Komatsu HD785-5LC Dump Truck Shop Manual CEBM013801 PDF

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Komatsu HD785-5LC Dump Truck Shop Manual CEBM013801 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD785-5LC Dump Truck Shop Manual CEBM013801 – PDF DOWNLOAD 

Language : English
Pages : 1152
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HD785-5LC Dump Truck Shop Manual CEBM013801 – PDF DOWNLOAD 

FOREWORD:

• This manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when performing repairs on 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 area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only 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 of U.S. standard and metric (SI) units throughout, and 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 are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ± 10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame upright in front of the left side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• 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 Gross Vehicle Weight (GVW) is what determines the load on the drivetrain, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
  (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
• To determine allowable payload: Ensure the dump body is empty, all lubricants (including fuel) are at the proper level. All accessories that will be used (body liners, tailgates, etc.) should be in place on the truck. When the truck is in its operating condition, it can now be weighed. Record this value and subtract from the GVW rating. The remainder is the allowable payload.

TABLE OF CONTENTS:

Komatsu HD785-5LC Dump Truck Shop Manual CEBM013801 – PDF DOWNLOAD 

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

S.V 15/12/24