements are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
• The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter E, when present, designates an electrical wheel motor drive system. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
• This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload. To determine allowable payload, fill all lubricants and fuel tank to the proper level. Weigh the truck and record this value. Subtract it from the GVW to determine the allowable payload.

TABLE OF CONTENTS:

KOMATSU HD785-5LC DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10316 & UP) KOMATSU HD785-5LC

COVER
...............................................................................................................................................................................................................................   1
FOREWORD.............................................................................................................................................................................................................................   5
TABLE OF CONTENTS....................................................................................................................................................................................................................   7
SECTION A GENERAL INFORMATION
.......................................................................................................................................................................................................   9
	MAJOR COMPONENTS AND SPECIFICATIONS..............................................................................................................................................................................................  11
		SPECIFICATIONS...............................................................................................................................................................................................................  13
	GENERAL SAFETY AND OPERATING INSTRUCTIONS
.......................................................................................................................................................................................  15
		GENERAL SAFETY...............................................................................................................................................................................................................  17
			Safety Rules.............................................................................................................................................................................................................  17
			Safety Features..........................................................................................................................................................................................................  17
			Clothing And Personal Protective Items...................................................................................................................................................................................  17
			Unauthorized Modification................................................................................................................................................................................................  17
			Leaving The Operator's Seat..............................................................................................................................................................................................  18
			Mounting And Dismounting.................................................................................................................................................................................................  18
			Fire Prevention For Fuel And Oil.........................................................................................................................................................................................  18
			Precautions When Handling At High Temperatures...........................................................................................................................................................................  19
			Asbestos Dust Hazard Prevention..........................................................................................................................................................................................  19
			Prevention Of Injury By Work Equipment...................................................................................................................................................................................  19
			Fire Extinguisher And First Aid Kit......................................................................................................................................................................................  19
			Precautions When Using ROPS..............................................................................................................................................................................................  20
			Precautions For Attachments..............................................................................................................................................................................................  20
		PRECAUTIONS DURING OPERATION.................................................................................................................................................................................................  21
			BEFORE STARTING ENGINE...................................................................................................................................................................................................  21
				Safety At Worksite...................................................................................................................................................................................................  21
				Fire Prevention......................................................................................................................................................................................................  21
				In Operator's Cab....................................................................................................................................................................................................  21
				Ventilation For Enclosed Areas.......................................................................................................................................................................................  21
				In Operator's Cab - Before Starting Engine...........................................................................................................................................................................  22
			OPERATING THE MACHINE....................................................................................................................................................................................................  22
				When Starting Engine.................................................................................................................................................................................................  22
				Truck Operation - General............................................................................................................................................................................................  22
				Check When Traveling In Reverse......................................................................................................................................................................................  23
				Traveling............................................................................................................................................................................................................  23
				Traveling On Slopes..................................................................................................................................................................................................  24
				Ensure Good Visibility...............................................................................................................................................................................................  24
				Operate Carefully On Snow............................................................................................................................................................................................  24
				Avoid Damage To Dump Body............................................................................................................................................................................................  24
				Do Not Go Close To High-voltage Cables...............................................................................................................................................................................  24
				When Dumping.........................................................................................................................................................................................................  25
				Working On Loose Ground..............................................................................................................................................................................................  25
				When Loading.........................................................................................................................................................................................................  25
				Parking The Machine..................................................................................................................................................................................................  25
			TOWING...................................................................................................................................................................................................................  25
			WORKING NEAR BATTERIES...................................................................................................................................................................................................  26
				Battery Hazard Prevention............................................................................................................................................................................................  26
				Starting With Booster Cables.........................................................................................................................................................................................  26
		PRECAUTIONS FOR MAINTENANCE..................................................................................................................................................................................................  27
			BEFORE PERFORMING MAINTENANCE............................................................................................................................................................................................  27
				Warning Tag..........................................................................................................................................................................................................  27
				Proper Tools.........................................................................................................................................................................................................  27
				Stopping The Engine Before Service...................................................................................................................................................................................  27
				Securing The Dump Body...............................................................................................................................................................................................  28
			DURING MAINTENANCE.......................................................................................................................................................................................................  28
				Personnel............................................................................................................................................................................................................  28
				Attachments..........................................................................................................................................................................................................  28
				Work Under The Machine...............................................................................................................................................................................................  28
				Keep The Machine Clean...............................................................................................................................................................................................  28
				Rules To Follow When Adding Fuel Or Oil..............................................................................................................................................................................  28
				Radiator Water Level.................................................................................................................................................................................................  29
				Use Of Lighting......................................................................................................................................................................................................  29
				Precautions With The Battery.........................................................................................................................................................................................  29
				Handling High-Pressure Hoses.........................................................................................................................................................................................  29
				Precautions With High-Pressure Oil...................................................................................................................................................................................  29
				Precautions When Carrying Out Maintenance At High Temperature Or High Pressure.......................................................................................................................................  30
				Rotating Fan And Belt................................................................................................................................................................................................  30
				Waste Materials......................................................................................................................................................................................................  30
			TIRES....................................................................................................................................................................................................................  31
				Handling Tires.......................................................................................................................................................................................................  31
				Storing Tires After Removal..........................................................................................................................................................................................  31
		ADDITIONAL JOB SITE RULES....................................................................................................................................................................................................  32
		OPERATING INSTRUCTIONS.......................................................................................................................................................................................................  33
			PREPARING FOR OPERATION..................................................................................................................................................................................................  33
				At The Truck - Ground Level Walk Around Inspection...................................................................................................................................................................  33
			ENGINE START-UP SAFETY PRACTICES.........................................................................................................................................................................................  37
				Before Starting The Engine...........................................................................................................................................................................................  37
				Starting The Engine..................................................................................................................................................................................................  38
				Starting The Engine In Cold Weather..................................................................................................................................................................................  38
			AFTER ENGINE HAS STARTED.................................................................................................................................................................................................  39
			MACHINE OPERATION SAFETY PRECAUTIONS.....................................................................................................................................................................................  40
			LOADING..................................................................................................................................................................................................................  40
			HAULING..................................................................................................................................................................................................................  41
			RETARDER OPERATION.......................................................................................................................................................................................................  41
				Engine Overspeed.....................................................................................................................................................................................................  42
			PASSING..................................................................................................................................................................................................................  43
			DUMPING..................................................................................................................................................................................................................  43
				To Raise dump body:..................................................................................................................................................................................................  43
				To Lower Body:.......................................................................................................................................................................................................  44
			SAFE PARKING PROCEDURES..................................................................................................................................................................................................  44
			SHUTDOWN PROCEDURE.......................................................................................................................................................................................................  44
			TOWING...................................................................................................................................................................................................................  45
			BRAKE RELEASE............................................................................................................................................................................................................  46
				Release Of Parking Brake.............................................................................................................................................................................................  46
				Release Of Emergency Brake...........................................................................................................................................................................................  46
	WARNINGS AND CAUTIONS............................................................................................................................................................................................................  47
	STANDARD CHARTS AND TABLES.......................................................................................................................................................................................................  57
		INDEX OF TABLES..............................................................................................................................................................................................................  57
			Sealants and Adhesives...................................................................................................................................................................................................  61
	STANDARD VALUE TABLES............................................................................................................................................................................................................  63
SECTION B STRUCTURES
................................................................................................................................................................................................................  75
	STRUCTURAL COMPONENTS
...........................................................................................................................................................................................................  77
		STRUCTURAL COMPONENTS........................................................................................................................................................................................................  79
			GRILLE AND HOOD..........................................................................................................................................................................................................  79
				Removal..............................................................................................................................................................................................................  79
				Installation.........................................................................................................................................................................................................  79
			DECKS....................................................................................................................................................................................................................  79
			LEFT DECK AND CAB........................................................................................................................................................................................................  80
				Removal..............................................................................................................................................................................................................  80
				Installation.........................................................................................................................................................................................................  80
			RIGHT DECK...............................................................................................................................................................................................................  81
				Removal..............................................................................................................................................................................................................  81
				Installation.........................................................................................................................................................................................................  81
			CENTER DECK..............................................................................................................................................................................................................  82
				Removal..............................................................................................................................................................................................................  82
				Installation.........................................................................................................................................................................................................  82
	DUMP BODY
.......................................................................................................................................................................................................................  83
		DUMP BODY....................................................................................................................................................................................................................  85
			Removal..................................................................................................................................................................................................................  85
			Installation.............................................................................................................................................................................................................  86
			BODY PAD.................................................................................................................................................................................................................  87
				Removal..............................................................................................................................................................................................................  87
				Installation.........................................................................................................................................................................................................  87
			BODY PAD ADJUSTMENT (SIDE)...............................................................................................................................................................................................  87
				(With pads in place).................................................................................................................................................................................................  87
				(With pads removed)..................................................................................................................................................................................................  87
			BODY PAD ADJUSTMENT (FRONT)..............................................................................................................................................................................................  88
			BODY GUIDE...............................................................................................................................................................................................................  88
			BODY PIN.................................................................................................................................................................................................................  88
			ROCK EJECTORS............................................................................................................................................................................................................  89
				Inspection...........................................................................................................................................................................................................  89
	FUEL TANK
.......................................................................................................................................................................................................................  91
		FUEL TANK....................................................................................................................................................................................................................  93
			Removal..................................................................................................................................................................................................................  93
			Installation.............................................................................................................................................................................................................  94
			Cleaning.................................................................................................................................................................................................................  94
			VENT.....................................................................................................................................................................................................................  94
			QUICK FUEL INSTALLATION (OPTION).........................................................................................................................................................................................  94
SECTION C ENGINE
....................................................................................................................................................................................................................  95
	COOLING SYSTEM
..................................................................................................................................................................................................................  97
		COOLING SYSTEM...............................................................................................................................................................................................................  99
			COOLING SYSTEM COMPONENTS................................................................................................................................................................................................  99
			RADIATOR.................................................................................................................................................................................................................  99
				Removal..............................................................................................................................................................................................................  99
				Service.............................................................................................................................................................................................................. 101
				Installation......................................................................................................................................................................................................... 101
			BRAKE OIL COOLER......................................................................................................................................................................................................... 102
				Removal.............................................................................................................................................................................................................. 102
				Installation......................................................................................................................................................................................................... 102
			FAN...................................................................................................................................................................................................................... 102
				Removal.............................................................................................................................................................................................................. 102
				Installation......................................................................................................................................................................................................... 102
			FAN BELT................................................................................................................................................................................................................. 103
				Fan Belt Replacement................................................................................................................................................................................................. 103
				Fan Belt Adjustment.................................................................................................................................................................................................. 103
	ENGINE
.......................................................................................................................................................................................................................... 105
		ENGINE....................................................................................................................................................................................................................... 107
			GENERAL INSTRUCTIONS..................................................................................................................................................................................................... 107
			PREPARATION FOR ENGINE REMOVAL........................................................................................................................................................................................... 107
				Removal.............................................................................................................................................................................................................. 107
				Installation......................................................................................................................................................................................................... 110
			DRIVE LINE ADAPTER....................................................................................................................................................................................................... 112
				Drive Line Adapter Removal........................................................................................................................................................................................... 112
				Drive Line Adapter Installation...................................................................................................................................................................................... 113
				Drive Line Adapter Damper Disassembly................................................................................................................................................................................ 114
				Drive Line Adapter Damper Assembly................................................................................................................................................................................... 115
			RECOMMENDED LUBRICANTS................................................................................................................................................................................................... 115
	AIR FILTRATION SYSTEM
........................................................................................................................................................................................................... 117
		AIR FILTRATION SYSTEM........................................................................................................................................................................................................ 119
			AIR CLEANER.............................................................................................................................................................................................................. 119
				Service Checks....................................................................................................................................................................................................... 119
				Filter Element Replacement........................................................................................................................................................................................... 119
				Main Filter Element Cleaning......................................................................................................................................................................................... 121
				Air Intake Troubleshooting........................................................................................................................................................................................... 122
SECTION D ELECTRICAL SYSTEM
......................................................................................................................................................................................................... 123
	24V ELECTRIC SUPPLY SYSTEM
...................................................................................................................................................................................................... 125
		24VDC ELECTRIC SUPPLY SYSTEM................................................................................................................................................................................................. 127
			ELECTRICAL SYSTEM DESCRIPTION............................................................................................................................................................................................ 127
			BATTERY.................................................................................................................................................................................................................. 127
				Service.............................................................................................................................................................................................................. 127
				Storage.............................................................................................................................................................................................................. 127
				Maintenance and Troubleshooting...................................................................................................................................................................................... 128
				Spillage............................................................................................................................................................................................................. 129
			BATTERY DISCONNECT SWITCH (Optional)..................................................................................................................................................................................... 129
			BATTERY CHARGING CIRCUIT COMPONENTS...................................................................................................................................................................................... 130
				Battery Charging Alternator.......................................................................................................................................................................................... 130
				Operation............................................................................................................................................................................................................ 131
				Magnetizing The Rotor................................................................................................................................................................................................ 131
		ENGINE PRELUB SYSTEM......................................................................................................................................................................................................... 132
			OPERATION................................................................................................................................................................................................................ 132
				Pressure Switch...................................................................................................................................................................................................... 132
				Check Valve.......................................................................................................................................................................................................... 132
				Timer Solenoid....................................................................................................................................................................................................... 132
			MAINTENANCE.............................................................................................................................................................................................................. 134
				Prelub™ System Operation............................................................................................................................................................................................. 134
				Starter/Prelub Pump.................................................................................................................................................................................................. 134
				Check Valve.......................................................................................................................................................................................................... 134
				Timer Solenoid....................................................................................................................................................................................................... 134
			Troubleshooting Prelub Starter Circuit................................................................................................................................................................................... 135
	24VDC ELECTRICAL SYSTEM COMPONENTS
.............................................................................................................................................................................................. 137
		24VDC ELECTRICAL SYSTEM COMPONENTS........................................................................................................................................................................................... 139
			VEHICLE MONITOR SYSTEM................................................................................................................................................................................................... 139
				General Description.................................................................................................................................................................................................. 139
				Normal Mode.......................................................................................................................................................................................................... 139
				Service Mode......................................................................................................................................................................................................... 139
			NETWORK SIGNALS.......................................................................................................................................................................................................... 139
			VEHICLE MONITOR PANEL.................................................................................................................................................................................................... 142
			SENSORS, SWITCHES........................................................................................................................................................................................................ 142
				Engine Water Temperature Sensor...................................................................................................................................................................................... 142
				Retarder Oil Temperature Sensor...................................................................................................................................................................................... 142
				Torque Converter Oil Temperature Sensor.............................................................................................................................................................................. 142
				Air Pressure Sensor.................................................................................................................................................................................................. 142
				Fuel Level Sensor.................................................................................................................................................................................................... 143
				Engine Speed Sensor.................................................................................................................................................................................................. 143
			MONITOR PANEL DISPLAYS................................................................................................................................................................................................... 144
			INSTRUMENT PANEL INDICATORS, TEST SWITCH................................................................................................................................................................................. 148
			ELECTRONIC ACCELERATOR PEDAL............................................................................................................................................................................................. 150
				Operation............................................................................................................................................................................................................ 150
				AISS (Automatic Idling Setting System)............................................................................................................................................................................... 151
			TRANSMISSION CONTROLLER.................................................................................................................................................................................................. 152
				Outline.............................................................................................................................................................................................................. 152
			OPERATION:............................................................................................................................................................................................................... 153
	INTRODUCTION TO ELECTRICAL TROUBLESHOOTING
...................................................................................................................................................................................... 155
		POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................................................................................................... 157
		POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE............................................................................................................................................................................... 158
			POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT...................................................................................................................................................................... 158
				Handling Controller Boxes............................................................................................................................................................................................ 163
		POINTS TO REMEMBER WHEN SERVICING HYDRAULIC EQUIPMENT........................................................................................................................................................................ 164
		CHECKS BEFORE TROUBLESHOOTING................................................................................................................................................................................................ 166
			CONNECTOR TYPE AND LOCATION.............................................................................................................................................................................................. 167
			CONNECTOR LOCATION (Chassis)............................................................................................................................................................................................. 174
			CONNECTOR LOCATION (Instrument Panel, Console)........................................................................................................................................................................... 176
			CONNECTOR LOCATION (Transmission, Rear Cab Area)......................................................................................................................................................................... 177
			CONNECTOR LOCATION (General Cab Area).................................................................................................................................................................................... 178
			CONNECTOR TYPE IDENTIFICATION CHARTS..................................................................................................................................................................................... 179
		EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM........................................................................................................................................................... 189
			SYSTEM FUNCTION.......................................................................................................................................................................................................... 189
			SELF-DIAGNOSTIC DISPLAY FUNCTIONS........................................................................................................................................................................................ 189
			CHECKING OPERATION OF ELECTRICAL SYSTEM (No System Faults)............................................................................................................................................................... 191
			LOCK-UP FUNCTION CHECK................................................................................................................................................................................................... 192
			OPTIONAL CONTROLLERS..................................................................................................................................................................................................... 192
		MONITOR PANEL ACTION CODES AND SERVICE MODE.................................................................................................................................................................................. 193
			OUTLINE.................................................................................................................................................................................................................. 193
			ACTION CODE DISPLAY...................................................................................................................................................................................................... 193
				Service Mode......................................................................................................................................................................................................... 194
			SERVICE MODE OPERATION................................................................................................................................................................................................... 198
				Brake Air Pressure Sensor............................................................................................................................................................................................ 206
		SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS............................................................................................................................................................. 207
			MONITOR PANEL............................................................................................................................................................................................................ 207
			TRANSMISSION CONTROLLER.................................................................................................................................................................................................. 207
		TABLE OF SERVICE CODES AND ACTION CODES...................................................................................................................................................................................... 212
			1. Table of service codes and action codes related to Monitor Panel...................................................................................................................................................... 212
			2. Table of service codes and action codes related to Transmission Controller............................................................................................................................................ 213
			METHOD OF USING TABLE.................................................................................................................................................................................................... 216
			METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................................................................... 217
			ADJUSTING ELECTRONIC MONITOR............................................................................................................................................................................................. 219
				Adjustment procedure................................................................................................................................................................................................. 219
			SETTING ROTARY SWITCH.................................................................................................................................................................................................... 220
			METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY.............................................................................................................................................................. 221
	TRANSMISSION CONTROLLER SYSTEM TROUBLESHOOTING................................................................................................................................................................................... 225
		POINTS TO REMEMBER WHEN TROUBLESHOOTING TRANSMISSION CONTROLLER.............................................................................................................................................................. 228
		TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND PROBLEMS ON TRUCK.................................................................................................................................................. 230
		TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND PROBLEMS ON TRUCK.................................................................................................................................................. 231
			TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS............................................................................................................................................................ 250
			A-1 FAULTS IN POWER SOURCE SYSTEM........................................................................................................................................................................................ 252
				a) (OFF) Controller self-diagnostic display LED does not light up.................................................................................................................................................... 252
				b) Drop in voltage of controller power source is displayed........................................................................................................................................................... 253
				c) Drop in voltage of battery direct power source is displayed....................................................................................................................................................... 254
				d) Drop in voltage of main power source is displayed................................................................................................................................................................. 255
				e) Faults in transmission cut relay power source is displayed........................................................................................................................................................ 256
			A-2 FAULT IN NEUTRAL SAFETY SYSTEM DISPLAYED............................................................................................................................................................................. 257
			A-3 DOUBLE ENGAGEMENT FOR CLUTCH DISPLAYED............................................................................................................................................................................... 258
			A-4 FAULTS IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED.................................................................................................................................................................. 259
			A-5 FAULTS IN REAR BRAKE SOLENOID CIRCUIT DISPLAYED...................................................................................................................................................................... 260
			A-6 FAULTS IN EXHAUST BRAKE SOLENOID CIRCUIT IS DISPLAYED................................................................................................................................................................ 261
			A-7 FAULTS IN BCV VALVE SYSTEM........................................................................................................................................................................................... 262
				a) Short circuit with ground in BCV rear solenoid is displayed....................................................................................................................................................... 262
				b) Short circuit in BCV rear solenoid is displayed................................................................................................................................................................... 263
				c) Disconnection in BCV rear solenoid is displayed................................................................................................................................................................... 264
			A-8 FAULT IN SPEED SENSOR................................................................................................................................................................................................ 265
				a) Disconnection in engine speed sensor [B] is displayed on truck or Failure of engine speed sensor is displayed on truck............................................................................................ 265
				b) Disconnection in input shaft speed sensor is displayed or Failure of input shaft speed sensor is displayed........................................................................................................ 266
				c) Disconnection in intermediate shaft speed sensor is displayed or Failure of intermediate shaft speed sensor is displayed.......................................................................................... 267
				d) Disconnection in speed sensor (transmission output shaft speed sensor) is displayed or Failure of output shaft speed sensor is displayed.......................................................................... 268
			A-9 SPEED SENSOR, CLUTCH SLIPPING........................................................................................................................................................................................ 269
				a) Input shaft speed sensor or H,L clutch is displayed............................................................................................................................................................... 269
				b) Output shaft speed sensor or speed clutch (1,2,3,4,R) system is displayed......................................................................................................................................... 270
			A-10 FAULT IN MODEL SELECTION (WIRING HARNESS) DISPLAYED................................................................................................................................................................. 271
				a) Fault in model selection (wiring harness) is displayed............................................................................................................................................................ 271
				b) Fault in model selection (rotary switch) is displayed............................................................................................................................................................. 272
			A-11 FAULT IN SHIFT LEVER CIRCUIT........................................................................................................................................................................................ 273
				a) Short circuit in shift lever assembly power source is displayed................................................................................................................................................... 273
				b) Shift lever position signal input for 2 or more circuits is displayed............................................................................................................................................. 274
				c) Shift lever position signal is not inputted....................................................................................................................................................................... 276
			A-12 FAULT IN ACCELERATOR SIGNAL IS DISPLAYED............................................................................................................................................................................ 278
			A-13 FAULT IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED........................................................................................................................................................... 279
			A-14 FAULT IN PRESSURE CONTROL VALVE..................................................................................................................................................................................... 280
				a) Fill switch (clutch ON) is displayed regardless of command........................................................................................................................................................ 280
				b) Fill switch signal is not input and clutch slipping is displayed.................................................................................................................................................. 282
			A-15 NO FILL SWITCH SIGNAL INPUT (FLOW DETECTOR VALVE)................................................................................................................................................................... 284
			A-16 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID DISPLAYED or DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID DISPLAYED............................................................................................ 285
			A-17 FAULT IN SENSOR CIRCUITS............................................................................................................................................................................................ 287
				a) Fault in torque converter oil temperature sensor is displayed..................................................................................................................................................... 287
				b) Fault in fuel level sensor is displayed........................................................................................................................................................................... 288
				c) Fault in cooling water temperature sensor is displayed............................................................................................................................................................ 289
				d) Fault in air pressure sensor is displayed......................................................................................................................................................................... 290
				e) Fault in retarder brake oil temperature sensor is displayed....................................................................................................................................................... 291
			A-18 WARNING DISPLAY..................................................................................................................................................................................................... 292
				a) Transmission filter restricted warning displayed.................................................................................................................................................................. 292
				b) Tilt warning is displayed......................................................................................................................................................................................... 293
				c) Drop in radiator water level warning is displayed................................................................................................................................................................. 294
				d) Battery charge warning is displayed............................................................................................................................................................................... 295
				e) Steering oil temperature overheat warning is displayed............................................................................................................................................................ 296
				f) Drop in engine oil pressure warning is displayed.................................................................................................................................................................. 297
				g) Rear brake oil pressure warning is displayed...................................................................................................................................................................... 298
			A-19 FAULT IN ENGINE OIL PRESSURE SENSOR DISPLAYED....................................................................................................................................................................... 299
			A-20 FAULT IN CONNECTOR CONNECTION DISPLAYED............................................................................................................................................................................. 300
			A-21..................................................................................................................................................................................................................... 301
				a) Torque converter oil temperature overheat warning displayed....................................................................................................................................................... 301
				b) Engine water temperature overheat warning displayed............................................................................................................................................................... 301
				c) Air pressure drop warning displayed............................................................................................................................................................................... 301
				d) Retarder brake oil temperature overheat warning displayed......................................................................................................................................................... 301
				e) Engine overrun actuated displayed................................................................................................................................................................................. 302
				f) Engine overshoot actuated displayed............................................................................................................................................................................... 302
	MONITOR PANEL TROUBLESHOOTING.................................................................................................................................................................................................... 303
		MONITOR PANEL AND CONTROLLER SELF-DIAGNOSTIC DISPLAY......................................................................................................................................................................... 305
		ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON TRUCK................................................................................................................................................................. 306
		TROUBLESHOOTING.............................................................................................................................................................................................................. 310
			P-1 Check pattern for wiring harnesses between modules................................................................................................................................................................... 310
			P-2 Nothing on Monitor Panel Operates.................................................................................................................................................................................... 313
			P-3 LH, RH Module and fuel gauge do not operate.......................................................................................................................................................................... 314
			P-4 LH, RH Module and fuel gauge do not operate.......................................................................................................................................................................... 315
			P-5 RH Module does not operate........................................................................................................................................................................................... 316
			P-6 LH module does not operate........................................................................................................................................................................................... 317
			P-7 Odometer does not operate............................................................................................................................................................................................ 318
			P-8 Service meter does not operate correctly............................................................................................................................................................................. 319
			P-9 Central Warning Lamp does not operate, or monitor panel detects fault code (monitor panel display) [A002]............................................................................................................ 320
			P-10 Central warning lamp stays ON....................................................................................................................................................................................... 321
			P-11 Alarm buzzer does not operate. or Monitor Panel detects fault code A003:............................................................................................................................................ 322
			P-12 Alarm buzzer continues to sound..................................................................................................................................................................................... 323
			P-13 All data from Shift Controller (speedometer, tachometer, shift indicator, etc.) is faulty (nothing is displayed, or display does not change), or Monitor Panel detects service code A013, or service code A0018:.... 324
			P-14 Suspension mode, power/economy mode displays are faulty (nothing is displayed, or display does not change), or Monitor Panel detects service code A016:............................................................. 325
			P-15 Gauge displays are faulty (nothing is displayed or display does not change)......................................................................................................................................... 326
			P-16 Cooling water level drop caution lamp does not operate, or Monitor Panel detects service code A001:................................................................................................................. 327
			P-17 Cooling water level drop caution lamp stays ON...................................................................................................................................................................... 328
			P-18 Emergency steering pilot lamp does not operate, or monitor panel detects service code A001:......................................................................................................................... 329
			P-19 Emergency steering pilot lamp stays ON.............................................................................................................................................................................. 330
			P-20 Engine oil pressure drop caution lamp does not operate, or monitor panel detects service code A001:................................................................................................................. 331
			P-21 Engine oil pressure drop caution lamp stays ON...................................................................................................................................................................... 332
			P-22 Exhaust brake (Optional) pilot lamp does not operate, or monitor panel detects service code A001:................................................................................................................... 333
			P-23 Exhaust brake pilot lamp stays ON (Optional)........................................................................................................................................................................ 334
			P-24 Charging circuit fault caution lamp does not operate. or monitor panel detects service code A001:................................................................................................................... 335
			P-25 Charging circuit fault caution lamp stays ON........................................................................................................................................................................ 336
			P-26 Transmission filter clogging caution lamp does not operate, or monitor panel detects service code A001:............................................................................................................. 337
			P-27 Transmission filter clogging caution lamp stays ON.................................................................................................................................................................. 338
			P-28 Brake stroke caution lamp does not operate, or monitor panel detects service code A001:............................................................................................................................. 339
			P-29 Brake stroke caution lamp stays ON.................................................................................................................................................................................. 340
			P-30 Preheating switch pilot lamp does not work, or monitor panel detects service code A001:............................................................................................................................. 341
			P-31 Preheating switch pilot lamp stays ON............................................................................................................................................................................... 342
			P-32 Tilt warning lamp does not operate, or monitor panel detects service code A001:..................................................................................................................................... 343
			P-33 Tilt warning lamp stays ON.......................................................................................................................................................................................... 344
			P-34 Body FLOAT (except FLOAT) pilot lamp does not operate, or monitor panel detects service code A001:.................................................................................................................. 345
			P-35 Body FLOAT (except FLOAT) pilot lamp stays ON....................................................................................................................................................................... 346
			P-36 Rear brake pilot lamp does not work, or monitor panel detects service code A001:.................................................................................................................................... 347
			P-37 Rear brake pilot lamp stays ON...................................................................................................................................................................................... 348
			P-38 Parking brake pilot lamp does not operate, or monitor panel detects service code A001:.............................................................................................................................. 349
			P-39 Parking brake pilot lamp stays ON................................................................................................................................................................................... 350
			P-40 Maintenance caution lamp does not operate, or monitor panel detects service code A001:.............................................................................................................................. 351
			P-41 Maintenance caution lamp stays ON................................................................................................................................................................................... 352
			P-42 Steering oil temperature caution lamp does not operate, or monitor panel detects service code A001:................................................................................................................. 353
			P-43 Steering oil temperature caution lamp stays ON...................................................................................................................................................................... 354
			P-46 High beam display does not light up................................................................................................................................................................................. 355
			P-47 Turn signal lamp (right) does not light up.......................................................................................................................................................................... 357
			P-48 Turn signal lamp (left) does not light up........................................................................................................................................................................... 358
			P-49 Lamp check switch does not operate.................................................................................................................................................................................. 359
			P-50 AISS switch does not operate........................................................................................................................................................................................ 360
			P-51 Exhaust brake switch does not operate (Optional).................................................................................................................................................................... 361
			P-52 Mode change switch (1) does not operate............................................................................................................................................................................. 362
			P-53 Mode change switch (2) does not operate............................................................................................................................................................................. 363
			P-54 KPH/MPH speedometer unit selector does not operate.................................................................................................................................................................. 364
			P-55 Improper operation of all switch inputs............................................................................................................................................................................. 365
			P-56 Monitor panel detects service codes A014 or A019:................................................................................................................................................................... 366
			P-58 Monitor panel detects service code A011:............................................................................................................................................................................ 367
			P-59 Monitor panel detects service code A012:............................................................................................................................................................................ 367
			P-60 Monitor panel detects service code A000:............................................................................................................................................................................ 367
	ENGINE ELECTRONIC DIAGNOSTIC SYSTEM
............................................................................................................................................................................................. 369
		ENGINE ELECTRONIC DIAGNOSTIC SYSTEM.......................................................................................................................................................................................... 371
			SYSTEM DESCRIPTION....................................................................................................................................................................................................... 371
				Engine Shutdown Light (Stop Engine).................................................................................................................................................................................. 372
				Engine Maintenance Light (Check Engine).............................................................................................................................................................................. 372
				Engine Maintenance Light (Protect Engine)............................................................................................................................................................................ 372
				Fault Check Switch................................................................................................................................................................................................... 372
				Fault Scroll Switch.................................................................................................................................................................................................. 372
				Determining Fault Codes.............................................................................................................................................................................................. 373
			EXITING THE DIAGNOSTICS MODE............................................................................................................................................................................................. 373
		FAULT CODE INFORMATION (T01-001)............................................................................................................................................................................................. 374
			ELECTRICAL SPECIFICATIONS................................................................................................................................................................................................ 377
			SENSOR SPECIFICATIONS.................................................................................................................................................................................................... 377
	HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING
................................................................................................................................................................................ 379
		HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING............................................................................................................................................................................. 381
			H-1 Truck does not move.................................................................................................................................................................................................. 381
			H-2 Truck does not travel smoothly (truck jerks)......................................................................................................................................................................... 383
			H-3 Lock-up clutch cannot be disengaged (engine stalls).................................................................................................................................................................. 383
			H-4 Excessive shock when starting to move or shifting.................................................................................................................................................................... 383
			H-5 Transmission does not shift up....................................................................................................................................................................................... 384
			H-6 Truck lacks power or speed when moving............................................................................................................................................................................... 385
			H-7 Time lag is excessive when starting to move, or shifting gear........................................................................................................................................................ 389
			H-8 Torque converter oil temperature is high............................................................................................................................................................................. 391
			H-9 Torque converter oil pressure is low................................................................................................................................................................................. 392
			H-10 Front brakes are ineffective, or effective only on one side......................................................................................................................................................... 393
			H-11 Rear brakes are ineffective, or effective on one side only.......................................................................................................................................................... 394
			H-12 Steering wheel is difficult to turn................................................................................................................................................................................. 395
			H-13 Steering wheel is inoperative....................................................................................................................................................................................... 396
			H-14 Steering wheel vibrates............................................................................................................................................................................................. 396
			H-15 Hoist cylinder lacks lifting force (lifting speed).................................................................................................................................................................. 397
			H-16 Hoist cylinders do not operate...................................................................................................................................................................................... 399
			H-17 Excessive dump body hydraulic drift................................................................................................................................................................................. 401
			H-18 Air pressure does not increase (low-pressure buzzer does not turn off. Air pressure does not increase to green range.).............................................................................................. 402
SECTION F TRANSMISSION
.............................................................................................................................................................................................................. 403
	TRANSMISSION
.................................................................................................................................................................................................................... 405
		TRANSMISSION................................................................................................................................................................................................................. 407
			TORQUE CONVERTER......................................................................................................................................................................................................... 408
			TORQUE CONVERTER VALVE................................................................................................................................................................................................... 410
			TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING....................................................................................................................................................................... 411
			HYDRAULIC PUMP........................................................................................................................................................................................................... 412
			MAIN RELIEF VALVE........................................................................................................................................................................................................ 413
				Function............................................................................................................................................................................................................. 413
				Operation............................................................................................................................................................................................................ 413
				Actuating Pressure:.................................................................................................................................................................................................. 413
			TORQUE CONVERTER RELIEF VALVE............................................................................................................................................................................................ 413
				Function............................................................................................................................................................................................................. 413
				Operation............................................................................................................................................................................................................ 413
				Actuating Pressure:.................................................................................................................................................................................................. 413
			LOCKUP SOLENOID VALVE.................................................................................................................................................................................................... 414
			LOCKUP VALVE............................................................................................................................................................................................................. 415
				Function............................................................................................................................................................................................................. 415
				Operation............................................................................................................................................................................................................ 415
			TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE..................................................................................................................................................................... 418
				Testing Main Relief Pressure......................................................................................................................................................................................... 418
				Testing Hydraulic Pressure At Torque Converter Inlet Port (Relief)................................................................................................................................................... 418
				Testing Hydraulic Pressure At Torque Converter Outlet Port (Regulator)............................................................................................................................................... 418
				Testing Torque Converter Lockup Pressure.............................................................................................................................................................................   0
			TORQUE CONVERTER STALL SPEED CHECK....................................................................................................................................................................................... 419
				Preparing For Stall Speed Check...................................................................................................................................................................................... 419
		TRANSMISSION................................................................................................................................................................................................................. 421
			TRANSMISSION SHIFT VALVES................................................................................................................................................................................................ 422
			ECMV (Electronic Control Modulation Valve)............................................................................................................................................................................... 425
				Pressure Control Valve............................................................................................................................................................................................... 425
				Flow Sensor Valve.................................................................................................................................................................................................... 425
				ECMV and Proportional Solenoid....................................................................................................................................................................................... 425
				ECMV and Fill Switch................................................................................................................................................................................................. 425
			ECMV REPAIR PROCEDURE.................................................................................................................................................................................................... 429
				Filter Cleaning Procedure............................................................................................................................................................................................ 429
				ECMV Removal......................................................................................................................................................................................................... 430
				Disassembly.......................................................................................................................................................................................................... 430
				Reassembly........................................................................................................................................................................................................... 431
			CLUTCH PRESSURE CHECK & ADJUSTMENT....................................................................................................................................................................................... 433
			LUBRICATION RELIEF VALVE................................................................................................................................................................................................. 435
				Function............................................................................................................................................................................................................. 435
				Specifications....................................................................................................................................................................................................... 435
			TRANSMISSION............................................................................................................................................................................................................. 436
				Transmission Removal................................................................................................................................................................................................. 436
				Transmission Installation............................................................................................................................................................................................ 438
			TRANSMISSION FILTER...................................................................................................................................................................................................... 440
				Service.............................................................................................................................................................................................................. 440
	TRANSMISSION OIL COOLER
......................................................................................................................................................................................................... 441
		TRANSMISSION OIL COOLER...................................................................................................................................................................................................... 443
			Removal And Installation................................................................................................................................................................................................. 443
			Repair................................................................................................................................................................................................................... 443
			TRANSMISSION STRAINER.................................................................................................................................................................................................... 443
				Removal.............................................................................................................................................................................................................. 443
				Installation......................................................................................................................................................................................................... 443
			TORQUE CONVERTER CONTROL VALVE........................................................................................................................................................................................... 444
				Removal.............................................................................................................................................................................................................. 444
				Installation......................................................................................................................................................................................................... 444
				Disassembly.......................................................................................................................................................................................................... 444
				Assembly............................................................................................................................................................................................................. 445
	DRIVELINES
...................................................................................................................................................................................................................... 447
		DRIVELINES................................................................................................................................................................................................................... 449
			FRONT DRIVELINE.......................................................................................................................................................................................................... 449
				Removal.............................................................................................................................................................................................................. 449
				Installation......................................................................................................................................................................................................... 449
				Disassembly.......................................................................................................................................................................................................... 449
				Assembly............................................................................................................................................................................................................. 449
			REAR DRIVELINE........................................................................................................................................................................................................... 450
				Removal.............................................................................................................................................................................................................. 450
				Installation......................................................................................................................................................................................................... 450
				Disassembly.......................................................................................................................................................................................................... 450
				Assembly............................................................................................................................................................................................................. 450
			LUBRICATION.............................................................................................................................................................................................................. 450
	AUTOMATIC SHIFT CONTROL SYSTEM
.................................................................................................................................................................................................. 451
		AUTOMATIC SHIFT CONTROL SYSTEM............................................................................................................................................................................................... 453
			GENERAL INFORMATION...................................................................................................................................................................................................... 453
			TRANSMISSION SHIFT CONTROLLER............................................................................................................................................................................................ 453
				Power Mode........................................................................................................................................................................................................... 453
				Braking Mode......................................................................................................................................................................................................... 453
				Lock-up And Engine Overspeed......................................................................................................................................................................................... 453
				Transmission Speeds Monitoring....................................................................................................................................................................................... 453
				Self Diagnostics..................................................................................................................................................................................................... 454
			RANGE SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES.............................................................................................................................................................. 456
			TRANSMISSION OPERATION MODES............................................................................................................................................................................................. 456
				Braking Mode:........................................................................................................................................................................................................ 456
				Power Mode:.......................................................................................................................................................................................................... 456
				Economy Mode:........................................................................................................................................................................................................ 457
			AUTOMATIC GEAR SHIFTING.................................................................................................................................................................................................. 457
				Automatic Shifting Sequence.......................................................................................................................................................................................... 457
				Gear shifting time lag............................................................................................................................................................................................... 458
				Safety Functions..................................................................................................................................................................................................... 459
			TRANSMISSION RANGE SELECTOR.............................................................................................................................................................................................. 460
			SENSORS, SWITCHES........................................................................................................................................................................................................ 461
				Transmission Speed Sensors........................................................................................................................................................................................... 461
				Adjustment Procedure................................................................................................................................................................................................. 461
				Transmission and Torque Converter Oil Temperature Sensors............................................................................................................................................................ 462
				Oil Temperature Sensor Tests......................................................................................................................................................................................... 462
				Insulation Resistance Test:.......................................................................................................................................................................................... 462
				Thermistor Resistance Calibration Test:.............................................................................................................................................................................. 462
				Fill Switch.......................................................................................................................................................................................................... 464
				Shift Limit Switch................................................................................................................................................................................................... 465
				Power Mode Switch.................................................................................................................................................................................................... 465
			TRANSMISSION TROUBLESHOOTING PROCEDURES.................................................................................................................................................................................. 466
				Clutch Combinations.................................................................................................................................................................................................. 466
				Solenoid Valves...................................................................................................................................................................................................... 466
			HARNESS CONNECTORS AND SIGNALS........................................................................................................................................................................................... 467
SECTION G DRIVE AXLE, SPINDLES AND WHEELS
........................................................................................................................................................................................... 471
	TIRES AND RIMS
.................................................................................................................................................................................................................. 473
		TIRES AND RIMS............................................................................................................................................................................................................... 475
			GENERAL INFORMATION AND RECOMMENDATIONS.................................................................................................................................................................................. 475
			FRONT TIRES AND RIMS..................................................................................................................................................................................................... 476
				Removal.............................................................................................................................................................................................................. 476
				Installation......................................................................................................................................................................................................... 477
			REAR TIRE AND RIM........................................................................................................................................................................................................ 477
				Removal.............................................................................................................................................................................................................. 477
				Installation Of Rear Wheel Assembly.................................................................................................................................................................................. 478
			TIRE MATCHING............................................................................................................................................................................................................ 480
	FRONT WHEEL HUB AND SPINDLE
..................................................................................................................................................................................................... 481
		FRONT WHEEL HUB AND SPINDLES................................................................................................................................................................................................. 483
			FRONT WHEEL HUB.......................................................................................................................................................................................................... 483
				Removal.............................................................................................................................................................................................................. 483
			DISASSEMBLY OF FRONT WHEEL HUB ASSEMBLY.................................................................................................................................................................................. 484
				Inspection........................................................................................................................................................................................................... 485
			ASSEMBLY OF FRONT WHEEL HUB ASSEMBLY..................................................................................................................................................................................... 485
				Front Wheel Hub Bearing Adjustment................................................................................................................................................................................... 485
			FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION............................................................................................................................................................................. 486
			SUSPENSION A-FRAME....................................................................................................................................................................................................... 486
				Removal.............................................................................................................................................................................................................. 486
				Installation......................................................................................................................................................................................................... 486
			CENTER TIE ROD PIVOT..................................................................................................................................................................................................... 487
				Removal.............................................................................................................................................................................................................. 487
				Inspection........................................................................................................................................................................................................... 487
				Installation......................................................................................................................................................................................................... 487
	FINAL DRIVE ATTACHMENTS
......................................................................................................................................................................................................... 489
		FINAL DRIVE ATTACHMENTS...................................................................................................................................................................................................... 491
			FINAL DRIVE ANCHOR....................................................................................................................................................................................................... 491
				Lower Link Removal................................................................................................................................................................................................... 491
				Inspection........................................................................................................................................................................................................... 492
				Installation......................................................................................................................................................................................................... 492
			DIAGONAL PANHARD ROD..................................................................................................................................................................................................... 492
				Removal.............................................................................................................................................................................................................. 492
				Inspection........................................................................................................................................................................................................... 493
				Installation......................................................................................................................................................................................................... 493
	FINAL DRIVE CENTER CASE ASSEMBLY
................................................................................................................................................................................................ 495
		FINAL DRIVE CENTER CASE ASSEMBLY............................................................................................................................................................................................. 497
			Specifications:.......................................................................................................................................................................................................... 497
			OPERATION................................................................................................................................................................................................................ 498
				Straight-away-travel................................................................................................................................................................................................. 498
				Turning.............................................................................................................................................................................................................. 499
				To Check Oil Level................................................................................................................................................................................................... 499
				Specifications:...................................................................................................................................................................................................... 499
			REAR AXLE................................................................................................................................................................................................................ 499
				Removal.............................................................................................................................................................................................................. 499
				Installation......................................................................................................................................................................................................... 500
			DIFFERENTIAL ASSEMBLY.................................................................................................................................................................................................... 501
				Removal.............................................................................................................................................................................................................. 501
				Installation......................................................................................................................................................................................................... 502
			DIFFERENTIAL ASSEMBLY.................................................................................................................................................................................................... 502
				Disassembly.......................................................................................................................................................................................................... 502
				Disassembly of Pinion Carrier Assembly............................................................................................................................................................................... 503
				Differential Gear Unit............................................................................................................................................................................................... 504
				Disassembly Of Differential Gear Unit................................................................................................................................................................................ 504
			ASSEMBLY of DIFFERENTIAL................................................................................................................................................................................................. 507
				Differential Bearing................................................................................................................................................................................................. 507
				Assembly Of Differential Gear Assembly............................................................................................................................................................................... 507
				Installation Of Differential Assembly................................................................................................................................................................................ 509
				Input Pinion and Carrier Assembly.................................................................................................................................................................................... 510
				Adjusting Tooth Contact, Backlash.................................................................................................................................................................................... 513
	FINAL DRIVE PLANETARIES AND WHEEL HUBS
.......................................................................................................................................................................................... 517
		FINAL DRIVE PLANETARIES AND WHEEL HUBS....................................................................................................................................................................................... 519
			FINAL DRIVE.............................................................................................................................................................................................................. 519
			CARRIER ASSEMBLY......................................................................................................................................................................................................... 520
				Removal.............................................................................................................................................................................................................. 520
				Installation......................................................................................................................................................................................................... 521
			FINAL DRIVE CARRIER...................................................................................................................................................................................................... 521
				Disassembly.......................................................................................................................................................................................................... 521
				Assembly............................................................................................................................................................................................................. 522
			FINAL DRIVE ASSEMBLY..................................................................................................................................................................................................... 522
				Disassembly.......................................................................................................................................................................................................... 522
				Assembly............................................................................................................................................................................................................. 525
SECTION H SUSPENSIONS
............................................................................................................................................................................................................... 527
	FRONT SUSPENSIONS
............................................................................................................................................................................................................... 529
		SUSPENSION SYSTEM............................................................................................................................................................................................................ 531
			SUSPENSION SYSTEM OPERATION.............................................................................................................................................................................................. 531
			FRONT SUSPENSION......................................................................................................................................................................................................... 532
				Removal.............................................................................................................................................................................................................. 533
				Installation......................................................................................................................................................................................................... 535
			SUSPENSION REBUILD....................................................................................................................................................................................................... 536
				Disassembly.......................................................................................................................................................................................................... 536
				Inspection........................................................................................................................................................................................................... 537
				Assembly............................................................................................................................................................................................................. 537
			ATTENUATION VALVE (FIXED RATE)........................................................................................................................................................................................... 539
				Disassembly.......................................................................................................................................................................................................... 539
				Assembly............................................................................................................................................................................................................. 539
	REAR SUSPENSIONS
................................................................................................................................................................................................................ 541
		REAR SUSPENSIONS............................................................................................................................................................................................................. 543
			SUSPENSION OPERATION..................................................................................................................................................................................................... 543
				Removal.............................................................................................................................................................................................................. 544
				Installation......................................................................................................................................................................................................... 544
			SUSPENSION REBUILD....................................................................................................................................................................................................... 545
				Disassembly.......................................................................................................................................................................................................... 545
				Cleaning and Inspection.............................................................................................................................................................................................. 545
				Assembly............................................................................................................................................................................................................. 546
			REAR SUSPENSION SPHERICAL BEARING REPAIR................................................................................................................................................................................. 547
				Disassembly.......................................................................................................................................................................................................... 547
				Inspection........................................................................................................................................................................................................... 547
				Assembly............................................................................................................................................................................................................. 547
	OILING AND CHARGING PROCEDURES
.................................................................................................................................................................................................. 549
		OILING AND CHARGING PROCEDURES............................................................................................................................................................................................... 551
			GENERAL.................................................................................................................................................................................................................. 551
				Equipment List....................................................................................................................................................................................................... 551
			FRONT SUSPENSION......................................................................................................................................................................................................... 551
				Front Suspension Oiling.............................................................................................................................................................................................. 552
				Front Suspension Nitrogen Charging................................................................................................................................................................................... 553
			REAR SUSPENSION.......................................................................................................................................................................................................... 555
				Rear Suspension Oiling............................................................................................................................................................................................... 555
				Rear Suspension Nitrogen Charging.................................................................................................................................................................................... 556
SECTION J BRAKE SYSTEM
.............................................................................................................................................................................................................. 559
	BRAKE CIRCUIT OPERATION
......................................................................................................................................................................................................... 561
		BRAKE CIRCUIT OPERATION...................................................................................................................................................................................................... 563
			COMPONENT DESCRIPTION.................................................................................................................................................................................................... 563
			AIR TREADLE VALVE........................................................................................................................................................................................................ 563
			EMERGENCY RELAY (RE-6) VALVE............................................................................................................................................................................................. 564
			HAND BRAKE VALVE (Retarder control valve)................................................................................................................................................................................ 567
				Function............................................................................................................................................................................................................. 568
			PARKING BRAKE PILOT VALVE................................................................................................................................................................................................ 569
				Function............................................................................................................................................................................................................. 569
				Operation............................................................................................................................................................................................................ 569
			PARKING BRAKE RELAY VALVE................................................................................................................................................................................................ 570
				Function............................................................................................................................................................................................................. 570
			BRAKE CHAMBER............................................................................................................................................................................................................ 571
			SLACK ADJUSTER........................................................................................................................................................................................................... 572
				Specifications....................................................................................................................................................................................................... 572
				Function............................................................................................................................................................................................................. 573
			PRESSURE SWITCH.......................................................................................................................................................................................................... 574
				Function............................................................................................................................................................................................................. 574
			STOP LIGHT SWITCH........................................................................................................................................................................................................ 574
				Function............................................................................................................................................................................................................. 574
			PARKING BRAKE SWITCH..................................................................................................................................................................................................... 575
				Function............................................................................................................................................................................................................. 575
			AUTOMATIC RETARDER VALVE................................................................................................................................................................................................. 575
				Function............................................................................................................................................................................................................. 575
			FRONT BRAKE CUT-OFF VALVE................................................................................................................................................................................................ 576
				Function............................................................................................................................................................................................................. 576
			BRAKE COOLING VALVE (BCV)................................................................................................................................................................................................ 577
			2-WAY AIR CONTROL VALVE.................................................................................................................................................................................................. 578
				Function............................................................................................................................................................................................................. 578
			EMERGENCY BRAKE CONTROL VALVE............................................................................................................................................................................................ 579
				Function............................................................................................................................................................................................................. 579
				Operation............................................................................................................................................................................................................ 580
			BRAKE VALVE.............................................................................................................................................................................................................. 583
				Function............................................................................................................................................................................................................. 584
	BRAKE CIRCUIT COMPONENT SERVICE
................................................................................................................................................................................................. 587
		BRAKE CIRCUIT COMPONENT SERVICE.............................................................................................................................................................................................. 589
			BRAKE TREADLE ASSEMBLY................................................................................................................................................................................................... 589
				Removal.............................................................................................................................................................................................................. 589
				Installation......................................................................................................................................................................................................... 589
				Disassembly.......................................................................................................................................................................................................... 590
				Assembly............................................................................................................................................................................................................. 591
			FRONT BRAKE CHAMBER ASSEMBLY............................................................................................................................................................................................. 592
				Removal.............................................................................................................................................................................................................. 592
				Installation......................................................................................................................................................................................................... 592
				Disassembly.......................................................................................................................................................................................................... 592
				Assembly............................................................................................................................................................................................................. 595
			REAR BRAKE CHAMBER ASSEMBLY.............................................................................................................................................................................................. 596
				Removal.............................................................................................................................................................................................................. 596
				Installation......................................................................................................................................................................................................... 596
				Disassembly.......................................................................................................................................................................................................... 597
				Assembly............................................................................................................................................................................................................. 599
			SLACK ADJUSTER........................................................................................................................................................................................................... 600
				Removal.............................................................................................................................................................................................................. 600
			EMERGENCY BRAKE CONTROL VALVE............................................................................................................................................................................................ 603
				Removal.............................................................................................................................................................................................................. 603
				Installation......................................................................................................................................................................................................... 603
				Disassembly.......................................................................................................................................................................................................... 604
				Inspection........................................................................................................................................................................................................... 604
				Assembly............................................................................................................................................................................................................. 604
	BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT
........................................................................................................................................................................................... 607
		BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT........................................................................................................................................................................................ 609
			CHECKING FRONT BRAKE PAD WEAR............................................................................................................................................................................................ 609
			TESTING BRAKE PRESSURE................................................................................................................................................................................................... 609
			CHECKING WEAR OF REAR BRAKE DISCS........................................................................................................................................................................................ 610
			BRAKE BLEEDING........................................................................................................................................................................................................... 611
				Rear Brakes.......................................................................................................................................................................................................... 611
				Front Brakes......................................................................................................................................................................................................... 611
		TROUBLESHOOTING.............................................................................................................................................................................................................. 612
	FRONT BRAKES
.................................................................................................................................................................................................................... 615
		FRONT BRAKES................................................................................................................................................................................................................. 617
			FRONT BRAKE CALIPER PAD.................................................................................................................................................................................................. 617
				Removal.............................................................................................................................................................................................................. 617
				Installation......................................................................................................................................................................................................... 617
			BRAKE CALIPER ASSEMBLY................................................................................................................................................................................................... 617
				Removal.............................................................................................................................................................................................................. 617
				Installation......................................................................................................................................................................................................... 618
				Disassembly.......................................................................................................................................................................................................... 618
				Assembly............................................................................................................................................................................................................. 619
	REAR WET DISC BRAKE ASSEMBLY
.................................................................................................................................................................................................... 621
		REAR WET DISC BRAKE ASSEMBLY................................................................................................................................................................................................. 623
			WET DISC BRAKE ASSEMBLY.................................................................................................................................................................................................. 623
				Removal.............................................................................................................................................................................................................. 623
				Installation......................................................................................................................................................................................................... 624
			WET DISC BRAKE........................................................................................................................................................................................................... 625
				Disassembly.......................................................................................................................................................................................................... 625
				Inspection........................................................................................................................................................................................................... 626
				Assembly............................................................................................................................................................................................................. 626
	PARKING BRAKE
................................................................................................................................................................................................................... 629
		PARKING BRAKE................................................................................................................................................................................................................ 631
			Inspection............................................................................................................................................................................................................... 631
			Pad Removal.............................................................................................................................................................................................................. 631
			Pad Installation......................................................................................................................................................................................................... 631
			PARKING BRAKE CALIPER.................................................................................................................................................................................................... 631
				Caliper Removal...................................................................................................................................................................................................... 631
				Caliper Installation................................................................................................................................................................................................. 632
				Caliper Disassembly.................................................................................................................................................................................................. 632
				Caliper Assembly..................................................................................................................................................................................................... 633
			PARKING BRAKE SPRING CYLINDER............................................................................................................................................................................................ 633
				Removal.............................................................................................................................................................................................................. 633
				Installation......................................................................................................................................................................................................... 633
				Disassembly.......................................................................................................................................................................................................... 633
				Assembly............................................................................................................................................................................................................. 634
			PARKING BRAKE ADJUSTMENT................................................................................................................................................................................................. 635
				Testing.............................................................................................................................................................................................................. 635
				Adjusting............................................................................................................................................................................................................ 635
			PARKING BRAKE DISC....................................................................................................................................................................................................... 636
				Driveshaft Removal................................................................................................................................................................................................... 636
				Parking Brake Disc Removal........................................................................................................................................................................................... 636
				Parking Brake Disc Installation...................................................................................................................................................................................... 637
				Driveshaft Installation.............................................................................................................................................................................................. 637
			BRAKE RELEASE............................................................................................................................................................................................................ 637
				Release Of Parking Brake............................................................................................................................................................................................. 637
				Release Of Emergency Brake........................................................................................................................................................................................... 638
SECTION K AIR SYSTEM
................................................................................................................................................................................................................ 639
	AIR SYSTEM
...................................................................................................................................................................................................................... 641
		AIR SYSTEM................................................................................................................................................................................................................... 643
			GENERAL DESCRIPTION...................................................................................................................................................................................................... 643
			AIR DRYER................................................................................................................................................................................................................ 644
				Operation............................................................................................................................................................................................................ 644
			SAFETY VALVE............................................................................................................................................................................................................. 647
			AIR GOVERNORS............................................................................................................................................................................................................ 647
			AUTOMATIC DRAIN VALVE (HEATED)........................................................................................................................................................................................... 648
				Function............................................................................................................................................................................................................. 648
				Operation............................................................................................................................................................................................................ 648
			HORN SOLENOID............................................................................................................................................................................................................ 648
				Function............................................................................................................................................................................................................. 648
	AIR SYSTEM COMPONENT REPAIR
..................................................................................................................................................................................................... 649
		AIR SYSTEM COMPONENT REPAIR.................................................................................................................................................................................................. 651
			GENERAL PRECAUTIONS...................................................................................................................................................................................................... 651
			AIR DRYER................................................................................................................................................................................................................ 651
				Removal.............................................................................................................................................................................................................. 651
				Installation......................................................................................................................................................................................................... 651
				Desiccant Cartridge Service.......................................................................................................................................................................................... 652
				Desiccant Cartridge Replacement...................................................................................................................................................................................... 652
				Unloader Valve Service............................................................................................................................................................................................... 653
				Unloader Valve Replacement........................................................................................................................................................................................... 653
				Bleed Valve Service.................................................................................................................................................................................................. 654
				Bleed Valve Replacement.............................................................................................................................................................................................. 654
				Check Valve Service.................................................................................................................................................................................................. 654
				Operational Check.................................................................................................................................................................................................... 654
				Check Valve Replacement.............................................................................................................................................................................................. 654
				Turbo Valve Service.................................................................................................................................................................................................. 655
				Operational Check:................................................................................................................................................................................................... 655
				Turbo Valve Replacement.............................................................................................................................................................................................. 655
				Heater Assembly Service.............................................................................................................................................................................................. 655
				Operational Checks................................................................................................................................................................................................... 655
				Heater Assembly Replacement.......................................................................................................................................................................................... 655
		AIR DRYER TROUBLESHOOTING.................................................................................................................................................................................................... 656
		AIR DRYER TROUBLESHOOTING (Continued)........................................................................................................................................................................................ 657
			AIR COMPRESSOR........................................................................................................................................................................................................... 658
			AIR GOVERNORS............................................................................................................................................................................................................ 658
				Removal.............................................................................................................................................................................................................. 658
				Installation......................................................................................................................................................................................................... 658
				Disassembly.......................................................................................................................................................................................................... 659
				Cleaning and Inspection.............................................................................................................................................................................................. 659
				Assembly............................................................................................................................................................................................................. 659
				Adjustment........................................................................................................................................................................................................... 660
				Primary Governor..................................................................................................................................................................................................... 660
				Secondary Governor................................................................................................................................................................................................... 660
	 RETARDER VALVE
................................................................................................................................................................................................................. 661
		RETARDER VALVE............................................................................................................................................................................................................... 663
			RETARDER FUNCTION........................................................................................................................................................................................................ 663
				Removal.............................................................................................................................................................................................................. 663
				Installation......................................................................................................................................................................................................... 663
				Disassembly.......................................................................................................................................................................................................... 665
				Assembly............................................................................................................................................................................................................. 665
SECTION L HYDRAULIC SYSTEM
.......................................................................................................................................................................................................... 667
	HYDRAULIC SYSTEM................................................................................................................................................................................................................. 669
		HYDRAULIC SYSTEM............................................................................................................................................................................................................. 671
			HYDRAULIC SYSTEM OPERATION............................................................................................................................................................................................... 671
			COMPONENT DESCRIPTION.................................................................................................................................................................................................... 671
				Pump................................................................................................................................................................................................................. 671
				Tank................................................................................................................................................................................................................. 672
	HYDRAULIC SYSTEM COMPONENT REPAIR
............................................................................................................................................................................................... 675
		HYDRAULIC SYSTEM COMPONENT REPAIR............................................................................................................................................................................................ 677
			HYDRAULIC PUMP........................................................................................................................................................................................................... 677
				Removal.............................................................................................................................................................................................................. 677
				Installation......................................................................................................................................................................................................... 678
			HYDRAULIC TANK........................................................................................................................................................................................................... 678
			HYDRAULIC TANK FILTERS................................................................................................................................................................................................... 679
				Filter Replacement................................................................................................................................................................................................... 679
			HYDRAULIC TANK BREATHER.................................................................................................................................................................................................. 679
				Cleaning............................................................................................................................................................................................................. 679
			BRAKE COOLING OIL STRAINER............................................................................................................................................................................................... 680
				Cleaning............................................................................................................................................................................................................. 680
			HIGH PRESSURE HYDRAULIC FILTERS.......................................................................................................................................................................................... 680
				Filter Assembly Removal.............................................................................................................................................................................................. 680
				Filter Assembly Installation......................................................................................................................................................................................... 681
				Filter Element Replacement........................................................................................................................................................................................... 681
	STEERING CIRCUIT
................................................................................................................................................................................................................ 683
		STEERING CIRCUIT............................................................................................................................................................................................................. 685
			STEERING CIRCUIT OPERATION............................................................................................................................................................................................... 685
			DEMAND VALVE............................................................................................................................................................................................................. 686
			STEERING CONTROL VALVE................................................................................................................................................................................................... 686
			CROSSOVER RELIEF VALVE................................................................................................................................................................................................... 687
			OPERATION OF DEMAND AND STEERING CONTROL VALVE........................................................................................................................................................................... 688
			EMERGENCY STEERING SYSTEM................................................................................................................................................................................................ 696
				Flow Switch.......................................................................................................................................................................................................... 697
				Operation............................................................................................................................................................................................................ 697
				Relay Timer.......................................................................................................................................................................................................... 697
	STEERING VALVE ASSEMBLY
......................................................................................................................................................................................................... 699
		STEERING VALVE ASSEMBLY...................................................................................................................................................................................................... 701
			Removal.................................................................................................................................................................................................................. 701
			Installation............................................................................................................................................................................................................. 701
			Disassembly.............................................................................................................................................................................................................. 702
			Preparation.............................................................................................................................................................................................................. 702
			Assembly................................................................................................................................................................................................................. 707
	STEERING CIRCUIT COMPONENT REPAIR
............................................................................................................................................................................................... 715
		STEERING CIRCUIT COMPONENT REPAIR............................................................................................................................................................................................ 717
			EMERGENCY STEERING MOTOR PUMP ASSEMBLY................................................................................................................................................................................... 717
				Removal.............................................................................................................................................................................................................. 717
				Installation......................................................................................................................................................................................................... 717
			STEERING CYLINDER ASSEMBLY............................................................................................................................................................................................... 718
				Removal.............................................................................................................................................................................................................. 718
				Installation......................................................................................................................................................................................................... 718
				Disassembly.......................................................................................................................................................................................................... 719
				Assembly............................................................................................................................................................................................................. 721
			DEMAND VALVE ASSEMBLY.................................................................................................................................................................................................... 723
				Removal.............................................................................................................................................................................................................. 723
				Installation......................................................................................................................................................................................................... 723
				Disassembly.......................................................................................................................................................................................................... 724
				Assembly............................................................................................................................................................................................................. 724
			RELIEF VALVE ASSEMBLY.................................................................................................................................................................................................... 725
				Disassembly.......................................................................................................................................................................................................... 725
				Assembly............................................................................................................................................................................................................. 725
	HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION
............................................................................................................................................................................... 727
		HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION............................................................................................................................................................................ 729
			HOIST CIRCUIT OPERATION.................................................................................................................................................................................................. 729
			HOIST CIRCUIT COMPONENT DESCRIPTION...................................................................................................................................................................................... 729
				Hoist Cylinders...................................................................................................................................................................................................... 729
				Hydraulic Filter..................................................................................................................................................................................................... 729
				Hoist Valve.......................................................................................................................................................................................................... 729
				RAISE................................................................................................................................................................................................................ 730
				HOLD................................................................................................................................................................................................................. 731
				POWER DOWN........................................................................................................................................................................................................... 732
				FLOAT................................................................................................................................................................................................................ 733
	HOIST CIRCUIT COMPONENT REPAIR
.................................................................................................................................................................................................. 735
		HOIST CIRCUIT COMPONENT REPAIR............................................................................................................................................................................................... 737
			HOIST VALVE ASSEMBLY..................................................................................................................................................................................................... 737
				Removal.............................................................................................................................................................................................................. 737
				Installation......................................................................................................................................................................................................... 737
				Disassembly.......................................................................................................................................................................................................... 738
				Assembly............................................................................................................................................................................................................. 738
			HOIST CYLINDER........................................................................................................................................................................................................... 740
				Removal.............................................................................................................................................................................................................. 740
				Installation......................................................................................................................................................................................................... 741
				Disassembly.......................................................................................................................................................................................................... 742
				Assembly............................................................................................................................................................................................................. 742
	HYDRAULIC CHECKOUT
.............................................................................................................................................................................................................. 745
		HYDRAULIC CHECKOUT........................................................................................................................................................................................................... 747
			DUMP BODY CONTROL........................................................................................................................................................................................................ 747
			ADJUSTING HOIST LEVER LINKAGE............................................................................................................................................................................................ 748
			ADJUSTING HOIST LIMITER.................................................................................................................................................................................................. 749
			TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT...................................................................................................................................................... 750
				Steering Circuit..................................................................................................................................................................................................... 750
				Hoist Circuit........................................................................................................................................................................................................ 751
SECTION M OPTIONS AND SPECIAL TOOLS
................................................................................................................................................................................................. 759
	WIGGINS QUICK FILL FUEL SYSTEM
.................................................................................................................................................................................................. 761
		WIGGINS QUICK FILL FUEL SYSTEM............................................................................................................................................................................................... 763
			FUEL TANK BREATHER VALVE................................................................................................................................................................................................. 763
				Removal.............................................................................................................................................................................................................. 763
				Installation......................................................................................................................................................................................................... 763
				Disassembly.......................................................................................................................................................................................................... 763
				Assembly............................................................................................................................................................................................................. 763
			FUEL RECEIVER............................................................................................................................................................................................................ 763
	  FAN DRIVE CLUTCH
.............................................................................................................................................................................................................. 765
		FAN DRIVE CLUTCH............................................................................................................................................................................................................. 767
			GENERAL DESCRIPTION...................................................................................................................................................................................................... 767
			MAJOR COMPONENTS......................................................................................................................................................................................................... 767
				Input................................................................................................................................................................................................................ 767
				Output............................................................................................................................................................................................................... 768
				Stationary Components................................................................................................................................................................................................ 768
			OPERATION MODES.......................................................................................................................................................................................................... 768
				Fully Engaged........................................................................................................................................................................................................ 768
				Modulated Variable Speed............................................................................................................................................................................................. 769
				Fully Released....................................................................................................................................................................................................... 769
				Lubricating & Cooling Oil............................................................................................................................................................................................ 770
			MAINTENANCE.............................................................................................................................................................................................................. 771
			TROUBLESHOOTING.......................................................................................................................................................................................................... 772
				Basic Preliminary Checks............................................................................................................................................................................................. 772
			FIELD CHECK DIAGNOSIS.................................................................................................................................................................................................... 773
				Preliminary Checks With Engine Off................................................................................................................................................................................... 773
				Off Truck Test....................................................................................................................................................................................................... 776
			TROUBLESHOOTING CHART.................................................................................................................................................................................................... 777
		FAN CLUTCH REBUILD........................................................................................................................................................................................................... 779
			DISASSEMBLY.............................................................................................................................................................................................................. 780
				Preparation.......................................................................................................................................................................................................... 780
				Cleaning And Inspection.............................................................................................................................................................................................. 787
			ASSEMBLY INSTRUCTIONS.................................................................................................................................................................................................... 790
				General Instructions................................................................................................................................................................................................. 790
				Assembly............................................................................................................................................................................................................. 790
			FAN CLUTCH TEST.......................................................................................................................................................................................................... 800
				Operational Test..................................................................................................................................................................................................... 800
	COOLANT AND OIL HEATERS
......................................................................................................................................................................................................... 805
		COOLANT AND OIL HEATERS...................................................................................................................................................................................................... 807
			SYSTEM OPERATION......................................................................................................................................................................................................... 807
			ENGINE COOLANT HEATERS................................................................................................................................................................................................... 809
				Troubleshooting...................................................................................................................................................................................................... 809
			OIL HEATERS.............................................................................................................................................................................................................. 810
				Troubleshooting...................................................................................................................................................................................................... 810
	SPECIAL TOOLS.................................................................................................................................................................................................................... 813
	PAYLOAD METER II - ON BOARD WEIGHING SYSTEM...................................................................................................................................................................................... 823
		GENERAL INFORMATION.......................................................................................................................................................................................................... 825
			Haul Cycles.............................................................................................................................................................................................................. 825
		LIGHTS, SWITCHES AND COMPONENTS.............................................................................................................................................................................................. 826
		TIPS FOR OPERATION........................................................................................................................................................................................................... 827
		EXTERNAL DISPLAY LIGHTS...................................................................................................................................................................................................... 827
		THEORY OF OPERATION.......................................................................................................................................................................................................... 828
			Basic Description........................................................................................................................................................................................................ 828
			Inclinometer............................................................................................................................................................................................................. 828
			Linkage Factor........................................................................................................................................................................................................... 828
			Gain Factor.............................................................................................................................................................................................................. 829
			Brake Lock............................................................................................................................................................................................................... 829
			Sources of Error......................................................................................................................................................................................................... 829
			Typical Data From Service Check Mode..................................................................................................................................................................................... 829
			Example Calculation of Payload........................................................................................................................................................................................... 830
			Viewing Payload Calculation Inputs....................................................................................................................................................................................... 830
			Checking the Gain........................................................................................................................................................................................................ 831
			Adjusting the Gain....................................................................................................................................................................................................... 831
		TYPES OF DATA STORED......................................................................................................................................................................................................... 832
			Cycle Data............................................................................................................................................................................................................... 832
			Engine ON/OFF Data....................................................................................................................................................................................................... 833
			Fault Codes and Warning Data............................................................................................................................................................................................. 833
			Engine Operation......................................................................................................................................................................................................... 834
			Total Payload and Total Number of Cycles................................................................................................................................................................................. 834
			Other Data............................................................................................................................................................................................................... 834
		OPERATOR FUNCTIONS........................................................................................................................................................................................................... 835
			Using the Operator Load Counter.......................................................................................................................................................................................... 835
			Viewing the Operator Load Counter........................................................................................................................................................................................ 835
			Clearing the Operator Load Counter....................................................................................................................................................................................... 835
			Dimming the Lights on the Display........................................................................................................................................................................................ 835
		INITIAL SETUP OF PAYLOAD METER............................................................................................................................................................................................... 836
			Switch Settings.......................................................................................................................................................................................................... 836
			Checking the Operator Check Mode......................................................................................................................................................................................... 837
			Checking the Service Check Mode.......................................................................................................................................................................................... 837
			Checking the Gt setting:................................................................................................................................................................................................. 838
			Checking the Inclinometer Settings....................................................................................................................................................................................... 838
			Calibrating a Truck...................................................................................................................................................................................................... 838
		DISPLAYS AT START-UP......................................................................................................................................................................................................... 839
			Normal Operation......................................................................................................................................................................................................... 839
		SETUP AND MAINTENANCE........................................................................................................................................................................................................ 840
			Setting The Speed Limit.................................................................................................................................................................................................. 840
			Setting the Option Code.................................................................................................................................................................................................. 840
			Setting The Machine I.D. Code............................................................................................................................................................................................ 841
			Setting The Operator I.D. Code........................................................................................................................................................................................... 841
			Setting The Time and Date................................................................................................................................................................................................ 841
		DOWNLOAD OF INFORMATION...................................................................................................................................................................................................... 842
		DISPLAY OF FAULT CODES....................................................................................................................................................................................................... 842
			Monitoring Input Signals................................................................................................................................................................................................. 846
			Service Check Mode....................................................................................................................................................................................................... 846
		UP FACTOR - PAYLOAD CALCULATION GAIN......................................................................................................................................................................................... 847
		PL MODE -LOAD CALCULATION TIMING............................................................................................................................................................................................. 847
		FINAL GEAR RATIO SELECTION................................................................................................................................................................................................... 848
		BATTERY REPLACEMENT PROCEDURE................................................................................................................................................................................................ 849
			Replacing the Battery.................................................................................................................................................................................................... 849
			After Replacing the Battery.............................................................................................................................................................................................. 850
		SUSPENSION PRESSURE SENSOR................................................................................................................................................................................................... 850
			Removal.................................................................................................................................................................................................................. 850
			Installation............................................................................................................................................................................................................. 851
		INCLINOMETER................................................................................................................................................................................................................. 851
			Removal.................................................................................................................................................................................................................. 851
			Installation............................................................................................................................................................................................................. 851
			Adjustment............................................................................................................................................................................................................... 851
		PAYLOAD METER BACK PANEL..................................................................................................................................................................................................... 852
		CONNECTIONS.................................................................................................................................................................................................................. 853
		PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE................................................................................................................................................................................ 854
		PAYLOAD CIRCUIT NUMBERS...................................................................................................................................................................................................... 855
		TROUBLESHOOTING.............................................................................................................................................................................................................. 856
			COMMON PROBLEMS.......................................................................................................................................................................................................... 856
				Suspension Charging.................................................................................................................................................................................................. 856
				Symptom Table........................................................................................................................................................................................................ 857
				Missing Body-Up Signal............................................................................................................................................................................................... 857
				Missing Speed Signal................................................................................................................................................................................................. 858
				F-18: Alternator R-Terminal, Oil Pressure Signals.................................................................................................................................................................... 858
				Shorted 18v Sensor Power Supply (930E)............................................................................................................................................................................... 858
			FAULT TREE DIAGNOSIS..................................................................................................................................................................................................... 859
				Payload Lights Won't Illuminate...................................................................................................................................................................................... 859
				Red, Amber or Green Payload Light Does Not Illuminate................................................................................................................................................................ 860
				Cannot Download - PC Communications.................................................................................................................................................................................. 861
				PC Communications Configuration...................................................................................................................................................................................... 862
				F.CAL: Payload Meter Won't Calibrate................................................................................................................................................................................. 863
				F-20: Sensor Power Fault............................................................................................................................................................................................. 864
				F-21, F-25: Left Front Pressure Sensor............................................................................................................................................................................... 866
				F-22, F-26: Right Front Pressure Sensor.............................................................................................................................................................................. 866
				F-23, F-27: Left Rear Pressure Sensor................................................................................................................................................................................ 866
				F-24, F-28: Right Rear Pressure Sensor............................................................................................................................................................................... 866
				F-31, F-32: Inclinometer............................................................................................................................................................................................. 868
				Body Up Input........................................................................................................................................................................................................ 870
				Brake Lock Input..................................................................................................................................................................................................... 871
				Speed Signal......................................................................................................................................................................................................... 872
				Adjusting the Speed Sensor........................................................................................................................................................................................... 872
			CONNECTORS AND PRESSURE SENSORS.......................................................................................................................................................................................... 874
		REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM.................................................................................................................................................................................. 877
			Menu Functions........................................................................................................................................................................................................... 880
			Using Scope.............................................................................................................................................................................................................. 880
			Log File Information..................................................................................................................................................................................................... 880
			Connections to Payload Meter II™......................................................................................................................................................................................... 881
		USING SCOPE.................................................................................................................................................................................................................. 882
			Monitoring Inputs Using Scope............................................................................................................................................................................................ 882
			Monitoring Suspension Charging Using Scope............................................................................................................................................................................... 882
			Pressure Sensor Dummy Loads.............................................................................................................................................................................................. 885
		GAIN ADJUSTMENT WORKSHEET.................................................................................................................................................................................................... 886
	EXHAUST BRAKE
................................................................................................................................................................................................................... 887
		EXHAUST BRAKE................................................................................................................................................................................................................ 889
			FUNCTION................................................................................................................................................................................................................. 889
			SYSTEM OPERATION......................................................................................................................................................................................................... 890
			SYSTEM COMPONENTS........................................................................................................................................................................................................ 891
				Exhaust Brake Pressure Switch........................................................................................................................................................................................ 891
				Exhaust Brake Solenoid Valve......................................................................................................................................................................................... 891
				Exhaust Brake Assembly............................................................................................................................................................................................... 892
			MAINTENANCE.............................................................................................................................................................................................................. 893
				1000 Hour Maintenance................................................................................................................................................................................................ 893
				Gate Adjustment...................................................................................................................................................................................................... 893
			TROUBLESHOOTING.......................................................................................................................................................................................................... 894
				Operational Characteristics.......................................................................................................................................................................................... 894
				System Component Checks.............................................................................................................................................................................................. 895
	AUTOMATIC SPIN REGULATOR (ASR) SYSTEM
........................................................................................................................................................................................... 897
		AUTOMATIC SPIN REGULATOR (ASR) SYSTEM........................................................................................................................................................................................ 899
			ASR SYSTEM............................................................................................................................................................................................................... 899
			ASR SYSTEM DESCRIPTION................................................................................................................................................................................................... 900
				Torque Control....................................................................................................................................................................................................... 900
				Compensation for Steering............................................................................................................................................................................................ 900
				System Diagnostics................................................................................................................................................................................................... 900
				System Components.................................................................................................................................................................................................... 900
			OPERATION................................................................................................................................................................................................................ 902
		ASR SYSTEM TROUBLESHOOTING................................................................................................................................................................................................... 904
			GENERAL TROUBLESHOOTING INFORMATION...................................................................................................................................................................................... 904
				Preliminary Troubleshooting Procedures............................................................................................................................................................................... 904
				Troubleshooting Specific Problems.................................................................................................................................................................................... 904
			NORMAL SYSTEM OPERATION.................................................................................................................................................................................................. 905
				Clearing Fault Codes................................................................................................................................................................................................. 905
		TROUBLESHOOTING SYSTEM COMPONENTS............................................................................................................................................................................................ 908
			AS-1: Fault Code 0.1 Abnormality in power source voltage................................................................................................................................................................. 908
			AS-2: Fault Code 1.0 Engine speed sensor, open circuit................................................................................................................................................................... 909
			AS-3: Fault Code 1.1 Right rear wheel speed sensor, open circuit......................................................................................................................................................... 910
			AS-4: Fault Code 1.2 Left rear wheel speed sensor, open circuit.......................................................................................................................................................... 911
			AS-5: Fault Code 1.3 Transmission output speed sensor, open circuit...................................................................................................................................................... 912
			AS-6: Fault Code 1.6 Steering angle sensor failure....................................................................................................................................................................... 913
			AS-7: Fault Code 1.7 Accelerator signal system fault..................................................................................................................................................................... 914
			AS-8: Fault Code 4.3 ASR/ARSC caution lamp system, open circuit.......................................................................................................................................................... 915
			AS-9: Fault Code 4.5 Central warning lamp and buzzer system, open circuit................................................................................................................................................ 916
			AS-10: Fault Code 5.3 ASR/ARSC caution lamp system, short to ground...................................................................................................................................................... 917
			AS-11: Fault Code 5.5 Central warning lamp and buzzer system output, short to ground..................................................................................................................................... 918
			AS-12: Fault Code 6.0 Engine speed system failure........................................................................................................................................................................ 919
			AS-13: Fault Code 6.1 Right rear wheel speed sensor failure.............................................................................................................................................................. 920
			AS-14: Fault Code 6.2 Left rear wheel speed sensor failure............................................................................................................................................................... 921
			AS-15: Fault Code 8.0 Left pressure control valve failure - valve does not open.......................................................................................................................................... 922
			AS-16: Fault Code 8.1 Short to ground in right pressure control valve circuit............................................................................................................................................ 923
			AS-17: Fault Code 8.2 Short to ground in left pressure control valve circuit............................................................................................................................................. 924
			AS-18: Fault Code 8.3 Right pressure control valve system, open circuit.................................................................................................................................................. 925
			AS-19: Fault Code 8.4 Failure in right pressure control valve system - LH valve does not close........................................................................................................................... 926
			AS-20: Fault Code 8.5 Right pressure control valve system failure (valve does not close)................................................................................................................................. 927
			AS-21: Fault Code 8.6 Left pressure control valve system failure (valve does not close).................................................................................................................................. 928
			AS-22: Fault Code 8.7 Right pressure control valve system failure (valve does not open).................................................................................................................................. 929
			AS-23: Fault Code 8.9 Short to ground in shut-off valve system........................................................................................................................................................... 930
			AS-24: Fault Code 9.0 Open circuit in shut-off valve system.............................................................................................................................................................. 931
			AS-25: Fault Code 9.1 Failure in shut-off valve system - valve does not close............................................................................................................................................ 932
			AS-26: Fault Code 9.2 Failure in shut-off valve system - valve does not open............................................................................................................................................. 933
			AS-101: Nothing is displayed in the controller display window............................................................................................................................................................ 934
			AS-102: Fault code remains cleared (“--” is always displayed) or cannot be cleared in controller display window.......................................................................................................... 935
			AS-103 : Another controller has failed................................................................................................................................................................................... 936
				Transmission Controller System....................................................................................................................................................................................... 936
				Payload Meter System................................................................................................................................................................................................. 936
			AS-104: Central warning lamp (buzzer) stays ON (or OFF).................................................................................................................................................................. 937
			AS-105: Open circuit in ASR system ON/OFF switch......................................................................................................................................................................... 938
			AS-106: Short circuit to ground in ASR system ON/OFF switch.............................................................................................................................................................. 939
			AS-107: ASR operation lamp does not light up............................................................................................................................................................................. 940
			AS-108 ASR operation lamp remains On..................................................................................................................................................................................... 942
	AUTOMATIC RETARD SPEED CONTROL SYSTEM (ARSC) TROUBLESHOOTING
.................................................................................................................................................................... 945
		AUTOMATIC RETARD SPEED CONTROL SYSTEM (ARSC) TROUBLESHOOTING................................................................................................................................................................. 947
			TROUBLESHOOTING SYSTEM COMPONENTS........................................................................................................................................................................................ 951
				R-1: Fault Code 0.1 Power source voltage fault....................................................................................................................................................................... 951
				R-2: Fault Code 1.0 Engine speed sensor, open circuit................................................................................................................................................................ 952
				R-3: Fault Code 1.3 Transmission output speed sensor, open circuit................................................................................................................................................... 953
				R-4: Fault Code 1.5 Retarder oil temperature sensor system fault..................................................................................................................................................... 954
				R-5: Fault Code 1.7 Accelerator signal system fault.................................................................................................................................................................. 955
				R-6: Fault Code 1.8 Left suspension pressure sensor system fault..................................................................................................................................................... 956
				R-7: Fault Code 1.9 Right suspension pressure sensor system fault.................................................................................................................................................... 957
				R-8: Fault Code 4.2 Exhaust brake selector signal, open circuit...................................................................................................................................................... 958
				R-9: Fault Code 4.3 ASR/ARSC caution lamp system, open circuit....................................................................................................................................................... 959
				R-10: Fault Code 4.4 ARSC operation (standby) lamp system, open circuit.............................................................................................................................................. 960
				R-11: Fault Code 4.5 Central warning lamp and buzzer system, open circuit............................................................................................................................................ 961
				R-12: Fault Code 5.2 Exhaust brake selector signal output system, short to ground.................................................................................................................................... 962
				R-13: Fault Code 5.3 ASR/ARSC caution lamp system, short to ground................................................................................................................................................... 963
				R-14: Fault Code 5.4 Short to ground in ARSC operation (standby) lamp output circuit................................................................................................................................. 964
				R-15: Fault Code 5.5 Central warning lamp and buzzer system output, short to ground.................................................................................................................................. 965
				R-16: Fault Code 6.0 Engine speed system failure..................................................................................................................................................................... 966
				R-17: Fault Code 7.1 Travel speed display system UP output, open circuit............................................................................................................................................. 967
				R-18: Fault Code 7.1 Travel speed display system DOWN output, open circuit........................................................................................................................................... 968
				R-19: Fault Code 7.2 Travel speed display system CLEAR output, open circuit.......................................................................................................................................... 969
				R-20: Fault Code 7.3 Travel speed display system UP output, short to ground.......................................................................................................................................... 970
				R-21: Fault Code 7.4 Travel speed display system DOWN output, short to ground........................................................................................................................................ 971
				R-22: Fault Code 7.5 Travel speed display system CLEAR output, short to ground....................................................................................................................................... 972
				R-23: Fault Code 8.1 Pressure control valve system, short to ground.................................................................................................................................................. 973
				R-24: Fault Code 8.3 Pressure control valve system, open circuit..................................................................................................................................................... 974
				R-25: Fault Code 8.5 Pressure control valve failure (valve remains open)............................................................................................................................................. 975
				R-26: Fault Code 8.7 Pressure control valve failure (valve fails to open)............................................................................................................................................ 976
				R-27: Fault Code 8.9 Shut-off valve system, short to ground.......................................................................................................................................................... 977
				R-28: Fault Code 9.0 Shut-off valve system, open circuit............................................................................................................................................................. 978
				R-29: Fault Code 9.1 Shut-off valve system failure (valve remains open).............................................................................................................................................. 979
				R-30: Fault Code 9.2 Shut-off valve system failure (valve fails to open)............................................................................................................................................. 980
				R-31: Fault Code 9.3 ARSC system switch, open circuit................................................................................................................................................................ 981
				R-32: Fault Code 9.4 ARSC system switch, short to ground............................................................................................................................................................. 982
				R-33: Fault Code 9.5 Travel speed setting switch, open circuit or short to ground.................................................................................................................................... 983
				R-101: Set speed cannot be set....................................................................................................................................................................................... 984
				R-102: No failure code displayed on controller (display always shows “- -”) or failure cannot be cleared............................................................................................................. 987
				R-103: Retarding effort excessive when empty or ineffective when truck is loaded..................................................................................................................................... 988
				R-104: Fault appears in another controller........................................................................................................................................................................... 988
				R-105: No retarder control when traveling downhill even when set speed is exceeded................................................................................................................................... 989
				R-106: Central warning lamp (or buzzer) stays on (or off)............................................................................................................................................................ 990
				R-107: STANDBY (READY) lamp does not light (or remains lit).......................................................................................................................................................... 991
				R-108: Exhaust brake does not work properly.......................................................................................................................................................................... 993
				R-109: Travel speed value and machine value model do not agree....................................................................................................................................................... 995
				R-110: Retarder lamp does not light or remains lit................................................................................................................................................................... 998
				R-111: Travel speed always displayed or no display at all............................................................................................................................................................ 999
			PRELIMINARY TROUBLESHOOTING PROCEDURES................................................................................................................................................................................... 947
				Troubleshooting Specific Problems.................................................................................................................................................................................... 947
				Set Travel Speed Display............................................................................................................................................................................................. 948
			NORMAL SYSTEM OPERATION.................................................................................................................................................................................................. 948
				Clearing Fault Codes................................................................................................................................................................................................. 948
SECTION N 
OPERATOR'S CAB............................................................................................................................................................................................................1003
	TRUCK CAB
.......................................................................................................................................................................................................................1005
		TRUCK CAB....................................................................................................................................................................................................................1007
			Removal..................................................................................................................................................................................................................1007
			Installation.............................................................................................................................................................................................................1007
	CAB COMPONENTS
..................................................................................................................................................................................................................1009
		CAB COMPONENTS...............................................................................................................................................................................................................1011
			WINDSHIELD WIPER /WASHER.................................................................................................................................................................................................1011
				Operation............................................................................................................................................................................................................1011
				Removal..............................................................................................................................................................................................................1011
				Installation.........................................................................................................................................................................................................1011
			WINDSHIELD WASHER........................................................................................................................................................................................................1012
				Operation............................................................................................................................................................................................................1012
				Service..............................................................................................................................................................................................................1012
			AIR CLEANER INDICATOR GAUGE..............................................................................................................................................................................................1012
			BODY DUMP CONTROL LINKAGE................................................................................................................................................................................................1012
			STEERING COLUMN SERVICE..................................................................................................................................................................................................1014
				Removal..............................................................................................................................................................................................................1014
				Installation.........................................................................................................................................................................................................1014
	OPERATOR COMFORT
................................................................................................................................................................................................................1017
		OPERATOR COMFORT.............................................................................................................................................................................................................1021
			OPERATOR SEAT............................................................................................................................................................................................................1021
				Removal..............................................................................................................................................................................................................1022
				Installation.........................................................................................................................................................................................................1022
			OPERATOR SEAT ASSEMBLY REPAIR............................................................................................................................................................................................1022
			HEATER AND AIR CONDITIONER UNIT..........................................................................................................................................................................................1024
				Removal..............................................................................................................................................................................................................1024
				Installation.........................................................................................................................................................................................................1024
			HEATER AND AIR CONDITIONER CORE REPLACEMENT..............................................................................................................................................................................1024
				Disassembly..........................................................................................................................................................................................................1024
				Assembly.............................................................................................................................................................................................................1024
			FILTER MAINTENANCE.......................................................................................................................................................................................................1026
				Cab Fresh Air Filter.................................................................................................................................................................................................1026
				Service (Cab Air Fresh Air Intake)...................................................................................................................................................................................1026
				Heater/Air Conditioner Air Filter....................................................................................................................................................................................1026
				Service (Inside Air Filter)..........................................................................................................................................................................................1026
			DASH LEVER CONTROLS......................................................................................................................................................................................................1027
				Removal..............................................................................................................................................................................................................1027
				Installation.........................................................................................................................................................................................................1027
			DASH PANEL...............................................................................................................................................................................................................1027
				Removal..............................................................................................................................................................................................................1027
				Installation.........................................................................................................................................................................................................1027
		AIR CONDITIONING SYSTEM......................................................................................................................................................................................................1028
			Environmental Impact.....................................................................................................................................................................................................1028
			OPERATOR CAB AIR CONDITIONING............................................................................................................................................................................................1029
			PRINCIPLES OF REFRIGERATION..............................................................................................................................................................................................1029
				Air Conditioning.....................................................................................................................................................................................................1029
				Refrigeration - The Act Of Cooling...................................................................................................................................................................................1030
				The Refrigeration Cycle..............................................................................................................................................................................................1030
			AIR CONDITIONER SYSTEM COMPONENTS........................................................................................................................................................................................1031
				Compressor (Refrigerant Pump)........................................................................................................................................................................................1031
				Service Valves.......................................................................................................................................................................................................1031
				Condenser............................................................................................................................................................................................................1031
				Expansion Block Valve................................................................................................................................................................................................1032
				Evaporator...........................................................................................................................................................................................................1032
			ELECTRICAL CIRCUIT.......................................................................................................................................................................................................1033
				Thermostat...........................................................................................................................................................................................................1033
				Compressor Clutch....................................................................................................................................................................................................1033
				Trinary™ Switch......................................................................................................................................................................................................1034
			SYSTEM SERVICING.........................................................................................................................................................................................................1035
			SYSTEM OIL...............................................................................................................................................................................................................1036
				Handling and Reusing PAG Oil.........................................................................................................................................................................................1036
				Oil Quantity.........................................................................................................................................................................................................1036
				Replacing Oil After Servicing the System.............................................................................................................................................................................1036
				Setting Up a New Compressor..........................................................................................................................................................................................1036
			REFRIGERANT..............................................................................................................................................................................................................1037
				Recycled Refrigerant.................................................................................................................................................................................................1037
				Reclaimed Refrigerant................................................................................................................................................................................................1037
				Refrigerant Quantity.................................................................................................................................................................................................1037
				R-134a Refrigerant Containers........................................................................................................................................................................................1037
			SERVICE TOOLS AND EQUIPMENT..............................................................................................................................................................................................1038
				Recovery/Recycle Station.............................................................................................................................................................................................1038
				Leak Detector........................................................................................................................................................................................................1038
				Service Valves.......................................................................................................................................................................................................1039
				Vacuum Pump..........................................................................................................................................................................................................1039
				Manifold Gauge Set...................................................................................................................................................................................................1040
				Installing Manifold Gauge Set........................................................................................................................................................................................1041
				Purging Air From Service Hoses.......................................................................................................................................................................................1042
				Stabilizing the AC System............................................................................................................................................................................................1043
			SYSTEM PERFORMANCE TEST..................................................................................................................................................................................................1043
			SYSTEM LEAK TESTING......................................................................................................................................................................................................1044
				Electronic leak detector.............................................................................................................................................................................................1044
				Tracer dyes..........................................................................................................................................................................................................1044
				Soap and water.......................................................................................................................................................................................................1044
			SYSTEM REPAIR............................................................................................................................................................................................................1045
				System Cleaning......................................................................................................................................................................................................1045
				Hoses and Fittings...................................................................................................................................................................................................1045
				Lines................................................................................................................................................................................................................1045
				Expansion Valve......................................................................................................................................................................................................1045
				Receiver-Drier.......................................................................................................................................................................................................1046
				Thermostat...........................................................................................................................................................................................................1046
				Compressor...........................................................................................................................................................................................................1046
				Clutch...............................................................................................................................................................................................................1046
				Servicing the Compressor Clutch......................................................................................................................................................................................1047
				Pulley Removal.......................................................................................................................................................................................................1049
				Clutch Coil Check....................................................................................................................................................................................................1049
				Pulley Installation..................................................................................................................................................................................................1049
				Clutch Assembly Installation.........................................................................................................................................................................................1050
			RECOVERING AND RECYCLING THE REFRIGERANT.................................................................................................................................................................................1051
				Performing the Recovery Cycle........................................................................................................................................................................................1051
				Performing the Recycling Procedure...................................................................................................................................................................................1051
				Evacuating and Charging the AC System................................................................................................................................................................................1051
			EVACUATING THE SYSTEM....................................................................................................................................................................................................1052
			CHARGING THE AC SYSTEM...................................................................................................................................................................................................1053
			TROUBLESHOOTING..........................................................................................................................................................................................................1054
				Pre-Diagnosis Checks.................................................................................................................................................................................................1054
				Preparing For Diagnosis..............................................................................................................................................................................................1054
				Preliminary Steps....................................................................................................................................................................................................1054
				System Performance Test..............................................................................................................................................................................................1054
				Diagnosis Of Gauge Readings And System Performance...................................................................................................................................................................1055
		PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM..............................................................................................................................................................................1062
	OPERATOR CAB AND CONTROLS
.......................................................................................................................................................................................................1063
		OPERATOR CAB AND CONTROLS....................................................................................................................................................................................................1067
			STEERING WHEEL AND CONTROLS..............................................................................................................................................................................................1067
				Tilt Lever...........................................................................................................................................................................................................1067
				Turn Signal Lever Switch.............................................................................................................................................................................................1067
				Horn.................................................................................................................................................................................................................1067
				Windshield Wiper / Washer Switch.....................................................................................................................................................................................1067
				Headlights and Dimmer Switch.........................................................................................................................................................................................1068
				Retard Control Lever.................................................................................................................................................................................................1068
			BRAKE PEDAL..............................................................................................................................................................................................................1068
			THROTTLE PEDAL...........................................................................................................................................................................................................1068
			CENTER CONSOLE AND CONTROLS..............................................................................................................................................................................................1068
				Transmission Range Selector..........................................................................................................................................................................................1068
				Shift Limiter Switch.................................................................................................................................................................................................1070
				Economy / Power Mode Switch..........................................................................................................................................................................................1070
				Emergency Steering Switch............................................................................................................................................................................................1070
				Emergency Brake Lever................................................................................................................................................................................................1071
				Parking Brake Valve Lever............................................................................................................................................................................................1071
			ENGINE ELECTRONIC CONTROL SYSTEM.........................................................................................................................................................................................1072
				Engine Shutdown Light (Stop Engine)..................................................................................................................................................................................1072
				Engine Maintenance Light (Check Engine)..............................................................................................................................................................................1072
				Engine Maintenance Light.............................................................................................................................................................................................1072
			ENGINE DIAGNOSTICS.......................................................................................................................................................................................................1073
				Fault Check Switch...................................................................................................................................................................................................1073
				Fault Scroll Switch..................................................................................................................................................................................................1073
				Determining Fault Codes..............................................................................................................................................................................................1073
				Exiting The Diagnostics Mode.........................................................................................................................................................................................1073
			HOIST CONTROL............................................................................................................................................................................................................1074
				Safety Lock..........................................................................................................................................................................................................1074
			ASR / ARSC (OPTIONAL)....................................................................................................................................................................................................1075
			ASR SYSTEM CONTROLS......................................................................................................................................................................................................1075
				System Switch........................................................................................................................................................................................................1076
				ASR/ARSC Caution Lamp................................................................................................................................................................................................1076
				ASR Operation Lamp...................................................................................................................................................................................................1076
				Central Warning Lamp.................................................................................................................................................................................................1076
				Retarder Control Lever...............................................................................................................................................................................................1076
				Accelerator Pedal....................................................................................................................................................................................................1076
				Brake Pedal..........................................................................................................................................................................................................1076
			PRECAUTIONS WHEN USING THE ASR SYSTEM....................................................................................................................................................................................1076
			ARSC SYSTEM CONTROLS.....................................................................................................................................................................................................1077
				System Switch........................................................................................................................................................................................................1077
				ARSC Set Lever.......................................................................................................................................................................................................1077
				Brake Pedal..........................................................................................................................................................................................................1077
				Accelerator Pedal....................................................................................................................................................................................................1077
				ASR/ARSC Caution Lamp................................................................................................................................................................................................1077
				ARSC Standby Lamp....................................................................................................................................................................................................1077
				Set Speed Display....................................................................................................................................................................................................1077
				Retarder Control Lever...............................................................................................................................................................................................1077
				Central Warning Lamp.................................................................................................................................................................................................1077
			ARSC SYSTEM ACTUATION....................................................................................................................................................................................................1078
				Traveling Again At Set Speed.........................................................................................................................................................................................1078
				Relationship With Exhaust Brake......................................................................................................................................................................................1079
				Recommended Set Speed................................................................................................................................................................................................1079
			TROUBLESHOOTING THE ASR/ARSC SYSTEMS.....................................................................................................................................................................................1080
				When a problem occurs in the system..................................................................................................................................................................................1080
				Model Selection, Tire Selection, And Failure Code Display............................................................................................................................................................1080
				Failure Codes........................................................................................................................................................................................................1080
		INSTRUMENT PANEL AND INDICATORS..............................................................................................................................................................................................1083
			WARNING & CAUTION LAMPS..................................................................................................................................................................................................1084
			GAUGE AND MONITOR PANEL..................................................................................................................................................................................................1085
				Air Pressure Monitor.................................................................................................................................................................................................1085
				Air Pressure Gauge...................................................................................................................................................................................................1085
				Coolant Temperature Monitor..........................................................................................................................................................................................1085
				Engine Cooling Water Temperature Gauge...............................................................................................................................................................................1085
				Torque Converter Oil Temperature Monitor.............................................................................................................................................................................1086
				Torque Converter Oil Temperature Gauge...............................................................................................................................................................................1086
				Retarder Oil Temperature Monitor.....................................................................................................................................................................................1086
				Retarder Oil Temperature Gauge.......................................................................................................................................................................................1086
				High Beam Pilot Lamp.................................................................................................................................................................................................1086
				Left Turn Signal Pilot Lamp..........................................................................................................................................................................................1086
				Right Turn Signal Pilot Lamp.........................................................................................................................................................................................1086
				Speedometer..........................................................................................................................................................................................................1086
				Tachometer...........................................................................................................................................................................................................1086
				Shift Limiter Pilot Lamp.............................................................................................................................................................................................1086
				Lock-up Pilot Lamp...................................................................................................................................................................................................1087
				Transmission Shift Position Pilot Lamp...............................................................................................................................................................................1087
				Shift Indicator......................................................................................................................................................................................................1087
				Engine Controller Monitor............................................................................................................................................................................................1087
				Automatic Transmission Mechatronics Monitor..........................................................................................................................................................................1087
				Other Mechatronics Monitor (OPTIONAL)................................................................................................................................................................................1087
				Fuel Level Monitor...................................................................................................................................................................................................1087
				Fuel Gauge...........................................................................................................................................................................................................1087
				Service Meter........................................................................................................................................................................................................1088
				Service Meter Indicator..............................................................................................................................................................................................1088
				Odometer.............................................................................................................................................................................................................1088
				Power Mode Indicator.................................................................................................................................................................................................1088
			INDICATORS AND CONTROLS PANEL............................................................................................................................................................................................1088
				Optional Equipment...................................................................................................................................................................................................1088
				Coolant Level Monitor................................................................................................................................................................................................1089
				Engine Oil Pressure Monitor..........................................................................................................................................................................................1089
				Charge Monitor.......................................................................................................................................................................................................1089
				Transmission Oil Filter Monitor......................................................................................................................................................................................1089
				Hazard Warning Lights................................................................................................................................................................................................1089
				Front Brake On/Off Switch............................................................................................................................................................................................1089
				Panel Dimmer Switch..................................................................................................................................................................................................1089
				AISS/Auto Switch.....................................................................................................................................................................................................1090
				Manual Starting Aid Switch...........................................................................................................................................................................................1090
				Starting Switch......................................................................................................................................................................................................1090
				Pilot Lamp Bulb Check Switch.........................................................................................................................................................................................1090
				Rear Brake Pilot Lamp................................................................................................................................................................................................1090
				Body Float Caution Monitor...........................................................................................................................................................................................1090
				Parking Brake Monitor................................................................................................................................................................................................1091
				Emergency Steering Monitor...........................................................................................................................................................................................1091
				Exhaust Brake (Optional).............................................................................................................................................................................................1091
				Cold Start...........................................................................................................................................................................................................1091
				Steering Oil Temperature.............................................................................................................................................................................................1091
				Side Slope Warning (Optional)........................................................................................................................................................................................1091
				Rear Brake Caution Lamp..............................................................................................................................................................................................1091
				Exhaust Brake Switch (Optional)......................................................................................................................................................................................1092
				Fog Light Switch (Optional)..........................................................................................................................................................................................1092
				Central Warning Lamp (Red Convex Lens)...............................................................................................................................................................................1092
			HEATER/AIR CONDITIONER CONTROLS..........................................................................................................................................................................................1093
				Temperature Adjustment Lever.........................................................................................................................................................................................1093
				Blower Switch........................................................................................................................................................................................................1093
				Air Selector Lever...................................................................................................................................................................................................1093
				Vent Selector Lever..................................................................................................................................................................................................1093
				Air Vent.............................................................................................................................................................................................................1094
				Glove Box Storage Compartment........................................................................................................................................................................................1094
				Air Conditioner Switch...............................................................................................................................................................................................1094
				Correction Code Display..............................................................................................................................................................................................1094
SECTION P LUBRICATION AND SERVICE
...................................................................................................................................................................................................1095
	LUBRICATION AND SERVICE
.........................................................................................................................................................................................................1097
		LUBRICATION AND SERVICE......................................................................................................................................................................................................1099
			10 HOUR (DAILY) INSPECTION...............................................................................................................................................................................................1101
			FLUID LEVELS & OTHER CHECKS..............................................................................................................................................................................................1101
			10 HOUR (DAILY) INSPECTION (continued)...................................................................................................................................................................................1103
				ENGINE...............................................................................................................................................................................................................1103
				WHEELS AND TIRES.....................................................................................................................................................................................................1103
					Tires............................................................................................................................................................................................................1103
			10 HOUR (DAILY) INSPECTION (continued)...................................................................................................................................................................................1104
				Wheels...............................................................................................................................................................................................................1104
				OPERATIONAL CHECKS...................................................................................................................................................................................................1105
			250 HOUR SERVICE.........................................................................................................................................................................................................1107
				INITIAL 250 HOUR SERVICE.............................................................................................................................................................................................1107
				EVERY 250 HOUR SERVICE...............................................................................................................................................................................................1107
				500 HOUR SERVICE.....................................................................................................................................................................................................1109
				1000 HOUR SERVICE....................................................................................................................................................................................................1110
				EVERY 2000 HOUR SERVICE..............................................................................................................................................................................................1111
				EVERY 5000 HOUR SERVICE..............................................................................................................................................................................................1112
				HYDRAULIC TANK SERVICE...............................................................................................................................................................................................1113
					Filling Instructions (Hoist Oil Supply)..........................................................................................................................................................................1113
					Filling Instructions (Rear Brake Cooling Oil Supply).............................................................................................................................................................1113
				HYDRAULIC FILTERS....................................................................................................................................................................................................1114
					Filter Replacement...............................................................................................................................................................................................1114
				HYDRAULIC TANK BREATHER..............................................................................................................................................................................................1114
					Cleaning.........................................................................................................................................................................................................1114
				HIGH PRESSURE HYDRAULIC FILTERS......................................................................................................................................................................................1115
					Filter Assembly Removal..........................................................................................................................................................................................1115
					Filter Assembly Installation.....................................................................................................................................................................................1115
					Filter Element Replacement.......................................................................................................................................................................................1116
				TRANSMISSION FILTER..................................................................................................................................................................................................1117
					Service..........................................................................................................................................................................................................1117
			PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES...............................................................................................................................................................1118
	AUTOMATIC LUBRICATION SYSTEM
....................................................................................................................................................................................................1119
		AUTOMATIC LUBRICATION SYSTEM.................................................................................................................................................................................................1121
			OPERATION................................................................................................................................................................................................................1121
			COMPONENTS...............................................................................................................................................................................................................1121
				Component Location...................................................................................................................................................................................................1122
			GENERAL INFORMATION......................................................................................................................................................................................................1124
				Lubricant Required for System........................................................................................................................................................................................1124
				Air Pressure Regulator...............................................................................................................................................................................................1124
				Initial Reservoir Fill...............................................................................................................................................................................................1124
				System Priming.......................................................................................................................................................................................................1124
			SYSTEM CHECKOUT..........................................................................................................................................................................................................1125
				Lubrication Cycle Timer Check........................................................................................................................................................................................1125
				Timer Adjustment.....................................................................................................................................................................................................1125
			INJECTORS (SL-1 Series “H”)..............................................................................................................................................................................................1126
				Injector Specifications..............................................................................................................................................................................................1126
				Injector Adjustment..................................................................................................................................................................................................1126
				Injector Operation...................................................................................................................................................................................................1127
			TROUBLESHOOTING CHART....................................................................................................................................................................................................1128
ALPHABETICAL INDEX...................................................................................................................................................................................................................1131
SECTION R SYSTEM SCHEMATICS
.........................................................................................................................................................................................................1135
	HA207 AIR CIRCUIT DIAGRAM
.......................................................................................................................................................................................................1137
	HA208 AIR SCHEMATIC
.............................................................................................................................................................................................................1138
	HH345 HYDRAULIC SCHEMATIC
.......................................................................................................................................................................................................1139
	HH346 HYDRAULIC PIPING
..........................................................................................................................................................................................................1140
	KT-T01 TRANSMISSION
.............................................................................................................................................................................................................1141
	HE482 ELECTRICAL SCHEMATIC
......................................................................................................................................................................................................1142

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.